4 -Technical Specifications.pdf

202 - 1

SECTION 202

REMOVAL OF STRUCTURES AND OBSTRUCTIONS

202-1.01 DESCRIPTION. Remove and dispose or salvage all, fences, guardrail, structures, old pavements, old concrete, abandoned utilities and any other obstructions which are not designated or permitted to remain, except for the obstructions to be removed and disposed of under other items in the Task Order. Backfill the resulting trenches, holes and pits.

202-2.01 MATERIALS. None.

CONSTRUCTION REQUIREMENTS

202-3.01 GENERAL. Remove, and dispose of, or salvage structures, and other obstructions, any portions of which are within the work limits, except utilities and those for which other provisions have been made for removal.

Fill holes, or cavities left by removal, to the level of the surrounding ground and, if within the prism of construction, compact backfill as specified under Section 203.

Stockpile all materials which are designated for use on the project at approved locations. Dispose of debris at a designated JBER Site or at an off-Base site of the Contractor’s choice. If the JBER Site is used, the material shall be placed in lifts no greater than 36 - inches and graded to drain. All loads shall be covered during transporting outside of the project site and within JBER.

202-3.02 CULVERTS AND OTHER DRAINAGE STRUCTURES. Do not remove fish passage, culverts, other drainage structures, or culverts in use by traffic until satisfactory accommodations are in place.

Do not remove manholes, inlets, valves or any other portion or portions of the sewer or water systems until the new systems are in operation or suitable arrangements have been made for the diversion, interruption, or a temporary system has been installed.

When flexible pipe is designated on the Plans to be abandoned in place, crush and flatten the ends before covering. Securely plug other conduits by an approved method.

202-3.03 REMOVAL OF PAVEMENT, SIDEWALKS, AND CURBS. Dispose of all concrete pavement, base course, sidewalks, curbs, gutters, etc., designated for removal, in an acceptable manner.

In removing pavements, curbs, walks, driveways and similar structures, make all cuts clean, vertical, and true to designated lines where an abutting structure or a part of a structure is to be left in place. Saw cutting existing asphalt and concrete will be paid for under items 202(12) and 202(13) respectively.

202-3.04 PAVEMENT PLANING. Remove existing asphalt pavement by cold planing at locations shown in the Plans. Adjust planing machine to remove all ruts in the roadway surface and as directed by the Government. The surface of the pavement after planing shall be a uniformly fine milled textured surface.

Notify the Government of pavement areas that may be thin or unstable. Where the planing equipment breaks through the existing pavement, repair as specified in Sections 401 and 408. Repair with Section 401 HMA;

Type II, Class B. Repair work and materials will be paid for under HMA Pay Items.

Pavement material planed from the project is the property of the Government. Remove planed material from the project immediately after planing. Stockpile planed material at the on-Base material site adjacent to the Richardson Highway. Coordinate with the Chief of Project Execution at (907) 384-3081 for acceptance of material and desired location of stockpile. Planed material not acceptable will be disposed of in an acceptable manner, or incorporated into the road structure prism as directed by the Government. Handle, transport, store, or dispose material according to Subsection 202-3.03.

During planing operations, sweep the streets according to 643-3.04 Traffic Control Devices, No. 5., Street Sweeping and Power Brooming to control dust and remove loose material from the planed areas. The removal operation shall follow within 50 feet of the planing machine.

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Do not allow traffic to travel on surfaces that have an abrupt longitudinal planed edge greater than 2 inches. In the event it is necessary to route traffic across such edges, an asphalt pavement transition 2 feet in width shall be placed adjacent to the edge and to gutters.

Where existing asphalt pavement overlays gutters adjacent to the area being planed remove the existing pavement.

The existing curb, gutter, and edge of existing Portland cement pavement not designated for removal shall not be damaged or disturbed. Damage caused by the planing operation shall be removed and replaced by the Contractor at the Contractor’s expense.

The planing machine shall have the following capabilities:

1. Self-propelled and capable of milling at speeds from 0 ft to 40+ ft per minute.

2. Able to spray water inside the milling chamber to reduce dust.

3. Able to mill adjacent to a gutter without damaging gutter.

4. Automatic cross slope and depth control combined with automatic longitudinal grade control actuated by sonic or laser ski sensors.

5. Produce a "fine milled" textured surface with a tool spacing of 5/16 inch.

6. Able to uniformly maintain a planar surface across adjacent lanes (no elevation differential or ridges between adjacent passes).

Provide a small machine (producing a "fine milled" textured surface) to trim areas that are inaccessible to the larger machine at manholes, valve covers, curb returns, and intersections.

The Government may reject any machine that does not comply with the above noted requirements.

202-3.05 REMOVAL OF UNDERGROUND STORAGE TANKS AND VAULTS. Remove existing underground storage tanks and concrete vaults at locations shown on the Plans. Remove and dispose of tanks or vaults according to the Department of Environmental Conservation (DEC) regulations.

Some concrete vaults may be electrical or communication vaults. Removed electrical or communication concrete vaults may be placed in the concrete disposal site on-JBER.

202-3.06 REMOVAL OF CONCRETE. Remove and dispose of existing plain or reinforced concrete slabs, concrete encased conduits, or other unclassified concrete at locations shown on the Plans. Dispose of concrete debris at a JBER disposal site or at an off-base site of the Contractor’s choice. Saw cutting the existing concrete slab will be paid for under item 202(13).

203 - 1

SECTION 203

EXCAVATION AND EMBANKMENT

203-1.01 DESCRIPTION. Excavate, haul, place, and compact or dispose of specified materials necessary to construct the project. Conform to the lines, grades, depths and typical cross sections shown on the Plans or as established. The Task Order will designate material to be removed within the excavation limits as classified or unclassified excavation.

Ditch linear grading shall consist of the final shaping of designated ditches and slopes for drainage by grading with a small dozer, motor grader, or other suitable means approved by the Government.

203-2.01 MATERIALS.

1. Unclassified Excavation. All materials of whatever character encountered in the work. May include common or muck.

2. Classified Excavation:

a. Common Excavation. Silt, sand, gravel, and granular material other than rock or muck.

b. Muck Excavation. Soils, organic matter, and other material not suitable for foundation material regardless of moisture content.

3. Borrow. Approved material required for embankments or for other portions of the work, and obtained from sources outside the limits for the project.

CONSTRUCTION REQUIREMENTS

203-3.01 GENERAL. Perform all necessary clearing and grubbing prior to beginning excavation, grading, and embankment operations in any area.

Keep excavation and embankment areas free draining at all times as the work progresses. Finish the excavation and embankments to reasonably smooth and uniform surfaces.

Excavate and embank material only within the limits on the Plans or as directed. Prevent disturbing material and vegetation outside of the slope limits.

The Government may designate excavated soils that cannot be properly compacted in embankments, as unsuitable.

If unsuitable material is encountered at the required depth of excavation, stop excavation and notify the Engineer.

Dispose of unsuitable material or excess usable material at approved JBER location or at an off-Base site of the Contractor’s choice. If the JBER site is used, the material shall be placed in lifts no greater than 36-inches and graded to drain.

When existing roadway embankment slopes are used as disposal sites for waste or surplus material, finish the slopes with a motor grader or other approved method.

When the volume of suitable excavation is not sufficient for constructing the fill to the grades indicated, furnish the necessary borrow from approved sources. Borrow may be necessary even though not shown on the Plans. The source and acceptability of borrow is subject to approval.

Do not place borrow material until after the Usable Roadway Excavation has been placed in the fill. If you place more borrow than is required, resulting in or as a result of the unnecessary wasting of usable excavation, the amount of such waste will be deducted from the borrow quantity.

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203-3.02 EMBANKMENT CONSTRUCTION. Prepare the areas upon which embankments are to be placed, construct dikes within or outside the work area when required, place and compact approved material within the roadway areas where unsuitable material has been removed, and place and compact embankment material in holes, pits, and other depressions within the roadway area. Use only approved materials in the construction of embankments and backfills. Embankment material will be approved for gradation following placement but prior to compaction.

Construct the embankment with selected material meeting the requirements of Subsection 703-2.07. Selected material may be obtained from unclassified excavation, common excavation or borrow.

Do not place rocks, broken concrete or other solid materials in embankment areas where culvert placement is required.

Bench slopes that are steeper than 4:1, when measured at right angles to the roadway, when embankment is to be placed and compacted on hillsides, or when new embankment is to be compacted against existing embankments, or when embankment is built half-width at a time. Continuously bench over those areas as the work is brought up in layers. Make benches wide enough to permit placing and compacting operations. Begin each horizontal cut at the intersection of the original ground and the vertical side of the previous bench.

Incorporate material cut out, and deemed suitable, into the new embankment and recompact along with the new material.

Scarify existing roadways, lying within 3 feet of subgrade, to a depth of 6 inches and recompact to meet Subsection 203-3.03 or 203-3.04.

When excavation is performed when freezing weather is imminent, place the specified backfill promptly, following the excavation work, at least up to a level which will allow the surface to adequately drain. Make arrangements for the timely availability of such embankment or backfill materials prior to commencement of the stripping or excavation operations, when required.

When embankment is to be placed on both sides of a concrete wall or box type structure, keep the embankment at approximately the same elevation on both sides of the structure.

Place roadway embankment of earth materials in horizontal layers not to exceed 8 inches (uncompacted) for the full width of the embankment, except as required for traffic, and compact as specified in the Task Order before the next layer is placed. Use spreading equipment on each lift to obtain uniform thickness prior to compacting. Maintain uniform density, during compaction. Add or remove water, as necessary, to obtain the required density. Route compaction equipment uniformly over the entire surface of each layer.

Place rock embankment in lifts not thinner than the thickness of the largest rocks. Restrict maximum rock dimension to 3 feet. Distribute spalls and finer rock fragments to level and smooth each lift. Place succeeding lifts without damaging previously completed lifts. Dump rock on the lift being constructed and distribute by blading or dozing to fill voids and to form a dense, well- compacted embankment. Do not place rocks over 8 inches within 2 feet of finished subgrade.

Rock is considered usable material, regardless of size. Rocks too large to be embanked, as specified above, may either be reduced to a suitable size for incorporation into the embankment or disposed of in approved areas, at your option. Replace all wasted rock from excavation with borrow at no additional cost to the Government, unless such rock is excess to project embankment requirements.

Finish the subgrade surface so it will not vary more than 0.10 foot when tested using a 10-foot straightedge nor vary more than 0.10 ft from the established grade.

When embankment is to be placed over swampy or saturated ground, end dump an initial lift of material of sufficient depth to support hauling equipment, as directed.

Repair damage to embankment caused by hauling equipment.

Construct all embankments with moisture and density control unless the Government determines that such controls are not feasible.

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203-3.03 COMPACTION WITH MOISTURE AND DENSITY CONTROL. The maximum density and optimum moisture will be determined by ASTM D1557.

Adjust the moisture content of the embankment material to within 2% of the optimum moisture content and compact each layer as specified in the Task Order.

203-3.04 COMPACTION WITHOUT MOISTURE AND DENSITY CONTROL. Except for rock fills and the first layer of fills over swampy ground, deposit embankment materials in layers not exceeding 8 inches in thickness before compaction.

Compact by routing construction equipment and/or rollers uniformly over the entire surface of each layer before the next layer is placed. Compact until embankment does not rut under the loaded hauling equipment.

Keep dumping and rolling areas separate. Do not cover any lift by another until the required compaction has been completed.

301 - 1

SECTION 301

AGGREGATE BASE AND SURFACE COURSE

301-1.01 DESCRIPTION. Construct an aggregate base course or aggregate surface course on an approved foundation, as shown on the Plans.

301-2.01 MATERIALS. Use aggregate conforming to Subsection 703-2.03.

CONSTRUCTION REQUIREMENTS

301-3.01 PLACING. Place material in layers not exceeding 8 inches in depth. Maintain the roadway surface to drain freely at all times.

Place base course material, used for sidewalk and pathway foundations, with equipment capable of providing a specified depth and uniform surface.

When paving is specified in the project, schedule the work so that any base course placed will be covered prior to winter shutdown.

301-3.02 MIXING. Mix the aggregate, incorporating any specified additives. Add water, as needed, to provide the approximate optimum moisture content for compaction.

Mix the aggregate by one of the following methods:

1. Stationary Plant Method

2. Travel Plant Method

3. Road Mix Method

The aggregate may be accepted for gradation based on random samples taken for each lift from the roadway after spreading but prior to compaction.

301-3.03 SHAPING AND COMPACTION. The maximum density and optimum moisture shall be determined by ATM 212.

Spread and shape the material to the required grade and section. Water or aerate as necessary to provide the approximate optimum moisture content for compaction. Compact each layer to a density of not less than 98% of the maximum density. Acceptance densities will be determined by ATM 213 and ATM 214.

Maintain the surface of each layer during the compaction operations in such manner that a uniform texture is produced and the aggregates firmly keyed.

The finished surface will be tested using a 10-foot straightedge at selected locations. Limit surface deviations to 3/8 inch, as measured from the testing edge of the straightedge between two contacts with the surface.

401 - 1

SECTION 401

HOT MIX ASPHALT PAVEMENT

401-1.01 DESCRIPTION. Construct one or more courses of plant-produced Hot Mix Asphalt (HMA) pavement on an approved surface, to the lines, grades, and depths shown on the Plans.

MATERIALS

401-2.01 ASPHALT BINDER. Conform to Subsection 702-2.01. Asphalt binder may be conditionally accepted at the source providing a manufacturers certification of compliance according to Subsection 107-7.01, and test results of the applicable requirements of Section 702.

401-2.02 LIQUID ANTI-STRIP ADDITIVE. Use anti-strip agents in the proportions determined by ATM 414 and included in the approved Job Mix Formula (JMF). At least 70% of the aggregate must remain coated when tested according to ATM 414. A minimum of 0.30% by weight of asphalt binder is required.

401-2.03 JOINT ADHESIVE. Conform to Subsection 702-2.05.

401-2.04 JOINT SEALANT. Conform to Subsection 702-2.06.

401-2.05 ASPHALT RELEASE AGENT. Conform to Subsection 702-2.07.

401-2.06 AGGREGATES. Conform to Subsection 703-2.04. Use a minimum of three stockpiles of crushed aggregate (coarse, intermediate, and fine). Place blend material, if any, in a fourth pile.

401-2.07 RECYCLED ASPHALT PAVEMENT. Recycled asphalt pavement (RAP) may be used in the production of HMA. The RAP may be from pavements removed under the Contract, or from an existing stockpile. Conform to Subsection 703-2.15.

401-2.08 JOB MIX FORMULA. Provide target values for gradation that satisfy both the broad band gradation limits shown in Table 703-4 and the requirements of Table 401-1, for the Type and Class of HMA specified.

TABLE 401-1

HMA MARSHALL DESIGN REQUIREMENTS

DESIGN PARAMETER CLASS

“A”

CLASS

“B”

HMA (Including Asphalt Binder) Stability, Pounds 1800 Min. 1200 Min.

Flow, 0.01 Inch 8 – 14 8 - 16 Voids in Total Mix (VTM), % 3.0 – 5.0 3.0 – 5.0

Compaction, Number of Blows Each Side of Test Specimen 75 50

Asphalt Binder Binder Grade* PG 58-34 PG 52-28 Voids Filled with Asphalt (VFA), % 65 - 75 65 - 78 Asphalt Content, Min. % 5.0 5.0

Dust-Asphalt Ratio** 0.6 - 1.4 0.6 - 1.4 Voids in the Mineral Aggregate (VMA), %, Min.

Type II 13.0 12.0 Liquid Anti-Strip Additive***,%, Min. 0.30 0.30 RAP, %, Max. 15.0 25.0

* Unless specified otherwise in the Task Order

**Dust-Asphalt ratio is the percent of material passing the No. 200 sieve divided by the percent of effective asphalt binder (calculated by weight).

*** By Weight of Asphalt Binder

401 - 2

The approved JMF will specify the Target Values (TV) for gradation, the TV for asphalt binder content, the Maximum Specific Gravity (MSG) of the HMA, the additives, and the recommended mixing temperature range.

Provide a JMF following the requirements specified in this section. Submit the JMF to the Government each calendar year least 15 working days before HMA production for the first Task Order of the year. Submit samples to the Government upon request for JMF verification testing. Obtain approval of the JMF prior to producing HMA for payment.

Anti-strip evaluation (ATM 414) of HMA mix designs that include RAP will be completed without the inclusion of the RAP.

All Contractor-furnished JMFs must be sealed by a professional Engineer registered in the State of Alaska.

The Professional Engineer shall certify that the JMF was performed according to the specified procedures, and meets all project specifications.

Changes. Submit a new JMF with changes noted and new samples in the same manner as the original JMF submittal when:

a. The results of the JMF evaluation do not achieve the requirements specified in Table 401-1

b. The asphalt binder source is changed

c. The source of aggregate, aggregate quality, or gradation is changed.

Changes to the JMF apply only to HMA produced after the approval of changes.

CONSTRUCTION REQUIREMENTS

401-3.01 PRE-PAVING MEETING. Meet with the Government for a pre-paving meeting in the presence of project superintendent and paving foreman at least five (5) working days before beginning paving operations under each Task Order. Submit a paving plan and pavement inspection plan (per 401-3.20) at the meeting.

Include the following elements in the paving plan and address these elements at the meeting:

a. Sequence of operations

b. List of equipment that will be used for production, transport, pick-up (if applicable), laydown, and compaction

c. Procedures to produce consistent HMA

d. Procedures to minimize material and thermal segregation

e. Procedures to minimize premature cooling

f. Procedures to achieve HMA density

g. Procedures for joint construction including corrective action for joints that do not meet surface tolerance requirements

h. Quality control testing methods, frequencies and sample locations for gradation, asphalt binder content, and density, and

i. Any other information or procedures necessary to provide completed HMA construction that meets the contract requirements

Include the following elements in the pavement inspection plan and address these elements at the meeting:

j. Process for daily inspections

k. Means and methods to remove and dispose of project materials

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401-3.02 CONTRACTOR QUALITY CONTROL. Perform quality control (QC) of HMA materials in accordance with Subsection 107-5.01.

401-3.03 WEATHER LIMITATIONS. Place HMA on a stable/non-yielding roadbed. Do not place HMA when the base material is wet or frozen, or when weather conditions prevent proper handling or finishing of the mix.

Do not place HMA leveling course when the roadway surface temperature is colder than 40° F.

401-3.04 EQUIPMENT, GENERAL. Use equipment in good working order and free of HMA buildup. Make all equipment available for inspection and demonstration of operation a minimum of 24 hours before placement of HMA.

401-3.05 ASPHALT MIXING PLANT. Meet AASHTO M 156. Use an HMA plant capable of producing at least 150 tons of HMA per hour noted on posted DEC air quality permit, designed to dry aggregates, maintain consistent and accurate temperature control, and accurately proportion asphalt binder and aggregates.

Calibrate the HMA plant and furnish copies of the calibration data to the Government yearly.

Provide a scalping screen at the asphalt plant to prevent oversize material or debris from being incorporated into the HMA.

Provide a tap on the asphalt binder supply line just before it enters the plant (after the 3-way valve) for sampling asphalt binder. Provide aggregate and asphalt binder sampling locations meeting OSHA safety requirements.

You may use belt conveyor scales to proportion plant blends and mixtures if the scales meet the general requirements for weighing equipment and are calibrated according to the manufacturer’s instructions.

401-3.06 HAULING EQUIPMENT. Haul HMA in trucks with tight, clean, smooth metal beds. Keep beds free of petroleum oils, solvents, or other materials that would adversely affect the mixture. Apply a thin coat of approved asphalt release agent to beds as necessary to prevent mixture adherence. Provide trucks with covers attached and available for use.

401-3.07 ASPHALT PAVERS. Use self-propelled asphalt pavers with heated vibratory screed assemblies to spread and finish HMA to the specified section widths and thicknesses without introducing thermal or material segregation.

Equip the paver with a receiving hopper having sufficient capacity for a uniform spreading operation and a distribution system to place the HMA uniformly in front of screed. Use a screed assembly that produces a finished surface of the required smoothness, thickness and texture without tearing, shoving or displacing the HMA. Heat and vibrate screed extensions. Place auger extensions within 20 inches of the screed extensions or per written manufacturer’s recommendations.

Equip the paver with a means of preventing segregation of the coarse aggregate particles from the remainder of the HMA when carried from the paver hopper back to the augers.

Equip the paver with automatic screed controls capable of operating from a reference line or a ski from either or both sides of the paver.

The use of a “Layton Box” or equivalent towed paver is allowed on bike paths, sidewalks, cart paths, and driveways.

401-3.08 ROLLERS. Use rollers designed to compact HMA and capable of reversing without shoving or tearing the mixture. Select rollers that will not crush the aggregate or displace the HMA. Equip vibratory rollers with separate vibration and propulsion controls.

Equip the rollers with an infrared thermometer that measures and displays the surface temperature to the operator. Infrared thermometer may be hand-held or fixed to the roller.

Use a pneumatic roller in the complement of rollers to compact the leveling course. Use fully skirted pneumatic-tire roller having a minimum operating weight of 3000 pounds per tire.

401 - 4

401-3.09 RESERVED.

401-3.10 PREPARATION OF EXISTING SURFACE. Prepare existing surfaces according to the Task Order.

Prior to placing HMA, clean existing surfaces of loose material and uniformly coat contact surfaces of curbing, gutters, manholes and other structures with tack coat material meeting Section 402. Treat cold joint surfaces according to 401-3.17.

Before applying tack coat to an existing paved surface, clean and patch the surface. Remove irregularities to provide a reasonably smooth and uniform surface. Remove and replace unstable areas with HMA. Clean the edges of existing pavements, which are to be adjacent to new pavement, to permit the adhesion of asphalt materials. Clean loose material from cracks. Fill the cleaned cracks, wider than 1 inch, with HMA tamped in place. Wash and/or sweep the paved surface clean and free of loose materials.

Preparation of a milled surface:

1. Prelevel remaining ruts, pavement delaminations, and depressions having a depth greater than 1/2 inch with an approved HMA.

2. Notify the Government of pavement areas that appear thin or unstable. Where milling operation creates thin or unstable pavement areas, or where it breaks through existing pavement, remove thin and unstable pavement, and 2 inches of existing base material, compact and replace with an approved HMA.

401-3.11 PREPARATION OF ASPHALT. Provide a continuous supply of asphalt binder to the asphalt mixing plant at a uniform temperature, within the recommended mixing temperature range.

401-3.12 PREPARATION OF AGGREGATES. Dry the aggregate so the moisture content of the HMA, sampled at the point of acceptance for asphalt binder content, does not exceed 0.5% (by total weight of mix), as determined by ATM 407.

Heat the aggregate for the HMA to a temperature compatible with the mix requirements specified.

Adjust the burner on the dryer to avoid damage to the aggregate and to prevent the presence of unburned fuel on the aggregate. HMA containing soot or fuel is unacceptable per Subsection 106-1.12.

401-3.13 MIXING. Combine the aggregate, asphalt binder, and additives in the mixer in the amounts required by the JMF. Mix to obtain at least 98% coated particles when tested according to AASHTO T195.

For batch plants, put the dry aggregate in motion before addition of asphalt binder.

Mix the HMA within the temperature range determined by the JMF.

Upon the Government’s request, provide daily burner charts showing start/stop times and temperatures.

401-3.14 TEMPORARY STORAGE OF HMA. Silo type storage bins may be used, provided the characteristics of the HMA remain unaltered.

Signs of visible segregation, heat loss, changes from the JMF, change in the characteristics of asphalt binder, lumpiness, and stiffness of the mixture, are causes for rejection.

401-3.15 PLACING AND SPREADING. Use asphalt pavers to distribute HMA, including leveling course and temporary HMA. Place the HMA upon the approved surface, spread, strike off, and adjust surface irregularities. The maximum compacted lift thickness allowed is 3 inches.

When multiple lifts are specified in the Task Order, do not place the final lift until all lower lifts throughout that section, are placed and accepted.

Do not place HMA abutting curb and gutter until curb and gutter are installed.

Do not pave against new Portland cement concrete curbing until it has cured for at least 72 hours.

401 - 5

When practicable, adjust elevation of metal fixtures before paving the final lift, so they will be between 1/4 and 1/2 inch below the top surface of the final lift. Metal fixtures include, but are not limited to manholes, valve boxes, monument cases, hand holes, and drains.

Use hand tools to spread, rake, and lute the HMA in areas where irregularities or unavoidable obstacles make mechanical spreading and finishing equipment impracticable.

Do not mix HMA produced from different plants for testing or paving.

401-3.16 COMPACTION. Thoroughly and uniformly, compact the HMA by rolling. In areas not accessible to large rollers, compact with mechanical tampers or trench rollers.

The Lower Specification Limit for density is 92.0% of the Maximum Specific Gravity (MSG) as determined by ATM 409. The MSG from the approved JMF is used for the first lot of each type of HMA. The MSG for additional lots is determined from the first sublot of each lot.

401-3.17 JOINTS. Place and compact the HMA to provide a continuous bond, texture, and smoothness between adjacent sections of the HMA.

Minimize the number of joints. Do not construct longitudinal joints in the driving lanes unless approved by the Engineer in writing at the pre-paving meeting. Offset the longitudinal joints in one layer from the joint in the layer immediately below by at least 6 inches. Align the joints of the top layer at the centerline or lane lines.

Where preformed marking tape striping is required, offset the longitudinal joint in the top layer not more than 6 inches from the edge of the stripe.

Form transverse joints by saw-cutting back on the previous run to expose the full depth of the course or by using a removable bulkhead. Skew transverse joints 15 to 25 degrees.

For all joints below the top lift, uniformly coat joint surfaces with tack coat material meeting Section 402.

When Item 401(3) is included in the Task Order, uniformly coat the joint face of all top lift joints with a joint adhesive. Otherwise use tack coat material meeting Section 402. Follow joint adhesive manufacturer’s recommendations for temperatures and application method. Remove joint adhesive applied to the top of pavement surface.

The Lower Specification Limit for top lift longitudinal joint density is 91.0% of the MSG of the panel completing the joint. MSG will be determined according to ATM 409.

For top lift panels that have a longitudinal joint density less than 91.0% of the MSG, seal the surface of the longitudinal joints with joint sealant. Apply joint sealant according to the manufacturer’s recommendations while the HMA is clean, free of moisture and prior to final traffic marking. Place the sealant at a maximum application rate of 0.15 gallons per square yard, and at least 12 inches wide centered on the longitudinal joint.

After surface sealing, inlay by grinding pavement striping into the sealed HMA. Use grooving equipment that grinds a dry cut to groove the width, length, and thickness of the striping within the specified striping tolerances.

Correct improperly formed joints that result in surface irregularities according to a corrective action plan.

Complete all hot lapped joints formed by paving in echelon while the mat temperature is over 200°F as measured by the Engineer, within 3 inches of the joint. Tack coat and joint adhesive are not required for hot lapped joints. Cutting back joints that have cooled shall be subsidiary to the respective HMA pay item.

401-3.18 SURFACE REQUIREMENTS AND TOLERANCE. The finished surface of all HMA paving must match dimensions shown in the contract for horizontal alignment and width, profile grade and elevation, crown slope, and pavement thickness. Water must drain across the pavement surface without ponding. The surface must have a uniform texture, without ridges, puddles, humps, depressions, and roller marks. The surface must not exhibit raveling, cracking, tearing, asphalt bleeding, or aggregate segregation. Leave no foreign material, uncoated aggregate or oversize aggregate on the HMA surface.

The Government will test the finished surface after final rolling at selected locations using a 16-foot

401 - 6 straightedge. The Government will identify pavement areas that deviate more than 3/16 inch from the straightedge, including joints, as defective work. Perform corrective work by removing and replacing, grinding, cold milling or infrared heating such areas as required. Do not surface patch. After the Contractor performs corrective work, the Government will retest the area.

Perform Corrective Actions according to one of the following or by a method approved by the Government:

1. Diamond Grinding. If the required pavement thickness is not decreased by more than 0.25”, grind to the required surface tolerance and cross section. Remove and dispose of all waste materials. Apply joint sealant and sand to exposed aggregates per the manufacturer’s recommendations.

2. Overlaying. Mill or sawcut the existing pavement to provide a vertical transverse joint face to match the overlay to the existing pavement. Apply tack coat on the milled surface and joint adhesive to all vertical joints and overlay the full width of the underlying pavement surface. Use the same approved HMA for overlays. Place a minimum overlay thickness of 2.0 inches.

3. Mill and Fill. Mill the existing pavement to provide a vertical transverse joint face. Apply tack coat to the milled surface and joint adhesive to all vertical joints prior to inlay new HMA to match the existing pavement. Use the same approved HMA. Place a minimum thickness of 2.0 inches.

401-3.19 REPAIRING DEFECTIVE AREAS. Remove HMA that is contaminated with foreign material, is segregated (determined visually or by testing), flushing, or bleeding asphalt. Remove and dispose defective HMA for the full thickness of the course. Cut the pavement so that edges are vertical and the sides are parallel to the direction of traffic. Coat edges with a tack coat according to Section 402. Place and compact fresh HMA so that compaction, grade and smoothness requirements are met.

401-3.20 ROADWAY MAINTENANCE. Inspect daily according to pavement inspection plan. Remove, and dispose of project materials incorrectly deposited on existing and new pavement surfaces(s) inside and outside the project area including haul routes.

The Contractor is responsible for damage caused by not removing these materials and any damage to the roadway from the removal method(s).

Repair damage to the existing roadway that results from fugitive materials or their removal.

401-4.01 METHOD OF MEASUREMENT. Section 109 and the following:

1. Hot Mix Asphalt. By weight. No deduction is made for the weight of asphalt binder or anti stripping additive or cutting back joints.

Quality control necessary to fulfil the requirements of Subsection 401-4.02 is subsidiary.

2. Joint Adhesive. By the linear foot of longitudinal and transverse joint.

3. Crack Repair. From end of the crack repaired according to 401-3.10, measured horizontally along the centerline of the crack. Cleaning loose material from cracks, asphalt binder, and HMA to fill cracks will not be measured separately but are subsidiary.

401-4.02 ACCEPTANCE SAMPLING AND TESTING. The Contractor shall, through his Quality Control Plan, evaluate the HMA for conformance to the Specifications.

The quantity of each type of HMA produced and placed will be divided into lots and the lots evaluated individually for acceptance.

A lot is normally 5,000 tons. The lot is divided into sublots of 1,000 tons, each randomly sampled and tested for asphalt binder content, density, and gradation according to this Subsection. Seasonal startup or a new JMF requires starting a new lot.

If the project has more than 1 lot, and less than 8 additional sublots have been sampled at the time a lot is terminated, either due to completion of paving operations or the end of the construction season (winter shutdown), the material in the shortened lot will be included as part of the prior lot.

401 - 7

If 8 or 9 samples have been obtained at the time a lot is terminated, they will be considered as a lot and evaluation will be based on the actual number of test results (excluding outliers) in the shortened lot.

If the project quantity is between 500 tons and 5,000 tons, the project quantity will be considered one lot. The lot will be divided into sublots of 500 tons and randomly sampled for asphalt binder content, density, and gradation according to this subsection except that a determination for outliers will not be performed. HMA quantities of less than 500 tons remaining after dividing the project quantity into sublots will be included in the last sublot.

For project quantity of less than 500 tons, the Government may accept the HMA based on the approved JMF and the placement and compaction of the HMA to the specified depth and finished surface requirements and tolerances. The Government reserves the right to require the Contractor to perform any testing required in order to determine acceptance. Remove and replace any HMA that does not conform to the approved JMF.

The Contractor’s sampling and testing shall include the following:

1. Asphalt Binder Content. HMA samples shall be taken randomly by the Contractor in the presence of the Government from behind the paver screed before initial compaction, or will be taken randomly at the direction of the Government from the windrow, according to ATM 402 or ATM 403. The location (behind the paver screed or windrow) will be determined at the pre-paving meeting. Random sampling locations will be determined by the Government.

Two separate samples will be taken, one for acceptance testing and one held in reserve for retesting if requested. Asphalt binder content will be determined according to ATM 405 or ATM 406.

2. Aggregate Gradation. Aggregates tested for gradation acceptance will have the full tolerances from Table 401-2 applied.

a. Drum Mix Plants. Samples will be taken from the combined aggregate cold feed conveyor via a diverter device, from the stopped conveyor belt or from the same location as samples for determination of asphalt binder content, at the discretion of the Government. Two separate samples will be taken, one for acceptance testing and one held in reserve for retesting if requested. The aggregate gradation for samples from the conveyer system will be determined according to ATM 304.

For HMA samples, the gradation will be determined according to ATM 408 from the aggregate remaining after the ignition oven (ATM 406) has burned off the asphalt binder. Locate diverter devices for obtaining aggregate samples from drum mix plants on the conveyor system delivering combined aggregates into the drum. Divert aggregate from the full width of the conveyor system and maintain the diverter device to provide a representative sample of aggregate incorporated into the HMA.

b. Batch Plants. Samples will be taken from dry batched aggregates according to ATM 301 or from the same location as samples for determination of asphalt binder content, at the discretion of the Engineer. Two separate samples will be taken, one for acceptance testing and one held in reserve for retesting if requested. The aggregate gradation for dry batch samples will be determined according to ATM 304. For HMA samples, the gradation will be determined according to ATM 408 from the aggregate remaining after the ignition oven (ATM 406) has burned off the asphalt binder.

3. Density. The Government will determine and mark the location(s) where the Contractor takes each core sample.

a. Mat Cores: The location(s) for taking core samples is determined using a set of random numbers (independent of asphalt binder and aggregate sampling set of random numbers) and the Engineer's judgment. Take no mat cores within 1 foot of a joint or edge.

b. Longitudinal Joint Cores: The Government will mark the location(s) to take the core sample, centered on the visible surface joint, and adjacent to the mat core sample taken in the panel completing the joint.

Take core samples according to ATM 413 in the presence of the Government. Cut full depth core samples, centered on the marks and as noted above, from the finished HMA within 24 hours after

401 - 8 final rolling. Neatly core drill one six inch diameter sample at each marked location. Use a core extractor to remove the core - do not damage the core. The Contractor’s Quality Control personnel will immediately take possession of the samples. Backfill and compact voids left by coring with new HMA within 24 hours. The Contractor shall determine density of samples according to ATM 410.

4. Retest. When test results have failed to meet specifications, retest of acceptance test results for asphalt binder content, gradation, and density may be requested provided the quality control requirements of Subsection 401-3.02 are met. Deliver this request in writing to the Government within 7 days of receipt of the final test of the lot. The Government will mark the sample location for the density retest within a 2 foot radius of the original core. The original test results are discarded and the retest result is used to evaluate the material for acceptance. Only one retest per sample is allowed. When gradation and asphalt binder content are determined from the same sample, a request for a retest of either gradation or asphalt binder content results in a retest of both. Both gradation and asphalt binder content retest results are used for acceptance.

TABLE 401-2

HMA LOWER SPECIFICATION LIMIT (LSL) & UPPER SPECIFICATION LIMIT (USL)

Measured Characteristics LSL USL ¾” or largest sieve size 99 100

½ inch sieve or first sieve TV-6 TV+6

3/8 inch sieve TV-6 TV+6 No. 4 sieve TV-6 TV+6 No. 8 sieve TV-6 TV+6 No. 16 sieve TV-5 TV+5 No. 30 sieve TV-4 TV+4 No. 50 sieve TV-4 TV+4

No. 100 sieve TV-3 TV+3 No. 200 sieve TV-2.0 TV+2.0

Asphalt Binder Content, % TV-0.4 TV+0.4 Mat Density, % 92.0 100.0

501 - 1

SECTION 501

STRUCTURAL CONCRETE

501-1.01 DESCRIPTION. Furnish, place, finish, and cure Portland cement concrete for structures and incidental construction as shown on the Plans. Use the following classes of concrete, as specified.

Class A: Reinforced and non-reinforced concrete structures Class A-A: High strength reinforced concrete structures Class W: Minor concrete construction

501-2.01 MATERIALS. Use materials that conform to the following:

Portland Cement, Blended Hydraulic Cement, and Grout Section 701 Fine Aggregate Subsection 703-2.01 Coarse Aggregate Subsection 703-2.02 Joint Materials Section 705 Curing Materials Subsection 711-2.01 Chemical Admixtures Subsection 711-2.02 Fly Ash Subsection 711-2.03 Water Subsection 712-2.01

501-3.01 PROPORTIONING. Be responsible for the design, construction, and performance of all concrete mixes used in structures.

1. Contractor Mix Design. Design normal weight concrete, according to ACI Publication 301, Section 4 and ACI Publication 214 using the absolute volume method per ACI Publication 211.1.

Submit a mix design for each class of concrete to the Government for approval. Include the following:

a. Amount of cement and admixture per cubic yard of concrete. Include name, type, source and brand of each product. Include manufacturer’s certificate of compliance for each product.

b. Amounts of fine and coarse aggregate (in a saturated surface-dry condition) per cubic yard of concrete, including the specific gravity and absorption values for the aggregates.

c. Amount of mix water.

d. Supporting documentation of test results.

Determine the final proportions to produce concrete meeting Table 501-1. Verify mix design.The Government may require material samples to verify the mix design.

TABLE 501-1 CLASS OF CONCRETE

A A-A W

Cement Content*, sacks/ yd3, minimum

6.0 7.0 5.0

Water Cement Ratio, lbs/lbs, maximum

0.50 0.44 0.58

Slump Range, inches 2-4** 1-3 1-5 Entrained Air Range, % 4-7 5-8 3-7 Coarse Aggregate Gradation, AASHTO M 43

No. 57 or

No. 57 or

No. 57 or

Compressive Strength, psi, min. 4,000 5,000 2,500 *Cement content is based on 94-pound sacks.

**Slump may be adjusted to less than 2 inches, for slip-formed concrete.

501 - 2

Alternative sizes of coarse aggregate, as shown in Table 1 of AASHTO M 43, may be used only when approved in writing.

2. Adjustment for New Materials. Do not use new materials until the Government has approved such materials and has approved the mix design designating new proportions, based on tests of trial mixes as provided in Subsection 501-3.01.1.

3. Using Fly Ash. Use fly ash in concrete only with the Government’s approval. Comply with Subsection 711-2.03 and the following:

a. Use fly ash as a substitute for Portland cement up to a maximum of 20% by weight of Portland cement.

b. Replace cement with fly ash according to these ratios:

Class of Fly Ash Replacement Ratio Fly Ash/Cement (lb/lb)

Class F 1.25 Class C 1.00 - 1.25

c. Do not use fly ash in high early strength concrete.

In the request to use fly ash, include a single substitution percentage and a single replacement ratio for each class of concrete in which fly ash is proposed.

As an alternative to using fly ash and cement as separate components, you may use a blended hydraulic cement meeting Subsection 701-2.02.

4. Using Admixtures. Include test results demonstrating that the admixture conforms to these Specifications.

When using two or more admixtures in the same mix from different manufacturers, provide manufacturer’s certifications showing that they are compatible.

5. Approval. Obtain the Government’s approval of all mix designs, prior to use.

501-3.02 ACCEPTANCE OF CONCRETE.

1. General. The Government will accept concrete based on conformance to the requirements for temperature, slump, air content, water cement ratio, and the specified 28-day strength for sublots as tested and determined by the Contractor’s Quality Control personnel and the Government’s testing.

A sublot is defined as 25 cubic yards of concrete production.

Each sublot will meet the specified strength requirement when both of the following conditions are met:

a. Individual strength tests do not fall below the specified strength by more than 12.5% or 500 psi, whichever is least.

b. An individual strength test averaged with the two proceeding individual strength tests meets or exceeds specified strength (for the same class of concrete on the same contract).

2. Certification of Compliance. Provide a Certificate of Compliance for each truckload of concrete. Certify that the delivered concrete is in compliance with the mix design and include the following information:

a. Manufacturer plant (batching facility)

b. Task Order number

c. Date

d. Time batched

501 - 3

e. Truck No.

f. Initial revolution counter reading

g. Quantity (quantity batched this load)

h. Type of concrete by class and producer design mix number

i. Cement producer, type, and manufacturer’s mill test report number

j. Fly ash (if used) brand and Type

k. Approved aggregate gradation designation

l. Mix design weight per cubic yard and actual batched weights for:

i. Cement

ii. Fly ash (if used)

iii. Coarse concrete aggregate and moisture content (each size)

iv. Fine concrete aggregate and moisture content

v. Water (including free moisture in aggregates

vi. Admixtures brand and total quantity batched

vii. Air-entraining admixture

viii. Water reducing admixture

ix. Other admixture

The Certificate of Compliance must be signed by a responsible representative of the concrete producer, affirming the accuracy of the information provided.

3. Conformance to Mix Design. Produce a concrete mix which conforms to the approved mix design, within the following tolerances:

a. Coarse Aggregate weights ±2%

b. Fine Aggregate weights ±2%

c. Fine Aggregate Fineness Modulus ±0.2

d. Cementitious Material weight ±1%

If the total cementitious material weight is made up of different components, keep the component weights within the following tolerances:

(1) Portland cement ±1%

(2) Fly ash ±5%

(3) Microsilica ±10%

4. Test Methods. Acceptance testing shall be performed according to the following test methods:

WAQTC TM 2 Sampling Freshly Mixed Concrete

WAQTC FOP for ASTM C1064/C1064M Temperature of Freshly Mixed Portland Cement Concrete

AASHTO T 22 Compressive Strength of Cylindrical Concrete Specimens

WAQTC FOP for AASHTO T 27/T 11 Sieve Analysis of Fine and Coarse Aggregates, and Materials Finer Than No. 200 Sieve in Mineral Aggregate by Washing

WAQTC FOP for AASHTO T 23 Making and Curing Concrete Test Specimens in the Field

WAQTC FOP for AASHTO T 119 Slump of Hydraulic Cement Concrete

WAQTC FOP for AASHTO T 121 Mass per Cubic Foot, Yield, and Air Content of Concrete

WAQTC FOP for AASHTO T 152 Air Content of Freshly Mixed Concrete by the Pressure Method

501 - 4

AASHTO T 231 Capping Cylindrical Concrete Specimens

5. Point of Acceptance. The Contractor’s Quality Control personnel will determine aggregate gradation for acceptance based on random samples taken at the plant.

The Contractor’s Quality Control personnel will determine concrete strength, slump, temperature, and entrained air (if applicable) for acceptance based on samples taken at the discharge point of the placement system.

Provide adequate and representative samples of the fresh concrete as directed at locations designated by the Government for the testing of concrete properties and making of strength specimens.

At the Government’s discretion, concrete with compressive strengths (f’c) which fails to meet specified acceptance level requirements may be rejected or accepted at a reduced rate in accordance with Subsection 501-4.01.

6. Water/Cement Ratio Conformance. The Contractor’s Quality Control personnel will determine the actual water cement ratio from the certified proportions of the mix. For slip-formed concrete, do not exceed the maximum water cement ratio in the mix design or the slump limits under 501-3.01.1.

7. Rejecting Concrete. The Government may reject any batch or load of concrete that fails to meet the minimum specified acceptance levels for temperature, slump, or air content. The Government may reject any batch or load of concrete, prior to sampling that appears defective in composition. Do not incorporate rejected material into the structure.

The Government may reject any structure or portion of a structure containing…