GROUP 31555 – Liquid Bituminous Materials Page 1 of 57 (2026 VPP NYSDOT Specific Projects) (Federal & State Funds)

23434_Detailed Specifications – Liquid Bituminous Materials

DETAILED SPECIFICATIONS

LIQUID BITUMINOUS MATERIALS

AWARD# 23434

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23434_Detailed Specifications – Liquid Bituminous Materials

Contents

SECTION 1: CHIP SEAL – DETAILED SPECIFICATIONS

SECTION 2: COLD RECYCLING – DETAILED SPECIFICATIONS

SECTION 3: HEATER SCARIFICATION – DETAILED SPECIFICATIONS

SECTION 4: JOINT & CRACK FILLER/SEALER – DETAILED SPECIFICATIONS

SECTION 5: MASTIC JOINT & CRACK FILLER – DETAILED SPECIFICATIONS

SECTION 6: MICRO-SURFACING – DETAILED SPECIFICATIONS

SECTION 7: PAVER PLACED SURFACE TREATMENT - CONVENTIONAL – DETAILED

SPECIFICATIONS

SECTION 8: PAVER PLACED SURFACE TREATMENT - MODIFIED – DETAILED SPECIFICATIONS

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 1: CHIP SEAL – DETAILED SPECIFICATIONS

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

410.10 Chip Seal (1A) Square Yard

410.20 Chip Seal (1ST) Square Yard

410.30 Bituminous Material (Chip Seal) Gallons

410.40 Bituminous Material (Fog Seal) Gallons

410.50 Cover Sand Square Yard

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.

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 1: CHIP SEAL – DETAILED SPECIFICATIONS (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.

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 1: CHIP SEAL – DETAILED SPECIFICATIONS (Cont’d)

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.

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 1: CHIP SEAL – DETAILED SPECIFICATIONS (Cont’d)

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

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 2: COLD RECYCLING – DETAILED SPECIFICATIONS

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.

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 2: COLD RECYCLING – DETAILED SPECIFICATIONS (Cont’d)

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

MD 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.

416.3.03 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.

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

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 2: COLD RECYCLING – DETAILED SPECIFICATIONS (Cont’d)

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.D.4.

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.

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 2: COLD RECYCLING – DETAILED SPECIFICATIONS (Cont’d)

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.

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.

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

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 2: COLD RECYCLING – DETAILED SPECIFICATIONS (Cont’d)

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 MP 404-10 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.

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 2: COLD RECYCLING – DETAILED SPECIFICATIONS (Cont’d)

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.

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.

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

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 2: COLD RECYCLING – DETAILED SPECIFICATIONS (Cont’d)

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.

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

416-3 have been met.

TABLE 416-3 – CURE TIME

Bituminous Material Used Cure Period

PG Binder 3 Day

Asphalt Emulsion 10 Days

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 2: COLD RECYCLING – DETAILED SPECIFICATIONS (Cont’d)

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.

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SECTION 2: COLD RECYCLING – DETAILED SPECIFICATIONS (Cont’d)

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

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SECTION 3: HEATER SCARIFICATION – DETAILED SPECIFICATIONS

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.

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SECTION 2: HEATER SCARIFICATION – DETAILED SPECIFICATIONS (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. The tines shall be arranged such that the lateral spacing between tines on immediately adjacent rows does not exceed 1-inch.

The unit shall be capable of conforming to the pavement contours to ensure a uniform penetration from the tines and prevent damage to utility structures.

2. Sprayer

This unit shall be immediately behind the scarifying unit and capable of uniformly applying the recycling agent to the scarified asphalt pavement at the approved rate.

The size of the nozzles located on the spray bar and pump shall be selected based upon the rate of application and the forward speed of the Heater Scarification unit.

This unit shall be equipped with a mass flow meter and measuring system which is capable of maintaining the required application rate of the recycling agent within a tolerance of ± 5% of the mix design. The measuring system shall continuously verify and display the application rate of recycling agent and cumulative total with respect to the volume of scarified material.

3. Mixer/Miller

Immediately following the application of the recycling agent, an enclosed unit shall mill the asphalt pavement to the loose mix depth specified in the contract documents and thoroughly mix the recycling agent with the scarified and milled pavement. If a loose mix depth is not specified, the loose mix depth shall be 1.5-inches. The unit shall be located between the spray unit and the screed. This unit shall be operated hydraulically, be capable to maintain depth control, and capable of working at variable speeds up to 120 revolutions per minute. The unit shall be adjustable up to 14-feet wide.

4. Screed

The screed shall be an attached heated, augured vibratory screed capable of uniformly distributing the rejuvenated asphalt to the desired longitudinal and transverse section.

The screed shall be adjustable up to 14-feet wide, equipped with an adjustable crown control and each end of the screed shall have hand wheel adjusting screws for providing the desired longitudinal grade and transverse slope.

C. Rollers

Rollers shall be in good mechanical condition, capable of reversing without backlash and operated at speeds slow enough to avoid displacement of the newly placed mixture. The weight of the rollers shall be sufficient to compact the mixture without crushing aggregate.

Rollers shall be equipped with tanks and spray bars for wetting the drums or tires.

D. Safety Requirements

Each unit shall have an integrated water spray system and water misters to pre-wet vegetation and provide heat control. Hand hoses with adjustable nozzles shall be placed on each unit to allow for pre-wetting specific plants or objects. Each unit shall have integrated water tanks having a minimum 500-gallon capacity. The operation of these systems shall be demonstrated to the Engineer to be fully functional prior to the commencement of work and shall be refilled as required during daily production.

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 2: HEATER SCARIFICATION – DETAILED SPECIFICATIONS (Cont’d)

All propane tanks on recycling equipment units shall conform to Federal, State, and local regulations and laws relative to the transportation of Liquid Propane Gas. Tanks are to be inspected and certified by a Federal and DOT registered inspection and repair facility.

Certification compliance stickers shall be prominently displayed on recycling units. Each propane tank on the recycling units shall have a ground fill system and meter to ensure safety of personnel during propane fill operations.

Recycling units shall be equipped with a wireless remote safety shut down system. This allows the operators to immediately shut down propane flow, hydraulic power units, and activate brakes on the recycling units. Each recycling unit operator shall carry a wireless remote-control device. The wireless remote system shall meet all FCC requirements and have proper documentation.

417.3.02 Calibration

Calibrate the metering system in accordance with NYSDOT’s Materials Procedure (MP) 417- 01 - Calibration of Metering System for Recycling Equipment. A minimum 2-week notice is required when scheduling this calibration. Perform the calibration of the metering system in the presence of the Regional Materials Engineer or designee. Work shall not progress until the calibration has been completed and verified. Approved calibrations are valid for 90 days and may be used for more than one project.

If equipped with a mass flow meter capable of self-calibration, the system calibration can be submitted in lieu of the above method. The self-calibrating meter shall be a continuous flow system that verifies and validates the application rate on-demand and at any time during production. The measuring system shall continuously verify and display the application rate of recycling agent and cumulative total with respect to volume of recycled material for the recycled surface.

Calibration of the self-calibration system shall be performed prior to the start of a project in the presence of the Regional Materials Engineer or designee.

417.3.03 Weather Limitations

Heater Scarification shall be performed only when the existing pavement surface temperature is 45˚F or above.

417.3.04 Surface Preparation

A. Pavement Markings

Remove epoxy or thermoplastic pavement markings, and other markings in accordance with §635-3.01 and 3.04.

B. Cleaning

Clean the existing pavement and shoulder to be Heater Scarified by using mechanical sweepers, or other effective means until the surface is free of all debris material, which might interfere with the scarification process.

C. Mastic Repair Material

All mastic patches greater than 5 square feet shall be removed. Other mastic patches shall be removed at the discretion of the Engineer.

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 2: HEATER SCARIFICATION – DETAILED SPECIFICATIONS (Cont’d)

417.3.05 Recycling and Placement

Asphalt pavement to be recycled shall be heated in a manner such that the underlying asphalt layers not to be recycled, are not disturbed or overheated. When operating the heating unit(s), care shall be taken not to damage adjacent property and vegetation. All adjacent property and vegetation that becomes heat-damaged shall be repaired immediately, at no additional cost to the State.

The Heater Scarification equipment shall maintain the temperature of the scarified material, 5-feet beyond the screed, between 275˚F and 325˚F during recycling.

The speed of the equipment shall be controlled to ensure that the recycled pavement is properly milled, mixed, and uniformly distributed to the proper thickness, slope, and crown shown on the contract plans. Material placed shall be consistent and free from segregation.

The width of each pass shall be set to provide proper placement of longitudinal joints, including a 3-inch overlap onto adjacent lane passes.

The final recycled pavement shall conform to the requirements of §404-3.10, Surface Tolerance and §404-3.11, Thickness Tolerance. The depth of the loose scarified mix behind the screed unit shall be measured prior to the rolling operation. Adjust the paving equipment if the loose mix depth does not provide the compacted depth specified in the contract documents.

In areas not accessible to scarifying equipment, such as around catch basins or manholes, the Engineer shall determine any required repairs. Repair all designated areas, as approved by the Engineer, at no additional cost to the State.

417.3.06 Compaction

The recycled mixture shall be compacted in accordance with 404-3.07, D., 80 Series Compaction Method.

417.3.07 Quality Control and Quality Assurance

At the start of and during production, provide the AECTA and documented quantities to the Engineer for each shipment of recycling agent. Samples for every shipment shall be taken in accordance with NYSDOT Materials Method 702-2 Asphalt Emulsion – Quality Assurance.

A. First day

Prior to the start of work, the Engineer shall select two coring locations within one lane mile of each other. The Contractor shall extract two cores from each location. The Contractor shall extract asphalt binder from the surface layer of one core at each location and test it for penetration. The second core at each location shall be provided to the Engineer for companion testing by the Department. All required core and loose mix samples shall be taken at least 500 feet beyond the day’s production start location.

If approved by the Engineer, the Contractor may sample dry loose mix of the scarified pavement, prior to rejuvenation, in the locations indicated by the Engineer in lieu of coring. The same testing requirements as noted above apply to dry loose samples.

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 2: HEATER SCARIFICATION – DETAILED SPECIFICATIONS (Cont’d)

If approved by the Engineer, the Contractor shall take two dry loose mix samples of the scarified pavement, prior to rejuvenation, at the two core locations or as determined by the Engineer. One dry loose sample from each location shall be retained by the Contractor and one dry loose sample shall be provided to the Engineer to be tested or retained by the Department.

At each location where the two dry loose samples are taken, four rejuvenated loose samples shall be taken either behind the screed or in any place after the spraying and mixing units. These samples shall represent the day’s production. All samples shall be identified by their locations at the project site. Two of the rejuvenated loose mix samples from each location shall be tested for penetration by the Contractor. The remaining rejuvenated loose mix companion samples shall be provided to the Engineer.

Penetration test results shall be submitted to the Engineer by the end of the next day’s production. If test results are not provided, the Engineer may shut down the scarification process until the results are submitted. Penetration of the PG binder recovered from the recycled mixture shall be determined in accordance with AASHTO T 49. The average penetration value of the rejuvenated loose mix samples shall be a minimum of 30% or more of the penetration value of the samples taken from the existing pavement cores. The Contractor shall test the dry loose mix samples for penetration when requested by the Engineer.

Failing penetration results from the rejuvenated loose mix samples shall be addressed as follows: A new application rate shall be determined and submitted to the Engineer for approval. The sampling and testing procedure in this section shall be repeated. New penetration test results shall be submitted to the Engineer by end of the next day’s production. This process shall be repeated until the average penetration value of the rejuvenated loose mix is 30% or more of the penetration value of the core samples from existing pavement.

B. Routine Day

The sampling and testing procedures in section 417-3.07 A shall be repeated every third day of production.

The average penetration value of the rejuvenated loose mix shall not exceed 90. Any pavement sections where average penetration of samples from rejuvenated mix exceeds 90 shall be subject to evaluation by the Engineer. Additional testing as ordered by the Engineer in this evaluation shall be completed by the Contractor at no additional cost to the State.

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 2: HEATER SCARIFICATION – DETAILED SPECIFICATIONS (Cont’d)

417.4 METHOD OF MEASURMENT

417.4.01 Heater Scarification (HS)

This work shall be measured as the number of square yards of pavement surface recycled as detailed in this specification.

417.4.02 Recycling Agent

This material will be measured by the number of pounds incorporated in the work.

417.5 BASIS OF PAYMENT

417.5.01 Heater Scarification (HS)

The unit price bid per square yard for this item shall include the cost of all labor, materials, and equipment necessary to satisfactorily complete the work, including heating, scarifying, mixing, paving, compacting, coring, and testing of the recycled materials. No deduction will be made in areas such as catch basins or manholes where the scarifying equipment cannot be used.

417.5.02 Recycling Agent

The unit price bid per gallon of recycling agent shall include the cost of all labor, materials, and equipment necessary to complete the work satisfactorily. The Regional Materials Engineer will evaluate the material represented by any failing sample of recycling agent.

Payment will be made under:

Item No. Item Unit

417.01 Heater Scarification Square Yards

417.0101 Recycling Agent Pounds

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 4: JOINT & CRACK FILLER/SEALER – DETAILED SPECIFICATIONS

SECTION 412 – CLEANING AND SEALING CRACKS AND JOINTS USING HOT APPLIED

SEALANT IN ASPHALT PAVEMENT (LANE MILES)

412.1 DESCRIPTION

Clean and seal cracks 1/8” to 1” wide. Clean and seal in locations shown in the contract documents or where directed by the Engineer along the entire length of the crack or joint.

412.2 MATERIAL REQUIREMENTS

Use a sealant meeting the requirements of Section 705-02, Highway Joint Sealants, and ASTM D6690 Type II. Deliver the sealant in the manufacturer's original sealed containers legibly marked with the following information:

Manufacturer’s name.

Trade name of sealant.

Manufacturer’s batch or lot number.

Sealer only: ASTM D6690, Type II.

Minimum application temperature.

Maximum (or Safe) heating temperature.

Provide the Engineer with a copy of the manufacturer's recommendations pertaining to heating and application of the sealant as well as the material MSDS, prior to commencing work.

412.3 CONSTRUCTION DETAILS

412.3.01 General

Furnish all equipment that is necessary for cleaning and sealing the pavement cracks and joints.

Use equipment meeting the description and/or performance requirements described herein and approved by the Engineer.

Do not burn, scorch, or ignite the adjoining pavement when using a hot air lance. Protect the public from potentially objectionable and/or hazardous airborne debris.

Replace pavement markings, in kind, that become covered and/ or obliterated more than 25% of their width with sealant. Replace with the appropriate items in accordance with §640 Reflectorized Pavement Markings at no additional cost to the State.

412.3.02 Crack and Joint Preparation

Prepare cracks and joints for sealing on the same day that they are to be sealed or filled.

The following cracks should not be sealed:

Multiple nearby cracks which have raveled.

Multiple cracks that include broken asphalt.

Multiple longitudinal cracks in the wheel path within a 10-foot segment, which are separated by less than 10-inches.

Install suitable traps or devices on the compressed air equipment to prevent moisture and oil from contaminating the crack and joint surfaces. Maintain these devices and see that they are functioning properly.

Use a high-pressure air lance or hot air lance to thoroughly clean and dry primary cracks and joints of dust, dirt, foreign material, sand, and any other extraneous materials immediately prior to sealing or filling cracks and joints.

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 4: JOINT & CRACK FILLER/SEALER – DETAILED SPECIFICATIONS (Cont’d)

412.3.03 Sealant Melting

Heat and melt the sealant in a kettle constructed as a double boiler filled with a heat-transfer medium between the inner and outer shells. The kettle will be equipped with separate thermometers to indicate the temperature of the heat transfer medium and the sealant material, positive temperature controls and with a mechanical agitator. Maintain the sealant at the pouring temperature ± 10ºF indicated on the material packaging.

Check the discharge temperature of the sealant with a non-contact infrared thermometer. Discharge the sealant at a temperature between the manufacturer's recommended pouring and safe heating temperatures indicated on the material packaging. Submit an alternate method for measuring the discharge temperature to the Engineer for approval if desired.

Sealing is not permitted if the kettle and discharge temperatures do not meet with the requirements described above.

Equip the discharge hose with a thermostatically controlled heating apparatus or insulate it to maintain the proper sealant pouring temperature. Holster the discharge hose to the kettle if it is not thermostatically heat controlled. Circulate the sealant from the discharge hose and the kettle to maintain the proper sealant pouring temperature.

Do not use sealant material heated beyond the safe heating temperature.

If the manufacturer's recommendations allow the sealant to be reheated or heated in excess of six hours, recharge the kettle with fresh material amounting to at least 20 percent of the volume of the material remaining in the kettle.

Apply material to clean, dry surfaces and only when the ambient air and pavement temperature is at or above 40°F. Prepare cracks and joints for treatment on the same day that they are to be sealed or filled.

Seal the crack by placing the applicator wand in or directly over the recess and carefully discharging the sealant. Strike-off the sealant flush with the pavement surface using a squeegee or sealing shoe pressed firmly against the pavement.

Sealant application should produce a film approximately 1/16 inch thick. The total width of the sealant cannot exceed 2-inches. If the sealant sinks into the reservoir more than 3/8-inch below the pavement surface, clean it with high pressure air and seal it to meet the specified thin film amount.

A low pressure, light spray of water may be used to accelerate cooling of the sealant.

Blotting the sealant with fine aggregate is not allowed.

Remove and dispose of sealant in excess of the specified thin "film" dimensions or that has not bonded to both sides of the reservoir.

Do not allow traffic on the sealed cracks until the seal has cured so as not to track. Clean sealed cracks damaged from traffic with high pressure air and reseal them to meet the specified thin film amount at no additional cost to the State.

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23434_Detailed Specifications – Liquid Bituminous Materials

SECTION 4: JOINT & CRACK FILLER/SEALER – DETAILED SPECIFICATIONS (Cont’d)

412.4 METHOD OF MEASUREMENT

The Engineer will measure the number of lane miles of pavement that has been cleaned and sealed in accordance with this specification. The cost to clean and seal cracks in shoulders and tapers are included in the adjacent travel lane. Full width ramps and turn lanes are considered separate travel lanes. All measurements will be made to the nearest

0.01 miles.

412.5 BASIS OF PAYMENT

The unit price bid shall include the cost of furnishing all…