Attachment 2 Specifications Air Field.pdf

673 CIVIL ENGINEERING

SQUADRON

CES/CENM

STANDARD

SPECIFICATIONS

FOR

AIRFIELD CONSTRUCTION

A SUPPLEMENT TO THE 2019 SSRC

Edition

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FA500019RA002 JBER Paving

Attachment 2 - Specifications for Airfields

Contents

SECTION 106 DEFINITIONS AND TERMS

SECTION 301 AGGREGATE BASE AND SURFACE COURSE

SECTION 306 ASPHALT TREATED BASE COURSE

SECTION 308 CRUSHED ASPHALT BASE COURSE

SECTION 309 AGGREGATE DRAINAGE LAYER

SECTION 403 JOINT SEALING FILLER, BITUMINOUS PAVEMENT

SECTION 404 SEAL COAT AND BITUMINOUS SURFACE TREATMENT

SECTION 409 ASPHALT PAVING FOR AIRFIELDS

SECTION 502 CONCRETE PAVING FOR AIRFIELDS AND OTHER HEAVY DUTY PAVEMENTS

SECTION 504 RESEALING OF JOINTS IN RIGID PAVEMENT

SECTION 601 PAVEMENT GROOVING

SECTION 602 AIRCRAFT TIE-DOWN AND GROUNDING

SECTION 605 AIRFIELD MANHOLES AND INLETS

SECTION 612 JET BLAST DEFLECTOR

SECTION 615 STANDARD SIGNS

SECTION 643 TRAFFIC MAINTENANCE

SECTION 660 SIGNALS AND LIGHTING

SECTION 661 UNDERGROUND CABLE

SECTION 664 CONDUIT

SECTION 670 TRAFFIC MARKINGS

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NOTE TO USERS

These Specifications are a supplement to the 2019 Standard Specifications for Road Construction, 2019 Edition (SSRC). Descriptions, scope of work, and materials in the SSRC will be the same for work and materials used in airfield construction unless otherwise amended here.

When using these Specifications for airfield work, replace references to “roadways” with “airfield”, “taxiway”, “runway”, etc. as appropriate.

Work items required for use on airfields, but which are not contained in this Supplement are located in, and will be paid for using, the Standard Specifications for Road Construction.

SECTION 106

DEFINITIONS AND TERMS

Add the following Subsections:

106-1.18 AIRFIELD WORK REQUIREMENTS AND RESTRICTIONS. The Contractor shall coordinate all airfield work thru the Project Manager to the Chief, Airfield Manager and the Airfield Manager at least 30 days in advance to plan the airfield work schedule. Notify the Airfield Manager again 10 days prior to starting work.

The Contractor will be required to immediately move his equipment and personnel a minimum of 500 feet from the edge of the runway or taxiway or parking apron at times of aircraft emergencies, ground movement of heavy cargo aircraft, or operational exercises. Such removals, when required, will be given on 5 minutes notice, usually by the control tower, and expedient action by the Contractor is required.

The Contractor shall be aware of the restricted areas on the airfield and shall not enter these areas unless approved by the Airfield Manager and Security Forces. Delay time should be expected for work in these areas.

The Contractor’s Superintendent and each work crew shall have a 2-way radio when working on the airfield to maintain radio contact with the control tower at all times. The frequency required shall be arranged with the Chief of Airfield Management.

“No closure” runway work shall be accomplished on the weekends from 1800 hours on Friday to 0600 hours on Monday, and on week nights from 1800 hours to 0600 hours, unless approved otherwise by the Government. This runway work typically involves spall repairs, concrete joint and crack resealing, and AC crack sealing. “No closure” means that take-offs and landings are occurring on the runway being worked on but on a limited basis.

The runway will remain open during “no closure” times for landings and takeoffs and the Contractor will be required to vacate described above. The Contractor should expect long delays in getting on the runways and several interruptions requiring vacating the runways. The Contractor shall coordinate all runway work with the Government as described above. The Chief of Airfield Management will attempt to provide a partial or complete closure of the runway or re-route air traffic to the other runway.

When aircraft are arriving or departing an active runway, the Contractor will be restricted from operations 1,000 feet beyond the threshold and 300 feet from the centerline of the active runway. Additionally, the Contractor shall have no equipment, workers or other obstacles that extend above a line that has a 1:35 slope along the longitudinal axis of the runway centerline and a 1:7 slope perpendicular to the runway centerline. The Contractor may return his equipment and/or workers to this restricted area upon clearance from the Elmendorf Ground Control after the aircraft has taxied and taken off or landed.

Excavate for trenches only when material is on hand and ready for placing. Immediately after material has been placed and work approved, trenches shall be backfilled and compacted as required by the Contract. During the work, all hazardous conditions shall be marked and lighted in accordance with these Specifications.

Any stockpile area within the airfield will require approval from the Government. Only approved clean fill, asphalt, and concrete shall be placed stored there.

106-1.19 SCHEDULE OF WORK ON AIRFIELD. Construction work hours on the airfield other than the runways shall be limited to Monday thru Saturday from 0600 to 2100 hours, excluding federal holidays, unless approved otherwise by the Government. However, the Contractor may have to schedule work on the airfield to conform to aircraft operating schedules which may differ from the above work hours.

The Contractor shall request permission from the Airfield Manager thru the Project Manager at least 72 hours in advance when the Contractor plans on working after 1800 hours on weekdays and on Saturdays and Sundays for accomplishing runway work or to work outside of permitted hours in other areas of the airfield.

Submit to the Government a schedule and work plan for airfield work. The work plan shall include: the location of the work; distances from the ends of runways, taxiways, buildings, and other structures as necessary; and dates and hours during which the work will be performed. Notify the Government of any changes prior to beginning each day's work.

The Government will attempt to schedule and route aircraft so as to permit the maximum amount of time for the Contractor's activities. However, in the event of an emergency, intense operational demands, adverse wind conditions and other such unforeseen difficulties, the Contractor shall discontinue operations at the specified work locations of the airfield.

It is estimated that approximately 50 flights per day between the hours of 0700 to 1600, and approximately 5 flights between 1600 to 0700 will occur.

The Contractor shall not perform any work within the airfield or surrounding roads (as defined by the Government) during the JBER Air Show. The work restriction begins at 1200 on Thursday and ends at 0600 on Monday. The Contractor will be notified as soon as possible after an established date is confirmed.

The Contractor may experience construction delays in accomplishing work on the airfield during military exercises. Some work areas will not be available to the Contractor during military exercises and some work areas during military exercises will be available to the Contractor only from 1800 to 0600 hours on weeknights and on weekends from 1800 hours on Friday to 0600 hours on Monday. The Contractor should plan on four 10-day to 14-day military exercises on the airfield between the months of May thru September. The Contractor will be notified as soon as possible after established dates are confirmed.

The Contractor may experience construction delays of up to 4 hours in performing work on the airfield during Military Distinguished Visitor (DV) Visits, Change of Command Ceremonies, and other Special Events. Some work areas will not be available to the Contractor during these events. The Contractor should plan for delays or shutdowns of four delays on the airfield between the months of May thru September. The Contractor will be notified as soon as possible after established dates are confirmed.

106-1.20 WORK IN LANDING AREAS. The Contractor shall place nothing upon the landing areas without authorization of the Airfield Manager.

Unless otherwise authorized by the Airfield Manager, the Contractor shall outline those landing areas hazardous to aircraft, with red flags by day, & with electric, battery-operated, low-intensity red flasher lights by night.

Each time before entering any landing area, additional permission must be obtained from the Elmendorf Ground Control, unless the landing area is marked as hazardous to aircraft in accordance with the preceding paragraph.

All vehicles which the Contractor operates in landing areas shall be identified by means of a flag on a staff attached to and flying above the vehicle. The flag shall be three feet square and shall consist of a checkered pattern of international orange and white squares of one foot on each side (except that the flag may vary up to 10 percent from each of these dimensions).

Unless otherwise authorized by the Airfield Manager, all other equipment and materials in the landing areas shall be marked with red flags by day, and with electric, battery-operated, low-intensity red flasher lights by night.

Work shall be carried on so as to leave that portion of the landing area which is available to aircraft free from hazards, holes, piles of material and projecting shoulders that might damage an airplane tire.

SECTION 301

AGGREGATE BASE AND SURFACE COURSE

Add the following Pay Items:

Pay Item Pay Unit 301(3) Crushed Aggregate Base Course for Airfields, Grading D-1 Ton 301(4) Crushed Aggregate Base Course for Airfields, Grading C-1 Ton

SECTION 306

ASPHALT TREATED BASE COURSE

306-6.01 BASIS OF PAYMENT. Add the following Pay Item:

306(2) Asphalt Treated Base (ATB) Course for Airfields Ton

SECTION 308

CRUSHED ASPHALT BASE COURSE

308-5.01 BASIS OF PAYMENT. Add the following Pay Items:

308(3) Crushed Asphalt Base Course for Airfields Ton 308(4) CSS-1 Asphalt for Base Course on Airfields Ton

Add the following Section:

SECTION 309

AGGREGATE DRAINAGE LAYER

309-1.01 DESCRIPTION. Construct a drainage layer under the pavements, as indicated on drawings, consisting of Rapid Draining Material (RDM) or Open Graded Material (OGM) stabilized with cement or bituminous material.

309-2.01 MATERIALS. Asphalt or cement stabilized material will require Government notification and approval in accordance with this Section.

309-2.02 AGGREGATE. If a JBER gravel extraction site is not used, select the aggregate source at least 60 days prior to field use in the test section. Tentative approval of the source will be based on certified test results to verify that materials proposed for use meet the contract requirements. Final approval of both the source and the material will be based on test section performance and tests for gradation, soundness, wear, flat and/or elongated particles tests and fractured faces tests. For aggregate drainage layer materials, perform these tests on samples taken from the completed and compacted drainage layer course within the test section. For bituminous or cement stabilized drainage layer material, perform these tests on aggregate samples taken prior to addition of bituminous or cementitious material and subsequent placement in the test section.

Provide aggregates consisting of clean, sound, hard, durable, angular particles of crushed stone, crushed slag, or crushed gravel which meet the specification requirements. Slag must be an air-cooled, blast-furnace product having a dry weight of not less than 65 pcf determined by ASTM C29. Provide aggregates free of silt and clay as defined by ASTM D2487, vegetable matter, and other objectionable materials or coatings.

Provide aggregate with a soundness loss not greater than 18 percent weighted averaged at 5 cycles when tested in magnesium sulfate in accordance with ASTM C88 and a percentage of loss on abrasion not exceeding 40after 500 revolutions as determined by ASTM C131. Determine the percentage of flat and/or elongated particles by ASTM D4791 with the following modifications:

1) Separate the aggregates into two size fractions, particles greater than 1/2 inch sieve and particles passing the 1/2 inch sieve and retained on the No. 4 sieve.

2) The percentage of flat and/or elongated particles in either fraction must not exceed 20.

3) A flat particle is one having a ratio of width to thickness greater than 3; an elongated particle is one having a ratio of length to width greater than 3.

4) When the aggregate is supplied from more than one source, aggregate from each source must meet the specified requirements.

When the aggregate is supplied from crushed gravel it must be manufactured from gravel particles, 90 percent of which by weight are retained on the maximum-size sieve listed in Table 1. In the portion retained on each sieve specified, the crushed gravel must contain at least 90 percent by weight of crushed pieces having two or more freshly fractured faces with the area of each face being at least equal to 75 percent of the smallest midsectional area of the face. When two fractures are contiguous, the angle between planes of the fractures must be at least 30 degrees in order to count as two fractured faces.

Provide drainage layer aggregates that are well graded within the limits specified in Table 1.

Table 1 – Gradation of Drainage Layer Material – Percent by Weight Passing Sieve Designation Rapid Draining Material (RDM) Open Grated Material (OGM)

1-1/2 inch 100 100 1 inch 70-100 95-100 ¾ inch 55-100 - ½ inch 40-80 25-80 3/8 inch 30-65 -

No. 4 10-50 0-10 No. 8 0-25 0-5

No. 16 0-5 -

The values are based on aggregates of uniform specific gravity, and the percentages passing the various sieves may require appropriate correction by the Government when aggregates of varying specific gravities are used.

For RDM, the coefficient of uniformity (CU) must be greater than 3.5. (CU = D60/D10). The Contractor is responsible for adjusting the RDM gradation within the ranges listed in Table 1 to provide a stable construction surface for the proposed equipment and method of transporting materials. The drainage layer may be stabilized with Portland cement or asphalt at no additional cost to the government, if approved during the test section.

Asphalt cement or Portland cement is required to stabilize the OGM.

309-2.03 BITUMINOUS MATERIAL. Asphalt cement to be mixed with aggregates must conform to Performance Grade 52-28. In addition, the asphalt cement must show a negative spot when subjected to the spot test in accordance with AASHTO T 102, using the standard naphtha specified.

Submit bituminous or cementitious sources and certified material test results for approval not less than 60 days prior to field use in the test section.

309-2.04 CEMENTITIOUS MATERIAL. Portland cement to be mixed with aggregates must conform to ASTM C150 Type I, IA, II or IIA.

309-2.05 BITUMINOUS OR CEMENT STABILIZED JOB-MIX FORMULA. The bituminous stabilized mix consists of a mixture of OGM and a minimum of 2 percent asphalt cement by weight. Maintain tolerances for bituminous stabilized material for field production at plus or minus 0.25 percent for asphalt cement and plus or minus 25 degrees F for mixing temperatures. Provide cement stabilized mix consisting of OGM and a minimum of 200 pounds of Portland cement per cubic yard with a water/cement ratio of 0.37. Based on the test section performance, the Contractor will be responsible for adjustments (increases) in asphalt cement or Portland cement quantities to ensure the stabilized drainage layer will not rut or be disturbed by the Contractor's proposed paving method. Submit a job-mix formula (JMF) with the test section report for Government approval.

309-3.01 SAMPLING AND TESTING. Sampling and testing are the responsibility of the Contractor. Perform sampling and testing using a laboratory approved in accordance with these Specifications. Test the materials to establish compliance with the specified requirements and perform testing at the specified frequency. The Government may specify the time and location of the tests. Furnish copies of test results to the Government within 24 hours of completion of the tests.

Take aggregate samples in accordance with ASTM D75. Take bituminous samples in accordance with ASTM D140. Take bituminous or cement stabilized mixture samples using methods approved by the Government.

At a minimum, the Contractor shall perform the following tests:

1. Sieve Analysis. Perform sieve analyses in accordance with ASTM C117 and ASTM C136 using sieves conforming to ASTM E11.

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FA500019RA002 JBER Paving

2. Field Density Tests. Perform field density tests for RDM drainage layers in accordance with ASTM

D6938 by Direct Transmission Method for the full depth of the lift, use ASTM D6938 to determine the moisture content of the aggregate drainage layer material. Check the calibration curves furnished with the moisture gauges along with density calibration checks as described in ASTM D6938. Make the calibration checks of both the density and moisture gauges using the prepared containers of material method, as described in paragraph "Calibration" of ASTM D6938, on each different type of material being tested at the beginning of a job and at intervals as directed by the Government. Submit copies of field test results within 24 hours after the tests are performed.

3. Soundness Test. Perform soundness tests in accordance with ASTM C88.

4. Wear Test. Perform wear tests in conformance with ASTM C131.

5. Flat or Elongated Particles Test. Perform flat and/or elongated particles tests in accordance with ASTM D4791.

6. Fractured Faces Test. When aggregates are supplied from crushed gravel, use approved test methods to ensure the aggregate meets the requirements for fractured faces.

7. Bitumen Content. Perform bitumen extraction tests in accordance with ASTM D2172 or ignition tests in accordance with ASTM D6307.

309-3.02 INITIAL TESTS. Perform one of each of the following tests (309-3.01.1, 3, 4, 5, 6) on the proposed material, prior to commencing construction, to demonstrate that the proposed material meets all specified requirements when furnished. If the material source changes during the life of the Task Order, perform the tests again on the material from the new source. Submit material sources and material test results prior to field use.

309-3.03 IN-PLACE TESTS.

1. Aggregate Layer. Perform field density and moisture content tests at a rate of at least one test for every 2,000 square yards of completed area and not less than one test for each day's production.

Perform sieve analyses at a rate of at least one test for every 6,000 square yards of completed area.

Perform soundness tests, wear tests, fractured faces tests and flat and/or elongated particles tests at the rate of one test for every 12,000 square yards of production.

2. Stabilized Layer. Perform sieve analyses on aggregates prior to addition of asphalt or Portland cement, at a rate of at least one test for every 6,000 square yards of completed area and not less than one test for each days production. Make extraction tests on bituminous stabilized material at the same frequency.

Perform soundness tests, Los Angeles abrasion tests, fractured faces tests, and flat and/or elongated particles tests at the rate of one test for every 12,000 square yards of production.

309-4.01 SURFACE PREPARATION. Clean the underlying course of all foreign materials prior to constructing the drainage layer. Do not construct the drainage layer on underlying course that is frozen. Construct the underlying course in accordance with the Specifications and Drawings. Correct ruts or soft yielding spots in the underlying courses having inadequate compaction and deviations of the surface from the requirements set forth herein by loosening and removing soft or unsatisfactory material and by adding approved material, reshaping to line, and grade, and recompacting to specified density. Do not allow traffic or other operations to disturb the finished underlying course and maintain in a satisfactory condition until the drainage layer is placed.

309-4.02 TRANSPORTING MATERIAL. Transport aggregate drainage layer material to the site in a manner

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FA500019RA002 JBER Paving which prevents segregation and contamination of materials.

Transport bituminous stabilized material from the mixing plant to the site in trucks having tight, clean, smooth beds lightly coated with an approved releasing agent to prevent adhesion of the stabilized material to the truck beds. Drain excessive releasing agent prior to loading. Cover each load with canvas or other approved material of ample size to protect the stabilized material from the weather and to prevent loss of heat. Loads that have crusts of cold, unworkable material or have become wet will be rejected. Hauling over freshly placed material will not be permitted.

Transport cement stabilized material from the mixing plant to the site in trucks equipped with protective covers.

Loads that have crusts of unworkable material or have become excessively wet will be rejected. Hauling over freshly placed material will not be permitted.

309-4.03 PLACEMENT. Place drainage layer material when the atmospheric temperature is above 35 degrees F. Correct areas of completed drainage layer or underlying courses that are damaged by freezing, rainfall, or other weather conditions or by contamination from sediments, dust, dirt, or foreign material to meet specified requirements.

Place drainage layer material on the underlying course in lifts of uniform thickness using equipment meeting the requirements listed below. When a compacted layer 6 inches or less in thickness is required, place the material in a single lift. When a compacted layer in excess of 6 inches is required, place the material in lifts of equal thickness. No lift may be thicker than 6 inches nor be thinner than 3 inches in compacted thickness. Place and compact lifts true to the grades or levels required with the least possible surface disturbance. Where the drainage layer is placed in more than one lift, clean the previously constructed lift of loose and foreign material.

Make adjustments in placing procedures or equipment as needed to obtain true grades and minimize segregation and degradation of the drainage layer material.

1. Placement Equipment. Use an asphalt paving machine to place drainage layer material. Alternate methods may be used if it can be demonstrated in the test section that these methods obtain the specified results.

2. Compaction Equipment. Use a dual or single smooth 2000 lb (min.) vibratory drum roller, which provides a maximum compactive effort without crushing the drainage layer aggregate, to compact drainage layer material.

3. Bituminous Mixing Plant. Use a bituminous mixing plant that is an automatic or semiautomatic controlled, commercially manufactured unit capable of producing a bituminous stabilized aggregate mixture consistent with the job-mix formula (JMF).

4. Cementitious Mixing Plant. Use a cementitious mixing plant that is an automatic or semiautomatic controlled, commercially manufactured unit capable of producing a cement stabilized aggregate mixture consistent with the approved job mix formula. Dry mix aggregate and cement sufficiently to prevent cement balls from forming when water is added.

Bituminous stabilized material having temperatures less than 175 degrees F when dumped into the asphalt paving machine will be rejected. Adjust the paving machine so that the surface of the lift being laid will be smooth and continuous without tears and pulls. Correct irregularities in alignment of the lift left by the paving machine by trimming directly behind the machine. Immediately after trimming, thoroughly compact the edges of the lift by a method approved by the Government. Distortion of the lift during tamping will not be permitted. If more than one lift is required, offset the longitudinal joint in one lift over that in the lift immediately below by at least 1 foot;

however, construct the joint in the top layer at the centerline of the pavement. Offset transverse joints in one layer by at least 2 feet from transverse joints in the previous layer. Offset transverse joints in adjacent strips by a minimum of 10 feet. At the end of each day's construction, form a straight transverse construction joint by cutting

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FA500019RA002 JBER Paving back into the completed work to form a true vertical face free of loose or shattered material. Remove material along construction joints not properly compacted.

Place drainage layer material when the atmospheric temperature is above 35 degrees F. Correct areas of completed drainage layer or underlying courses that are damaged by freezing, rainfall, or other weather conditions or by contamination from sediments, dust, dirt, or foreign material to meet specified requirements.

309-4.04 PLACING ADJACENT STABILIZED STRIPS. Place the stabilized material in consecutive adjacent strips having a minimum width of 10 feet, except where edge lanes require strips less than 10 feet to complete the area. When placing adjacent strips, operate the paving machine so that the screed overlaps the previously placed strip 3 to 4 inches and is sufficiently high so that compaction will produce a smooth, dense joint. Push back the stabilized material placed on the edge of the previously placed strip by the paver to the edge of the strip being placed. Remove and waste excess stabilized material.

309-4.05 HAND SPREADING. Spread by hand drainage layer material in areas where machine spreading is impractical. Spread the material uniformly in a loose layer to prevent segregation. Construct the layer so that the compacted material conforms to the required grade and thickness after compaction.

309-5.01 TEST SECTION. Construct a test section to evaluate the ability to carry traffic, including placement of overlaying material and the constructability of the drainage layer including required mixing, placement, and compaction procedures. Test section data will be used by the Government to validate the required number of compaction passes given in this Section and the field dry density requirements for full scale production.

One test section will be required each year regardless of the number of drainage layers contained in the Task Orders for that year. Construct the test section a minimum of 30 days prior to the start of full scale production of the first drainage layer contained in the Task Order for that year to provide sufficient time for an evaluation of the proposed materials, equipment and procedures including Government QA testing.

Provide certified test results, approved by the Government prior to the start of the test section, to verify that the materials proposed for use in the test section meet the Contract requirements.

Place the test section inside the production paving limits. Do not construct the drainage layer in the test section until the underlying courses and subgrade preparation, required for the pavement section, have been completed, inspected and approved. Place the test section a minimum of 100 feet long and two full paving lanes wide side by side.

Perform mixing, placement, and compaction using equipment described in this Section. Operate compaction equipment at speeds no greater than 1.5 mph. Start compaction from the outside edges of the paving lane and proceed to the centerline of the lift being placed. Keep the roller a minimum of one half the roller width from the outside edge of the drainage layer being placed until the desired density is obtained. Then roll the outside edge.

309-5.02 RDM AGGREGATE DRAINAGE LAYER TESTS. Construct the test section with aggregate in a wet state so as to establish a correlation between number of roller passes and dry density achievable during field production. Designate three separate areas within the test section, test each area for density, moisture, and gradation. Complete all testing in the middle third of the test section being placed. Conduct density and moisture content tests in accordance with ASTM D6938. Conduct sieve analysis tests on samples, taken adjacent to the density test locations. Take one set of tests (i.e. density, moisture, and sieve analysis) before the third compaction pass and after each subsequent compaction pass at three separate locations as directed by the Government. Define a pass as the movement of a roller over the drainage layer area for one direction only.

Compact the RDM using a maximum of 5 passes in the vibrating state and one final pass in the static state.

Continue compaction passes and density readings until the difference between the average dry densities of any two consecutive passes is less than or equal to 1.0 pcf.

309-5.03 BITUMINOUS/CEMENT STABILIZED DRAINAGE LAYER. Construct the test section with the same equipment used for production. Designate three separate areas within the test section for sampling. Complete all testing in the middle third of the test section being placed. The Government will perform visual examination of each sample to determine if and when crushing of aggregate occurs. Take one sample before compaction and after each subsequent compaction pass at three separate locations as directed by the Government. Continue compaction for a maximum of 6 passes. A pass is defined as the movement of a roller over the drainage layer area for one direction only. Use placement procedures and equipment as described herein. The Contractor shall determine the number of passes required for compaction from the test section.

309-5.04 EVALUATION. Within 10 days of completion of the test section, submit to the Government a Test Section Construction Report complete with all required test data, correlations, and recommendations. The Report shall include an evaluation of the data, validate the required number of passes of the roller, the need for a final static pass of the roller, and the dry density for field density control during construction.

309-6.01 COMPACTION. Base field compaction requirements on the results of the test section, using the materials, methods, and equipment proposed for use in the work.

Perform compaction using rollers meeting the requirements of this Section and operating at a rolling speed of no greater than 1.5 miles per hour. Compact each lift of drainage material, including shoulders when specified under the shoulders, with the number of passes of the roller as follows: for RDM material use 4 passes in the vibratory state and one in the static. For cement or Bituminous stabilized OGM material use 3 passes in the vibratory state and one in the static state. The Government will validate the number of roller passes after the test section is evaluated and before production starts.

Maintain a minimum field dry density as specified by testing. If the required field dry density is not obtained, adjust the number of roller passes in accordance with this Section. Compact aggregate in a moisture state as determined in the test section. Avoid crushing of aggregate particles by excessive rolling. Begin compaction of bituminous stabilized material immediately when the material has cooled to 170 degrees F. Not more than 30 minutes may elapse between the start of moist mixing of cement stabilized material and the start of field compaction. Complete field compaction within 60 minutes. In all places not accessible to the rollers, compact the drainage layer material with mechanical hand operated tampers.

Place shoulder material along the edges of the drainage layer course in a quantity that will compact to the thickness of the layer being constructed. Roll and compact at least a 3 feet width of the shoulder simultaneously with the rolling and compacting of each lift of the drainage layer.

Compact the drainage layer to a thickness that is within 1/2 inch of the thickness indicated. Measure thickness at intervals providing at least one measurement for each 500 square yards of drainage layer. Make measurements in test holes at least 3 inches in diameter unless the Contractor can demonstrate, for Government approval, that a steel rod pushed through the drainage layer clearly stops at the material interface. Where the measured thickness is more than 1/2 inch deficient, correct such areas in accordance with this Section. Where the measured thickness is 1/2 inch more than indicated, it will be considered as conforming to the requirements provided the surface of the drainage layer is within 1/2 inch of established grade. The average job thickness will be the average of all job measurements as specified above but within 1/4 inch of the thickness shown on the drawings.

309-7.01 FINISHING. Finish the top surface of the drainage layer after final compaction, as determined from the test section. Make adjustments in rolling and finishing procedures to obtain grades and minimize segregation and degradation of the drainage layer material.

309-8.01 CURING OF CEMENT STABILIZED MATERIAL. Cure the completed cement stabilized drainage layer with water for a period of 12 hours following completion of compaction. Commence curing operations within 3 hours after compaction. Curing consists of one of the following:

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1. Sprinkling the surface of the drainage layer with a fine spray of water every 2 hours for the required 12 hour period,

2. By continuously saturated burlap or cotton mats, or by continuously saturated plastic coated burlap,

3. Impervious sheet curing.

Apply curing water so that the cement paste on the surface of the mixture will not be eroded. Water trucks will not be permitted on the completed cement stabilized drainage layer. Impervious sheeting curing consists of all surfaces being thoroughly wetted and then completely covered with the sheeting. Place sheeting at least 18 inches wider than the stabilized drainage layer surface to be covered. Lay covering with light-colored side up.

Lap covering not less than 12 inches; securely weight covering to prevent displacement so that it remains in contact with the surface during the specified length of curing. Fold down coverings over exposed edges of slabs and secure by approved means. Immediately repair or replace sheets if tears or holes appear during the curing period.

309-9.01 SMOOTHNESS TEST. Construct the top lift so that the surface shows no deviations in excess of 3/8 inch when tested with either a 12 foot straightedge applied parallel with and at right angles to the centerline of the area to be paved. Correct deviations exceeding 3/8 inch in accordance with this Section.

309-10.01 DEFICIENCIES.

1. Grade and Thickness. Correct deficiencies in grade and thickness so that both grade and thickness tolerances are met. Do not add thin layers of material to the top surface of the drainage layer to meet grade or increase thickness. Trim the top of the drainage layer to grade and finish in accordance with Subsection 309-6.01 if the surface elevation is more than 1/2 inch above the plan grade. If the elevation of the top surface of the drainage layer is 1/2 inch or more below the required grade, scarify the surface of the drainage layer to a depth of at least 3 inches, add new material, and blend and recompact the layer to bring it to grade. Where the measured thickness of the drainage layer is more than 1/2 inch deficient, correct such areas by excavating to the required depth and replace with new material to obtain a compacted lift thickness of at least 3 inches. Control the depth of required excavation to keep the final surface elevation within grade requirements and to preserve layer thicknesses of materials below the drainage layer.

2. Density. Density will be considered deficient if the field dry density test results are below the dry density specified in the Test Section Construction Report. Roll the layer with 2 additional passes of the specified roller if the densities are deficient. If the dry density is still deficient, work will be stopped until the cause of the low dry densities can be determined and reported to the Government.

3. Smoothness. Correct deficiencies in smoothness as if they are deficiencies in grade or thickness.

Maintain all tolerances for grade and thickness while correcting smoothness deficiencies.

309-11.01 METHOD OF MEASUREMENT. Section 109. Deductions will be made for any material wasted, unused, rejected, or used for the convenience of the Contractor.

Measure the quantity of aggregate drainage layer material, completed and accepted, as determined by the Government, in cubic yards.

Measure the quantity of bituminous or cement stabilized drainage layer material, completed and accepted, in cubic yards, including the asphalt or Portland cement used in the mix.

309-12.01 BASIS OF PAYMENT. The quantities of drainage layer aggregates and stabilized drainage layer aggregates including bituminous or cementitious materials, as specified above, will be paid for at the contract

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FA500019RA002 JBER Paving unit prices, which will constitute full compensation for the construction and completion of the drainage layer, including the test section, and the furnishing of all other necessary labor and incidentals.

Payment will be made under:

309(1) Drainage Layer, Aggregate Cubic Yard 309(2) Drainage Layer, Bituminous Stabilized Cubic Yard 309(3) Drainage Layer, Cement Stabilized Cubic Yard

SECTION 403

JOINT SEALING FILLER, BITUMINOUS PAVEMENT

403-1.01 DESCRIPTION. This item shall consist of providing and installing a resilient and adhesive joint sealing filler capable of effectively sealing joints and cracks in bituminous pavements.

403-2.01 MATERIALS.

1. Joint Sealant. Joint sealing material shall meet the requirements of ASTM D 6690, Type IV.

Each lot or batch of sealing compound shall be delivered to the jobsite in the manufacturer's original sealed container. Each container shall be marked with the manufacturer's name, batch or lot number, and the safe heating temperature and shall be accompanied by the manufacturer's certification stating that the compound meets the requirements of this specification.

Submit to the Government for approval: Installation instructions from the manufacturer, laboratory test results, and samples when requested.

2. Backer Rod. Provide backer rod material that is a compressible, nonshrinking, nonstaining, nonabsorptive material and nonreactive with the crack sealant. Use backer rod with a melting point temperature of at least 5 degrees F greater than the maximum pouring temperature of the sealant being used, when tested in accordance with ASTM D789. Use material that has a water absorption of not more than 5 percent by weight when tested in accordance with ASTM C509. Use backer rod material that is 25 percent (plus or minus 5 percent) larger in diameter than the nominal width of the crack.

403-2.02 QUALITY CONTROL. Test the crack sealant and backup material, when required, for conformance with the referenced applicable material specification. Submit reports of all tests. Samples will be retained by the Government for possible future testing, should the materials appear defective during or after application. Furnish samples of materials, in sufficient quantity to be tested upon request. Conformance with the test requirements of the laboratory tests specified will not constitute final acceptance of the materials. Final acceptance will be based on the performance of materials that have been satisfactorily installed.

1. Crack Cleaning. Provide quality control provisions during the crack cleaning process to correct improper equipment and cleaning techniques that damage the bituminous pavement in any manner. Cleaned cracks must be approved by the Government prior to installation of the crack sealant.

2. Crack Seal Application Equipment. Inspect the application equipment to ensure conformance to temperature requirements and proper installation. Evidences of bubbling, improper installing, and failing to cure or set will cause to suspend operations until causes of the deficiencies are determined and corrected.

3. Crack Sealant. Inspect the crack sealant for proper cure and set rating, tack free surface, bonding to the bituminous pavement, cohesive separation within the sealant, reversion to liquid, and entrapped air and voids. Remove sealants exhibiting any of these deficiencies, at any time prior to the final acceptance of the project, and replace as specified herein at no additional cost to the Government.

403-2.03 DELIVERY, STORAGE, AND HANDLING. Inspect materials delivered to the job site for defects;

unload, and store them with a minimum of handling to avoid damage. Provide storage facilities at the job site to protect materials from weather and maintain them at the temperatures recommended by the manufacturer.

403-2.04 EQUIPMENT, TOOLS, AND MACHINES. Equipment, tools, and machines used in performance of the work are subject to approval by the Government. Maintain in a satisfactory working condition at all times.

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FA500019RA002 JBER Paving

1. Routing Equipment. Provide routing equipment which is a self-powered machine operating a power driven tool or bit specifically designed for routing bituminous pavements. Use a bit rotating about a vertical axis at sufficient speed to cut a smooth vertical-walled reservoir in the pavement surface and maintain accurate cutting without damaging the sides or top edges of the reservoir. Provide a router capable of following the trace of the crack without deviation. The use of rotary impact routing devices may be permitted if vertical-sided carbide tipped bits are used.

2. Concrete Saw. Provide a self-propelled power saw with small diameter (6 inches or less) water-cooled diamond or abrasive saw blades for cutting cracks to the depths and widths specified and for removing filler that is embedded in the cracks or adhered to the crack faces. Use a saw blade with a diameter small enough to allow the saw to closely follow the trace of the crack.

3. Waterblasting Equipment. Include with the waterblasting equipment a trailer-mounted water tank, pumps, high-pressure hose, wand with safety release cutoff control, nozzle, and auxiliary water resupply equipment. Use water tank and auxiliary resupply equipment with sufficient capacity to permit continuous operations. Use hoses, wands, and nozzles capable of cleaning the crack faces and the pavement surface on both sides of the crack for a width of at least 1/2 inch beyond the crack. Use pumps with a mounted pressure gauge that shows the pressure in psi at which the equipment is operating at all times.

Limit the pressure so that the sides of the crack are not damaged during the cleaning operation.

4. Hand Tools. Hand tools may be used, when approved, for removing defective sealant from cracks and repairing or cleaning the crack faces.

5. Crack Sealing Equipment. Provide unit applicators, used for heating and installing the hot-poured crack sealant materials, that are mobile and equipped with a double-boiler, agitator-type kettle with an oil medium in the outer space for heat transfer; a direct-connected pressure-type extruding device with a nozzle shaped for inserting in the crack to be filled; positive temperature devices for controlling the temperature of the transfer oil and sealant; and a recording type thermometer for indicating the temperature of the sealant. Allow the sealant to circulate through the delivery hose and return to the inner kettle when not in use, due to the applicator unit design.

403-2.05 ENVIRONMENTAL REQUIREMENTS. Apply the materials only when the ambient air temperature and the pavement temperature within the joint wall are at least 50 degrees F and rising. Do not apply sealant if moisture is observed in the crack.

403-3.01 PREPARATION OF CRACKS. Immediately before the installation of the crack sealant, thoroughly dry and clean the cracks to remove oxidized pavement, loose aggregate and foreign debris. Prepare cracks as follows:

1. Cracks

a. Hairline Cracks. Cracks that are less than 1/4 inch wide do not need to be sealed.

b. Small Cracks. Route cracks that are 1/4 to 3/4 inch wide to a nominal width 1/8 inch greater than the existing nominal width and to a depth not less than 3/4 inch. Cracks shall be waterblasted, wire brushed, cleaned and dried using compressed air.

c. Medium Cracks. Waterblast or wire brush cracks that are 3/4 to 2 inches wide and clean and dry using compressed air.

d. Large Cracks. Repair cracks that are greater than 2 inches wide using pothole repair techniques instead of sealing.

2. Existing Sealant Removal. Cut loose any in-place sealant from both crack faces using a concrete saw or hand tools as specified in Subsection 403-2.04. Remove sealant to a depth sufficient to accommodate any backer rod material that is required to maintain the depth of new sealant to be installed. Prior to

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FA500019RA002 JBER Paving further cleaning operations, remove all old loose sealant remaining in the crack opening by blowing with compressed air.

3. Routing. Perform routing of the cracks using a rotary router with a bit that is at least 1/8 inch wider than the nominal width of the crack to remove all residual old sealant (resealing), oxidized pavement and any loose aggregate in the crack wall.

4. Sawing. Perform sawing of the cracks using a power-driving concrete saw as specified in Subsection 403-2.04. Stiffen the blade as necessary with suitable dummy (or used) blades or washers. Immediately following the sawing operation, clean the crack opening using a water jet to remove all saw cuttings and debris.

5. Waterblasting. Waterblast clean the crack faces and the pavement surfaces extending a minimum 1/2 inch from the crack edges. Use a multiple-pass technique until the surfaces are free of dust, dirt, old sealant residue, or foreign debris that might prevent the sealant material from bonding to the asphalt pavement. After final cleaning and immediately prior to sealing, blow out the cracks with compressed air and leave them completely free of debris and water. Ensure that waterblasting does not damage the pavement.

6. Backer Rod Material. When required, use backer rod material in all cracks that otherwise would require excessive sealant. Insert the backer rod material into the lower portion of the crack as shown on the drawings. Place the backer rod so that the top of the backer rod is at least 3/4 inch below the top of the pavement. Ensure that the backer rod material is placed at the required depth and is not stretched or twisted during installation.

7. Rate of Progress of Crack Preparation. Limit the stages of crack preparation, which include routing, sandblasting of the crack faces, air pressure cleaning and placing of the backer rod material, to only that linear footage that can be sealed during the same day.

403-3.02 PREPARATION OF SEALANT. Do not heat hot-poured sealants in excess of the safe heating temperature recommended by the manufacturer, as shown on the sealant containers. Withdraw and waste sealant that has been overheated or subjected to application temperatures for over 4 hours or that has remained in the applicator at the end of the day's operation.

403-3.03 INSTALLATION OF SEALANT. Submit manufacturer's instructions 14 days prior to the use of the material on the project. Installation of the material will not be allowed until the instructions are received.

1. Time of Application. Seal cracks immediately following final cleaning and drying of the crack walls and following the placement of the backer rod material (when required). Place sealant only when cracks are dry. Re-clean cracks that cannot be sealed under the conditions specified, or when rain interrupts sealing operations, and allow to air dry or dry by mechanical means prior to installing the sealant.

2. Sealing the Crack. Immediately preceding, but not more than 50 feet ahead of the crack sealing operations, perform a final cleaning and drying with compressed air. Fill the cracks from the bottom of reservoir formed by the routing or the top of the backer rod up to 1/8 inch below the pavement surface.

Remove excess or spilled sealant from the pavement by approved methods and discard it. Install the sealant in a manner which prevents the formation of voids and entrapped air. Several passes with the applicator wand may be necessary to obtain the specified sealant depth from the pavement surface. Do not use gravity methods or pouring pots to install the sealant material. Do not permit traffic over newly sealed pavement until authorized by the Government. Check cracks frequently to ensure that the newly installed sealant is cured to a tack-free condition within 3 hours. Immediately notify the Government of the location of any sealant that has not cured to a tack-free condition within 3 hours.

403-3.04 CLEANUP. Upon completion of the project, remove unused materials from the site and leave the pavement in a clean condition.

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FA500019RA002 JBER Paving

403-3.01 TIME OF APPLICATION. Joints shall be sealed as soon after completion of the curing period as feasible and before the pavement is opened to traffic, including construction equipment. The pavement temperature shall be above 50 °F at the time of installation of the poured joint sealing material.

403-3.02 PREPARATION OF JOINTS. Immediately before sealing, the joints shall be thoroughly cleaned of all laitance, curing compound, and other foreign material. Cleaning shall be accomplished by wire brushing. Upon completion of cleaning, the joints shall be blown out with compressed air. The joint faces shall be surface dry when the seal is applied.

Prior to resealing joints, the existing joint material shall be removed. If joint sealer other than that originally used is specified, all existing joint sealer shall be removed.

403-3.03 INSTALLATION OF SEALANT. Joints shall be inspected for proper width, depth, alignment, and preparation, and shall be approved by the Government before sealing is allowed.

The joint sealant shall be applied uniformly solid from bottom to top and shall be filled without formation of entrapped air or voids. A backing material shall be placed and shall be non-adhesive to the concrete or the sealant material.