Attachment 2_Hot Mix Asphalt Specifications.pdf

Attachment 2: Asphalt Mix Design Specifications; Tinian, Attachment 2: Asphalt Mix Design Specifications; Tinian, CNMI

Asphalt Batch Plant & Equipment Specifications – Tinian, CNMI

1.0 General Requirements:

1.1 Scope

Provide all material, equipment, vehicles, parts, labor, tools, appurtenances, etc., as required to continuously produce 240 Tons/hour of asphalt meeting the requirements specified herein and deliver the asphalt to the RED HORSE paving equipment as requested by the COR. Production capacity shall be scalable down to 100 Tons/hour to support smaller paving areas.

1.2 Laboratory Accreditation and Validation

Develop the Job Mix Formula (JMF), perform acceptance testing, and Contractor Quality Control testing that meet the requirements of ASTM D3666. Perform all required test methods by an accredited and validated laboratory including field standards. In addition, all testing laboratories performing JMF, acceptance testing, and Contractor Quality Control requires USACE validation by the Material Testing Center (MTC) for both parent laboratory and plant testing laboratory. Validation on all laboratories is required to remain current throughout the duration of the contract.

1.3 ENVIRONMENTAL REQUIREMENTS

Attach ment 2: Asphalt Mix Design Specifications; Tinian, waived by the Government, if requested; provided all other requirements, including in-place density, are met.

Surface Temperature Limitations of Underlying Course Mat Thickness, mm/inches Degrees C/F

75/3 or greater 4/40 Less than 75/3 7/45

Table 6

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

This section is intended to stand alone for production and delivery of asphalt pavement to the RED HORSE Troops on Tinian, CNMI.

Provide hot mix asphalt (HMA) composed of mineral aggregate and asphalt material heated and mixed in a central mixing plant to be placed on a prepared course by Government forces. required by the Government. Provide proposed Production and Delivery Plan, indicating production capacity, delivery methodology including delivering asphalt at required quantities and temperature to the asphalt pavers.

2.2 Equipment

Provide product data for all components below.

2.2.1 Asphalt Production and Mixing Plant

Provide plants used for the preparation of asphalt mixture conforming to the requirements of AASHTO M 156, including calibration data.

2.2.1.1 Truck Scales

Weigh the asphalt mixture on approved scales, or on certified public scales at no additional expense to the Government. Scales shall be calibrated according to governing US standards, and weight tickets shall have net, gross, and tare weights, pre and post loading.

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2.2.1.3 Storage Silos/Containers

The asphalt mixture may be stored in non-insulated storage silos/containers for a period of time not exceeding 3 hours. The asphalt mixture may be stored in insulated storage silos for a period of time not exceeding 8 hours. No differences in the mix removed from silos and the mix loaded into trucks are allowed.

2.2.2 Hauling Equipment

Provide trucks used for hauling asphalt mixture that have tight, clean, and smooth metal beds. To prevent the mixture from adhering to them, lightly coat the truck beds with a minimum amount of paraffin oil, lime solution, or other approved material. Do not use petroleum-based products as a release agent. Cover the bed of each truck with a tarp or other suitable cover at all times during transport. When necessary to ensure that the mixture is delivered to the site at the specified temperature, provide insulated or heated truck beds with covers (tarps) that are securely fastened.

2.2.3 Material Transfer Vehicle (MTV)

Provide an adequate number of self-propelled MTV’s with a swing conveyors that deliver material to the pavers from outside the paving lane and without making contact with the pavers. Provide MTV’s capable to move back and forth between the hauling equipment and the pavers providing material transfer to the pavers, while allowing the pavers to operate at a constant speed. Provide Material Transfer Vehicles with remixing and onboard storage to meet the production and delivery rate required. The contractor shall comply with directions of the RH provided material transfer coordinator managing the transfer of HMA from the MTV to the Pavers.

2.3 AGGREGATES

Obtain samples in accordance with ASTM D75/D75M and be representative of the materials to be delivered. Provide aggregates consisting of crushed stone, crushed gravel, crushed slag, screenings, natural sand and mineral filler, as required. The portion of material retained on the 4.75 mm sieve is coarse aggregate. The portion of material passing the 4.75 mm sieve and retained on the 0.075 mm sieve is fine aggregate. The portion passing the 0.075 mm sieve is defined as mineral filler. Submit sufficient materials to produce 90 kg of blended mixture for mix design verification. Submit all aggregate test results and samples to the Government at least 14 days prior to the start of work. Aggregate tests can be no older than 6 months prior to test section.

2.3.1 Coarse Aggregate

Provide coarse aggregate consisting of sound, tough, durable particles, free from films of material that would prevent thorough coating and bonding with the asphalt material and free from organic matter and other deleterious substances. Provide coarse aggregate particles meeting the following requirements:

a. The percentage of loss not greater than 40 percent after 500 revolutions when tested in accordance with ASTM C131/C131M.

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b. The sodium sulfate soundness loss not exceeding 12 percent, or the magnesium sulfate soundness loss not exceeding 18 percent after five cycles when tested in accordance with ASTM C88.

At least 75 percent by weight of coarse aggregate contain at least two or more fractured faces when tested in accordance with ASTM D5821 with fractured faces produced by crushing.

c. The particle shape essentially cubical and the aggregate containing not more than 5 percent, by weight, of flat particles, elongated particles, or flat and elongated particles (5:1 ratio of maximum to minimum) when tested in accordance with ASTM D4791 Method A.

d. Slag consisting of air-cooled, blast furnace slag, with a compacted weight of not less than 1200 kg per cubic meter when tested in accordance with ASTM C29/C29M.

e. Clay lumps and friable particles not exceeding 0.3 percent, by weight, when tested in accordance with ASTM C142/C142M.

2.3.2 Fine Aggregate

Provide fine aggregate consisting of clean, sound, tough, durable particles. Provide aggregate particles that are free from coatings of clay, silt, or any objectionable material, contain no clay balls, and meet the following requirements:

a. Quantity of natural sand (non-crushed material) added to the aggregate blend not exceeding 15 percent by weight of total aggregate.

b. Individual fine aggregate sources with a sand equivalent value greater than 45 when tested in accordance with ASTM D2419.

c. Fine aggregate portion of the blended aggregate with an uncompacted void content greater than 45.0 percent when tested in accordance with ASTM C1252 Method A.

d. Clay lumps and friable particles not exceeding 0.3 percent, by weight, when tested in accordance with ASTM C142/C142M.

2.3.3 Mineral Filler

Provide mineral filler consisting of a non-plastic material meeting the requirements of ASTM D242/D242M.

2.3.4 Aggregate Gradation

Provide a combined aggregate gradation that conforms to gradations specified in Table 7, when tested in accordance with ASTM C136/C136M and ASTM C117 and does not vary from the low limit on one sieve to the high limit on the adjacent sieve or vice versa, but grades uniformly from coarse to fine. Provide a JMF within the specification limits; however, the gradation can exceed the limits when the allowable deviation from the JMF shown in Tables 10 and 11 are applied.

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Table 7

Aggregate Gradations

Gradation 2

Sieve Size, mm Percent Passing by Mass

25.0 ---

19.0 97-100

12.5 90-100

9.5 69-89

4.75 53-73

2.36 38-60

1.18 26-48

0.60 18-38

0.30 11-27

0.15 6-18

0.075 3-6

2.4 ASPHALT BINDER

Select one of the two asphalt binder options from Table Polymer Modified Asphalt Binder and identify selection to the Government.

Cox, Benjamin C (Ben) CIV USARMY CEERD-GSL (USA) Note that this was changed from 100% to 97-100%

Polymer Modified Asphalt Binder(1)

Standard Grade Additional Requirements Option 1

ASTM D6373, Table 1 PG 76-22 Minimum Percent Recovery of 75(2)

Maximum Separation of Polymer, Percent Difference, of 10(3)

Option 2 ASTM D8239 PG 64E-22 Minimum Percent Recovery of 75(2)

Maximum Separation of Polymer, Percent Difference, of 10(3)

(1) No Polyphosphoric Acid (PPA) is allowed. Provide statement on CoA indicating no PPA was used in production of the asphalt binder.

(2) Determine percent recovery in accordance with ASTM D7405 at a test temperature of 64°C.

(3) Determine separation of polymer in accordance with ASTM D7173 on original binder followed by dynamic shear rheometer (DSR) testing. Prepare the DSR samples from the top and bottom portion of aluminum tubes as described in ASTM D7173. Perform DSR at 64°C on the top and bottom materials using 25mm parallel plate geometries in accordance with AASHTO T 315 and determine the G*/(sin*delta) values at 12% strain, 10 rad/sec by averaging the last 10 cycles out of 20 cycles. Calculate the difference in top and bottom results

(D) as a percentage of the average values. Report results to the nearest 0.1.

D = [{(G*/Sin(delta))top - (G*/Sin(delta))bottom}/{(G*/Sin(delta))top + (G*/Sin(delta))bottom / 2}] * 100

Provide test data indicating grade certification by the supplier at the time of delivery of each load to the mix plant. Submit copies of these certifications to the Government. The supplier is defined as the last source of any modification to the binder. Obtain samples for this verification testing in accordance with ASTM D140/D140M. Provide these samples to the Government for the verification testing. Submit 20 L sample of the asphalt binder specified for mix design verification and approval not less than 14 days before start of the test section.

2.5 MIX DESIGN

Develop the mix design and provide results of the Job Mix formula (JMF) and aggregates testing with adequate time for review, revision, and approval prior to CTORD. Provide asphalt mixture composed of well-graded aggregate, mineral filler if required, and asphalt material. Provide aggregate fractions sized, handled in separate size groups, and combined in such proportions that the resulting mixture meets the grading requirements of Table 7.

Design the asphalt mixture using hand-held (manual) Marshall hammer procedures contained in AI MS-2 and the criteria shown in Table 8. Mechanical hammers are not permitted during JMF development. Prepare samples at various asphalt contents and compacted in

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SECTION 32 12 15.13 Page 7 accordance with ASTM D6926. Use laboratory compaction temperatures for Polymer Modified Asphalts as recommended by the asphalt binder supplier. For tensile strength ratio (TSR) testing, adjust the compactive effort, as required, to provide specimens with an air void content of 7 plus or minus 1 percent. If the Tensile Strength Ratio (TSR) of the composite mixture, as determined by ASTM D4867/D4867M is less than 75, reject the aggregates or treat the asphalt mixture with an anti-stripping agent. Add a sufficient amount of anti-stripping agent to produce a TSR of not less than 75. If an antistrip agent is required, provide it at no additional cost to the Government. Provide sufficient materials to produce 90 kg of blended mixture to the Government for verification of mix design at least 14 days prior to making of test section.

2.5.1 JMF Requirements

Submit the proposed JMF in writing, for approval, at least 14 days prior to the start of the test section, including as a minimum:

a. Percent passing each sieve size.

b. Optimum asphalt content.

c. Percent of each aggregate and mineral filler to be used.

d. Asphalt viscosity grade, penetration grade, or performance grade and additional test requirements as specified in paragraph ASPHALT BINDER.

e. Number of blows of hammer per side of molded specimen.

f. Laboratory mixing and compaction temperatures.

g. Supplier-recommended field mixing and compaction temperatures.

h. Percentage and properties (asphalt content aggregate gradation, and aggregate properties) of RAP in accordance with paragraph RECYCLED ASPHALT PAVEMENT, if RAP is used.

i. Temperature-viscosity relationship of the asphalt binder.

j. Plot of the combined gradation on the 0.45 power gradation chart, stating the nominal maximum size.

k. Graphical plots and summary tabulation of stability, flow, air voids, voids in the mineral aggregate, and unit weight versus asphalt content as shown in AI MS-2.

Include summary tabulation that includes individual specimen data for each specimen tested.

l. Specific gravity and absorption of each aggregate.

m. Percent natural sand.

n. Percent particles with two or more fractured faces (in coarse aggregate).

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o. Fine aggregate angularity.

p. Percent flat or elongated particles (in coarse aggregate).

q. Tensile Strength Ratio and wet/dry specimen test results.

r. Type and amount of antistrip agent (if required).

s. List of all modifiers.

t. Percentage and properties (asphalt content aggregate gradation, and aggregate properties) of RAP in accordance with paragraph RECLAIMED ASPHALT PAVEMENT, if RAP is used.

u. Date the JMF was developed. Mix designs that are not dated, or which are from a prior period or contract may not be accepted.

Table 8

Marshall Design Criteria

Test Property 75 Blow Mix

Stability, N minimum 9560(1)

Flow, 0.25 mm 8-16(2)

Air voids, percent 4.0(4)

Percent Voids in mineral aggregate (minimum) See Table 9

Dust Proportion(3) 0.8-1.2

TSR, minimum percent 75

TSR Conditioned Strength (minimum kPa) 415

(1) This is a minimum requirement. Provide significantly higher average during production to ensure compliance with the specifications.

(2) The flow requirement is not applicable for Polymer Modified Asphalts

(3) Dust Proportion is calculated as the aggregate content, expressed as a percent of mass, passing the 0.075 mm sieve, divided by the effective asphalt content, in percent of total mass of the mixture.

(4) Select the JMF asphalt content corresponding to an air void content of 4.0 percent. Verify the other properties of Table 8 meet the specification requirements at this asphalt content.

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Table 9

Minimum Percent Voids in Mineral Aggregate (VMA)(1)

Mix Design Minimum VMA, percent

75 Blow Mix 14.0

(1) Calculate VMA in accordance with AI MS-2, based on ASTM C127 and ASTM C128 bulk specific gravity for the aggregate.

2.5.2 Adjustments to JMF

The JMF for each mixture is in effect until a new formula is approved in writing by the Government. Should a change in sources of any materials be made, perform a new mix design and a new JMF approved before the new material is used. Make minor adjustments within the specification limits to the JMF to optimize mix volumetric properties.

Adjustments to the original JMF are limited to plus or minus 4 percent on the 4.75 mm and coarser sieves; plus or minus 3 percent on the 2.36 mm to 0.30 mm sieves; and plus or minus 1 percent on the 0.15 mm sieve. Adjustments to the JMF are limited to plus or minus

1.0 percent on the 0.075 mm sieve. Asphalt content adjustments are limited to plus or minus

0.40 from the original JMF. If adjustments are needed that exceed these limits, develop a new mix design.

2.6 RECLAIMED ASPHALT PAVEMENT

Reclaimed asphalt is not allowed for the project.

2.7 RECYCLED ASPHALT SHINGLES

Recycled asphalt shingles (RAS) is not allowed for the project.

PART 3 EXECUTION

3.1 CONTRACTOR QUALITY CONTROL

3.1.1 General Quality Control Requirements

The contractor shall maintain a Pavement Quality Control Plan.

3.1.3.1 Asphalt Content

Determine asphalt content by one of the following methods: extraction method in accordance with ASTM D2172/D2172M, Method A or B, the ignition method in accordance with ASTM D6307, or the nuclear method in accordance with ASTM D4125/ D4125M, provided each method is calibrated for the specific mix being used. For the extraction method, determine the weight of ash, as described in ASTM D2172/D2172M, as part of the

Attach ment 2: Asphalt Mix Design Specifications; Tinian, first extraction test performed at the beginning of plant production. Use the last weight of ash value in the calculation of the asphalt content for the mixture. The asphalt content for the lot will be determined by averaging the test results.

3.1.3.2 Aggregate Properties

Determine aggregate gradations from mechanical analysis of recovered aggregate in accordance with ASTM D5444, ASTM C136/C136M, and ASTM C117. Determine the specific gravity of each aggregate size grouping for each 20,000 US tons in accordance with ASTM C127 or ASTM C128. Determine fractured faces for gravel sources for each 20,000 US tons in accordance with ASTM D5821. Determine the uncompacted void content of fine aggregate (including manufactured sand and blending aggregate) for each 20,000 US tons in accordance with ASTM C1252 Method A.

3.1.3.3 Temperatures

Check temperatures at necessary locations, to determine the temperature at the dryer, the asphalt binder in the storage tank, the asphalt mixture at the plant, and the asphalt mixture at the job site.

3.1.3.4 Moisture Content of Aggregate

Determine the moisture content of aggregate used for production in accordance with ASTM C566.

3.1.3.5 Moisture Content of Mixture

Determine the moisture content of the mixture in accordance with AASHTO T 329.

3.1.3.6 Laboratory Air Voids, TMD, and VMA, Marshall Stability and Flow

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Obtain mixture samples using 75 blows per side with the Marshall hand-held (manual) hammer as described in ASTM D6926. The mechanical Marshall hammer can be used only after JMF development and after correlation from hand-held (manual) Marshall hammer to mechanical Marshall hammer per guidance in AI MS-2. After compaction, measure the bulk density of laboratory compacted specimens in accordance with ASTM D2726/D2726M. Determine the laboratory air voids from the set (three laboratory compacted specimens) for each sample in accordance with ASTM D3203/D3203M.

Also calculate the VMA of each specimen in accordance with AI MS-2 based on ASTM C127 and ASTM C128 bulk specific gravity for the aggregate, as well as the Marshall stability and flow, as described in ASTM D6927. The asphalt is the contractor’s responsibility up to the placement into the paver. The Contractor will test asphalt to ensure it meets requirements. If asphalt is found to be not within specifications, the amount that didn’t meet specs will be re- batched by the contractors at the contractor’s expense. Provide VMA within the limits of Table 9.

3.2 PREPARATION OF ASPHALT BINDER MATERIAL

Heat the asphalt binder material while avoiding local overheating and providing a continuous supply of the asphalt material to the mixer at a uniform temperature. Maintain the temperature of unmodified asphalts to no more than 160 degrees C when added to the aggregates. The temperature of modified asphalts is not to exceed 175 degrees C.

3.3 PREPARATION OF MINERAL AGGREGATE

Heat and dry the aggregate for the mixture prior to mixing. No damage to the aggregates due to the maximum temperature and rate of heating used is allowed. Maintain the temperature no lower than is required to obtain complete coating and uniform distribution on the aggregate particles and to provide a mixture of satisfactory workability.

3.4 PREPARATION OF ASPHALT MIXTURE

Weigh or meter the aggregates and the asphalt binder and introduce into the mixer in the amount specified by the JMF. Limit the temperature of the asphalt mixture to 175 degrees C when the asphalt binder is added. Mix the combined materials until the aggregate obtains a thorough and uniform coating of asphalt binder (testing in accordance with ASTM D2489/D2489M may be required by the Contracting Officer) and is thoroughly distributed throughout the mixture. The moisture content of all asphalt mixture upon discharge from the plant is not to exceed 0.5 percent by total weight of mixture as measured by AASHTO T 329.

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3.6.1 Sampling and Testing for Test Section

The contractor is responsible for sampling from random trucks at the plant, compact triplicate specimens, and testing for stability, flow, and laboratory air voids. Perform random sampling in accordance with procedures contained in ASTM D3665. The contractor shall ensure that test results are within the tolerances and exceed the minimum values shown in Table 11. If all test results meet the specified requirements, the test section may remain as part of the project pavement. If test results exceed the tolerances shown, remove and replace the test section and construct another test section at no additional cost to the Government.

Table 11

Test Section Requirements for Material and Mixture Properties

Property Specification Limit

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Aggregate Gradation-Percent Passing (Individual Test Result)

4.75 mm No. 4 and larger JMF plus or minus 8

2.36, 1.18, 0.60, and 0.30 mmNo. 8, No. 16, No. 30, and No. 50

JMF plus or minus 6

0.15 and 0.075 mmNo. 100 and No.

JMF plus or minus 2.0

Asphalt Content, Percent (Individual Test Result)

JMF plus or minus 0.5

Laboratory Air Voids, Percent (Average of 3 specimens)

JMF plus or minus 1.0

VMA, Percent (Average of 3 specimens)

See Table 9

Tensile Strength Ratio (TSR) (At 7 percent plus/minus 1 percent air void content)

75 percent minimum

Conditioned Strength 415 kPa 60 psi minimum

Mat Density, Percent of TMD (Average of 4 Random Cores)

92.0 - 96.0

Joint Density, Percent of TMD (Average of 4 Random Cores)

90.5 minimum

3.6.2 Additional Test Sections

If the initial test section proves to be unacceptable, make the necessary adjustments to the JMF, plant operation, placing procedures, and rolling procedures before beginning making a second test section. Construct and evaluate additional test sections, as required, for conformance to the specifications.

3.7 TRANSPORTING AND PLACING

3.7.1 Transporting

Transport asphalt mixture from the mixing plant to the site in clean, tight vehicles.

Schedule deliveries so that placing and compacting of mixture is uniform with minimum stopping and starting of the paver. Provide adequate artificial lighting for night placements. Hauling over freshly placed material is not permitted until the material has been compacted as specified, and allowed to cool to 60 degrees C (140 degrees F).

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BITUMINOUS TACK AND PRIME COATS

PART 1 GENERAL

1.1 UNIT PRICES

The bituminous material paid for under the terms of the task order. Express measured quantities in gallons at 60 degrees F]. Correct volumes measured at temperatures other than 60 degrees F in accordance with ASTM D1250 using a coefficient of expansion of 0.00025 per degree F for asphalt emulsion.

1.2 REFERENCES

The publications listed below form a part of this specification to the extent referenced.

The publications are referred to within the text by the basic designation only.

Attachment 3: Bituminous Tack Coat and Prime Coat Specifications; Tinian, CNMI

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AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION

OFFICIALS (AASHTO)

AASHTO T 102 (2009; R 2013) Standard Method of Test for Spot Test of Asphaltic Materials

ASTM INTERNATIONAL (ASTM)

ASTM D140/D140M (2016) Standard Practice for Sampling Asphalt Materials

ASTM D946/D946M (2020) Standard Specification for Penetration- Graded Asphalt Cement for Use in Pavement Construction

ASTM D977 (2019a; E 2019) Standard Specification for Emulsified Asphalt

ASTM D1250 (2019; E 2020) Standard Guide for Use of the Joint API and ASTM Adjunct for Temperature and Pressure Volume Correction Factors for Generalized Crude Oils, Refined Products, and Lubricating Oils:

API MPMS Chapter 11.1

ASTM D2026/D2026M (2015) Cutback Asphalt (Slow-Curing Type)

ASTM D2027/D2027M (2019) Cutback Asphalt (Medium-Curing Type)

ASTM D2028/D2028M (2015) Cutback Asphalt (Rapid-Curing Type)

ASTM D2397/D2397M (2019a) Standard Specification for Cationic Emulsified Asphalt

ASTM D2995 (1999; R 2009) Determining Application Rate of Bituminous Distributors

ASTM D6373 (2016) Standard Specification for Performance Graded Asphalt Binder

U.S. GREEN BUILDING COUNCIL (USGBC)

LEED BD+C (2009; R 2010) Leadership in Energy and Environmental Design(tm) Building Design and Construction (LEED-NC)

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1.4 QUALITY ASSURANCE

Certificates of compliance for asphalt materials delivered will be obtained and checked to ensure that specification requirements are met. Quantities of applied material will be determined. Tack coat materials will not be diluted. Prime coat materials when emulsions are used can be diluted on site with potable water up to 1 part emulsion to 1 part water.

1.5 DELIVERY, STORAGE, AND HANDLING

Inspect the materials delivered to the site for contamination and damage. Unload and store the materials with a minimum of handling.

1.6 EQUIPMENT, TOOLS AND MACHINES

1.6.1 General Requirements

Equipment, tools and machines used in the work are subject to approval. Maintain in a satisfactory working condition at all times. Calibrate equipment such as asphalt distributors, scales, batching equipment, spreaders and similar equipment within 12 months of their use. If the calibration expires during project, recalibrate the equipment before work can continue.

1.6.2 Heating Equipment for Storage Tanks

Provide and use steam, electric, or hot oil heaters for heating the bituminous material.

Provide steam heaters consisting of steam coils and equipment for producing steam, so designed that the steam cannot come in contact with the bituminous material. Fix an armored thermometer to the tank with a temperature range from 40 to 400 degrees F so that the temperature of the bituminous material may be determined at all times.

PART 2 PRODUCTS

2.1 PRIME COAT

Provide asphalt conforming to one of the following grades:

2.1.1 Emulsified Asphalt

Provide emulsified asphalt conforming to [ASTM D977, Type [SS-1] [SS1h]] [ ASTM D2397/D2397M, Type [CSS-1] [CSS-1h]]. Asphalt emulsion can be diluted up to 1 part water to 1 part emulsion for prime coat use. Do not dilute asphalt emulsion for tack coat use.

2.2 TACK COAT

2.2.1 Emulsified Asphalt

Provide emulsified asphalt conforming to ASTM D977, Type SS1h ASTM D2397/D2397M, Type CSS-1h. For prime coats the emulsified asphalt can be diluted with up to 1 part emulsion to 1 part water.