3155523389detailedspecs.pdf

23389 – Detailed Specifications

DETAILED SPECIFICATIONS

LIQUID BITUMINOUS MATERIALS

AWARD# 23389

GROUP 31555 – LIQUID BITUMINOUS MATERIALS

(2025 VPP NYSDOT Specific Projects) (Federal & State Funds)

Table of Contents

DETAILED SPECIFICATIONS – CHIP SEAL 3

DETAILED SPECIFICATIONS – PG BINDER CHIP SEAL 7

DETAILED SPECIFICATIONS – COLD RECYCLING 16

DETAILED SPECIFICATIONS – HEATER SCARIFICATION 23

DETAILED SPECIFICATIONS – JOINT & CRACK FILLER/SEALER 29

DETAILED SPECIFICATIONS – MASTIC JOINT & CRACK FILLER 32

DETAILED SPECIFICATIONS – MICRO-SURFACING 35

DETAILED SPECIFICATIONS – PAVER PLACED SURFACE TREATMENT – CONVENTIONAL 45

DETAILED SPECIFICATIONS – PAVER PLACED SURFACE TREATMENT - MODIFIED 52

DETAIL SPECIFICATIONS - LIQUID BITUMINOUS MATERIALS

DETAILED SPECIFICATIONS – CHIP SEAL

SECTION 410 – CHIP SEAL

All Chip Seal items shall be furnished in accordance with Sections 410 of the New York State Department of Transportation Standard Specifications, Construction and Materials most current version at the time of the bid opening, except as modified below:

410.1 METHOD OF MEASUREMENT

§410-4 Method of Measurement shall apply except the Pay Unit for the optional Pick-Up Broom or Vacuum Sweeper be measured per day.

410.2 BASIS OF PAYMENT

Payment will be made under:

Item No. Item Pay Unit

410.60 Pick Up Broom or Vacuum Sweeper (optional) Per Day

410.3 SPECIAL NOTES CHIP SEALS

1. Fog Seal and Cover Sand are required for all NYSDOT projects.

2. Use 1ST aggregate if traffic volumes exceed 2000 AADT.

Note – Shoulders are assumed to have 0 AADT.

3. 1A aggregate produces a finer, less aggressive surface. Consider use of 1A aggregate in areas of frequent bicycle/pedestrian use.

4. Consider an optional pickup sweeper where loose stones on roadside would be undesirable.

5. Immediately after completion of the Chip Seal, the section shall be signed with black on orange W8-7 LOOSE STONE signs and black on orange 30 MPH W13-1P advisory speed plaques for a period of seven days. The warning sign and the advisory speed plaque shall be installed on the same post as specified in the MUTCD. The signs should be posted at ½ mile intervals. The first sign shall be posted in advance of the section in accordance with the MUTCD. The day and night visibility of the sign assemblies shall be enhanced by either 18-inch square orange flags for daytime visibility and low intensity Type A flashing warning lights for night visibility or high intensity Type B flashing warning lights for 24-hour visibility.

DETAILED SPECIFICATIONS – CHIP SEAL (Cont’d)

410.4 BONDING REQUIREMENTS

A. Within 10 calendar days of receipt of a purchase order from the State, the Contractor shall provide the State agency the following:

1. Maintenance Material Bond: A bond in the form similar to the sample included in this. Invitation for Bids with sufficient sureties approved by the State’s Resident Engineer guaranteeing replacement of deficient material in the form included in this Invitation for Bids. This bond shall remain in place for one year after final acceptance of the project by the State or until August 1 of the year following completion of the project, whichever is later.

2. Amount of Bond: The amount of the Maintenance Material Bond shall be 100% of the amount of the project’s cost.

3. Requirements of Bonds: All Bonds shall be issued by a surety company approved by NYSDOT and authorized to do business in the State of New York as a surety.

B. The procedure of the Maintenance Material Bond shall be as follows:

1. No later than June 1 of the year following the State’s acceptance of work completed under this contract, the State will evaluate the project for aggregate retention, flushing or bleeding, aggregate embedment, and bonding to the existing pavement.

2. The Contractor agrees to repair all areas that demonstrate less than 90% aggregate retention, as determined by the State, on the overall project caused by improper workmanship and/or defective materials. In addition, the Contractor agrees to repair individual areas that are flushed or bleeding, as determined by the State, caused by improper workmanship and/or defective materials irrespective of the percent of aggregate retained. Such repairs, however, shall not include any damage resulting from any forces or circumstances beyond the control of the Contractor. The evaluation of the Chip Seal (Conventional and Fiber Reinforced) shall be made by the State’s Resident Engineer. If the Contractor does not agree with the evaluation it may appeal to the State’s Regional Director of Operations whose decision shall be final. Any resultant property damage deemed by the State’s Regional Director of Operations caused by improper workmanship and/or defective materials shall be the responsibility of the Contractor.

3. On or before June 10, in the year immediately following the State’s acceptance of the Chip Seal project, the State shall notify the Contractor of any areas deemed deficient by the State. The Contractor will initiate and complete the remediation within 30 days of notification.

4. Prior to the performance of repairs in the field, the Contractor shall supply the State’s Resident Engineer with copies of applicable insurance certificates. During the performance of any necessary repairs, the Contractor shall comply with all provisions of the original contract including among other things the Work Zone Traffic Control provisions.

S A M P L E

MAINTENANCE BOND

KNOW ALL PEOPLE BY THESE PRESENTS, That we, (hereinafter called the “PRINCIPAL”) of

, and of

(hereinafter called the “SURETY”) are held and firmly bound unto the people of the State of New York in the full and just sum of Dollars

($ ) good and lawful money of the United States of America, to the payment of which said sum of money, well and truly to be made and done the said PRINCIPAL binds itself, its heirs, executors, administrators or assignees and the SURETY binds itself, its successors or assigns, jointly and severally, firmly by these presents.

Signed and dated this day of , 20 .

WHEREAS, the PRINCIPAL has entered into a certain written contract bearing date on the day of , 20 , with the People of the State of New York for the improvement of , in the County of , New York.

NOW THEREFORE, the PRINCIPAL warrants the workmanship and all materials used in the work and agrees that during the guarantee period of one year beginning after final acceptance by the State or political subdivision or until August 1 of the year following acceptance of work completed under the contract, whichever is later, it will, at its own expense make repairs which may become necessary by reason of improper workmanship or defective materials as per the following procedure:

1. No later than June 1 of the year following the State’s or the political subdivision’s acceptance of work completed under the contract, the State or political subdivision will evaluate the project for aggregate retention, flushing or bleeding, aggregate embedment, and bonding to the existing pavement.

2. The PRINCIPAL agrees to repair all areas that demonstrate less than 90% aggregate retention, as determined by the State, on the overall project caused by improper workmanship and/or defective materials. In addition, the PRINCIPAL agrees to repair individual areas that are flushed or bleeding, as determined by the State, caused by improper workmanship and/or defective materials irrespective of the percent of aggregate retained. Such repairs, however, shall not include any damage resulting from any forces or circumstances beyond the control of the PRINCIPAL. The evaluation of the Chip Seal (Conventional and Fiber Reinforced) shall be made by the State’s Resident Engineer. If the Contractor does not agree with the evaluation it may appeal to the State’s Regional Director of Operations whose decision shall be final.

3. On or before June 10, in the year immediately following the State’s acceptance of the Chip Seal project, the State shall notify the PRINCIPAL of any areas deemed deficient by the State. The PRINCIPAL will initiate and complete the remediation within 30 days of notification.

In the event of the failure of performance by the PRINCIPAL who has failed to make repairs which may become necessary by reason of improper workmanship or defective materials, said SURETY, for value received, hereby stipulates and agrees, if requested to do so by the State, to commence such repairs within five (5) days of notification by the State of such failure by the PRINCIPAL. Such repairs shall be performed in accordance with the provisions of the current contract which require among other provisions that the SURETY shall provide necessary Work Zone Traffic Control as well as provide the required insurance before any work is conducted.

In the event both the SURETY and the PRINCIPAL fail to perform such repairs, the State shall cause the repair to be completed by others and the SURETY and PRINCIPAL shall be jointly and severally liable for such costs.

And the said SURETY thereby stipulates and agrees that no change, extension, alteration, deduction, or addition in or to the terms of the said contract or the plans or specifications accompanying same, shall in any way affect the obligations of said SURETY of its bond.

PRINCIPAL

BY SURETY

BY

DETAILED SPECIFICATIONS – PG BINDER CHIP SEAL

SECTION 410PG – PG BINDER CHIP SEAL

This work shall consist of the construction of a single course Hot-Oil Chip Seal for pavements and/or shoulders in accordance with the contract documents.

410PG.1 MATERIALS

A. Bituminous Material: The bituminous material shall meet the applicable requirements of Section 702.

1. PG Binder: Ensure that the bituminous material is compatible with the selected aggregate; use material meeting the requirements of 702-64V22.

2. Fog Seal: The Contractor shall provide material meeting the requirements of 702-3002, 702-3601, 702-4002 or 702-4501.

B. Aggregates: The aggregate shall conform to the requirements of §703-02, Coarse Aggregates, except as modified herein. The aggregate size shall be No. 1ST. The aggregate’s flakiness index shall meet the requirements of Materials Method 410, Chip Seal Mix Design.

1. Aggregate: The aggregate shall meet one of the following requirements:

a. Limestone or a blend of limestone and dolomite having an acid insoluble residue content not less than 20.0%.

b. Dolomite.

c. Sandstone, granite, chert, trap rock, ore tailings, or other similar non-carbonate materials.

d. Use gravel or blend two or more of: gravel, limestone, dolomite, sandstone, granite, chert, trap rock, ore tailings, or other similar materials to produce a final blend having non-carbonate plus 1/4-inch particles comprising at least 20.0% of the total aggregate by weight with adjustments to equivalent volumes for materials of different specific gravities.

2. Pre-Coating: The aggregate shall be pre-coated in an asphalt mixing plant using material meeting the requirements of 702-64S22. Polymer Modified PG Binders may be allowed with the permission of the Regional Material Engineer. The asphalt binder shall have a minimum mixing temperature of 250°F and be applied at a rate of 0.40 to 0.80 percent asphalt cement by weight of aggregate.

C. Material Sampling and Testing

1. Aggregate Stockpile.

a. Contractor Testing: The Contractor shall perform the following tests and submit the results to the Regional Materials Engineer.

1. Obtain three samples, according to ASTM D75, Standard Practice for Sampling Aggregates. Each sample must contain material from each face of the stockpile.

2. Test samples in accordance with AASHTO T 11, Materials Finer than #200 Sieve in Mineral Aggregates by Washing, and AASHTO T 27, Sieve Analysis of Fine and Coarse Aggregates. Test results shall be based on the average of three tests.

3. When required, sample and test the aggregate in accordance with Materials Method 28, Friction Aggregate Control and Test Procedures.

4. Determine the aggregate’s flakiness index as defined by Materials Method 410, Chip Seal Mix Design.

DETAILED SPECIFICATIONS – PG BINDER CHIP SEAL (Cont’d)

5. Percent asphalt content of each sample following NY 400-13C or AASHTO T164 Method A or B.

b. Department Testing and Approval: The Department may elect to sample the uncoated aggregate stockpile prior to allowing the Contractor to begin work.

Aggregate is subject to quality assurance (QA) testing by the Regional Materials Engineer. Each day of work, the Department will witness and take possession of a pre-coated aggregate sample obtained by the Contractor. The sample will be taken from a haul unit used in that day’s production and represent the entire quantity of pre-coated aggregate placed that day.

The Department will evaluate any material failing QA testing to determine if it will be left in place. Material represented by a sample failing QA testing that is left in place will be subject to pay reductions.

Samples shall meet appropriate friction values. All Chip Seal previously placed with material from a stockpile rejected for non-carbonate or acid insoluble residue content will be rejected.

2. Bituminous Material: Bituminous material is subject to QA testing by the Materials Bureau. The Engineer will evaluate any material failing QA testing to determine if it will be left in place. Material represented by a sample failing QA testing that is left in place will be subject to pay reductions.

D. Mix Design: Complete a mix design for pavements and/or shoulders in accordance with Materials Method 410. A shoulder mix design is required when Contractor operations require the shoulder to be treated separately from the mainline. Mix designs shall be submitted to the Engineer a minimum of two weeks prior to the start of the work.

410PG.2 CONSTRUCTION DETAILS

A. General

1. Weather and Seasonal Limitations: Chip Seal shall be placed during the period from May 1st through September 7th. Material shall not be applied to a pavement surface when the:

a. Surface has standing water or is saturated.

b. Surface temperature is not less than 60°F and greater than 140°F.

c. Ambient temperature is less than 50°F.

d. Weather conditions would prevent proper construction of the Chip Seal.

2. Equipment: All equipment shall be maintained in satisfactory working conditions at all times.

a. Sweepers

1. Self-propelled Rotary Power Broom: The self-propelled rotary power broom shall be designed, equipped, maintained, and operated so the pavement surface can be swept clean.

2. Self-propelled Pick-Up Broom or Vacuum Sweeper: The self-propelled equipment shall be designed, equipped, maintained, and operated so that the pavement can be swept clean. Excess aggregate shall be contained in an onboard hopper and disposed of.

b. Bituminous Material Distributor

1. The distributor shall be equipped, maintained, and operated so that bituminous material can be applied uniformly on variable widths up to 15-feet; and at controlled temperature and rates from 0.05 to 0.55 gallons per square yard. Prior to starting work, the distributor shall be calibrated for transverse and longitudinal application rate by ASTM D 2995, Standard Practice for Estimating Application Rate of Bituminous Distributors, or an equivalent method approved by the Engineer. The Engineer will witness the equipment calibration or require the Contractor to provide documentation certifying the calibration.

2. The distributor shall uniformly apply the bituminous material at the specified rate with a maximum allowable variation of 0.02 gallons per square yard.

3. Distributor equipment shall include accurate volume measuring devices or a calibrated tank, and a thermometer for measuring temperatures of tank contents.

Distributors shall be equipped with full circulation spray bars adjustable laterally and vertically. The distributor shall be equipped with a bituminous material sampling valve.

c. Aggregate Spreader

The aggregate spreader shall be a self-propelled unit capable of uniformly spreading the aggregate at the required rate on a minimum width of 6-inches wider than the width of the lane to be treated. Prior to starting work, the spreader shall be calibrated using ASTM D 5624, Standard Test Method for Determining the Transverse- Aggregate Spread Rate for Surface Treatment Applications. The Engineer will witness the equipment calibration or require the Contractor to provide documentation certifying the calibration.

d. Pneumatic Tire Roller

Pneumatic tire rollers shall be self-propelled and have oscillating wheels with smooth tread tires and will have a minimum ground contact pressure of 80 psi. The tire pressure for all wheels shall be uniform within ± 5 psi. The rollers shall be operated at a maximum speed of 5 mph. Refer to Table 410-2 Number of Rollers for the minimum number of rollers required.

3. Surface Preparation: Perform all surface preparations immediately ahead of the Chip Seal operation.

a. Thoroughly clean the entire area to be overlaid of dirt, oil, and other foreign materials. Remove all debris and standing water.

b. Cover all manhole covers, water boxes, catch basins, and other such utility structures within the area being treated with plastic, building felt, or other material approved by the Engineer. Remove the covers each day.

c. The Contractor shall remove pavement markings.

d. The Contractor shall place Temporary Road Pavement Markers (Chip Seal Markers) every 100’ along the centerline of the roadway. If the roadway has multiple lanes Chip Seal markers shall be placed along the lane lines in addition to the centerline. If markers are damaged or missing prior to the Chip Seal passing the location of the marker, replace the marker.

B. Chip Seal

1. Application of PG Binder: PG binder shall be applied in a uniform, continuous spread over the section to be treated at a minimum temperature of 325°F. The PG binder application rate is 0.25 to 0.50 gallons per square yard. The Contractor shall document and report to the Engineer any field changes in application rates from the mix design submittal.

Where longitudinal joints are to occur, the application of PG binder from the initial pass shall extend 6-inches beyond the area to be covered with aggregate. Subsequent passes of the bituminous spreader shall overlap the exposed PG Binder and the edge of the initial aggregate pass.

Uncovered PG binder shall not be exposed to traffic. All PG binder shall be covered with aggregate before opening to traffic.

The distributor shall be moving forward at proper application speed at the time the spray bar is opened. If any skipped areas or deficiencies occur, the operation shall be immediately stopped. The PG binder shall not be applied more than 200-feet in advance of the self-propelled aggregate spreader. The distributor, when not spreading, shall be parked so that the spray bar or mechanism will not drip PG binder on the surface of the roadway.

2. Application of Pre-Coated Cover Aggregate: Immediately following the application of the bituminous material, pre-coated cover aggregate shall be spread between 20 to 30lbs per square yard.

Temperatures of the pre-coated cover aggregate shall be between 175°F to 225°F. The Contractor shall document and report to the Engineer any field changes in application rates from the mix design submittal. Spreading shall be accomplished in such a manner that construction equipment or other vehicles shall not drive on the uncovered and newly applied PG binder. Any free PG binder on the surface caused by a deficient amount of pre-coated cover aggregate shall be covered by broadcasting additional aggregate over the deficient area.

Longitudinal joints shall be parallel to the centerline. Ensure that longitudinal joints will correspond with the edges of the proposed traffic lane. Where any construction joint occurs, the edges shall be broomed back and blended so there are no gaps and the elevations are the same, and free from ridges and depressions.

Initial rolling of pre-coated cover aggregate shall occur within 5 minutes after the application of bituminous material. Cover aggregate shall receive a minimum of three roller passes within 30 minutes of bituminous material application. Use Table 410-1 Number of Rollers to determine the minimum number of rollers required:

Table 410-1 Number of Rollers

Overlay width (feet) Number of Rollers (minimum)

≤ 6 1 > 6 ≤ 9 2

> 9 ≤ 12 3 > 12 4

3. Sweeping: Prior to opening the roadway to unguided traffic, sweep loose stone from the newly treated surface. Additional sweeping shall be performed as directed by the Engineer during a 5-day period following placement of the Chip Seal.

4. Opening to Traffic: After Chip Seal application, controlled traffic may be permitted at the Contractor’s option. Traffic shall be maintained at a speed not to exceed 15 mph for a period of 3 hours after placement of the Chip Seal by the use of pilot vehicles or an alternative method approved by the Engineer.

Traffic Advisory Signs - immediately after completion of the Chip Seal, the section shall be signed with black on orange W8-7 LOOSE STONE signs and black on orange 30 MPH W13-1P advisory speed plaques for a period of seven days. The warning sign and the advisory speed plaque shall be installed on the same post as specified in the MUTCD.

The signs shall be posted at ½ mile intervals. The first sign shall be posted in advance of the section in accordance with the MUTCD. The day and night visibility of the sign assemblies shall be enhanced by either 18-inch square orange flags for daytime visibility and low intensity Type A flashing warning lights for night visibility or high intensity Type B flashing warning lights for 24-hour visibility.

Use Table 410-2 Pilot Vehicles to determine the number of pilot vehicles required:

Table 410-2 Pilot Vehicles

Lane Miles Surfaced in Previous Three Hours Number of Pilot Vehicles

< 2 1 ≥ 2 2

5. Application of Fog Seal: Prior to applying Fog Seal, the surface shall be swept. Follow the requirements of Application of PG Binder. The Fog Seal application rate is 0.05 to

0.15 gallons per square yard.

6. Opening to Traffic After Fog Seal: The Contractor shall determine when traffic may be permitted on the treated Chip Seal. More time may be required for areas with limited exposure to sunlight.

410PG.3 METHOD OF MEASUREMENT

The quantity of Chip Seal to be measured for payment will be square yards of material in place, making no deductions for minor untreated areas such as catch basins and manholes.

The PG Binder for the Chip Seal will be measured by the number of 60°F gallons incorporated in the work.

The bituminous material for the Fog Seal will be measured by the number of 60°F gallons incorporated in the work.

The following formula will be used to calculate bituminous material quantity at 60°F:

Volume @ 60°F = VolumeD x [1 - (ΔT x 0.00025)]

Where: ΔT = Delivered Temperature (°F) – 60 VolumeD = Quantity Delivered (gallons) Cover Sand will be measured by the number of square yards of material in place, making no deductions for minor untreated areas such as catch basins and manholes.

410PG.4 BASIS OF PAYMENT

The unit price bid per square yard for Chip Seal shall include the cost of all labor, materials, and equipment necessary to perform the work.

PG binder used for Chip Seal will be paid for under a separate item as the number of 60°F gallons of material used.

Bituminous material for the Fog Seal will be paid for under a separate item as the number of 60°F gallons of material used.

The Engineer will evaluate any bituminous material failing QA testing to determine if it will be left in place. If the material is left in place, the bituminous material will be subject to a reduction in payment according to Table 410-3:

Table 410-3 Bituminous Material Pay Table

Number of Failing QA Test Results Pay Reduction of Bituminous Material Item

1 15 % 2 25 %

Payment will be made under:

Item No. Item Pay Unit

410.20100009 PG Binder Chip Seal (1ST) Square Yard

410.30100009 PG Binder Gallons

410.40100009 Fog Seal Gallons

410.60100009 Pick Up Broome or Vacuum Sweeper Each

410PG.5 BONDING REQUIREMENTS

A. Within 10 calendar days of receipt of a purchase order from the State, the Contractor shall provide the State agency the following:

1. Maintenance Material Bond: A bond in the form similar to the sample included in this Invitation for Bids with sufficient sureties approved by the State’s Resident Engineer guaranteeing replacement of deficient material in the form included in this Invitation for Bids. This bond shall remain in place for one year after final acceptance of the project by the State or until August 1 of the year following completion of the project, whichever is later.

2. Amount of Bond: The amount of the Maintenance Material Bond shall be 100% of the amount of the project’s cost.

3. Requirements of Bonds: All Bonds shall be issued by a surety company approved by NYSDOT and authorized to do business in the State of New York as a surety.

B. The procedure of the Maintenance Material Bond shall be as follows:

1. No later than June 1 of the year following the State’s acceptance of work completed under this contract, the State will evaluate the project for aggregate retention, flushing or bleeding, aggregate embedment, and bonding to the existing pavement.

2. The Contractor agrees to repair all areas that demonstrate less than 90% aggregate retention, as determined by the State, on the overall project caused by improper workmanship and/or defective materials. In addition, the Contractor agrees to repair individual areas that are flushed or bleeding, as determined by the State, caused by improper workmanship and/or defective materials irrespective of the percent of aggregate retained. Such repairs, however, shall not include any damage resulting from any forces or circumstances beyond the control of the Contractor. The evaluation of the Chip Seal (Conventional and Fiber Reinforced) shall be made by the State’s Resident Engineer. If the Contractor does not agree with the evaluation it may appeal to the State’s Regional Director of Operations whose decision shall be final.

Any resultant property damage deemed by the State’s Regional Director of Operations caused by improper workmanship and/or defective materials shall be the responsibility of the Contractor.

3. On or before June 10, in the year immediately following the State’s acceptance of the Chip Seal project, the State shall notify the Contractor of any areas deemed deficient by the State. The Contractor will initiate and complete the remediation within 30 days of notification.

4. Prior to the performance of repairs in the field, the Contractor shall supply the State’s Resident Engineer with copies of applicable insurance certificates. During the performance of any necessary repairs, the Contractor shall comply with all provisions of the original contract including among other things the Work Zone Traffic Control provisions.

S A M P L E

MAINTENANCE BOND

KNOW ALL PEOPLE BY THESE PRESENTS, That we, (hereinafter called the “PRINCIPAL”) of

, and of

(hereinafter called the “SURETY”) are held and firmly bound unto the people of the State of New York in the full and just sum of Dollars

($ ) good and lawful money of the United States of America, to the payment of which said sum of money, well and truly to be made and done the said PRINCIPAL binds itself, its heirs, executors, administrators or assignees and the SURETY binds itself, its successors or assigns, jointly and severally, firmly by these presents.

Signed and dated this day of , 20 .

WHEREAS, the PRINCIPAL has entered into a certain written contract bearing date on the day of , 20 , with the People of the State of New York for the improvement of , in the County of , New York.

NOW THEREFORE, the PRINCIPAL warrants the workmanship and all materials used in the work and agrees that during the guarantee period of one year beginning after final acceptance by the State or political subdivision or until August 1 of the year following acceptance of work completed under the contract, whichever is later, it will, at its own expense make repairs which may become necessary by reason of improper workmanship or defective materials as per the following procedure:

7. No later than June 1 of the year following the State’s or the political subdivision’s acceptance of work completed under the contract, the State or political subdivision will evaluate the project for aggregate retention, flushing or bleeding, aggregate embedment, and bonding to the existing pavement.

8. The PRINCIPAL agrees to repair all areas that demonstrate less than 90% aggregate retention, as determined by the State, on the overall project caused by improper workmanship and/or defective materials. In addition, the PRINCIPAL agrees to repair individual areas that are flushed or bleeding, as determined by the State, caused by improper workmanship and/or defective materials irrespective of the percent of aggregate retained. Such repairs, however, shall not include any damage resulting from any forces or circumstances beyond the control of the PRINCIPAL. The evaluation of the Chip Seal (Conventional and Fiber Reinforced) shall be made by the State’s Resident Engineer. If the Contractor does not agree with the evaluation it may appeal to the State’s Regional Director of Operations whose decision shall be final.

9. On or before June 10, in the year immediately following the State’s acceptance of the Chip Seal project, the State shall notify the PRINCIPAL of any areas deemed deficient by the State. The PRINCIPAL will initiate and complete the remediation within 30 days of notification.

In the event of the failure of performance by the PRINCIPAL who has failed to make repairs which may become necessary by reason of improper workmanship or defective materials, said SURETY, for value received, hereby stipulates and agrees, if requested to do so by the State, to commence such repairs within five (5) days of notification by the State of such failure by the PRINCIPAL. Such repairs shall be performed in accordance with the provisions of the current contract which require among other provisions that the SURETY shall provide necessary Work Zone Traffic Control as well as provide the required insurance before any work is conducted.

In the event both the SURETY and the PRINCIPAL fail to perform such repairs, the State shall cause the repair to be completed by others and the SURETY and PRINCIPAL shall be jointly and severally liable for such costs.

And the said SURETY thereby stipulates and agrees that no change, extension, alteration, deduction, or addition in or to the terms of the said contract or the plans or specifications accompanying same, shall in any way affect the obligations of said SURETY of its bond.

PRINCIPAL

BY SURETY

BY

DETAILED SPECIFICATIONS – COLD RECYCLING

SECTION 416 – COLD RECYCLING

416.1 DESCRIPTION

This work shall consist of Cold Recycling (CR) asphalt pavement by either In-Place or Central Plant methods.

416.1.01 Cold In-Place Recycling (CIPR): Work for CIPR shall consist of sampling, mix design formulation, materials management plan, milling, recycling, paving, and compacting recycled asphalt pavement in accordance with the contract documents.

416.1.02 Cold Central Plant Recycling (CCPR): Work for CCPR shall consist of sampling, mix design formulation, materials management plan, recycling, hauling, paving, and compacting recycled asphalt pavement in accordance with the contract documents.

416.2 MATERIALS

416.2.01 General: All materials shall comply with the requirements of the following subsections of Section 700 Materials and Manufacturing, or as established by this section, and the contract documents.

Water 712-01 Portland Cement (Type I, II, or IL) 701-01 Coarse Aggregate (Crushed Bedrock) 703-02

416.2.02 Bituminous Materials: Materials shall comply with the requirements of §702.

A. Performance-Graded (PG) Binder: Material shall comply with material designation 702- 64S22. Other grades of performance-graded binder may be used with the approval of the Materials Bureau Director.

B. Asphalt Emulsion: Material shall comply with materials designation 702-3301 or 702- 4501.

C. Polymer-Modified Asphalt Emulsion: Material shall comply with materials designation 702-3301R or 702-4501R. Other grades of asphalt emulsion having a certified minimum of 65% asphalt residue may be used with the approval of the Materials Bureau Director.

D. Fog Seal: Material shall comply with Diluted Tack Coat.

416.2.03 Reclaimed Asphalt Pavement (RAP): Existing Stockpiles of RAP material to be used for CCPR shall be sourced from a NYSDOT highway. The Contractor shall provide RAP source documentation to the Engineer. RAP material not sourced from a NYSDOT highway, requires prior approval by the Department and will be subject to physical requirement testing.

416.3 CONSTRUCTION DETAILS.

416.3.01 Temperature & Seasonal Limitations: Work is not permitted when the air or surface temperature is below 45°F or is expected to drop below 40°F within 24 hours. Perform all work between May 1 and October 7.

416.3.02 Mix Design (MD): Formulate a MD in accordance with Materials Method 416-1. Submit the mix design to the Engineer, Regional Materials Engineer, and Materials Bureau Director at least 7 days prior to the pre-recycling meeting. Materials Bureau Director shall be emailed at DOT.sm.Pavement.Preservation.Friction@dot.ny.gov.

mailto:DOT.sm.Pavement.Preservation.Friction@dot.ny.gov

DETAILED SPECIFICATIONS – COLD RECYCLING (Cont'd)

416.3.03 Materials Management Plan (MMP): Complete a MMP in accordance with Materials Method 416-1. Submit to the Engineer, Regional Materials Engineer, and Materials Bureau Director at least 7 days prior to the pre-recycling meeting. Materials Bureau Director shall be emailed at DOT.sm.Pavement.Preservation.Friction@dot.ny.gov.

416.3.04 Pre-Recycling Meeting: The Engineer will conduct a pre-recycling meeting at least one week in advance of CR operations. At a minimum, attendance at this meeting will include the Engineer, Regional Materials Engineer, and the Recycling Contractor Paving Foreman. The Contractor and Department will discuss the requirements necessary to complete the work.

The Engineer should arrange for written minutes to be taken for the record and then distribute them appropriately. The attendees at the meeting are responsible for relaying the information covered and agreed upon to the paving crew and inspectors.

416.3.05 Equipment

A. Pilot Vehicle: Pilot vehicle shall be equipped with a two-way radio, construction sign meeting the requirements of Section 6F.58 of the MUTCD, an amber beacon, and have the name of the Contractor prominently displayed.

B. Milling Machine: Shall comply with §490-2.01.

C. Recyclers:

1. CIPR: Place millings, bituminous material, water, and recycling additives as a homogeneous mixture into a paver or windrow.

a. Recycler. Shall be capable of:

• Processing the reclaimed material to pass a 2-inch sieve.

• Measuring water usage with a totalizing water meter.

• Measuring bituminous material usage with a mass flow meter.

• Mixing the reclaimed material with water, bituminous material, and additives.

b. Miller/Recycler. Shall be capable of:

• Milling machine to comply with §490-2.01.

• Processing the reclaimed material to pass a 2-inch sieve.

• Measuring water usage with a totalizing water meter.

• Measuring bituminous material usage with a mass flow meter.

• Mixing the reclaimed material with water, bituminous material, and additives.

2. CCPR: Recycler shall be capable:

• Processing the reclaimed material to pass a 2-inch sieve.

• Weighing RAP, stone, and cement.

• Measure water usage with a totalizing water meter.

• Measuring bituminous material usage with a positive displacement meter - a mass flow meter will be required after 1 May 2024.

• Mixing the reclaimed material with water, bituminous material, and additives.

Meter calibration and validation shall be done annually prior to the start of the CR season, in accordance with Materials Procedure 417-01. Subsequent verifications shall be in accordance with manufacturer’s recommendations. At least 7 days prior to the start of season submit the validation results to the Director of Materials Bureau at DOT.sm.Pavement.Preservation.Friction@dot.ny.gov.

Scale checks for CCPR equipment shall comply with NYSDOT Materials Procedure 401, Section II.C.3.

D. Hauling Equipment: CCPR only, shall comply with §404.3.03.

E. Paver: Shall comply with §404.3.02.

F. Rollers: Shall comply with §404-3.04.

G. Power Broom: Capable of removing loose material from the recycled pavement surface.

H. Fog Seal: Distributor shall comply with §407-3.01.

416.3.06 Pilot Vehicle: Maintain traffic using a pilot vehicle to escort traffic through the work zone at a maximum speed of 20 mph.

416.3.07 Milling: Mill surfaces to comply with §490. Maintain existing grade and cross slope of the roadway, unless otherwise noted. CIPR milled surfaces will be repaved with recycled material the same day milling is performed.

416.3.08 Corrective Aggregate: Shall comply with §623. The maximum amount of aggregate to be added shall be 20% by weight of RAP. Do not adjust aggregate rates from mix design without the Regional Materials Engineer’s approval.

A. CIPR - Spread the aggregate in a uniform layer, at least 6-feet in width across the pavement, centered in front of the recycling equipment.

B. CCPR - Aggregate shall be added to pugmill via hopper or belt scale.

416.3.09 Cement: The maximum amount of cement to be added shall be 1% by weight of RAP.

A. CIPR - Dry Portland cement shall be metered and spread in a uniform manner, at least 8-feet in width across the pavement, centered in front of the recycling equipment.

Other methods of delivering cement to the recycled mixture require prior approval from the Director of the Materials Bureau.

Meter calibration and validation shall be done before start of work per the manufacturer’s written recommendations.

B. CCPR - Portland cement may be added dry or as a slurry.

Dry cement delivery shall meet the requirements of §501-2.03.B – E and §501-2.03.G Slurry meter calibration and validation shall be done before start of work per the manufacturer’s written recommendations.

416.3.10 Recycling: Maintain bituminous material and water rates to within 10% of the design rates.

Make field changes in 0.05% to 0.2% increments. Changes exceeding 10% of the design rates require Regional Materials Engineer’s approval. Meet minimum water rates in Table 416-1.

Table 416-1 – MINIMUM WATER RATE

Minimum Water Application Rates Gallons / Square Yard Recycled

Depth of Recycle Emulsion PG Binder

3-inch 0.36 0.72 4-inch 0.48 0.96

Recycling operations shall progress in the opposite direction of traffic. Change in direction shall have prior approval from the Engineer.

Maximum forward speed of 30-feet per minute.

A. Sampling and Testing.

1. Performance-Grade Binder: Shall be sampled first day and with any change in lot number. The Contractor shall perform an expansion/half-life test a minimum of once per day and with any change in lot number.

2. Asphalt Emulsion and Polymer-Modified Asphalt Emulsion: Shall be sampled first day and with any change in lot number. Samples shall be taken according to MM 702-2, Asphalt Emulsion Quality Assurance.

416.3.11 Paving: Use a paver to reestablish grade and cross slope of original surfaces unless otherwise noted. Construct recycled surface to a 3/8-inch tolerance in 15-feet parallel to centerline, and 10-feet perpendicular to centerline.

Tolerance requirements apply from the time of placement until the recycled material is overlaid, not to exceed 30 days.

416.3.12 Quality Control Testing: Once continuous production has been achieved, take a minimum of two samples from that day’s production of recycled mixture at two different locations. Test each sample for gradation and total asphalt content. Submit the test results to the Engineer, Regional Materials Engineer, and Materials Bureau Director before the end of the next workday.

For each subsequent day of production, take a minimum of one sample from that day’s production of recycled mixture from each lane mile of pavement recycled. Test each sample for gradation and total asphalt content. Submit the test results to the Engineer, Regional Materials Engineer, and Materials Bureau Director within two workdays.

If a second recycling train is brought to the project, take samples following the frequencies detailed above, including taking two samples on the first day of use.

Perform additional quality control tests as described in Materials Method 416-1.

Materials Bureau Director shall be emailed at DOT.sm.Pavement.Preservation.Friction@dot.ny.gov.

416.3.13 Compaction: Compact the mixture in accordance with §404-3.07 C., 70 Series Compaction Method and Table 416-2 – Rolling Requirements, with the following exception. Reestablish a new Project Target Density (PTD) when two consecutive density readings are less than 96%, or greater than 110% of the previous PTD.

A. Requirements: One roller shall be used on each compaction sequence for a minimum of three rollers on the project.

1 Either the initial or intermediate passes will use a pneumatic roller.

2 Either the initial or intermediate passes will use a vibratory compaction.

TABLE 416-2 – ROLLING REQUIREMENTS

Compaction Sequence Roller Type Compaction Type Minimum # of Passes

Initial Steel or Pneumatic1 Vibratory or Static2 2 Intermediate Steel or Pneumatic1 Vibratory or Static2 2

Finish Steel Static 2

Complete all turning of the compaction equipment on material which has had a minimum of one roller pass.

Remove material that cannot be properly and adequately compacted to a stable condition.

B. Reporting: The rolling pattern to achieve the PTD shall be noted on the back of the BR 340R form. At the end of each production day, the Contractor shall provide the Engineer with a copy of the BR 340R - In-Place Pavement Density Data Sheet # 1 and BR 341R - In-Place Pavement Density Data - Continuation Sheet form(s) relating to that day's work.

Changes to the roller pattern requires approval of the Engineer.

416.3.14 Longitudinal Joints

A. CIPR - Construct a longitudinal joint at the centerline. Construct other longitudinal joints at the edge of lane whenever possible. Subsequent CIPR passes will reclaim a minimum of 6-inches of the adjacent compacted recycled mat.

B. CCPR - Construct longitudinal joints at the edge of the lane whenever possible. If any length of the recycled materials longitudinal joint is exposed at the end of the working day, construct a wedge of recycled material at a slope of 1 on 8 or flatter to meet the existing pavement elevation. Do not overlap recycled material onto the existing pavement.

416.3.15 Transverse Joints CCPR: At the end of each production day, construct a transverse joint wedge of recycled material at a slope of 1 on 15 or flatter to meet the existing pavement elevation. Prior to commencing additional work, cut this wedge of material back to expose full depth of the paving course.

416.3.16 Temporary Pavement Markings: Apply temporary pavement markings meeting the requirements of Section 619 at the centerline and edge line of the recycled material before the end of each workday. Maintain temporary markings until the recycled material is overlaid, not to exceed 30 days.

416.3.17 Brooming: Broom the pavement and shoulders to remove loose stone or reclaimed material.

Brooming requirements apply from the time of placement until the recycled material is overlaid, not to exceed 30 days.

416.3.18 Fog Seal: Application of Fog Seal requires the Engineer’s daily approval. The maximum rate of application is 0.1 gallons/square yard.

Provide a Work Zone Traffic Control Plan for the Fog Seal operation and submit to the Engineer for approval. No traffic will be allowed on a Fog Seal surface until it has properly set. Stopped traffic will not be allowed on a Fog Sealed surface for a minimum of 1 hour after application.

A. Sampling: Shall be sampled according to MM 702-2, Asphalt Emulsion - Quality Assurance.

416.3.19 Damaged or Deficient Areas: Repair all areas that ravel, is loose or broken, or is not uniform. Correct any area showing an excess or deficiency of bituminous material. Correct all areas not meeting the requirements of the surface tolerance. The repair method will be approved by the Engineer.

All repairs of damaged areas will be completed at no additional cost to the State.

416.3.20 Cure Times: Recycled mixtures cannot be overlaid until the minimum cure times in Table 416-4 have been met.

TABLE 416-4 – CURE TIME

Bituminous Material Used Cure Period

PG Binder 3 Day Asphalt Emulsion 10 Days

416.4 METHOD OF MEASUREMENT.

416.4.01 Cold In-Place Recycling: This work will be measured as the number of square yards of recycled pavement surface.

416.4.02 Cold Central Plant Recycling: This work will be measured as the number of square yards of recycled pavement surface.

416.4.03 Fog Seal: Material will be measured by the number of gallons at 60°F incorporated in the work. The following formula will be used to calculate 60°F gallons:

Volume60°F = VolumeD x [1 – (ΔT x 0.00025)] Where:

ΔT = Delivered Temperature (°F) – 60 VolumeD = Quantity Delivered (gallons)

416.4.04 Performance-Grade Binder, Asphalt Emulsion, and Polymer-Modified Asphalt Emulsion: Material will be measured by the number of gallons at 60°F incorporated in the work. The following formula will be used to calculate gallons:

VolumeD = (MassD / 8.34 ppg) X Liquid Bituminous Material Specific Gravity at 600F Where:

MassD = Quantity Delivered measured by Mass Flow Meter (pounds) VolumeD = Quantity Delivered (gallons)

416.4.05 Portland Cement: Material will be measured by the number of tons incorporated into the work.

416.5 BASIS OF PAYMENT

416.5.01 Cold In-Place Recycling: The square yard price bid for CIPR asphalt concrete shall include the cost of all labor, materials, and equipment necessary to satisfactorily complete the work.

416.5.02 Cold Central Plant Recycling: The square yard price bid for CCPR asphalt concrete will include the cost of all labor, materials, and equipment necessary to perform the work.

416.5.03 Performance-Graded Binder, Asphalt Emulsion, or Polymer-Modified Asphalt Emulsion: The gallon at 60°F price bid for performance-grade binder or asphalt emulsions will include the cost of all labor, materials, and equipment necessary to perform the work.

416.5.04 Portland Cement: The ton price bid for dry Portland cement will include the cost of all labor, materials, and equipment necessary to perform the work.

416.5.05 Fog Seal: The gallon at 60°F price bid for Fog Seal will include the cost of all labor, materials, and equipment necessary to perform the work.

Payment will be made under:

Item No. Item Pay Unit

416.01 Cold In-Place Recycling Asphalt Pavement Square Yard

416.02 Cold Central Plant Recycling Asphalt Pavement Square Yard

416.20 Asphalt Emulsion for Recycling Gallon

416.21 Polymer Modified Asphalt Emulsion for Recycling Gallon

416.22 Performance Graded Binder for Recycling Gallon

416.30 Fog Seal Gallon

416.40 Portland Cement Ton

DETAILED SPECIFICATIONS – HEATER SCARIFICATION

SECTION 417 – HEATER SCARIFICATION

417.1 DESCRIPTION

This work shall consist of recycling an existing asphalt pavement surface in a continuous multi-step process of heating the asphalt pavement layer; scarifying into a loose mix; blending the mix with an asphalt recycling agent; spreading, leveling, then compacting the rejuvenated asphalt mixture.

417.2 MATERIALS

417.2.01 Recycling Agent

The recycling agent shall be specifically designed as a rejuvenator meeting the requirements outlined in Section 702 – Bituminous Materials, 8. Asphalt Recycling Agent, Table 702-9 Recycling Agent, or Table 702-10 Emulsified Recycling Agent. The use of any other grade of recycling agent or other product requires prior approval from the Director, Materials Bureau.

Requests for this approval shall be submitted to the Department at least 3 weeks prior to the pre-recycling meeting.

417.2.02 Mixture Design

The application rate of the asphalt recycling agent shall be determined by analyzing a minimum of three cores per lane mile or a maximum of 20 cores per project from the existing asphalt pavement. These cores shall come from locations that represent the entire project condition.

The design application rate of the recycling agent shall provide an average penetration value of at least 30% or more of the average penetration value of the recovered asphalt binder from the existing pavement cores. The final penetration value shall not exceed 90. All penetration testing shall be performed in accordance with AASHTO T 49, Penetration of Bituminous Materials.

The mix design shall be submitted to the Engineer, Regional Materials Engineer, and Materials Bureau Director at least 7 days prior to the pre-recycling meeting. Submissions to the Materials Bureau Director shall be emailed to DOT.sm.Pavement.Preservation.Friction@dot.ny.gov.

417.3 CONSTRUCTION DETAILS

417.3.01 Equipment

A. Preheating or Heating Unit

This unit shall generate sufficient radiant heat, with no open flame exposed to the pavement surface, to soften the asphalt pavement to the depth specified in the contract documents. The burner assembly shall be adjustable up to 14-feet wide. The entire heating unit shall be enclosed and vented to contain the heat and prevent damage to adjacent properties and landscape.

B. Heater Scarification Unit

The scarification unit shall be a self-contained, self-propelled machine capable of operating at speeds of between 8 and 26-feet per minute while uniformly heating and scarifying the existing asphalt pavement to the minimum loose mix depth specified in the contract documents. The unit shall spray the loose mix with the required recycling agent;

thoroughly blend the recycling agent and the loose mix asphalt into a homogenous mixture, and uniformly redistribute the resultant rejuvenated asphalt mixture onto the mat.

DETAILED SPECIFICATIONS – HEATER SCARIFICATION (Cont'd)

1. Scarifier

The scarifying unit shall contain at least 2 rows of spring-loaded tines that are adjustable to scarify up to 14-feet wide.