Attachment 4 - Specifications.pdf

SUMMARY 011000 - 1

Copyright © 2023 by the American Institute of Architects. Warning: This AIA MasterSpec based document is protected by U.S. Copyright Law and International Treaties. A valid, current MasterSpec license is required for editing or use of this document.

SECTION 011000 - SUMMARY

PART 1 - GENERAL

1.1 CONTRACTOR'S USE OF SITE AND PREMISES

A. Restricted Use of Site: Contractor shall have limited use of Project site for construction operations as indicated on Drawings by the Contract limits and as indicated by requirements of this Section.

B. Limits on Use of Site: Limit use of Project site to work in areas indicated on plans. Do not disturb portions of Project site beyond areas in which the Work is indicated.

C. Condition of Existing Grounds: Maintain portions of existing pavement and road prism affected by construction operations throughout construction period. Repair damage caused by construction operations.

1.2 WORK RESTRICTIONS

A. Comply with restrictions on construction operations.

1. Comply with limitations on use of public streets, work on public streets, rights of way, and other requirements of authorities having jurisdiction.

B. On-Site Work Hours: Limit work in the existing building to normal business working hours of 7:00 a.m. to 5:00 p.m., Monday through Friday, unless otherwise indicated.

1.3 SPECIFICATION AND DRAWING CONVENTIONS

A. Specification Content: The Specifications use certain conventions for the style of language and the intended meaning of certain terms, words, and phrases when used in particular situations.

These conventions are as follows:

1. Imperative mood and streamlined language are generally used in the Specifications. The words "shall," "shall be," or "shall comply with," depending on the context, are implied where a colon (:) is used within a sentence or phrase.

2. Text Color: Text used in the Specifications, including units of measure, manufacturer and product names, and other text may appear in multiple colors or underlined as part of a hyperlink; no emphasis is implied by text with these characteristics.

3. Hypertext: Text used in the Specifications may contain hyperlinks. Hyperlinks may allow for access to linked information that is not residing in the Specifications. Unless otherwise indicated, linked information is not part of the Contract Documents.

4. Specification requirements are to be performed by Contractor unless specifically stated otherwise.

END OF SECTION 011000

UNIT PRICES 012200 - 1

Copyright © 2023 by the American Institute of Architects. Warning: This AIA MasterSpec based document is protected by U.S. Copyright Law and International

SECTION 012200 - UNIT PRICES

1.1 DEFINITIONS

A. Unit price is a price per unit of measurement for materials, equipment, or services, or a portion of the Work, added to or deducted from the Contract Sum by appropriate modification, if the scope of Work or estimated quantities of Work required by the Contract Documents are increased or decreased.

1.2 PROCEDURES

A. Unit prices include all necessary material, plus cost for delivery, installation, insurance, applicable taxes, overhead, and profit.

B. Measurement and Payment: See the Schedule of Items for Units of Measure.

1. LF - LINEAR FEET

2. SF - SQUARE FEET

3. CF - CUBIC FEET

a. Measured In-Place

4. EA - EACH

5. LS - LUMPSUM

a. Payment for Completion of Entire Scope of Item.

6. LSQ - LUMPSUM QUANTITY

7. AQ - ACTUAL QUANTITY

a. Actual Quantity Installed.

C. Owner reserves the right to reject Contractor's measurement of work-in-place that involves use of established unit prices and confirm measurements independently prior to payment.

END OF SECTION 012200

CONSTRUCTION WASTE MANAGEMENT AND DISPOSAL 017419 - 1

Copyright © 2023 by the American Institute of Architects. Warning: This AIA MasterSpec based document is protected by U.S. Copyright Law and International

SECTION 017419 - CONSTRUCTION WASTE MANAGEMENT AND DISPOSAL

1.1 DEFINITIONS

Retain terms that remain after this Section has been edited for a project.

A. Construction Waste: Building, structure, and site improvement materials and other solid waste resulting from construction, remodeling, renovation, or repair operations. Construction waste includes packaging.

B. Demolition Waste: Building, structure, and site improvement materials resulting from demolition operations.

C. Disposal: Legal disposal of materials off Forest Service Lands.

PART 2 - EXECUTION

2.1 DISPOSAL

A. General: Remove and dispose of all asphalt millings and other construction and demolition waste off Forest Service Lands.

END OF SECTION 017419

EARTH MOVING 312000 - 1

1.1 SUMMARY

A. Section Includes:

1. Preparing subgrades for pavements.

2. Base course for asphalt paving.

1.2 DEFINITIONS

A. Base Course: Aggregate layer placed between the subbase course and hot-mix asphalt paving.

B. Excavation: Removal of material to lines and dimensions indicated.

1. Authorized Additional Excavation: Excavation below subgrade elevations or beyond indicated lines and dimensions as provided for in plans or by COR. Authorized additional excavation and replacement material will be paid for under item 1002 – Additional Base Repair.

2. Unauthorized Excavation: Excavation below subgrade elevations or beyond indicated lines and dimensions without direction by COR. Unauthorized excavation, as well as remedial work directed by COR, will be without additional compensation.

1.3 INFORMATIONAL SUBMITTALS

A. Stone Tickets for ¾” Crusher Run Stone.

PART 2 - PRODUCTS

2.1 SOIL MATERIALS

A. Base Course: ¾ Inch Crusher Run Limestone Material.

PART 3 - EXECUTION

3.1 PREPARATION

A. Protect and maintain erosion and sedimentation controls during earth-moving operations.

B. Protect subgrades and foundation soils from freezing temperatures and frost. Remove temporary protection before placing subsequent materials.

EARTH MOVING 312000 - 2

3.2 EXCAVATION FOR WALKS AND PAVEMENTS

A. Excavate surfaces under walks and pavements to indicated lines, cross sections, elevations, and subgrades.

3.3 BACKFILL

A. Place backfill on subgrades free of mud, frost, snow, or ice.

3.4 SOIL MOISTURE CONTROL

A. Do not place backfill or fill soil material on surfaces that are muddy, frozen, or contain frost or ice.

B. Remove and replace, or scarify and air dry, otherwise satisfactory soil material that exceeds optimum moisture content by 2 percent and is too wet to compact to specified dry unit weight.

3.5 COMPACTION OF SOIL BACKFILLS AND FILLS

A. Place backfill and fill soil materials in layers not more than 6 inches in loose depth for material compacted by heavy compaction equipment and not more than 4 inches in loose depth for material compacted by hand-operated tampers.

B. Compact soil materials to 95% of the standard proctor maximum unit weight.

3.6 SUBBASE AND BASE COURSES UNDER PAVEMENTS AND WALKS

A. Place base course on subgrades free of mud, frost, snow, or ice.

B. On prepared subgrade, place base course under pavements and walks as follows:

1. Place base course that exceeds 6 inches in compacted thickness in layers of equal thickness, with no compacted layer more than 6 inches thick or less than 3 inches thick.

3.7 PROTECTION

A. Repair and reestablish grades to specified tolerances where completed or partially completed surfaces become eroded, rutted, settled, or where they lose compaction due to subsequent construction operations, weather conditions, or traffic.

3.8 DISPOSAL OF SURPLUS AND WASTE MATERIALS

A. Remove surplus satisfactory soil and waste materials, including unsatisfactory soil, trash, and debris, and legally dispose of them off Forest Service Lands.

END OF SECTION 312000

ASPHALT PAVING 321216 - 1

SECTION 321216 - ASPHALT PAVING

1.1 SUMMARY

A. Section Includes:

1. Milling, Hot-mix asphalt paving & patching.

B. Related Requirements:

1. Section 312000 "Earth Moving" for subgrade preparation, fill material, and unbound-aggregate subbase and base courses.

2. Section 401 of the WVDOH 2023 Edition Standard Specifications Road and Bridges shall govern all Asphalt Patching Work, except where conflicting with requirements contained in section 321216 of these specifications. Sections 401.6 & 401.7 do not apply.

3. Asphalt Milling shall be done in accordance with Section 415.2 of the WVDOH 2023 Edition Standard Specifications Road and Bridges. Sections 415.2.6 & 415.2.7 do not apply.

4. Section 403 of the WVDOH 2023 Edition Standard Specifications Road and Bridges shall govern all Crack Sealing Work.

5. Section 420 of the of the WVDOH 2023 Edition Standard Specifications Road and Bridges shall govern all Slurry Seal Work.

6. Sections of the WVDOH specifications referenced in the above sections are also applicable, including but not limited to The 700 series specifications referenced.

1.2 ACTION SUBMITTALS

A. Hot-mix asphalt designs.

1. Submit a JMF for the Asphalt Mix Design. The JMF shall be suitable for asphalt patching per the WVDOH 2023 Edition Standard Specifications Roads and Bridges.

1.3 INFORMATIONAL SUBMITTALS

A. Material Certificates:

1. Aggregates.

2. Asphalt binder.

3. Tack coat.

1.4 TRAFFIC CONTROL/MAINTAINING TRAFFIC

A. Follow requirements for traffic control as described in the Statement of Work.

B. Milled/Sawcut areas which have not been permanently patched before traffic allowed on the road shall be temporarily made passable by one of the two options provided in Details 3 and 4 of plan sheet AR-01.

ASPHALT PAVING 321216 - 2

PART 2 - PRODUCTS

2.1 ASPHALT MATERIALS

A. All Aggregates & Mineral Fillers: Conform to Sections Specified under Section 401.2 of the WVDOH Standard Specifications.

B. Asphalt Binder: Per Section 705.5 & 401.2.1 of the WVDOH Standard Specifications binder designation PG 64S-22.

C. Tack Coat: ASHTO M 140 emulsified asphalt, or of suitable grade and consistency for application.

2.2 AUXILIARY MATERIALS

A. Herbicide: Herbicide use is not permitted for this project.

2.3 MIXES

A. Hot-Mix Asphalt: Dense-graded, hot-laid, hot-mix asphalt plant mixes approved by WVDOH for Asphalt Patching and complying with the following requirements:

1. Provide mixes with a history of satisfactory performance in geographical area where Project is located.

2. Mix shall conform to requirements of Section 401 of the WVDOH Standard Specifications.

ASPHALT PAVING 321216 - 3

PART 3 - EXECUTION

3.1 COLD MILLING

A. Clean existing pavement surface of loose and deleterious material immediately before cold milling. Remove existing asphalt pavement by cold milling to grades and cross sections indicated.

1. Mill to the depth shown on the plans for the type of patch required.

3.2 PATCHING

A. Asphalt Pavement: Mill area of patch and excavate existing pavement section to sound base per plan drawings. Excavate rectangular patches per the detail provided in the plans. Remove unsound base aggregate and replace and compact ¾” crusher run material to form the new base course subgrade.

B. Tack Coat: Before placing patch material, apply tack coat uniformly to asphalt surfaces abutting the patch. Apply at a rate of 0.10 to 0.15 gal./sq. yd.

1. Allow tack coat to cure undisturbed before applying hot-mix asphalt paving.

2. Avoid smearing or staining adjoining surfaces, appurtenances, and surroundings. Remove spillages and clean affected surfaces.

C. Placing Patch Material: Place aggregate and hot-mix asphalt base per the plans. Hot-mix asphalt base shall meet the requirements of this specification for full thickness of patch and, while still hot, compact flush with adjacent surface.

D. Shovel Patch: Clean loose material from pothole. Place and compact asphalt.

3.3 SURFACE PREPARATION

A. Ensure that prepared subgrade is ready to receive paving. Immediately before placing asphalt materials, remove loose and deleterious material from substrate surfaces.

3.4 HOT-MIX ASPHALT PLACEMENT

A. Machine place hot-mix asphalt on prepared surface, spread uniformly, and strike off. Place asphalt mix by hand in areas inaccessible to equipment in a manner that prevents segregation of mix. Place each course to required grade, cross section, and thickness when compacted.

1. Place hot-mix asphalt base course in number of lifts and thicknesses indicated.

2. Spread mix at a minimum temperature specified by the JMF or 250 deg F, whichever is higher.

B. Promptly correct surface irregularities in paving course. Use suitable hand tools to remove excess material forming high spots. Fill depressions with hot-mix asphalt to prevent segregation of mix; use suitable hand tools to smooth surface.

ASPHALT PAVING 321216 - 4

3.5 JOINTS

A. Construct joints to ensure a continuous bond between adjoining paving sections. Construct joints free of depressions, with same texture and smoothness as other sections of hot-mix asphalt course. Clean contact surfaces and apply tack coat to joints.

3.6 COMPACTION

A. General: Begin compaction as soon as placed hot-mix paving will bear roller weight without excessive displacement. Compact hot-mix paving with hot hand tampers or with vibratory-plate compactors in areas inaccessible to rollers.

1. Complete compaction before mix temperature cools to 185 deg F (85 deg C).

2. Compact to 90% minimum of of theoretical max density per JMF.

3. Compact until no visible deformation in the asphalt surface can be seen.

B. Edge Shaping: While surface is being compacted and finished, trim edges of pavement to proper alignment. Bevel edges while asphalt is still hot; compact thoroughly.

C. Protection: After final rolling, do not permit vehicular traffic on pavement until it has cooled and hardened. Erect barricades to protect paving from traffic until mixture has cooled enough not to become marked.

3.7 INSTALLATION TOLERANCES

A. Pavement Thickness: Compact each course to produce thickness indicated within the following tolerances: Base/Patching Coarse: Plus 1/4 inch.

B. Pavement Surface Smoothness: Compact each course to produce surface smoothness within the following tolerances as determined by using a 10-foot straightedge applied transversely or longitudinally to paved areas: Base Course: 1/4 inch.

3.8 FIELD QUALITY CONTROL

A. Remove and replace or install additional hot-mix asphalt where test results or measurements indicate that it does not comply with specified requirements.

B. The government reserves the right to have the asphalt cored and tested to prove compliance.

Contractor shall be responsible for filling up to 3 core holes with new hot mix asphalt without an increase in price.

3.9 WASTE HANDLING

A. General: Handle asphalt-paving waste by legally disposing of it off Forest Service Lands.

END OF SECTION 321216

SECTION 401

ASPHALT BASE, WEARING, AND

PATCHING AND LEVELING COURSES

401.1-DESCRIPTION:

This work shall consist of constructing one or more courses of asphalt concrete, mixed mechanically in a plant, composed of aggregate and asphalt material designed in accordance with either the Marshall or Superpave design system as specified in the contract documents, on a prepared foundation in accordance with these specifications and in reasonable close conformity with the lines, grades, weights or thicknesses, and cross sections shown on the Plans or established by the Engineer.

The unit of measurement for asphalt concrete will be by the ton, square yard or cubic yard.

The work will be accepted in accordance with these Specifications and the applicable requirements of Sections 105, 106, and 109.

401.2-MATERIALS:

The materials shall conform to the following requirements:

MATERIAL SUBSECTION

Coarse Aggregate 703.1 thru 703.3 Note 1 & Note 2 (See MP 401.02.28 for exceptions and additions required for Superpave Items.)

Fine Aggregate 702.3 (See MP 401.02.28 for additions required for Superpave Items)

Mineral Filler 702.4 Performance Graded Binders 705.5

Note 1 The total shale, coal and other lightweight deleterious material and friable particles shall not exceed 3%.

Note 2 When slag is specified in the contract, the coarse aggregate shall be slag which meets the requirements of 703.3, except as amended in this subsection.

401.2.1–Performance Graded Binder Grade: The standard grade for Performance

Graded (PG) binders shall be PG 64S-22, any deviation will be noted in the contract documents. PG 64H-22 shall be used on projects specified with over 20 million ESALs over the design life. PG 64S-22 binder may be used in asphalt placed below the top two lifts in any pavement section, scratch course and patching-and-leveling are not identified as lifts.

CONSTRUCTION METHODS

401.3-GENERAL:

Construction methods to be used in performing the work shall be submitted to the Engineer for review prior to the start of work. This review may require modification of the proposed methods to provide the desired end product. All equipment, tools, machinery, and plant shall be maintained in a satisfactory working condition.

401.4-COMPOSITION OF MIXTURES:

401.4.1-General: The aggregate for use in the designated mixture shall consist of a mixture of aggregate (coarse, fine, reclaimed asphalt pavement (RAP) if desired, or mixture thereof) and mineral filler if required. It shall be the responsibility of the Contractor to determine the percentage of RAP to be used in the mix. The amount and grade of virgin PG Binder to be used in the RAP designs shall be determined in accordance with Materials Procedure

(MP) 401.02.24.

401.4.2-Job Mix Formula: Job Mix Formula (JMF) is the specification for a single mix produced at a single plant. This mix may be specific to a single project or be used on multiple projects if the basic design criteria (design compaction level and PG Binder grade) are the same.

The Contractor shall submit a proposed JMF for each combination of aggregate and asphalt material for each type of asphalt concrete to be produced. Depending on the design type, the JMF gradations shall be within the tolerances set forth in either Table 401.4.2A or Table 401.4.2B. Marshall mix designs shall be developed in accordance with MP 401.02.22.

Superpave mix designs shall be developed in accordance with MP 401.02.28.

Each proposed JMF must be documented on the Division Form T400 and the entire JMF package shall be forwarded for review to the District Materials Engineer/Supervisor. The T400 and JMF package shall then be transmitted to the Materials Control, Soils and Testing Division for final review. If the JMF requires revision, it will be returned to the designer through the District. The T400 Form shall contain the following information:

i. Identification of the source and type of materials used in the design.

ii. The aggregate blend percentages and the percentage for each sieve fraction of aggregate considered the desirable target for that fraction.

iii. The percentage of asphalt binder representing the optimum asphalt content for the JMF submitted, which is to be considered the desirable target percentage.

iv. The temperature of the completed mixture at the plant which shall be within ± 25°F of the median mix temperature established by the temperature-viscosity chart or as recommended by the asphalt supplier.

v. The ratio (calculated to the nearest one-tenth percent) of the Fines to Asphalt (FA). For Marshall mixes the ratio is defined as the percentage of aggregate passing the No. 200 (75 µm) sieve, divided by the percentage of asphalt content calculated at the percentage optimum asphalt content of the design. For Superpave mixes the ratio is defined as the percentage of aggregate passing the 75 µm (No. 200) sieve, divided by the percentage of effective asphalt content calculated at the percentage optimum asphalt content of the design.

TABLE 401.4.2A

Design Aggregate Gradation Requirements for Marshall Mix Designs

Type of Mix

Base-I Base-II

(Patch & Level)

Wearing

IV

Wearing-I (Scratch-I)

Wearing-III (Scratch-III)

Sieve Size

Nominal Maximum Size 1 ½ in

(37.5 mm) ¾ in

(19 mm) ¾ in

(19 mm) 3/8 in

(9.5 mm) No. 4

(4.75 mm) 2 in (50 mm) 100 – – – – 1 ½ in (37.5 mm) 90-100 – – – – 1 in (25 mm) 90 max 100 100 – – ¾ in (19 mm) – 90-100 90-100 – – ½ in (12.5 mm) – 90 max 90 max 100 – 3/8 in (9.5 mm) – – – 85-100 100 No. 4 (4.75 mm) – – 47 min 80 max 90-100 No. 8 (2.36 mm) 15-36 20-50 20-50 30-55 90 max No. 16 (1.18 mm) – – – – 40-65 No. 30 (600 µm) – – – – – No. 50 (300 µm) – – – – – No. 200 (75 µm) 1-6 2-8 2-8 2-9 3-11

TABLE 401.4.2B

Design Aggregate Gradation Requirements for Superpave Mix Designs

Type of Mix

37.5

19 Note 1

(Patch & Level)

12.5 9.5

(Scratch) 4.75

(Scratch)

Standard Sieve Size

Nominal Maximum Size

37.5 mm

(1 ½ inch) 25 mm (1 inch)

19 mm (3/4 inch)

12.5 mm (1/2 inch)

9.5 mm (3/8 inch)

4.75 (No. 4)

50 mm (2”) 100 – – – – –

37.5 mm (1½”) 90-100 100 – – – – 25 mm (1”) 90 max 90-100 100 – – – 19 mm (3/4”) – 90 max 90-100 100 – –

12.5 mm (1/2”) – – 90 max 90-100 100 100

9.5 mm (3/8”) – – – 90 max 90-100 95-100

4.75 mm (No.4) – – – – 90 max 90-100

2.36 mm (No.8) 15-41 19-45 23- 49 28-58 32-67

1.18 mm (No.16) – – – – – 30-60 600 µm (No.30) – – – – – – 300 µm (No. 50) – – – – – – 75 µm (No.200) 0-6 1-7 2-8 2-10 2-10 6-12

Note 1 When a 19 mm mix is specified for use as a heavy duty surface mix, it shall be designed as a fine graded mix with the additional requirement of a minimum of 47% passing the 4.75 mm (No.4) screen.

If it becomes necessary to change aggregate sources, a new mix design shall be developed and submitted for approval. When using neat (unmodified) PG Binders, the binder source may be changed without requiring a new mix design, but the binder grade must always remain the same for each design. If a source change results in the use of an additive- enhanced modified binder of the same grade, a new mix design will be required.

If a modified binder source is changed or if the modification process is changed, a new mix design shall be developed and submitted for approval. A source change to a new location with the original manufacturer/supplier and the original modification process will not require a new mix design.

At no time shall different grades of PG Binders be mixed together in the same storage tank.

When it is necessary to switch to a new binder grade the tank shall be drawn down as far as possible, normally to the top of heating coils, before refilling with the new binder. The new binder shall be circulated thoroughly before restarting production.

401.4.2.1-Warm Mix Asphalt: When the Division allows an approved asphalt concrete design to be produced as warm-mix asphalt (WMA) using the water injection system, the temperature of the completed mixture at the plant may be lowered to an established range that has previously been determined through trial production. The allowable temperature range specified on the approved T400 mix design form shall be adjusted accordingly when producing WMA. In addition, all references to the minimum compaction temperatures in Sections 401.10.3 and 401.10.4 of this specification, may be waived if it can be established that additional density can be obtained at lower temperatures without damaging the pavement. Intermingling of WMA with non WMA materials on the same course should be avoided. If circumstances result in the need for intermingling, it must be approved by the Engineer. Upon approval, the location where intermingling occurs on the project shall be clearly defined and documented by the Contractor and submitted to the Engineer. If the intermingling occurs on a project where the density of the pavement is being controlled by the rollerpass compaction method, then a new test section shall be established on the new material beginning at the point where the WMA and standard asphalt concrete material meet. If the intermingling occurs on a project where the density is controlled via Lot by Lot testing, the location should be clearly marked so that the correct maximum theoretical density can be used. All testing requirements established for standard asphalt concrete mix designs and quality assurance/quality control testing shall also apply to WMA.

401.5-TESTING:

401.5.1-Procedures:

AASHTO R 47 Reducing Samples of Asphalt Mixtures to Testing Size AASHTO R 68 Preparation of Asphalt Mixtures by Means of The Marshall

Apparatus AASHTO T 11 Materials Finer Than No. 200 (75 µm) Sieve in Mineral Aggregates by Washing AASHTO T 27 Sieve Analysis of Fine and Coarse Aggregates AASHTO T 30 Mechanical Analysis of Extracted Aggregate AASHTO T 164 Quantitative Extraction of Asphalt Binder from HMA AASHTO T 166 Bulk Specific Gravity (Gmb) of Compacted Asphalt Mixtures Using

Saturated Surface-Dry Specimens AASHTO T 168 Sampling Bituminous Paving Mixtures AASHTO T 209 Maximum Specific Gravity and Density of Asphalt Mixtures AASHTO T 245 Resistance to Plastic Flow of Asphalt Mixtures Using Marshall

Apparatus AASHTO T 308 Asphalt Binder Content of Asphalt Mixtures by the Ignition Method

(Test Method A) AASHTO T 312 Preparing and Determining the Density of Asphalt Mixture

Specimens by Means of the Superpave Gyratory Compactor AASHTO T 355 Standard Method of Test for In-Place Density of Asphalt Mixtures by Nuclear Methods ASTM D5581 Resistance to Plastic Flow of Bituminous Mixtures Using Marshall

Apparatus (For Base-I Marshall Designs) MP 700.00.06 Aggregate Sampling Procedures

401.6-CONTRACTORS QUALITY CONTROL:

401.6.1-Quality Control Testing: Quality control of bituminous asphalt is the responsibility of the Contractor. The Contractor shall maintain equipment and qualified personnel including at least one certified Asphalt Plant Technician at each plant. The technician shall be in charge of all plant quality control activities such as mix proportioning and adjustment and all sampling and testing activities necessary to maintain the various properties of asphalt within the limits of the specification.

The Contractor shall maintain necessary equipment and qualified personnel including at least one certified Asphalt Field and Compaction Technician at each project during paving operations. Additionally, a certified Asphalt Field and Compaction Technician with certification to perform nuclear density testing of asphalt pavements shall perform all testing necessary to assure compaction of the asphalt meets specification requirements.

The Contractor, shall design a workable Quality Control Plan, detailing the type and frequency of sampling and testing deemed necessary to measure and control the magnitude of the various properties of the asphalt governed by these specifications. This plan, prepared in accordance with MP 401.03.50 shall be submitted to the Engineer for review prior to production of material under this specification.

401.6.2-Job Mix Formula (JMF) Field Verification: For each JMF, a mix design field verification shall be conducted during the first days of plant production. For Marshall designs, the verification shall be in accordance with the guidelines established in MP 401.02.27. For Superpave, designs it shall be in accordance with MP 401.02.29. The field verification is for the purpose of demonstrating that the JMF can be produced within the specified tolerances set forth in the MP. If the mix cannot be produced within these requirements, a new mix design will be required.

401.6.3-Quality Control Testing Requirements: After the JMF design field verification has been successfully completed, sampling frequency and test requirements for quality control shall be as set forth in MP 401.02.27 for Marshall designs and MP 401.02.29 for Superpave designs. If the Division determines that a mix cannot be consistently produced within the tolerance limits of the specified design properties, approval of the mix may be revoked and the contractor will be required to provide a new mix design.

401.6.4-Compaction: Projects shall be tested for compaction in accordance with the Lot-by-Lot test method described in Section 401.6.4.2 if the project limits meet all of the following requirements:

1. Measured roadway width greater than sixteen (16) feet

2. Total design overlay thickness of pavement greater than or equal to 1.5 inches.

3. Total projects length greater than or equal to 0.5 miles, excluding skip paving.

If a project does not meet the above criteria, testing for compaction shall be in accordance with the Rollerpass test method described in Section 401.6.4.3.

In addition, areas of Trench Paving, Pavement Widening, and Pavement Repairs shall be tested in accordance with the Rollerpass test method or to the satisfaction of the Engineer.

When asphalt is placed in areas that require a non-uniform thickness and tapers to a thin edge including patch and level and scratch, acceptance testing of the material is not required.

Compaction shall be accomplished with a minimum of eight (8) roller passes prior to reaching the temperature specified in section 401.10.4. A pass shall be defined as the entire roller traversing a spot on the pavement. Compaction shall be performed by a three-wheel (steel) roller or pneumatic-tire roller.

Acceptance testing is not required on areas which are too narrow to be compacted with the roller use for the mainline paving, as defined in the contractor’s QC plan; such areas shall be compacted to the satisfaction of the Engineer.

401.6.4.1-Density Testing: All Gauge standardization procedures, calibration procedures and all Density testing conducted shall be in accordance with AASHTO T355

- Standard Method of Test for In-Place Density of Asphalt Mixtures by Nuclear Methods.

Testing shall be conducted in the backscatter position and follow AASHTO T355 with the exception that no gauge rotation will be required. All gauge tests shall be conducted with the source end of the gauge in the direction of paving. The Gauges used for both QC and QA, shall also have a gauge comparison tested as prescribed in section 401.6.4.1.1.

401.6.4.1.1-Gauge Comparison: For purposes of an accurate comparison, nuclear gauges used for QC and QA shall be compared using the following procedure. If an alternate gauge is brought to the project, repeat the following procedure. Note, this process is required for informational purposes however density readings for Acceptance testing will not be adjusted to compensate for any differences in readings between gauges. The gauge used for the Contractor’s quality control testing shall be compared with the gauge used for the Division’s verification testing at the same locations.

1. Standardize both gauges according to AASHTO T 355.

2. Take five (5) one-minute wet density readings with each gauge in the backscatter position at three randomly located positions within the initial 500 feet of paving.

a. Locations shall be at least 100 feet from the initial construction joint and a minimum of one (1) foot from the edge of the pavement.

3. The range of the five readings at each location shall not exceed 25 kg/m3. If the readings exceed this range, perform a new set of five readings. A gauge should not be used if the repeatability of the gauge is not within this range.

4. Utilize the average of the 15 readings to note the difference between the gauges to be used for QC and QA. The Contractor shall take note of this difference whilst performing QC testing. All documentation shall consist of original wet density readings as shown on the gauge, no offset is permitted to be entered into the gauge.

a. Difference = QA Gauge – QC Gauge [note sign]

401.6.4.2-Lot-by-Lot Testing: Density of the traveled lanes, shoulders, and Longitudinal Joint will be accepted in the field on a lot by lot basis. Lots will be established cumulatively and will be specific for each JMF.A normal lot size shall not exceed 1000 linear feet of paving, unless operational conditions or project size dictates otherwise.

Each lot shall consist of five equal sublots. A standard sublot shall be 200 linear feet.

Sublots shall be tested with randomly located nuclear density tests.

If the remaining footage of the final two lots of a project combine to be less than 2000 linear feet following the following:

1. If the length is greater than 1000 feet but less than or equal to 1500 feet combine length into a single lot and, divide its length into five equal sublots;

2. If the remaining length is greater than 1500 feet and less than 2000 feet, divide the length into two equal lots with five equal sublots in each lot.

Breakdowns or stoppages of short periods due to such causes as weather or equipment failure will not be considered as reason to adjust the lot size. The original lot will be continued when work resumes. Relative density shall be calculated based on the Maximum Specific gravity from the Division approved JMF or the Maximum Specific Gravity established under section 401.6.2, Job Mix Formula Verification, whichever is more recently established.

401.6.4.2.1-Mat Density: Compaction testing for the mat density shall be performed for all traveled lanes and shoulders and will be evaluated based on an Upper Specification Limit (USL) of 97.0% relative density and a Lower Specification Limit (LSL) of 93.0% relative density. The average mat density of the Lot shall be calculated as the average of the sublot results. Acceptance of Mat Density shall be in accordance with Section 401.13.3.

401.6.4.2.2-Joint Density: Longitudinal joint density testing shall be performed on all constructed joints between traveled lanes. Testing of a longitudinal joint constructed between a travel lane and a shoulder is not required. Joint density testing is not required until both lanes of the joint are constructed. The first lane constructed shall be referred to as the cold side and the second lane shall be referred to as the hot side. Joint density testing shall be conducted on the hot side, with the gauge positioned four (4) inches from the constructed joint. Only longitudinal joints constructed on the surface course shall be subject to density testing.

Longitudinal joint density testing shall be accepted in the field on a lot by lot basis as described in Section 401.6.4.1. Compaction testing for the joint density will be evaluated based on an Upper Specification Limit (USL) of 97.0% relative density and a Lower Specification Limit (LSL) of 90.0% relative density. The average joint density of the Lot shall be calculated as the average of the sublot results. Acceptance of joint density shall be in accordance with Section 401.13.3.

401.6.4.3-Roller Pass Testing: A Rollerpass Control Section shall be completed on a daily basis, when roadway conditions change where they would affect the compaction effort, or when the Engineer determines the current rollerpass is unsatisfactory. A rollerpass shall be established prior to the mat reaching the temperature specified in section 401.10.4.

If a project does not meet the criteria in section 401.6.4, testing for compaction shall be in accordance with the rollerpass test method described in Section 401.6.4.2.

In addition, areas of trench paving, pavement widening, and pavement repairs shall be tested in accordance with the rollerpass test method or to the satisfaction of the Engineer.

A rollerpass shall be conducted in the following manor:

1. The Rollerpass Control Section shall be conducted 100 feet beyond the initial transverse construction joint. If an additional rollerpass is required by the Engineer conduct it immediately.

2. Apply four passes with the breakdown roller (a pass shall be defined as the entire roller traversing a spot on the pavement) to the roadway, then conduct two randomly located nuclear density testing within the section; record the results, the average, and the mat temperature at each test location.

3. Apply an additional two passes and repeat the nuclear density testing in the same locations; record the results, the average, and the mat temperature at each test location.

4. Repeat step 3 until one or more of the following conditions occur: (a) less than 5 kg/m3 increase occurs between the average of two sets of readings, (b) the density of the material exceeds 97.0% Gmm, (c) one of the two test location “breaks over” (i.e. shows a decrease in density) after exceeding 92.0% of Gmm, or (d) the temperature of the mat has fallen below 175 °F.

5. Compute the Percent of Gmm using the average of the two readings and record on the worksheet.

If the mat begins to show signs of distress (such as excessive surface aggregate breakage or mat cracking) before reaching 175 °F, then discontinue rolling and record the number of roller passes completed before the stress signs occurred. If a tender mix, as defined in Section 3.3, is encountered the Contractor may be allowed to continue rolling at lower temperatures if it can be demonstrated that additional densification can be achieved at a lower temperature without causing any pavement distress. Once the control section is completed, the density shall be equal to or greater than 92.0% of Gmm. If the density does not meet 92% of Gmm, repeat the procedure above immediately. If after two control sections the density still does not meet 92% of Gmm, contractor shall apply the number of passes associated with the highest percent density, minimum of 8 passes, unless the Engineer determines more appropriate means. To help with this decision, an evaluation may be made of the existing pavement condition and any density test results obtained prior to construction of the test section will be reviewed.

If the density within the control section meets 92% of Gmm conduct a proving section in the proceeding 1000 feet. Within the proving section, apply the established number of passes and conduct five randomly located nuclear density tests. The average of these five tests shall exceed a minimum density of 92% Gmm and be within ±50.0 kg/m3 of the average wet density determined in the Rollerpass control section. If this is not achieved a new rollerpass section shall be conducted.

All data shall be submitted the Engineer on associated Rollerpass forms.

401.7-VERIFICATION TESTING:

401.7.1-Acceptance Testing of Asphalt Concrete: Acceptance testing of asphalt is the responsibility of the Division. For Superpave mixes, the acceptance sampling and testing requirements for the mixture shall be as set forth in MP 401.02.29.

401.7.2-Surface Tolerance: Final smoothness testing of all new Asphalt surfaces shall be in accordance with Section 720.

When compaction is completed on the course, it shall present a uniform surface, true line and grade, conforming to the cross section shown on the Plans. When tested with a straightedge of approximately ten (10) feet in length and a template of the specified dimensions, the finished base course shall not show a deviation greater than ¼ inch and the finished wearing course shall not show a deviation from the required surface greater than 3/16 inch.

The Contractor shall provide the straightedge and template for checking the surfaces and an employee to use them under the direction of the Engineer. Any irregularity of the surface exceeding the limits specified shall be corrected. Depressions which develop after the initial rolling shall be corrected by loosening the mixture and adding new material. High places shall be corrected by removing excess material.

Areas of completed courses found to be defective shall be removed and replaced with approved mixtures laid in accordance with these specifications, and no additional compensation will be allowed for materials used or work involved in replacing defective areas.

401.7.3-Lot by Lot Compaction: Acceptance testing of mat and joint density is the responsibility of the Division. The Division will conduct density acceptance testing in accordance with section 401.6.4.1. Acceptance activities will be accomplished by conducting testing completely independent of the quality control activities.

401.7.3.1-Mat Density: Within a lot of materials offered by the contractor for acceptance, locate one random test. Perform a single 1-minute test in accordance with section 401.6.4.1. Compare the density to the specification range. If the value is within the range, the lot is accepted for density. If the density result is outside the specification range, divide the lot into five equal sublots and randomly locate a test site within each sublot. Average the five sublot results and utilize section 401.13.3 to determine any required price adjustments.

401.7.3.2-Joint Density: If a joint density lot is to be tested, it will be tested with the corresponding Mat lot. Testing of a joint density lot shall follow section 401.7.3.1.

401.7.4-Thickness: When a uniform thickness of three (3) inches or more is specified, excluding resurfacing, cores shall be taken to verify the thickness of the compacted pavement.

Cores will be taken by the Division at random locations. The sampling frequency shall be approximately five cores per 2,000 feet of two-lane construction, except that the sampling frequency shall normally be limited to a minimum of five and a maximum of 50 cores per project. The Division may elect to waive coring for short projects of less than 1,000 feet in length or for projects where a paving mat of uniform thickness cannot be expected (for example: tapered paving mats or pavement widening projects). The Division may also elect to take additional cores when needed to resolve problems related to pavement thickness.

The thickness shall be considered acceptable if one or both of the following criteria are met:

(a) The average thickness equals or exceeds the specified thickness.

(b) The average thickness is less than the specified thickness, but the difference is not statistically significant at the 95% confidence level. (Standard one tail “t” test at 0.05 significance).

The calculated ‘t’ value shall be less than or equal to the standard ‘t’ value at the 95% confidence level. The method for calculating Criteria ‘B’, shall be as follows:

t ≤ t95

Where:

t95 = value from standard “t” table for 95% confidence level t = xs − x s n − 1 xs = specified thickness = average thickness n = number of samples s = x = individual core thickness

If the average thickness is less than specified and is determined to be significant as determined by criteria ‘B’, the Division shall decide on a course of action as described in Section 401.13.4.

401.8-WEATHER RESTRICTIONS:

Bituminous asphalt shall only be placed when the surface is dry and when weather conditions are such that proper handling, finishing, and compaction can be accomplished. In no case however, shall asphalt be placed when the surface temperature is below the minimum established in Table 401.8.

TABLE 401.8

Course Thickness Minimum Surface Temperature

3 inches and over 35 °F Note 1

1.5 to 2.9 inches 40 °F Less than 1.5 inches 50 °F

Note 1 In lieu of 35 °F, a minimum air temperature of 40 °F shall be used when paving directly on an aggregate base, subbase, or subgrade.

In addition to the above surface temperature requirements, no wearing courses shall be placed when the air temperature is less than 40°F.

401.8.1-Cold Weather Paving: When the air temperature falls below 50° F or the surface temperature falls below 60° F the provisions for cold weather paving shall apply.

Paving shall be performed so that the transverse joints in adjacent lanes shall be no more than fifty (50) feet apart at the end of each day’s paving operations.

The surface temperature shall be taken a minimum of once every hour and shall be taken in all shaded areas. The temperature requirements as listed in Table 401.8 shall apply.

It shall be the Contractor’s responsibility to monitor the declining surface temperature to insure that material delivery from the plant be terminated so as to allow that all material can be placed prior to the surface temperature falling below the surface temperatures listed in Table 401.8.

The temperature of the delivered material and the mat temperature at the time final density is obtained shall be taken for every truck load. These temperatures shall be in accordance with Section 401.10.3 for delivered material and 401.10.4 for the mat temperature at the time final density is obtained.

401.9-EQUIPMENT:

401.9.1-Plants: All plants in West Virginia producing asphalt for the Division shall provide documented evidence of compliance with current requirements of the West Virginia Air Pollution Control Commission.

All plants which are not in West Virginia but producing asphalt for the West Virginia Division of Highways shall provide documented evidence of compliance with current requirements of the laws and regulations of the State in which they are producing, applicable to air pollution. All plants shall meet the general requirements set forth in AASHTO M 156 unless it can be demonstrated to the satisfaction of the Engineer that a consistent quality mix can be produced with modifications to any of these requirements.

401.9.2-Dust Collector: An efficient dust collecting system shall be provided to prevent the loss of fine material. The material collected may be returned to the mixture at a uniform rate or discarded.

401.9.3-Truck Scales: Truck scales shall be provided at each Plant, except that truck scales are not required at properly calibrated automatic batching plant facilities which are equipped with digital printout equipment, and which load the trucks directly from the mixer or the weigh hopper in a surge or storage bin.

A person designated as a weigher shall be provided by the producer. The weigher shall certify that the weight of the asphalt, as determined either by the truck scales or from the digital printout of the batch weights, is correct.

Each truck shall be weighed empty prior to each load, except at automatic batch plants approved to operate without truck scales.

All truck scales shall be mounted on solid foundations which will insure them remaining plumb and level.

Approval and sealing of scales shall be conducted at the frequency determined by the West Virginia Division of Labor, Bureau of Weights and Measures, and when the plant is moved, or upon the request of the Engineer. The Engineer shall be notified of any scale malfunctions when material is being furnished to Division of Highways projects. The Division may, at its option, accept inspection and sealing by out-of-state agencies when the mixing plant is located outside West Virginia.

A digital recorder shall be required on all truck scales. The digital recorder shall produce a printed record of the gross, tare and net weights, and the time, date, truck identification, and project number. Provision shall be made for constant zero compensation and further provision shall be made so that the scales may not be manually manipulated during the printing process.

The system shall be interlocked so as to allow printing only when the scale has come to rest.

In case of breakdown of the automatic equipment, the Engineer may permit manual operation for a reasonable time, normally not to exceed 48 hours, while the equipment is being repaired.

The scales shall be of sufficient size and capacity to weigh the loaded trucks that are used for delivery of asphalt from the plant.

401.9.4-Test Weights: As part of its standard equipment, each plant which proportions aggregate by weight shall provide a minimum of ten 50-pound test weights for the purpose of maintaining the continued accuracy of its weighing equipment.

Plants which proportion asphalt material by weight shall furnish, in addition to the above, one five pound test weight.

401.9.5-Surge and Storage Bins: During the normal daily operation of the plant, asphalt may be stored in a surge or storage bin for a maximum of 12 hours, provided the bin has received prior evaluation and acceptance through the District plant inspection. The resulting temperature of the material at time of placement and compaction shall be sufficient to comply with 401.10.3 and 401.10.4

Longer silo storage times, up to 24 hours, may be permitted for dense graded asphalt if the storage silo is insulated and/or heated to assure that the proper mix temperature is maintained.

The gates at the bottom of the storage silo shall be adequately heated and sealed when the asphalt is held for the extended period of time. An inert gas system may be used to purge the silo of oxygen to prevent oxidation of the asphalt. The asphalt delivered from the storage silo shall meet all of the specification requirements.

When asphalt is stored for the extended time period, it shall not be used until the temperature has been checked and the asphalt has been visually inspected for hardening of the mix and stripping of the asphalt from the aggregate. Approval of the extended storage time may be revoked if it is determined through inspection and/or testing that the extended storage is having a detrimental effect on the asphalt.

Loading of trucks through the storage bin will only be permitted when a minimum 25-ton buffer of material is being maintained or an amount as recommended by the bin manufacturer, means shall be provided for loading the trucks directly from the mixer when the storage bin is not in operation.

401.9.6-Inspection of Equipment and Plant Operations: The Engineer shall have access to the plant to assure the adequacy of the equipment in use, to inspect the conditions and operation of the plant, to verify weights, to verify the proportion and character of materials, and to determine if specified temperatures are being maintained in the preparation of the mixture.

401.9.7-Trucks for Transporting Mixture: The inside surfaces of trucks shall be thinly coated with a National Transportation Product Evaluation Program (NTPEP) approved asphalt release agent. The use of diesel fuel, kerosene, or similar solvent-based products which can dissolve the asphalt film from the aggregate particles will not be permitted. Any commercial release agent which can be certified by NTPEP as harmless to the mix may be used; however, the Division reserves the right to restrict any release agent that is shown to cause problems during placement of the mix. In the case of mixtures composed of PG Binders which contain polymer modification, truck surfaces should be coated with a release agent recommended by the binder supplier. All excess coating material shall be removed from the truck bed prior to loading the asphalt.

All truck beds shall be insulated with approved material. No trucks shall be used which cause segregation of the materials, which show large oil leaks, or which cause undue delays in delivery of material.