EN-25-PAVE-1 Book IIIA.pdf

2025 RESURFACING FROM TOLL PLAZA E TO I-25

CONTRACT NO. EN-25-PAVE-1

BOOK IIIA

PROJECT STANDARD SPECIAL PROVISIONS

Prepared for:

E-470 Public Highway Authority

Prepared by:

Short Elliot Hendrickson, Inc. (SEH)

2000 South Colorado Blvd, Suite 1200 Colorado Center Tower Two

Denver, CO 80222

(720) 490-4966

June 10, 2025 Invitation to Bid

E-470 – Resurfacing from Toll Plaza E to I-25 – Book IIIA Project Standard Special Provisions June 10, 2025

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STANDARD SPECIAL PROVISIONS

Date Page Revision of Section 401 – Tolerances for Hot Mix Asphalt (Voids Acceptance) (October 1, 2023) SS-1 Revision of Section 401 – Composition of Mixtures – Voids Acceptance (October 1, 2023) SS-2 Revision of Section 401 – Plant Mix Pavements - General (September 30, 2024) SS-3 Revision of Section 401 – Plant Mix Pavements - General (January 8, 2024) SS-4-6 Revision of Section 401 – Reclaimed Asphalt Pavement (October 1, 2023) SS-7-8 Revision of Section 627 – Pavement Marking Paint (March 21, 2025) SS-9-19 Revision of Section 627 – Pavement Marking Paint (Temporary) (April 2, 2024) SS-20

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October 1, 2023

REVISION OF SECTION 401

TOLERANCES FOR HOT MIX ASPHALT (VOIDS ACCEPTANCE)

Section 401 of the Standard Specifications is hereby revised for this project as follows:

In subsection 401.02(b) delete Table 401-1, including the footnotes, and replace with the following:

Table 401-1 Tolerances for Hot Mix Asphalt

Element Tolerance

Asphalt Cement Content + 0.3 %

Voids in the Mineral Aggregate (VMA) + 1.2 %

Air Voids + 1.2 %

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COMPOSITION OF MIXTURES – VOIDS ACCEPTANCE

Section 401 of the Standard Specifications is hereby revised for this project as follows:

Subsection 401.02(a) shall include the following:

On projects with voids acceptance of hot mix asphalt, mix designs based on a theoretical rejection of baghouse fines may be used when necessary to meet CDOT mix design requirements if the following additional requirements are met. Written approval for use of theoretical rejection of baghouse fines mixture design shall be obtained before production of project material.

(1) Price adjustment for the hot mix asphalt shall be made based on voids acceptance criteria as prescribed in the latest version of the Standard Special Provision, Revision of Sections 105 and 106, Conformity to the Contract of Hot Mix Asphalt (Voids Acceptance). All costs associated with theoretical rejection of baghouse fines mix design, production, and acceptance shall be at the Contractor’s expense.

The Contractor shall submit a separate Quality Control (QC) plan for handling the rejection of baghouse fines. The plan shall identify the plan, equipment, and procedures that will be used for the rejection of baghouse fines. The plan shall include detailed information on baghouse control systems and actual data demonstrating consistent system functionality. The QC plan shall be approved in writing before production.

(2) The Contractor shall demonstrate that the material can be produced per one of the two procedures listed below. The Contractor shall supply project aggregate material for use in establishing acceptance testing equipment correction factors. Aggregate samples that have been produced according to CP-L 5117 to represent plant-produced material shall be provided by the mix design lab.

(i) The Contractor shall produce a minimum of 3000 tons of material. This material shall be placed on non-thru lanes or offsite in locations approved by the Engineer. A minimum of 3 samples will be tested for AC content, air voids and VMA. QL’s for each element will be determined per the contract documents. If the QL is equal to or greater than 65 for VMA and Asphalt Cement Content and the QL for the element of air voids is equal to or greater than 70, full production may commence. This material may be considered a separate process, and price adjustment will be per subsection 105.05; or,

(ii) The Contractor shall construct a 500-ton test strip on the main line on the project. Tonnage other than 500 tons may be produced only if approved. Three samples in the last 200 tons will be tested for volumetric properties.

After construction of the test section, production shall be halted until the testing is complete and element QL’s are calculated. If the QL is equal to or greater than 65 for VMA and Asphalt Cement Content and the QL for the element of air voids is equal to or greater than 70, full production may commence. If the TQL is less than 65 or the QL for the element of air voids is less than 70, the material shall be removed and replaced at the Contractor's expense.

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September 30, 2024

PLANT MIX PAVEMENTS – GENERAL

Revise Section 401 of the Standard Specifications as follows:

Revise Subsection 401.10, eighth paragraph, of the Standard Specifications as shown:

The following specific requirements shall apply to the identified asphalt pavers:

(1) Blaw-Knox asphalt pavers manufactured prior to 2007 shall be equipped with the Blaw-Knox Materials Management Kit (MMK).

(2) Cedarapids asphalt pavers shall be those that were manufactured in 1989 or later.

(3) Caterpillar asphalt pavers manufactured prior to 2007 shall be equipped with deflector plates as identified in the December 2000 Service Magazine entitled “New Asphalt Deflector Kit {6630, 6631, 6640}”.

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January 8, 2024

PLANT MIX PAVEMENTS – GENERAL

Section 401 of the Standard Specifications shall be revised as follows:

Delete Subsection 401.17 of the Standard Specifications and replace with the following:

401.17 Compaction. The hot mix asphalt shall be compacted by rolling. Both steel wheel and pneumatic tire rollers will be required. The number, weight, and type of rollers furnished shall be sufficient to obtain the required density while the mixture is in a workable condition. Compaction shall begin immediately after the mixture is placed and be continuous until the required density is obtained. When the mixture contains unmodified asphalt cement (PG 58-28 or PG 64-22) or modified (PG 58-34), and the surface temperature falls below 185 °F, further compaction effort shall not be applied unless approved, provided the Contractor can demonstrate that there is no damage to the finished mat. If the mixture contains modified asphalt cement (PG 76-28, PG 70-28 or PG 64-28) and the surface temperature falls below 230 °F, further compaction effort shall not be applied unless approved, provided the Contractor can demonstrate that there is no damage to the finished mat.

Warm Mix Asphalt compaction requirements shall conform to CP 59.

All roller marks shall be removed with the finish rolling. Use of vibratory rollers with the vibrator on will not be permitted during surface course final rolling and will not be permitted on any rolling on bridge decks covered with waterproofing membrane.

SMA shall be compacted to a density of 93 to 98 percent of the daily theoretical maximum specific gravity, determined according to CP 51. All other HMA shall be compacted to a density of 92 to 98 percent of the daily theoretical maximum specific gravity, determined according to CP 51. If more than one theoretical maximum specific gravity test is taken in a day, the average of the theoretical maximum specific gravity results will be used to determine the percent compaction. Field density determinations will be made per CP 44 or 81.

The longitudinal joints shall be compacted to a density of 90 to 98 percent of the theoretical maximum specific gravity. The theoretical maximum specific gravity used to determine the joint density will be the average of the daily theoretical maximum specific gravities for the material that was placed on either side of the joint. Density (percent relative compaction) will be determined per CP 44.

The Contractor shall obtain one 6-inch diameter core at a random location within each longitudinal joint sampling section for determination of the joint density. The Contractor shall mark and drill the cores at the location directed by the Engineer and in the presence of the Engineer. The Engineer will take possession of the cores for testing. The Contractor may take additional cores at his own expense. Coring locations shall be centered on the visible line where the joint between the two adjacent lifts abuts the surface. The center of all joint cores shall be within 1 inch of this visible joint line. Core holes shall be repaired by the Contractor using materials and methods approved by the Engineer. PC and OA joint coring shall be completed within five calendar days of joint construction.

Longitudinal joint coring applies to all pavement layers. When constructing joints in an echelon paving process, the joints shall be clearly marked to ensure consistent coring location. In small areas, such as intersections, where the Engineer prescribes paving and phasing methods, the Engineer may temporarily waive the requirement for joint density testing.

Incentive or disincentive payment determined for joint density per subsection 105.05 will apply to the HMA on each side of the joint. If a layer of pavement has joints constructed on both sides, incentive or disincentive payment for each of those joints will apply to one half of the pavement between the joints.

Along forms, curbs, headers, walls, and all other places not accessible to the rollers, the mixture shall be thoroughly compacted with mechanical tampers.

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Any mixture that becomes loose and broken, mixed with dirt, or is in any way defective, shall be immediately removed and replaced with fresh hot mixture, and compacted to conform to the surrounding area.

The Contractor shall construct a compaction pavement test section (CTS) for each job mix where 2,000 or more tons are required for the project. The CTS will be used to evaluate the number of rollers and the most effective combination of rollers and rolling patterns for achieving the specified densities. Factors to be considered include, but are not limited to, the following:

(1) Number, size, and type of rollers.

(2) Amplitude, frequency, size and speed of vibratory rollers.

(3) Size, speed, and tire pressure of rubber tire rollers.

(4) Temperature of mixture being compacted.

(5) Roller patterns.

The CTS shall be constructed according to the following procedures:

The CTS shall be constructed to provide the nominal layer thickness specified. The first 500 tons of hot mix asphalt on the project location shall constitute the CTS. The production and placement rates of the CTS shall closely approximate the anticipated production and placement rates for the remainder of the Contract.

Compaction of the CTS shall commence immediately after the hot mix asphalt has been spread and shall be continuous and uniform over the entire CTS. For the CTS, compaction shall continue until no discernible increase in density is obtained by additional compactive efforts. All compaction shall be completed before the surface temperature of the mixture drops below 185 °F.

Approved types of rollers shall be used to achieve the specified density. The Contractor shall determine what methods and procedures are to be used for the compaction operation. The compaction methods and procedures shall be used uniformly over the entire last 200 tons. The Contractor shall record the following information and a copy of this data shall be furnished to the Engineer.

(1) Type, size, amplitude, frequency, and speed of roller.

(2) Tire pressure for rubber tire rollers, and whether the pass for vibratory rollers is vibratory or static.

(3) Surface temperature of mixture behind the laydown machine and subsequent temperatures and densities after each roller pass.

(4) Sequence and distance from laydown machine for each roller, and number of passes of each roller to obtain specified density.

Two sets of random cores shall be taken within the last 200 tons of the CTS. Each set shall consist of seven random cores.

The Engineer will determine the coring locations using a stratified random sampling process. The locations of these cores will be such that one set can serve as a duplicate of the other. One set of these cores shall be immediately submitted to the Engineer. This set will be used for determining acceptance of the CTS and determining density correction factors for nuclear density equipment. Densities of the random samples will be determined by cores according to CP 44. Density correction factors for nuclear density equipment will be determined according to CP 81. Coring shall be performed under CDOT observation. Coring will not be measured and paid for separately but shall be included in the work. For SMA, a CTS is not used. The Contractor shall follow the requirements for the demonstration control strip per the Revision of Section 403, Stone Matrix Asphalt Pavement.

The CTS meets requirements if the Quality Level of the random samples is greater than or equal to 75. The Quality Level will be determined according to CP 71. Once constructed and accepted, the CTS shall remain in place and become part of the hot mix asphalt on the project.

When the Quality level is less than 75 the Contractor shall construct an additional test section, utilizing different rollers, or roller positions, or roller patterns as required. A written proposal detailing the changes in methods and procedures that will be

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used to obtain density is to be submitted to the Engineer for review before constructing the additional test section.

If the Quality Level of a CTS is less than 75 and greater than or equal to 44, the Engineer may accept the material at a reduced price per Section 105.

If the Quality Level of a CTS is less than 44, the Engineer may:

(1) Require complete removal and replacement with specification material at the Contractor’s expense.

(2) Where the finished product is found to be capable of performing the intended purpose and the value of the finished product is not affected, as determined by the Engineer, permit the Contractor to leave the material in place with a pay factor, but not more than 75 percent of the bid price.

Each CTS shall be 500 tons. If in-place densities of the CTS, as determined by nuclear density equipment before determining density of the cores, meet the CTS density requirements, the Contractor may begin production paving and continue to place hot mix asphalt pavement under the following conditions:

(1) The period during which the Contractor continues to pave without test results from cores shall not exceed one workday.

(2) Construction proceeds at the Contractor's risk. If correlation with the cores reveals that the densities do not meet the CTS requirements, the hot mix asphalt pavement placed subsequently will be subject to price reduction or removal and replacement.

After production paving work has begun, a new CTS shall be required for different layers of pavement, unless otherwise approved by the Engineer. Each additional CTS shall be constructed and documented as specified herein, and shall be sampled, tested, and accepted or rejected as described herein.

All additional costs associated with construction of the CTS shall be at the Contractor’s expense. The hot mix asphalt placed in the CTS will be paid for per subsection 401.22, at the contract price for the hot mix asphalt.

If the Contractor requests changes to the roller pattern that was established during the CTS, the Contractor must perform a Roller Pass Study to demonstrate that the specified density is obtained with the new roller pattern before proceeding with the paving operation with Engineer Approval.

SS-6

REVISION OF SECTIONS 401

RECLAIMED ASPHALT PAVEMENT

Revise Section 401 of the Standard Specifications for this project as follows:

Subsection 401.02(b) shall include the following:

Reclaimed Asphalt Pavement (RAP) is allowed in hot mix asphalt (HMA) up to a maximum binder replacement of 23 percent for all lifts, provided all specifications for HMA are met. Fine Aggregate Angularity requirements shall apply only to the virgin fraction of the fine aggregate. The RAP shall not contain clay balls, vegetable matter, or other deleterious substances, and must meet the uniformity requirements as outlined below.

HMA Project Verification Testing for asphalt content and gradation will be performed at the frequencies listed in the Field Materials Manual per CP-L 5120.

The Contractor shall have an approved mix design for the amount of RAP to be used. The AC content of the RAP utilized in the Contractor RAP mix design shall be the average AC content determined per 1B or 1C, below, or alternatively, a minimum of five samples of the Contractors RAP stockpile may be sampled and the average AC content of the RAP be determined using AASHTO T-164, Method A or B, or per 1C below. The Contractor shall determine the total binder replaced by the binder in the RAP pursuant to the following equation:

Total Binder Replaced = (A x B) x 100/E

Where:

A = RAP % Binder Content *

B = RAP % in Mix *

E = Total Effective Binder Content *

* In decimal format (2% is 0.02)

The Total Binder Replaced by the binder in the RAP shall not exceed 23 percent of the effective binder content of either the mix design or the produced mix.

The use of RAP shall be controlled per subsections 105.05 and 106.05. If the Contractor elects to use RAP, the following additional conditions shall apply:

1. The Contractor shall have an approved Process Control (PC) Plan that details how the RAP will be processed and controlled. The PC plan shall address the following:

A. RAP Processing Techniques. This requires a schematic diagram and narrative that explains the processing (crushing, screening, and rejecting) and stockpile operation for this specific project.

B. Control of RAP Asphalt Binder Content (AASHTO T-164, Method A or B). RAP Asphalt Binder Content may also be determined per CP-L 5120, provided a RAP AC content correction factor is determined through correlation testing with AASHTO T-164, Method A or B. The correction factor shall be determined by performing correlation testing on the first five samples of the RAP AC content, then at a frequency of one for every five AC content tests thereafter.

The correction factor shall be determined by calculating the average difference in AC content between CP-L 5120 and AASHTO T-164, Method A or B, and applying the correction to the AC content determined per CP-L 5120 :

Frequency: 1/1000 tons of processed RAP material (minimum five tests)

C. Alternative Control of RAP Binder Content. The Contractor may propose a RAP asphalt content correction factor to be used in conjunction with CP-L 5120. The proposed CP-L 5120 RAP asphalt content correction factor shall be used with all RAP asphalt contents tested for the mixture design and quality control sampling and testing. The methodology of the proposed CP-L 5120 RAP asphalt content correction factor shall be outlined in detail in the

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approved RAP PC Plan. At a minimum, the proposed CP-L 5120 correction factor shall identify the principal source locations of the RAP aggregate, gradation of the material tested, and specific ignition oven serial number used in all the RAP asphalt content testing. The RAP source locations, material gradation, and specific equipment used shall substantiate the CP-L 5120 asphalt content correction factor used for the testing. The substantiation must be from data gathered from historical information or specific asphalt content correction data obtained from tests performed on similar virgin aggregate sources, virgin material gradations, and the specific equipment used.

D. Control of RAP Gradation (CP31 or AASHTO T-30):

Frequency: 1/1000 tons of processed RAP material (minimum three tests)

E. Process Control Charts shall be maintained for binder content and each screen listed in subsection 401.02(b), during addition of any RAP material to the stockpile. The Contractor shall maintain separate control charts for each RAP stockpile. The control charts shall be displayed and shall be made available, along with RAP AC extraction testing laboratory reports, to the Engineer upon request.

2. The processed RAP must be 100 percent passing the 31.5 mm (1 1/4 inch) sieve. The aggregate obtained from the processed RAP shall be 100 percent passing the 25.0 mm (1 inch) sieve. The aggregate and binder obtained from the processed RAP shall be uniform in all the measured parameters per the following:

Uniformity*

Parameter Standard Deviation

Binder Content 0.5 Percent Passing 19 mm (3/4”) 4.0 Percent Passing 12.5 mm (1/2”) 4.0 Percent Passing 9.5 mm (3/8”) 4.0 Percent Passing 4.75 mm (#4) 4.0 Percent Passing 2.36 mm (#8) 4.0 Percent Passing 600 µm (#30) 3.0

Percent Passing 75 µm (#200) 1.5

*Uniformity is the Maximum allowable Standard Deviation of test results of processed RAP.

3. If RAP millings generated are incorporated in the same project, per CPL 5145 the Contractor shall pave with a virgin mix design until sufficient amount of processed RAP has been stockpiled and tested to allow full production of a RAP HMA mix.

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March 21, 2025

REVISION OF SECTION 627

PAVEMENT MARKING

Revise Section 627 by removing and replacing the existing Section 627 of the Standard Specifications with the following:

Description

627.01 This work consists of furnishing and applying pavement marking, and furnishing, installing, and removing temporary pavement marking per these specifications, the Manual on Uniform Traffic Control Devices for Streets and Highways (MUTCD), the Colorado supplement thereto, and in conformity to the lines, dimensions, patterns, locations and details shown on the plans or established.

Materials

627.02 Materials shall conform to the requirements of the following subsections:

Material Requirements Subsection Paint 708.05

Glass Beads 713.08

Modified Epoxy Pavement Marking Material 713.17

Thermoplastic Marking Material 713.12

Pavement Primer 708.07

Preformed Plastic Pavement Marking Material 713.13

Pavement Marking Tape 713.15

Pavement Marking Tape (Removable) 713.16

Raised Pavement Marker 713.18

Preformed Thermoplastic Pavement Marking Material 713.14

Methyl Methacrylate Pavement Marking Material 713.19

Construction Requirements

627.03 General. All pavement markings shall be placed per the following requirements. When the term “full compliance” is used, it means the pavement markings shall meet the requirements of Standard Plan S-627-1.

(a) Pavement Marking Plan. When pavement-marking location details are not provided in the Contract, the Contractor shall submit a layout of existing conditions to the Project Engineer for approval. The approved layout is to be used as the final pavement-marking plan.

(b) Roadways Closed to Traffic During Construction. Full-compliance final markings shall be in place before opening the roadway to traffic.

Pavement markings on detour routes shall be full-compliance markings.

(c) Roadways Constructed Under Traffic. Full compliance final pavement markings shall be placed within two weeks after final surfacing is completed. Full compliance pavement markings shall also be placed on any roadways opened to traffic when the project pavement work is discontinued for more than two weeks.

(d) Temporary Pavement Markings. Temporary pavement markings and control points for the installation of those pavement markings for roadways that are being constructed under traffic shall be installed as follows:

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1. When one roadway of a normally physically divided highway is closed, and a crossover is constructed, full-compliance pavement markings shall be placed along the tapers and through the median crossovers to the two-way traffic section. Pavement markings through the two-way traffic section shall be as shown on the plans.

All temporary paved roadways shall have full-compliance centerline, lane line, and edge line markings before they are open for traffic.

Upon removal, markings applied to a final surface shall not leave a scar that conflicts with permanent markings.

2. The following criteria apply to all construction on roadways open to traffic other than (d)1.

above:

Full-compliance centerline, lane line, and edge line temporary markings shall be in place at the end of each workday.

No-passing zone restrictions shall be identified by full compliance no-passing zone markings. No-passing zone markings shall be in place daily.

Temporary pavement stencils (SCHOOL, RR Xing, etc.) are not required unless specified in the plans.

Temporary pavement markings shall be installed according to the manufacturer’s recommendations in such a way that the markings adequately follow the desired alignment.

3. Control Points consisting of 4-inch by 1-foot marks at 40-foot intervals may be placed as guide markers for the installation of temporary or final pavement markings. Raised flexible pavement markers may be substituted for these marks. Control points shall not be used as a substitute for any required marking.

(e) Pavement Marking for Seal Coats (Section 409).

1. Raised flexible pavement markers, suitable for use on seal coats, shall be installed as follows:

No-passing zones shall be marked with two markers placed side-by-side at 40-foot intervals throughout the zone.

Passing zones shall be marked with one marker at 40-foot centers. Closer spacing shall be used on curves, as deemed appropriate.

Raised flexible pavement markers, installed on 40-foot centers, may also be used to mark lane lines through multi-lane roadway sections. Auxiliary lanes and shoulder lines may be marked with flexible markers on 80-foot centers or as appropriate.

2. Full-compliance final pavement markings shall be placed within one week of completion of the seal coat project.

(f) Procedures for Items Paid by the Gallon

Either of the following methods are acceptable unless otherwise specified by the Project Engineer.

1. Method #1 - Use of Data Logging System (DLS)

Equipment: The Contractor shall use a “Skip-line by SPEC-RITE” Data Logger System (DLS) or equivalent DLS equipment as approved by the Project Engineer.

Calibration: Pavement marking vehicles using a Data Logging System (DLS) shall be calibrated at intervals no longer than 12 months. Calibration requirements and allowable tolerances will be determined by the equipment manufacturer. Prior to the installation of materials paid by the gallon, a copy of the most recent certification report for each DLS equipment system used shall be submitted to the Project Engineer.

Verification: A verification test section may be conducted at any time during production at the discretion of the Project Engineer. The verification test shall be performed according to Method #2 and the pavement marking shall be at least 1 mile (5,280 feet) in length, and shall be a width of four, six or eight inches. If the

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test section cannot be performed as a result of limitations, then method #2 shall be used to verify quantities for payment. If the calibration application rate cannot be verified, then method #2 shall be used to verify quantities for payment.

2. Method #2 - Performing Tank Stabs and Field Measurement Tank stab measurements shall be used to verify the application rate by calculating the volume of material used over the corresponding application (square foot) area. Tank stab measurements shall be performed by the Contractor at the beginning and end of the pavement marking installation with the pavement marking vehicle parked at the same location and direction of travel for each measurement. Tank stab measurements shall be taken to the top of the fluid level from a fixed point. These measurements will be visually observed and recorded before the pavement marking operations begin, at the end of the pavement marking operations, and before and after each tank is replenished. The difference in the height of the fluid level corresponds to the volume of material used per the manufacturer’s tank conversion chart. Measurements will be recorded to the nearest 1⁄4 inch.

Plural component materials, such as modified epoxy pavement markings, are applied as a combination of resins and catalysts from separate tanks. Tank stabs shall be recorded for each tank and the volumes combined to determine the total volume, in gallons, applied. Pavement markings shall be field measured to determine the total area of material installed. The tank stab and field measurements will be used to verify the application rate is within the rate specified by the contract.

627.04 Pavement Marking with Low Temperature Acrylic Paint and High Build Acrylic Paint. Striping shall be applied on asphalt or portland cement concrete pavements when the air and pavement temperatures are as follows: for high-build waterborne paint, at least 45 °F and expected to remain 45 °F or above for at least 24 hours; for low temperature waterborne paint, at least 35 °F and expected to remain 35 °F or above for at least 24 hours. The pavement surface shall be dry and clean, and free of all latent materials, per the manufacturer’s recommendations. Weather conditions shall be conducive to satisfactory results. Glass beads shall be applied into the paint by means of a low pressure, gravity drop bead applicator.

The Contractor shall use equipment that meets the following requirements, as approved:

(1) Equipment shall permit traffic to pass safely within the limits of the roadway surface and shoulder while operating.

(2) Equipment shall be designed for placement of both solid and broken line pavement markings with a reasonably clean-edged pavement marking of the width and location as shown on the contract and no overspray on the road surface.

(3) Equipment shall have a glass bead dispenser directly behind and synchronized with the paint applicator. Each applicator shall have individual control and automatic skip control that will paint a strip with a gap as shown in the Contract.

(4) The equipment may be equipped with a heat exchanger to heat the paint to reduce drying time.

(5) The operation shall include a trailing vehicle equipped with a flashing arrow board.\

The Contractor shall prevent traffic from crossing a wet pavement marking. Pavement markings that have been marred or picked up by traffic before they have dried shall be repaired at the Contractor’s expense.

Removal of paint material from vehicles that encountered wet paint shall be at the Contractor’s expense.

The water-based paint pavement markings shall fall within the following minimum and maximum ranges:

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Table 627-1 Application Rates and Tolerances for Pavement Markings

Description Units Pavement Marking Paint Low Temp

Pavement Marking Paint High Build

Pavement Marking Paint High Build (Temporary)

Alignment (Lateral Deviation)

Inches < 2.0 < 2.0 < 2.0

Application Rate Sq Ft/Gallon 89-94 67-70 100-105

Thickness Mil 17.5 ± 0.5 23.5 ± 0.5 15.5 ± 0.5

Width Inches Per Plans ± 0.25 Per Plans ± 0.25 Per Plans ± 0.25

No Tack Dry Time @ 77º F Minutes 5-10 7-12 5-10

Glass Bead Application Rate Lbs, Gallon 7+ 9+ 5+

(6) High Build (Temporary) shall only be used for temporary pavement marking applications.

Equipment shall have a bead dispenser directly behind, synchronized with the paint applicator and shall be capable of painting a clean-edged pavement marking of the designated width plus or minus 1/4 inch with no overspray on the road surface. For centerlines and lane lines, an automatic skip control shall be used.

Machines having multiple applicators shall be used for centerlines with “no passing zones.” In areas where machines are not practical, suitable hand-operated equipment shall be used as directed by the Project Engineer. Pavement markings shall be protected until dry.

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Modified Epoxy Pavement Marking. The modified epoxy pavement-marking compound shall be applied with equipment that will precisely meter the two components in the ratio given in subsection 713.17(a). The equipment shall automatically shut off or warn the operator if one component is not being mixed. The equipment shall produce the required amount of heat at the mixing head and gun tip to provide and maintain the temperatures specified.

Before mixing, the individual components A and B shall each be heated to a temperature of 80 to 140 °F.

After mixing, the application temperature for the combined material at the gun tip shall be 80 to 140 °F. The 140 °F upper limit is the maximum temperature under any circumstances.

Both pavement and air temperatures shall be at least 35 °F at the time of modified epoxy pavement marking application.

The surface areas of new portland cement concrete pavement and decks that are to receive markings shall be waterblasted before placement of the modified epoxy pavement marking. The amount of waterblasting shall be sufficient to remove all dirt, laitance, and curing compound residue.

The surface areas of new asphalt pavement, existing asphalt pavement, and existing concrete pavement that are to receive markings shall be cleaned with a high-pressure air blast to remove loose material before placement of the modified epoxy pavement marking. Should any pavement become dirty, from tracked mud etc. as determined by the Project Engineer, it shall be cleaned before the placement of the modified epoxy pavement marking.

When recommended by the modified epoxy manufacturer, a high-pressure water blast integrated into the gun carriage shall be used to clean the pavement surface before modified epoxy pavement marking application. The water blast shall be followed by a high- pressure air blast to remove all residual water, leaving only a damp surface.

Modified epoxy pavement marking shall be applied to the road surface according to the modified epoxy manufacturer’s recommended methods at the application rate or coverage shown below. Glass beads shall be applied into the modified epoxy pavement marking by means of a low pressure, gravity drop bead applicator.

Modified epoxy pavement markings and beads shall be applied within the following limits:

Table 627-2 Application Rates and Tolerances for Modified Epoxy Pavement Marking

Description Units Modified Epoxy Pavement Marking

Alignment (Lateral Deviation)

Inches < 2.0

Application Rate Sq Ft/Gallon 85 - 90

Thickness Mil 18.5 ± 0.5

Width Inches Per Plans ± 0.25

No Tack Dry Time @ 77º F Minutes 5 - 7

Glass Bead Application Rate Lbs per Gallon 23+

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627.06 Thermoplastic Pavement Marking.

(a) Equipment-General. The material shall be applied to the pavement by an extrusion method where one side of the shaping die is the pavement and the other three sides are contained by or are part of suitable equipment for heating, mixing, and controlling the flow of the material.

The equipment shall be constructed to provide continuous mixing and agitation of the material. Conveying parts of the equipment between the main material reservoir and the shaping die shall be so constructed as to prevent accumulation and clogging. All parts of the equipment that come in contact with the material shall be easily accessible and exposable for cleaning and maintenance.

All mixing and conveying parts up to and including the shaping die, shall maintain the material at the plastic temperature.

The equipment shall be so constructed as to assure continuous uniformity in the dimensions of the pavement marking. The applicator shall provide a means for cleanly cutting off square pavement marking ends and shall provide a method of applying "skip" lines. The use of pans, aprons or similar appliances that the die overruns will not be permitted under this specification.

Glass beads for the surface of the completed pavement marking shall be applied by an automatic bead dispenser attached to the applicator in such manner that the beads are dispensed almost instantly upon the completed line. The bead dispenser shall be equipped with an automatic cutoff control synchronized with the cutoff of the thermoplastic material.

The equipment shall be so constructed as to provide for varying die widths to produce varying widths of traffic markings.

The equipment shall be designed to permit agitation of the material to prevent scorching, discoloration or excessive high temperatures of any part of the material.

A special kettle shall be provided for melting and heating the composition. The kettle shall be equipped with an automatic thermostatic control device so that heating can be done by controlled heat transfer liquid rather than direct flame.

The applicator and kettle shall be so equipped and arranged as to satisfy the requirements of the National Fire Underwriters.

The equipment shall be so equipped as to permit preheating of the pavement immediately before application of the material.

The applicator shall be mobile and maneuverable to the extent that straight lines can be followed, and normal curves can be made in a true arc.

(b) Types of Equipment.

1. Portable Applicator. The portable applicator shall be a device typically used for painting crosswalk lines, stop bars, short lane lines and short centerlines. The applicator shall be easily maneuverable and capable of being propelled by the operator.

2. Mobile Applicator. The mobile applicator shall contain equipment to provide for automatic installation of skip lines in any combination of line and skip up to 40 feet. The mobile applicator shall be moved in conjunction with the melting and heating kettles in such a manner as to provide continuous highway operation of the kettles and the mobile applicator as an integral unit.

3. Epoxy Primer Equipment. The epoxy primer application shall be accomplished using equipment having the following features:

A. The main storage tank shall be equipped with a visible gauge that will allow the Project

Engineer to readily ascertain the rate of application.

B. The main storage tank shall be equipped with a heating device that will maintain the epoxy at a constant efficient temperature.

SS-14

C. The spray nozzle and epoxy spray shall be protected from the action of wind to ensure placement where needed.

4. Cleaning Equipment. Equipment must be provided to ensure removal of laitance, dust, debris, paint and other foreign matter from the road surface immediately before the installation of the composition, or immediately before the application of primer.

(c) Application. The pavement marking shall be applied to the pavement to either the right or left of the application unit, dependent upon roadway lane being used. The unit shall not occupy more than one lane of roadway while operating.

The finished lines shall have well defined edges and be free of waviness. All of the equipment necessary to the preheating and application of the material shall be so designed that the temperature of the material can be controlled within the limits necessary to its pourability for good application.

At the time of installation of thermoplastic materials, the pavement shall be clean, dry, and free of laitance, oil, dirt, grease, paint or other foreign contaminants. Pavement and ambient temperatures shall be at least 50 °F.

An epoxy resin primer conforming to subsection 708.07 shall be applied to all pavement surfaces before the application of the thermoplastic pavement marking.

The marking material shall not be applied until the epoxy resin primer reaches the tacky stage, approximately 15 minutes under normal conditions. An infrared heating device may be employed to shorten the curing time of the epoxy.

To ensure the best possible adhesion, the marking material as specified, shall be installed at the manufacturer's recommended temperature.

The minimum thickness of thermoplastic lines as viewed from a lateral cross section shall not be less than 3/32 inch at the edges, or less than 1/8 inch at the center.

Measurements shall be taken as an average throughout any 36-inch section of the line. The material, when formed into traffic pavement markings, must be readily renewable by placing an overlay of new material directly over an old line of compatible material. Such new material shall bond itself to the old line in such a manner that no splitting or separation takes place.

Glass beads shall be applied to the thermoplastic pavement marking by means of a low pressure, gravity drop bead applicator at a rate of 10 pounds per 100 square feet, minimum.

627.07 Methyl Methacrylate Pavement Marking. Methyl methacrylate pavement marking shall be installed per manufacturer’s recommendations. The Contractor shall use installation equipment, materials, equipment technicians and operators recommended by the manufacturer.

Methyl methacrylate pavement markings shall be applied to the road surface according to the manufacturer’s recommended methods at 60-mil minimum thickness. Glass beads shall be applied using a double drop bead application system. The first bead applicator shall apply glass beads at the rate of 3.2 pounds per square yard (10 pounds per gallon) minimum, and 1.9 pounds per square yard (6 pounds per gallon) minimum for the second bead applicator.

Methyl methacrylate pavement marking, and beads shall be applied within the following limits:

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Table 627-3 Application Rates and Tolerances for Methyl Methacrylate Pavement Marking

627.08 Preformed Plastic Pavement Marking. This retroreflective preformed plastic strip shall be suitable for application on asphaltic or portland cement concrete pavement. The strip shall be applied at the locations called for on the plans or as directed.

If recommended by the manufacturer, an epoxy resin primer conforming to subsection 708.07 shall be applied to all pavement surfaces before the application of the preformed plastic pavement marking.

The surface of the pavement shall be clean, free of loose foreign material, dry and have no moisture for a minimum of 48 hours before application of the markings.

The air and surface temperature shall be a minimum 40 °F or as recommended by the manufacturer.

The marking strip as applied shall be in good appearance, free of cracks and the edges shall be true and straight.

Description Units Methyl Methacrylate Pavement Marking

Alignment (Lateral Deviation)

Inches < 2.0

Application Rate Sq Ft per Gallon 26 - 28

Thickness Mil 60 ± 2.0

Width Inches Per Plans ± 0.25

No Tack Dry Time @ 77 ºF Minutes < 15

Glass Bead Application Rate Lbs per Gallon 1st Application = 10+ 2nd Application = 6+

SS-16

The preformed plastic pavement marking shall be Type I, Type II, or Type III as shown on the plans.

Before beginning installation operations, the Contractor shall submit to the Project Engineer instructions from the performed plastic pavement manufacturer detailing surface preparation, grooving requirements and material application. The instructions shall include the following:

(1) Equipment Requirements.

(2) Approved Work Methods and Procedures.

(3) Material Application Temperature Requirements.

(4) Ambient Air and Surface temperature Requirements.

(5) Weather Limitations.

(6) Special Precautions.

(7) Any other requirements necessary for successful installation and satisfactory performance of the material.

The Contractor shall secure from the manufacturer all warranties and guarantees with respect to materials, workmanship, performance, or combination thereof, and shall include these warranties and guarantees with the Certification of Compliance.

Materials supplied without installation instructions or with incomplete instructions will not be accepted for use.

Unless otherwise shown on the plans, typical pavement markings shall conform to the shapes and sizes as shown on Standard Plan S-627-1.

The Contractor shall make all arrangements to have a manufacturer-trained installer of the manufacturer’s products on-site during the placement of preformed plastic pavement marking to ensure proper installation. A minimum of two weeks before the placement of the preformed plastic pavement marking, the Contractor shall submit written documentation of the installer’s qualifications and training in the installation of preformed plastic pavement marking. Upon completion of the work, the Contractor shall obtain and submit to the Project Engineer written documentation from the manufacturer-trained installer certifying that the product was installed in full compliance with this specification and manufacturer’s recommendations.

The preformed plastic pavement marking shall be inlaid on new and existing pavements as shown in the Contract. The material shall be usable for patching worn areas of the same type according to the manufacturer’s recommendations.

The Contractor shall not perform wet cutting of pavement unless otherwise directed. Application and removal of temporary pavement marking associated with wet cutting of pavement shall be at the Contractor’s expense.

The preformed plastic pavement marking shall conform to pavement contours by the action of traffic, and shall be applicable on new, dense, and open graded asphalt wearing courses during the paving operations according to the manufacturer’s recommendations. After application, the markings shall be immediately ready for traffic.

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(a) Inlaid Preformed Plastic Pavement Marking. The grooved width for inlaid preformed plastic pavement marking is called for in the Contract. The grooved width shall be the pavement marking width plus 1 inch, with a tolerance of plus or minus 1/4 inch. The depth of the grooves shall be 130 mils plus or minus 5 mils. Groove position shall be a minimum of 2 inches from the edge of the pavement marking to the longitudinal pavement joint.

Grooving shall not be performed on bridge decks with Polyester Polymer Concrete Overlays.

The bottom of the groove shall have a smooth, flat finished surface. The spacers between blade cuts shall be such that there will be less than a 10-mil rise in the finished groove between the blades.

Grooves shall be clean, dry and free of laitance, oil, dirt, grease, paint or other foreign contaminants. The Contractor shall prevent traffic from traversing the grooves, and re- clean grooves, as necessary, before application of the preformed plastic pavement markings.

627.09 Preformed Thermoplastic Pavement Marking. The markings shall consist of a resilient white or yellow thermoplastic product with glass beads uniformly distributed throughout the entire cross-sectional area. Legends and symbols shall be capable of being affixed to bituminous pavements by heating.

The markings shall conform to pavement contours, breaks and faults through the action of traffic at normal pavement temperatures. The material shall have resealing characteristics with the capability of fusing with itself and previously applied thermoplastic markings under normal use.

The preformed thermoplastic markings shall be packaged in a protective plastic film with cardboard stiffeners where necessary to prevent damage in transit. The carton in that the material is packed shall be clearly labeled for ease of identification.

(a) Application. Application temperature shall be as recommended by the manufacturer. The pavement and air temperature shall be as recommended by the manufacturer at the time of application. The materials shall be applied using a heating method recommended by the manufacturer. The Contractor shall provide the Project Engineer a copy of the manufacturer's installation recommendations before beginning the work. The pavement shall be clean, dry and free from debris. The preformed thermoplastic markings may be installed on top of existing thermoplastic markings after all loose material has been removed. The preformed thermoplastic markings shall not be installed on top of existing preformed plastic pavement markings without first removing the existing markings to a depth that ensures removal of the adhesive backing of the preformed plastic.

It shall not be installed on top of pavement marking paint without first removing the paint.

(b) Equipment. The Contractor shall use a heating method specifically recommended by the manufacturer for the installation of preformed thermoplastic markings.

627.10 Pavement Marking Tape. Retroreflective tape shall be suitable for temporary use on asphaltic or portland cement concrete pavements. The tape shall be applied at the locations shown on the plans or as directed. The tape shall conform to subsection 713.15.

The surface that the tape is applied shall be clean, dry and free of dirt, oils and grease. The tape shall be pressed down immediately after application, until it adheres properly and conforms to the surface. Temporary marking tape sections longer than 1 foot shall be removed before placement of the final pavement course. All tape shall be removed on sections where tape conflicts with revised traffic lanes before opening of new lanes to traffic.

Pavement marking tape (removable) shall be installed per the manufacturer's recommendations and maintained throughout the required construction phase at no additional cost to the Department.

627.11 Raised Pavement Markers. Raised pavement markers (temporary) shall be installed on centerlines, edge lines, and lane lines where specified in the Contract. Single markers shall be installed at 5-foot intervals for solid lines. A group of four markers at 3-foot spacings and at 40- foot intervals shall be installed for skip lines.

SS-18

Markers supplementing lines shall be installed at the spacing shown on the plans. Raised pavement markers (temporary) shall be installed per the manufacturer's recommendations and shall be maintained throughout the required construction phase at the Contractor’s expense.

Method of Measurement

627.12 The types of pavement marking described will be measured by the following units, complete-in-place and accepted.

Pavement marking paint will be measured by the number of gallons used. Procedures Method #1 or Method #2 will be used to determine the quantities for pavement markings paid by the gallon. The material used in excess of the application rate specified, will not be paid.

Modified epoxy pavement marking, polyurea, and methyl methacrylate pavement marking will be measured by the total number of gallons of components A (pigment/resin) and B (hardener/catalyst) combined to achieve the application requirements as specified. Procedures Method #1 or Method #2 will be used to determine the quantities for pavement markings paid by the gallon. The material used in excess of the application rate specified, will not be paid.

Thermoplastic pavement marking, preformed thermoplastic pavement marking,…