ATCH 5_212800_FAA P-404 Fuel Resistant Asphalt Mix Pavement.pdf

12/21/2018 AC 150/5370-10H

Item P-404 Fuel-Resistant Asphalt Mix Pavement 322

Item P-404 Fuel-Resistant Asphalt Mix Pavement

Item P 404 is to be used only as a surface course for locations that need a fuel resistant surface.

P 404 is intentionally specified as a 50 blow Marshall mix due to the required low air voids and high asphalt content. The allowable lift thickness is between 1 ½ inches (37 mm) and 3 inches (75 mm).

DESCRIPTION

404-1.1 This item shall consist of surface courses composed of mineral aggregate, fuel-resistant asphalt binder, and additives mixed in a central mixing plant and placed as asphalt mix pavement in accordance with these specifications and shall conform to the lines, grades, thicknesses, and typical cross-sections shown on the plans. This mix is to be used only as a surface course. The purpose of this fuel-resistant asphalt is to provide a fuel-resistant surface where pavements are subjected to fuel spills. The course thickness shall be as shown on the plans.

MATERIALS

404-2.1 Aggregate. Aggregates shall consist of crushed stone, crushed gravel, crushed slag, screenings, and mineral filler, as required. The aggregate shall contain no natural sand. The aggregates should have no known history of detrimental pavement staining due to ferrous sulfides. Coarse aggregate is the material retained on the No. 4 (4.75 mm) sieve. Fine aggregate is the material passing the No. 4 (4.75

mm) sieve.

a. Coarse aggregate. Coarse aggregate shall consist of sound, tough, durable particles, free from films of matter that would prevent thorough coating and bonding with the asphalt material and free from organic matter and other deleterious substances. Coarse aggregate material requirements are given in the table below.

Item P-404 Fuel-Resistant Asphalt Mix Pavement 323

Coarse Aggregate Material Requirements

Material Test Requirement Standard Resistance to Degradation Loss: 40% maximum ASTM C131

Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate

Loss after 5 cycles:

10% maximum using Sodium sulfate - or - 13% maximum using magnesium sulfate

ASTM C88

Clay lumps and friable particles

0.3% maximum ASTM C142

Percentage of Fractured Particles

Minimum 70% by weight of particles with at least two fractured faces and 85% with at least one fractured face1

ASTM D5821

Flat, Elongated, or Flat and Elongated Particles

8% maximum, by weight, of flat, elongated, or flat and elongated particles at 5:1 2

ASTM D4791

Bulk density of slag 3 Weigh not less than 70 pounds per cubic foot (1.12 Mg/cubic meter)

ASTM C29

1 The area of each face shall be equal to at least 75% of the smallest mid-sectional area of the piece. When two fractured faces are contiguous, the angle between the planes of fractures shall be at least 30 degrees to count as two fractured faces.

2 A flat particle is one having a ratio of width to thickness greater than five (5); an elongated particle is one having a ratio of length to width greater than five (5).

3 Only required if slag is specified.

b. Fine aggregate. Fine aggregate shall consist of clean, sound, durable, angular shaped particles produced by crushing stone, slag, or gravel that meets the requirements for soundness specified for coarse aggregate. The aggregate particles shall be free from coatings of clay, silt, or other objectionable matter.

Fine aggregate material requirements are listed in the table below.

Fine Aggregate Material Requirements1

Material Test Requirement Standard Liquid limit 25 maximum ASTM D4318 Plasticity Index 4 maximum ASTM D4318 Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate

Loss after 5 cycles:

10% maximum using Sodium sulfate - or - 13% maximum using magnesium sulfate

ASTM C88

Clay lumps and friable particles

0.3% maximum ASTM C142

Sand equivalent 35 minimum ASTM D2419 1Natural sand is not allowed.

c. Sampling. ASTM D75 shall be used in sampling coarse and fine aggregate.

Item P-404 Fuel-Resistant Asphalt Mix Pavement 324

404-2.2 Mineral filler. Mineral filler (baghouse fines) may be added in addition to material naturally present in the aggregate. Mineral filler shall meet the requirements of ASTM D242.

Mineral filler Requirements

Material Test Requirement Standard Plasticity Index 4 maximum ASTM D4318

404-2.3 Asphalt binder. Asphalt binder shall conform to the following requirements of ASTM D6373 for performance grade (PG) 82-28 or 88-22 with the changes annotated below:

The original asphalt binder shall be tested according to ASTM D6084 Elastic Recovery at 25°C and shall be a minimum of 85%, using procedure A on the RTFO aged binder.

The original asphalt binder shall be tested according to ASTM D7173 and meet the maximum binder temperature difference of 4 degrees C when using the ASTM D36 Ring-and-Ball apparatus.

The asphalt specimens prepared with the asphalt binder must also meet the fuel resistance requirements in Table 1 when tested in accordance with paragraph 404-3.4. After passing the requirements of Table 1, the grade of the asphalt binder shall be identified as PG 82-28FR or 88-

22FR.

The Contractor shall provide a copy of the manufacturer’s Certificate of Analysis (COA) for the asphalt binder. The test reports shall be provided to and approved by the Resident Project Representative (RPR) before the asphalt binder is applied. The furnishing of the vendor’s certified test report for the asphalt material shall not be interpreted as a basis for final acceptance. The manufacturer’s COA may be subject to verification by testing the material delivered for use on the project.

401-2.4 Anti-stripping agent. Any anti-stripping agent or additive (anti-strip) shall be heat stable and shall not change the asphalt binder grade beyond specifications. Anti-strip shall be an approved material of the Department of Transportation of the State in which the project is located.

COMPOSITION

404-3.1 Composition of mixture. The asphalt plant mix shall be composed of a mixture of well-graded aggregate, filler and anti-strip agent if required, and asphalt material. The several aggregate fractions shall be sized, handled in separate size groups, and combined in such proportions that the resulting mixture meets the grading requirements of the job mix formula (JMF).

404-3.2 Job mix formula (JMF) laboratory. The laboratory used to develop the JMF shall possess a current certificate of accreditation, listing D3666 from a national accrediting authority and all test methods required for developing the JMF, and listed on the accrediting authority’s website. A copy of the laboratory’s current accreditation and accredited test methods shall be submitted to the RPR prior to start of construction.

404-3.3 Job mix formula (JMF). No asphalt mixture shall be placed until an acceptable mix design has been submitted to the RPR for review and accepted in writing. The RPR’s review shall not relieve the Contractor of the responsibility to select and proportion the materials to comply with this section.

Add anti-stripping agent to meet tensile strength requirements.

The JMF shall be prepared by an accredited laboratory that meets the requirements of paragraph 404-3.2.

The asphalt mixture shall be designed using procedures contained in the Asphalt Institute MS-2 Mix

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Design Manual, 7th Edition. Samples shall be prepared and compacted using a Marshall compactor in accordance with ASTM D6926.

If material variability exceeds the standard deviations indicated, the job mix formula and subsequent production targets shall be based on stability greater than shown in paragraph 404-3.3, Table 1, and the air voids shall be targeted close to the mid-range of the criteria in order to meet the acceptance requirements.

Should a change in sources of materials be made, a new JMF must be submitted to the RPR for review and accepted in writing before the new material is used. After the initial production JMF has been approved by the RPR and a new or modified JMF is required for whatever reason, the subsequent cost of the new or modified JMF, including a new control strip when required by the RPR, will be borne by the Contractor.

The RPR may request samples at any time for testing, prior to and during production, to verify the quality of the materials and to ensure conformance with the applicable specifications.

Table 1. Marshall Design Criteria

Test Properties All Aircraft Test Method Number of blows 50 ASTM D6926

Stability, minimum 2150 lbs. ASTM D6927 Air Voids1 2.5 ±0.2 % ASTM D3203

Minimum voids in mineral aggregate (VMA)

14% ASTM D6995

Maximum weight loss by fuel immersion

1.5% in accordance with procedures outlined in paragraph 404-3.4

Tensile Strength Ratio (TSR)2 not less than 80 at a saturation of 70-80%

ASTM D4867

Asphalt Pavement Analyzer

(APA)3

Less than 10 mm @ 4000 passes

AASHTO T340 at 250 psi hose pressure at 64°C test temperature 1 If the water absorption of the combined aggregates in the mix exceeds 1.7% (ASTM C127 and ASTM C128) then the mix must be short term aged in accordance with American Association of State Highway and Transportation Officials (AASHTO) PP-2 – Section 7.2. The short term aged material will then be used for the Marshall specimens and the maximum specific gravity test (ASTM D2041).

2 Test specimens for TSR shall be compacted at 7 ± 1.0 % air voids. Use freeze-thaw conditioning in lieu of moisture conditioning per ASTM D4867.

3 AASHTO T340 at 100 psi hose pressure at 64°C test temperature may be used in the interim. If this method is used the required value shall be less than 5 mm @ 8000 passes.

The APA procedure has shown that mixes that meet the requirements above perform well under aircraft loading. If APA is not available in an area, compacted mix design samples may be sent to a laboratory that has an APA or the Hamburg wheel test (AASHTO T 324) 10mm @ 20,000 passes may be used with FAA approval of ADO.

Item P-404 Fuel-Resistant Asphalt Mix Pavement 326

Specify a TSR of not less than 85 in areas with aggregate that have a history of stripping.

The JMF shall be submitted in writing by the Contractor to the RPR at least [ 30 ] days prior to the start of paving operations for the control strip in accordance with paragraph 404-3.3. The JMF shall be developed within the same construction season using aggregates currently being produced.

The JMF shall be dated, and stamped or sealed by the responsible professional Engineer of the laboratory and shall include the following items as a minimum:

Manufacturer’s Certificate of Analysis (COA) for the asphalt binder used in the JMF in accordance with paragraph 401-2.3. Certificate of asphalt performance grade is with modifier already added, if used and must indicate compliance with ASTM D6373. For plant modified asphalt binder, certified test report indicating grade certification of modified asphalt binder.

Manufacturer’s Certificate of Analysis (COA) for the anti-stripping agent if used in the JMF in accordance with paragraph 401-2.4.

Certified material test reports for the course and fine aggregate and mineral filler in accordance with paragraphs 401-2.1 and 401-2.2.

Percent passing each sieve size for individual gradation of each aggregate cold feed and/or hot bin; percent by weight of each cold feed and/or hot bin used; and the total combined gradation in the JMF.

Specific Gravity and absorption of each coarse and fine aggregate.

Percent fractured faces.

Percent by weight of flat particles, elongated particles, and flat and elongated particles (and criteria).

Percent of asphalt.

Number of blows

Laboratory mixing and compaction temperatures.

Supplier-recommended field mixing and compaction temperatures.

Plot of the combined gradation on a 0.45 power gradation curve.

Graphical plots of air voids, voids in the mineral aggregate, and unit weight versus asphalt content. To achieve minimum VMA during production, the mix design needs to account for material breakdown during production.

Tensile Strength Ratio (TSR).

Type and amount of Anti-strip agent when used.

Asphalt Pavement Analyzer (APA) results.

Date the JMF was developed. Mix designs that are not dated or which are from a prior construction season shall not be accepted.

Test results for asphalt resistance to fuel in accordance with paragraph 404-3.4.

Item P-404 Fuel-Resistant Asphalt Mix Pavement 327

The Owner may add additional testing to meet local conditions with FAA concurrence.

The mineral aggregate shall be of such size that the percentage composition by weight, as determined by laboratory screens, will conform to the gradation or gradations specified in paragraph 404-3.3, Table 2 when tested in accordance with ASTM C136 and ASTM C117.

The gradations in Table 2 represent the limits that shall determine the suitability of aggregate for use from the sources of supply; be well graded from coarse to fine and shall not vary from the low limit on one sieve to the high limit on the adjacent sieve, or vice versa.

Table 2. Aggregate – Fuel-Resistant Asphalt Pavement

Sieve Size ¾ inch (19.5MM) mix % passing by weight

1/2 inch (12.5 mm) mix % passing by weight

¾ inch (19.5mm) 100 1/2 inch (12.5 mm) 90-100 100 3/8 inch (9.5 mm) 72-88 90-100 No. 4 (4.75 mm) 53-73 58-78 No. 8 (2.36 mm) 38-60 40-60

No. 16 (1.18 mm) 26-48 28-48 No. 30 (600 μm) 18-38 18-38 No. 50 (300 μm) 11-27 11-27

No. 100 (150 μm) 6-18 6-18 No. 200 (75 μm) 3-6 3-6

Minimum Voids in Mineral Aggregate (VMA)1

15 16

Asphalt Percent Stone or gravel 5-7.5 5.5-8.0 Slag 6.5-9.5 7.0-10.5

Recommended Minimum Construction Lift Thickness

2” (51mm) 1 1/2 inch (37.0 mm)

1To achieve minimum VMA during production, the mix design needs to account for material breakdown during production.

The aggregate gradation shown is based on aggregates of uniform specific gravity. The percentages passing the various sieves shall be corrected when aggregates of varying specific gravities are used, as indicated in the Asphalt Institute MS-2 Mix Design Manual, 7th Edition.

404-3.4 Testing requirement for asphalt resistance to fuel. Procedures for testing asphalt resistance to fuel shall be as follows:

Item P-404 Fuel-Resistant Asphalt Mix Pavement 328

a. Prepare three test specimens in accordance with the Mix Design requirements at optimum asphalt binder content and 2.5 ±0.7% air voids.

b. Determine the percent air voids in each specimen, if any do not meet the requirements above discard and replace them. Dry the specimens under a fan at room temperature 68°F - 80°F (20°C - 27°C) for a minimum of 24 hours.

c. Totally immerse the sample in kerosene meeting ASTM D3699 at room temperature 68°F - 80°F (20°C - 27°C) for 2.0 minutes. (Suspending the sample with metal insect screen in a one gallon (4 liters) paint can has been found to be satisfactory.)

d. After submersing for 2.0 minutes ±30 sec, remove the sample and immediately surface dry it with a clean paper towel. Then immediately determine the weight in air to the nearest 0.1 grams. Report this as weight “A” (weight before).

e. Resubmerse the sample in kerosene for 24 hours.

f. After 24 hours ±10 minutes carefully remove the sample from the kerosene and suspension container and place it on an absorptive cloth or paper towel. Dry the specimen under a fan at room temperature for 24 hours.

g. After drying for 24 hours ±10 minutes weigh the sample in air to the nearest 0.1 grams. Report this as weight “B” (weight after immersion).

h. Calculations:

% of weight loss by fuel immersion = (A – B / A) × 100 Where: A = Weight before B = Weight after

404-3.5 Recycled Asphalt Mix Pavement. No reclaimed asphalt pavement (RAP) or recycled asphalt shingles (RAS) shall be permitted in this mix.

404-3.6 Control strip. [ A control strip is not required. ] [ Full production shall not begin until an acceptable control strip has been constructed and accepted in writing by the RPR. The Contractor shall prepare and place a quantity of asphalt according to the JMF. The underlying grade or pavement structure upon which the control strip is to be constructed shall be the same as the remainder of the course represented by the control strip.

The Contractor will not be allowed to place the control strip until the Contractor quality control program (CQCP), showing conformance with the requirements of paragraph 404-5.1, has been accepted, in writing, by the RPR.

The control strip will consist of at least 250 tons (227 metric tons) or 1/2 sublot, whichever is greater. The control strip shall be placed in two lanes of the same width and depth to be used in production with a longitudinal cold joint. The cold joint must be cut back in accordance with paragraph 404-4.14 using the same procedure that will be used during production. The cold joint for the control strip will be an exposed construction joint at least four (4) hours old or when the mat has cooled to less than 160°F (71°C). The equipment used in construction of the control strip shall be the same type, configuration and weight to be used on the project.

Item P-404 Fuel-Resistant Asphalt Mix Pavement 329

The control strip will be considered acceptable by the RPR if the gradation, asphalt content, and VMA are within the action limits specified in paragraph 404-5.5a; and Mat density, air voids, and joint density meet the requirements specified in paragraphs 404-6.2

If the control strip is unacceptable, necessary adjustments to the JMF, plant operation, placing procedures, and/or rolling procedures shall be made and another control strip shall be placed. Unacceptable control strips shall be removed at the Contractor’s expense.

Payment will only be made for an acceptable control strip in accordance with paragraph 401-8.1 using a lot pay factor equal to

100. ]

For small projects, less than 1,500 tons (1360 metric tons), a control strip is not required.

CONSTRUCTION METHODS

404-4.1 Weather limitations. The asphalt mixture shall not be placed upon a wet surface or when the surface temperature of the underlying course is less than 45°F (7°C). The temperature requirements may be waived by the RPR, if requested; however, all other requirements including compaction shall be met.

404-4.2 Asphalt plant. Plants used for the preparation of asphalt shall conform to the requirements of American Association of State Highway and Transportation Officials (AASHTO) M156 including the following items.

a. Inspection of plant. The RPR, or RPR’s authorized representative, shall have access, at all times, to all areas of the plant for checking adequacy of equipment; inspecting operation of the plant: verifying weights, proportions, and material properties; and checking the temperatures maintained in the preparation of the mixtures.

b. Storage bins and surge bins. The asphalt mixture stored in storage and/or surge bins shall meet the same requirements as asphalt mixture loaded directly into trucks. Asphalt mixture shall not be stored in storage and/or surge bins for a period greater than eight (8) hours. If the RPR determines there is an excessive heat loss, segregation or oxidation of the asphalt mixture due to temporary storage, temporary storage shall not be allowed.

404-4.3 Aggregate stockpile management. Aggregate stockpiles shall be constructed in such a manner that prevents segregation and intermixing of deleterious materials. Aggregates from different sources shall be stockpiled, weighed and batched separately at the asphalt batch plant. Aggregates that have become segregated or mixed with earth or foreign material shall not be used.

A continuous supply of materials shall be provided to the work to ensure continuous placement.

404-4.4 Hauling equipment. Trucks used for hauling asphalt mixtures shall have tight, clean, and smooth metal beds. To prevent the mixture from adhering to them, the truck beds shall be lightly coated with a minimum amount of paraffin oil, lime solution, or other approved material. Petroleum products shall not be used for coating truck beds. Each truck shall have a suitable cover to protect the mixture from adverse weather. When necessary, to ensure that the mixture will be delivered to the site at the specified temperature, truck beds shall be insulated or heated and covers shall be securely fastened.

Item P-404 Fuel-Resistant Asphalt Mix Pavement 330

404-4.5 Asphalts pavers. Asphalt pavers shall be self-propelled with an activated heated screed, capable of spreading and finishing courses of asphalt that will meet the specified thickness, smoothness, and grade. The paver shall have sufficient power to propel itself and the hauling equipment without adversely affecting the finished surface. The asphalt paver shall be equipped with a control system capable of automatically maintaining the specified screed grade and elevation.

If the spreading and finishing equipment in use leaves tracks or indented areas, or produces other blemishes in the pavement that are not satisfactorily corrected by the scheduled operations, the use of such equipment shall be discontinued.

The paver shall be capable of paving to a minimum width specified in paragraph 404-4.12.

404-4.6 Rollers. The number, type, and weight of rollers shall be sufficient to compact the asphalt to the required density while it is still in a workable condition without crushing of the aggregate, depressions or other damage to the pavement surface. Rollers shall be in good condition, capable of operating at slow speeds to avoid displacement of the asphalt. All rollers shall be specifically designed and suitable for compacting asphalt concrete and shall be properly used. Rollers that impair the stability of any layer of a pavement structure or underlying soils shall not be used.

404-4.7 Density device. The Contractor shall have on site a density gauge during all paving operations in order to assist in the determination of the optimum rolling pattern, type of roller and frequencies, as well as to monitor the effect of the rolling operations during production paving. The Contractor shall supply a qualified technician during all paving operations to calibrate the gauge and obtain accurate density readings for all new asphalt. These densities shall be supplied to the RPR upon request at any time during construction. No separate payment will be made for supplying the density gauge and technician.

404-4.8 Preparation of asphalt binder. The asphalt binder shall be heated in a manner that will avoid local overheating and provide a continuous supply of the asphalt binder to the mixer at a uniform temperature. The temperature of the asphalt binder delivered to the mixer shall be sufficient to provide a suitable viscosity for adequate coating of the aggregate particles, but shall not exceed 350°F (182°C), unless otherwise required by the manufacturer.

404-4.9 Preparation of mineral aggregate. The aggregate for the mixture shall be heated and dried prior to introduction into the mixer. The maximum temperature and rate of heating shall be such that no damage occurs to the aggregates. The temperature of the aggregate and mineral filler shall not exceed 350°F (175°C) when the asphalt is added. Particular care shall be taken that aggregates high in calcium or magnesium content are not damaged by overheating. The temperature shall not be lower than is required to obtain complete coating and uniform distribution on the aggregate particles and to provide a mixture of satisfactory workability.

404-4.10 Preparation of asphalt mixture. The aggregates and the asphalt binder shall be weighed or metered and introduced into the mixer in the amount specified by the job mix formula. The combined materials shall be mixed until the aggregate obtains a uniform coating of bitumen and is thoroughly distributed throughout the mixture. Wet mixing time shall be the shortest time that will produce a satisfactory mixture, but not less than 25 seconds for batch plants. The wet mixing time for all plants shall be established by the Contractor, based on the procedure for determining the percentage of coated particles described in ASTM D2489, for each individual plant and for each type of aggregate used. The wet mixing time will be set to achieve 95% of coated particles. For continuous mix plants, the minimum mixing time shall be determined by dividing the weight of its contents at operating level by the weight of the mixture delivered per second by the mixer. The moisture content of all asphalt mixtures upon discharge shall not exceed 0.5%.

Item P-404 Fuel-Resistant Asphalt Mix Pavement 331

For batch plants, wet mixing time begins with the introduction of asphalt binder into the mixer and ends with the opening of the mixer discharge gate. Mixing time should be the shortest time required to obtain uniform distribution of aggregate sizes and thorough coating of aggregate particles with asphalt binder.

401-4.11 Application of Tack Coat. Immediately before placing the asphalt mixture, the underlying course shall be cleaned of all dust and debris. A tack coat shall be applied in accordance with Item P-603 to all vertical and horizontal asphalt and concrete surfaces prior to placement of the first and each subsequent lift of asphalt mixture.

404-4.12 Laydown plan, transporting, placing, and finishing. Prior to the placement of the asphalt, the Contractor shall prepare a laydown plan with the sequence of paving lanes and width to minimize the number of cold joints; the location of any temporary ramps; laydown temperature; and estimated time of completion for each portion of the work (milling, paving, rolling, cooling, etc.). The laydown plan and any modifications shall be approved by the RPR.

Deliveries shall be scheduled so that placing and compacting of mixture is uniform with minimum stopping and starting of the paver. Hauling over freshly placed material shall not be permitted until the material has been compacted, as specified, and allowed to cool to atmospheric temperature. The Contractor, at their expense, shall be responsible for repair of any damage to the pavement caused by hauling operations.

Contractor shall survey each lift of asphalt surface course and certify to RPR that every lot of each lift meets the grade tolerances of paragraph 404-5.3h before the next lift can be placed.

Edges of existing asphalt pavement abutting the new work shall be saw cut and the cut off material and laitance removed. Apply a tack coat in accordance with P-603 before new asphalt material is placed against it.

The speed of the paver shall be regulated to eliminate pulling and tearing of the asphalt mat. Placement of the asphalt mix shall begin along the centerline of a crowned section or on the high side of areas with a one way slope unless shown otherwise on the laydown plan as accepted by the RPR. The asphalt mix shall be placed in consecutive adjacent lanes having a minimum width of [ ] feet (m) except where edge lanes require less width to complete the area. Additional screed sections attached to widen the paver to meet the minimum lane width requirements must include additional auger sections to move the asphalt mixture uniformly along the screed extension. [ ]

The Engineer should specify the widest paving lane practicable in an effort to hold the number of longitudinal joints to a minimum. Additional job specific construction limitations may be added as necessary covering such items as echelon paving, hot joint construction, etc.

The longitudinal joint in one course shall offset the longitudinal joint in the course immediately below by at least one foot (30 cm); however, the joint in the surface top course shall be at the centerline of crowned pavements. Transverse joints in one course shall be offset by at least 10 feet (3 m) from transverse joints in the previous course. Transverse joints in adjacent lanes shall be offset a minimum of 10 feet (3 m).On areas where irregularities or unavoidable obstacles make the use of mechanical spreading and finishing equipment impractical, the mixture may be spread and luted by hand tools.

Item P-404 Fuel-Resistant Asphalt Mix Pavement 332

The RPR may at any time, notwithstanding previous plant acceptance, reject and require the Contractor to dispose of any batch of asphalt mixture which is rendered unfit for use due to contamination, segregation, incomplete coating of aggregate, or improper mix temperature. Such rejection may be based on only visual inspection or temperature measurements. In the event of such rejection, the Contractor may take a representative sample of the rejected material in the presence of the RPR and, if it can be demonstrated in the laboratory, in the presence of the RPR, that such material was erroneously rejected, payment will be made for the material at the contract unit price.

Areas of segregation in the surface course, as determined by the RPR, shall be removed and replaced at the Contractor’s expense. The area shall be removed by saw cutting and milling a minimum of the construction lift thickness as specified in paragraph 404-3.3, Table 2 for the approved mix design. The area to be removed and replaced shall be a minimum width of the paver and a minimum of 10 feet (3 m) long.

404-4.13 Compaction of asphalt mixture. After placing, the asphalt mixture shall be thoroughly and uniformly compacted by rolling. The surface shall be compacted as soon as possible when the mixture has attained sufficient stability so that the rolling does not cause undue displacement, cracking or shoving.

The sequence of rolling operations and the type of rollers used shall be at the discretion of the Contractor.

The speed of the roller shall, at all times, be sufficiently slow to avoid displacement of the hot mixture and be effective in compaction. Any displacement occurring as a result of reversing the direction of the roller, or from any other cause, shall be corrected at once.

Sufficient rollers shall be furnished to handle the output of the plant. Rolling shall continue until the surface is of uniform texture, true to grade and cross-section, and the required field density is obtained.

To prevent adhesion of the mixture to the roller, the wheels shall be equipped with a scraper and kept properly moistened but excessive water will not be permitted.

In areas not accessible to the roller, the mixture shall be thoroughly compacted with approved power tampers.

Any mixture that becomes loose and broken, mixed with dirt, contains check-cracking, or in any way defective shall be removed and replaced with fresh hot mixture and immediately compacted to conform to the surrounding area. This work shall be done at the Contractor’s expense. Skin patching shall not be allowed.

404-4.14 Joints. The formation of all joints shall be made in such a manner as to ensure a continuous bond between the courses and obtain the required density. All joints shall have the same texture as other sections of the course and meet the requirements for smoothness and grade.

The roller shall not pass over the unprotected end of the freshly laid mixture except when necessary to form a transverse joint. When necessary to form a transverse joint, it shall be made by means of placing a bulkhead or by tapering the course. The tapered edge shall be cut back to its full depth and width on a straight line to expose a vertical face prior to placing the adjacent lane. In both methods, all contact surfaces shall be given a tack coat of asphalt material before placing any fresh mixture against the joint.

Longitudinal joints which have been left exposed for more than four (4) hours; the surface temperature has cooled to less than 175°F (80°C); or are irregular, damaged, uncompacted or otherwise defective shall be cut back with a cutting wheel or pavement saw a maximum of 3 inches (75 mm) to expose a clean, sound, uniform vertical surface for the full depth of the course. All cutback material and any laitance produced from cutting joints shall be removed from the project. Asphalt tack coat in accordance with P- 603 shall be applied to the clean, dry joint, prior to placing any additional fresh asphalt against the joint.

The cost of this work shall be considered incidental to the cost of the asphalt.

Item P-404 Fuel-Resistant Asphalt Mix Pavement 333

Cut back of all cold joints is required as specified above.

404-4.15 Diamond grinding. Diamond grinding shall be completed prior to pavement grooving.

Diamond grinding shall be accomplished by sawing with saw blades impregnated with industrial diamond abrasive.

Diamond grinding shall be performed with a machine designed specifically for diamond grinding capable of cutting a path at least 3 feet (0.9 m) wide. The saw blades shall be 1/8-inch (3-mm) wide with a minimum of 55 to 60 blades per 12 inches (300 mm) of cutting head width; grooves between 0.090 and

0.130 inches (2 and 3.5 mm) wide; and peaks and ridges approximately 1/32 inch (1 mm) higher than the bottom of the grinding cut. The actual number of blades will be determined by the Contractor and depend on the hardness of the aggregate. Equipment or grinding procedures that causes ravels, aggregate fractures, spalls or disturbance to the pavement will not be permitted.

Grinding will be tapered in all directions to provide smooth transitions to areas not requiring grinding.

The slurry resulting from the grinding operation shall be continuously removed and the pavement left in a clean condition. The Contractor shall apply a surface treatment per P-608 to all areas that have been subject to grinding.

404-4.16 Nighttime paving requirements. The Contractor shall provide adequate lighting during any nighttime construction. A lighting plan must be submitted by the Contractor and approved by the RPR prior to the start of any nighttime work. All work shall be in accordance with the approved CSPP and lighting plan.

CONTRACTOR QUALITY CONTROL (CQC)

All federally funded projects over $500K dollars where paving is the major work item must have a CQCP. It is strongly encouraged that a Contractor Quality Control Program (CQCP) be developed for all projects.

For projects that do not include a formal CQCP, this section can be edited to remove reference to a CQCP. However, QC testing is still required regardless of project size.

404-5.1 General. [ The Contractor shall develop a CQCP in accordance with Item C-100. No partial payment will be made for materials that are subject to specific QC requirements without an approved CQCP. ]

404-5.2 Contractor quality control (QC) facilities. [ The Contractor shall provide or contract for testing facilities in accordance with Item C-100. The RPR shall be permitted unrestricted access to inspect the Contractor’s QC facilities and witness QC activities. The RPR will advise the Contractor in writing of any noted deficiencies concerning the QC facility, equipment, supplies, or testing personnel and procedures.

When the deficiencies are serious enough to be adversely affecting the test results, the incorporation of the materials into the work shall

Item P-404 Fuel-Resistant Asphalt Mix Pavement 334 be suspended immediately and will not be permitted to resume until the deficiencies are satisfactorily corrected. ]

404-5.3 Contractor QC testing. The Contractor shall perform all QC tests necessary to control the production and construction processes applicable to these specifications [ and as set forth in the approved CQCP. The testing program shall include, but not necessarily be limited to, tests for the control of asphalt content, aggregate gradation, temperatures, aggregate moisture, field compaction, and surface smoothness. A QC Testing Plan shall be developed as part of the CQCP. ]

a. Asphalt content. A minimum of two tests shall be performed per day in accordance with ASTM D6307 or ASTM D2172 for determination of asphalt content. When using ASTM D6307, the correction factor shall be determined as part of the first test performed at the beginning of plant production; and as part of every tenth test performed thereafter. The asphalt content for the day will be determined by averaging the test results.

b. Gradation. Aggregate gradations shall be determined a minimum of twice per day from mechanical analysis of extracted aggregate in accordance with ASTM D5444, ASTM C136, and ASTM C117.

c. Moisture content of aggregate. The moisture content of aggregate used for production shall be determined a minimum of once per day in accordance with ASTM C566.

d. Moisture content of asphalt. The moisture content of the mixture shall be determined once per day in accordance with AASHTO T329 or ASTM D1461.

e. Temperatures. Temperatures shall be checked, at least four times per day, at necessary locations to determine the temperatures of the dryer, the asphalt binder in the storage tank, the mixture at the plant, and the asphalt at the job site.

f. In-place density monitoring. The Contractor shall conduct any necessary testing to ensure that the specified density is being achieved. A nuclear gauge may be used to monitor the pavement density in accordance with ASTM D2950.

g. Smoothness for Contractor Quality Control.

Note change in deviations on final surface course that require grinding, limited to deviations > 1/4 inch that trap water, intent here is to focus on areas that may cause issues with the safe operation of aircraft and to minimize grinding if it will not improve safety

The Contractor shall perform smoothness testing in transverse and longitudinal directions daily to verify that the construction processes are producing pavement with variances less than ¼ inch in 12 feet, identifying areas that may pond water which could lead to hydroplaning of aircraft. If the smoothness criteria is not met, appropriate changes and corrections to the construction process shall be made by the Contractor before construction continues

The Contractor may use a 12-foot (3.7 m) “straightedge, a rolling inclinometer meeting the requirements of ASTM E2133 or rolling external reference device that can simulate a 12-foot (3.7m) straightedge approved by the RPR. Straight-edge testing shall start with one-half the length of the straightedge at the edge of pavement section being tested and then moved ahead one-half the length of the

Item P-404 Fuel-Resistant Asphalt Mix Pavement 335 straightedge for each successive measurement. Testing shall be continuous across all joints. The surface irregularity shall be determined by placing the freestanding (unleveled) straightedge on the pavement surface and allowing it to rest upon the two highest spots covered by its length, and measuring the maximum gap between the straightedge and the pavement surface in the area between the two high points. If the rolling inclinometer or external reference device is used, the data may be evaluated using the FAA profile program, ProFAA, or FHWA ProVal, using the 12-foot straightedge simulation function.

Smoothness readings shall not be made across grade changes or cross slope transitions. The transition between new and existing pavement shall be evaluated separately for conformance with the plans.

Include detail for transition between new and existing pavement including smoothness and grade limitations.

(1) Transverse measurements. Transverse measurements shall be taken for each day’s production placed. Transverse measurements shall be taken perpendicular to the pavement centerline each 50 feet (15 m) or more often as determined by the RPR. The joint between lanes shall be tested separately to facilitate smoothness between lanes.

(2) Longitudinal measurements. Longitudinal measurements shall be taken for each day’s production placed. Longitudinal tests shall be parallel to the centerline of paving; at the center of paving lanes when widths of paving lanes are less than 20 feet (6 m); and at the third points of paving lanes when widths of paving lanes are 20 ft (6 m) or greater.

Deviations on the final surface course in either the transverse or longitudinal direction that will trap water greater than 1/4 inch (6 mm) shall be corrected with diamond grinding per paragraph 401-4.15 or by removing and replacing the surface course to full depth. Grinding shall be tapered in all directions to provide smooth transitions to areas not requiring grinding. All areas in which diamond grinding has been performed shall be subject to the final pavement thickness tolerances specified in paragraph 404- 6.2d. Areas that have been ground shall be sealed with a surface treatment in accordance with Item P-

608. To avoid the surface treatment creating any conflict with runway or taxiway markings, it may be necessary to seal a larger area.

Control charts shall be kept to show area of each day’s placement and the percentage of corrective grinding required. Corrections to production and placement shall be initiated when corrective grinding is required. If the Contractor’s machines and/or methods produce significant areas that need corrective actions in excess of 10 percent of a day’s production, production shall be stopped until corrective measures are implemented by the Contractor.

h. Grade. Grade shall be evaluated daily to allow adjustments to paving operations when grade measurements do not meet specifications. As a minimum, grade shall be evaluated prior and after the placement of the first lift and then after placement of the surface lift.

Measurements will be taken at appropriate gradelines (as a minimum at center and edges of paving lane) and longitudinal spacing as shown on cross-sections and plans. The final surface of the pavement will not vary from the gradeline elevations and cross-sections shown on the plans by more than 1/2 inch (12 mm) vertically [ and 0.1 feet (30 mm) laterally ]. The documentation will be provided by the Contractor to the RPR [ within 24 hours ] [ by the end of the following working day. ]

Item P-404 Fuel-Resistant Asphalt Mix Pavement 336

Areas of surface course that exceed grade or smoothness criteria and that retain water on the surface must be ground off provided the course thickness after grinding is not more than 1/2 inch (12 mm) less than the thickness specified on the plans. Grinding shall be in accordance with paragraph 404-4.15.

The Contractor shall repair low areas or areas that cannot be corrected by grinding by removal of deficient areas to the depth of the final course plus ½ inch and replacing with new material. Skin patching is not allowed.

404-5.4 Sampling. When directed by the RPR, the Contractor shall sample and test any material that appears inconsistent with similar material being sampled, unless such material is voluntarily removed and replaced or deficiencies corrected by the Contractor. All sampling shall be in accordance with standard procedures specified.

404-5.5 Control charts. The Contractor shall maintain linear control charts for both individual measurements and range (i.e. difference between highest and lowest measurements) for aggregate gradation, asphalt content, and VMA. The VMA for each day will be calculated and monitored by the QC laboratory.

Control charts shall be posted in a location satisfactory to the RPR and kept current. As a minimum, the control charts shall identify the project number, the contract item number, the test number, each test parameter, the Action and Suspension Limits applicable to each test parameter, and the Contractor’s test results. The Contractor shall use the control charts as part of a process control system for identifying potential problems and assignable causes before they occur. If the Contractor’s projected data during production indicates a problem and the Contractor is not taking satisfactory corrective action, the RPR may suspend production or acceptance of the material.

a. Individual measurements. Control charts for individual measurements shall be established to maintain process control within tolerance for aggregate gradation, asphalt content, and VMA. The control charts shall use the job mix formula target values as indicators of central tendency for the following test parameters with associated Action and Suspension Limits:

Control Chart Limits for Individual Measurements

Sieve Action limit Suspension limit 3/8 inch (9.5 mm) ±6% ±9% No. 4 (4.75 mm) ±6% ±9%

No. 16 (1.18 mm) ±5% ±7.5% No. 50 (300 μm) ±3% ±4.5% No. 200 (75 μm) ±2% ±3% Asphalt Content ±0.45% ±0.70% Minimum VMA -0.5% -1.0%

b. Range. Control charts shall be established to control gradation process variability. The range shall be plotted as the difference between the two test results for each control parameter. The Suspension Limits specified below are based on a sample size of n = 2. Should the Contractor elect to perform more than two tests per lot, the Suspension Limits shall be adjusted by multiplying the Suspension Limit by

1.18 for n = 3 and by 1.27 for n = 4.

Item P-404 Fuel-Resistant Asphalt Mix Pavement 337

Control Chart Limits Based on Range

Sieve Suspension Limit 3/8 inch (9.5 mm) 11% No. 4 (4.75 mm) 11%

No. 16 (1.18 mm) 9% No. 50 (300 μm) 6% No. 200 (75 μm) 3.5% Asphalt content 0.8%

c. Corrective action. [ The CQCP shall indicate that appropriate action shall be taken when the process is believed to be out of tolerance.

The Plan shall contain sets of rules to gauge when a process is out of control and detail what action will be taken to bring the process into control. As a minimum, a process shall be deemed out of control and production stopped and corrective action taken, if:

(1) one point falls outside the Suspension Limit line for individual measurements or range; or

(2) two points in a row fall outside the Action Limit line for individual measurements. ]

404-5.6 QC reports. The Contractor shall maintain records and shall submit reports of QC activities daily [ , in accordance with the CQCP described in Item C-100 ].

MATERIAL ACCEPTANCE

404-6.1 Acceptance sampling and testing. Unless otherwise specified, all acceptance sampling and testing necessary to determine conformance with the requirements specified in this section will be performed by the RPR at no cost to the Contractor except that coring as required in this section shall be completed and paid for by the Contractor.

a. Quality Assurance (QA) testing laboratory. The QA testing laboratory performing these acceptance tests will be accredited in accordance with ASTM D3666. The QA laboratory accreditation will be current and listed on the accrediting authority’s website. All test methods required for acceptance sampling and testing will be listed on the lab accreditation.

b. Lot size. A standard lot will be equal to one day’s production divided into approximately equal sublots of between 400 to 600 tons. When only one or two sublots are produced in a day’s production, the sublots will be combined with the production lot from the previous or next day.

Where more than one plant is simultaneously producing asphalt for the job, the lot sizes will apply separately for each plant.

For large projects with high production rates, the Engineer may adjust the lot size to be ½ days production.

Item P-404 Fuel-Resistant Asphalt Mix Pavement 338

For small projects, with multiple small placements or if the total project size is less than 3000 tons (2270 metric tons), acceptable material will be paid for by the ton (metric ton) placed per day.

c. Asphalt air voids. Plant-produced asphalt will be tested for air voids on a sublot basis.

(1) Sampling. Material from each sublot shall be sampled in accordance with ASTM D3665.

Samples shall be taken from material deposited into trucks at the plant or at the job site in accordance with ASTM D979. The sample of asphalt may be put in a covered metal tin and placed in an oven for [ not less than 30 minutes nor more than 60 minutes ] to maintain the material at or above the compaction temperature as specified in the JMF.

Engineer should increase hold times to not less than 60 minutes and not more than 90 minutes when absorptive aggregates are used.

(2) Testing. Air voids will be determined for each sublot in accordance with ASTM D3203 for a set of three compacted specimens prepared in accordance with [ ASTM D6926 ] [ ASTM D6925 ].

d. In-place asphalt mat and joint density. Each sublot will be tested for in-place mat and joint density as a percentage of the theoretical maximum density (TMD).

(1) Sampling. The [ Contractor ] [ RPR ] will cut minimum 5 inches (125 mm) diameter samples in accordance with ASTM D5361. The Contractor shall furnish all tools, labor, and materials for cleaning, and filling the cored pavement. Laitance produced by the coring operation shall be removed immediately after coring, and core holes shall be filled within one day after sampling in a manner acceptable to the RPR.

(2) Bond. Each lift of asphalt shall be bonded to the underlying layer. If cores reveal that the surface is not bonded, additional cores shall be taken as directed by the RPR to determine the extent of unbonded areas. Unbonded areas shall be removed by milling and replaced at no additional cost as directed by the RPR.

(3) Thickness. Thickness of each lift of surface course will be evaluated by the RPR for compliance to the requirements shown on the plans after any necessary corrections for grade.

Measurements of thickness will be made using the cores extracted for each sublot for density measurement. The maximum allowable deficiency at any point will not be more than 1/4 inch (6 mm) less than the thickness indicated for the lift. Average thickness of lift, or combined lifts, will not be less than the indicated thickness. Where the thickness tolerances are not met, the lot or sublot shall be corrected by the Contractor at his expense by removing the deficient area and replacing with new pavement. The Contractor, at his expense, may take additional cores as approved by the RPR to circumscribe the deficient area.

(4) Mat density. One core shall be taken from each sublot. Core locations will be determined by the RPR in accordance with ASTM D3665. Cores for mat density shall not be taken closer than one foot (30 cm) from a transverse or longitudinal joint. The bulk specific gravity of each cored sample will be determined in accordance with ASTM D2726.