ESBD_515557_1778767469133_Attachment C - 2024 TxDOT Specifications.pdf

2024 Specifications 351

Item 351

Flexible Pavement Structure Repair

1. DESCRIPTION

Repair localized sections of flexible pavement structure, including subgrade, base, and surfacing, as shown on the plans.

2. MATERIALS

Furnish materials unless otherwise shown on the plans. Provide materials of the type and grade as shown on the plans and in accordance with the following.

Item 132, “Embankment” Item 204, “Sprinkling” Item 247, “Flexible Base” Item 260, “Lime Treatment (Road-Mixed)” Item 275, “Cement Treatment (Road-Mixed)” Item 276, “Cement Treatment (Plant-Mixed)” Item 292, “Asphalt Treatment (Plant-Mixed)” Item 310, “Prime Coat” Item 316, “Seal Coat” Item 330, “Limestone Rock Asphalt Pavement” Item 334, “Hot-Mix Cold-Laid Asphalt Concrete Pavement” Item 341, “Dense-Graded Hot-Mix Asphalt” Item 344, “Superpave Mixtures”

For asphalt concrete materials, Contractor testing and payment adjustment provisions will be waived unless otherwise shown on the plans.

3. EQUIPMENT

Furnish equipment in accordance with pertinent Items. Use of a motor grader will be permitted for asphalt concrete pavement unless otherwise shown on the plans.

4. WORK METHODS

Repair using one or more of the following operations as shown on the plans. For Contracts with callout work, begin physical repair within 24 hr. of notification unless otherwise shown on the plans. Cut neat vertical faces around the perimeter of the work area when removing pavement structure layers. Removed materials are the property of the Contractor unless otherwise shown on the plans. Dispose of removed material in conformance with federal, state, and local regulations. Provide a smooth line and grade conforming to the adjacent pavement.

4.1. Removing Pavement Structure. Remove adjacent soil and vegetation if necessary to prevent contamination of the repair area and place it in a windrow. Do not damage adjacent pavement structure during repair operations. Remove flexible pavement structure layers from work area if subgrade work is required.

4.2. Preparing Subgrade. Fill holes, ruts, and depressions using approved material. Wet, reshape, and compact the subgrade thoroughly as directed.

Remove unstable subgrade material to the depth directed and replace with an approved material where subgrade has failed.

4.3. Mixing and Placing Base Material. Place, spread, and compact material in conformance with the applicable Item to the required or directed depth. Pulverize bituminous material to a maximum dimension of 2-1/2 in., and uniformly mix with existing base to the depth shown on the plans when the material is to remain in pavement structure.

4.3.1. Flexible Base. Use existing base and add new flexible base as required in accordance with Item 247 and details shown on the plans to achieve required section.

4.3.2. Lime-Stabilized Base. Use existing base, add new flexible base, and stabilize with a minimum lime content of 3% by weight of the total mixture. Construct in accordance with Item 260 and details shown on the plans to achieve required section.

4.3.3. Cement-Stabilized Base. Use existing base, add flexible base, and stabilize with a minimum cement content of 4% by weight of the total mixture. Construct in accordance with Item 275 or Item 276 and details shown on the plans to achieve required section.

4.3.4. Asphalt-Stabilized Base. Place asphalt-stabilized base in accordance with Item 292 or Item 341 and details shown on the plans to achieve required section.

4.3.5. Limestone Rock Asphalt. Place in accordance with Item 330 and details shown on the plans to achieve required section.

4.4. Curing Base. Cure in conformance with the appropriate Item unless otherwise directed or approved.

Maintain completed base sections until surfacing.

4.5. Surfacing. Apply surfacing to the completed base section using materials shown on the plans.

4.5.1. Prime Coat. Protect the compacted, finished, and cured flexible, lime-stabilized, or cement-stabilized base mixtures with a prime coat of the type and grade shown on the plans. Apply the prime coat at the rate shown on the plans.

4.5.2. Surface Treatments. Apply surface treatment with the type and grade of asphalt and aggregate as shown on the plans in accordance with Item 316.

4.5.3. Asphalt Concrete Pavement. Apply tack coat of the type and grade and at the rate shown on the plans unless otherwise directed. Construct in accordance with Item 330, Item 334, Item 341, or Item 344 to achieve required section.

4.6. Finishing. Regrade and compact disturbed topsoil. Clean roadway surface after repair operations.

4.7. Ride Quality. Use Surface Test Type A to determine the ride quality of the repaired areas, unless otherwise shown on the plans.

5. MEASUREMENT

This Item will be measured by the square yard. In areas where material is excavated, as directed, to depths greater than those specified on the plans, measurement will be made by dividing the actual depth of such area by the plan depth and then multiplying this figure by the area in square yard of work performed.

Calculations for each repaired area will be rounded up to the nearest 1/10 sq. yd. At each repair location, the minimum area for payment purposes will be 1 sq. yd.

The minimum quantity for Contracts with callout work is 5 sq. yd. per callout unless otherwise shown on the plans.

6. PAYMENT

The work performed and materials furnished in accordance with this Item and measured as provided under “Measurement” will be paid for at the unit price bid for “Flexible Pavement Structure Repair” of the specified depth. This price is full compensation for scarifying, removing, hauling, spreading, disposing of, and stockpiling existing pavement structure; removing objectionable or unstable material; furnishing and placing materials; maintaining completed section before surfacing; applying tack or prime coat; hauling, sprinkling, spreading, and compacting; and equipment, labor, tools, and incidentals.

1 - 32 10-19

Statewide

Special Specification 3077

Superpave Mixtures

1. DESCRIPTION

Construct a hot-mix asphalt (HMA) pavement layer composed of a compacted, Superpave (SP) mixture of aggregate and asphalt binder mixed hot in a mixing plant. Payment adjustments will apply to HMA placed under this specification unless the HMA is deemed exempt in accordance with Section 3077

2. MATERIALS

Furnish uncontaminated materials of uniform quality that meet the requirements of the plans and specifications.

Notify the Engineer of all material sources and before changing any material source or formulation. The Engineer will verify that the specification requirements are met when the Contractor makes a source or formulation change and may require a new laboratory mixture design, trial batch, or both. The Engineer may sample and test project materials at any time during the project to verify specification compliance in accordance with Item

2.1. Aggregate. Furnish aggregates from sources that conform to the requirements shown in Table 1 and as specified in this Section. Aggregate requirements in this Section, including those shown in Table 1, may be modified or eliminated when shown on the plans. Additional aggregate requirements may be specified when shown on the plans. Provide aggregate stockpiles that meet the definitions in this Section for coarse, intermediate, or fine aggregate. Aggregate from reclaimed asphalt pavement (RAP) is not required to meet Table 1 requirements unless otherwise shown on the plans. Supply aggregates that meet the definitions in Tex-100-E for crushed gravel or crushed stone. The Engineer will designate the plant or the quarry as the sampling location. Provide samples from materials produced for the project. The Engineer will establish the Surface Aggregate Classification (SAC) and perform Los Angeles abrasion, magnesium sulfate soundness, and Micro-Deval tests. Perform all other aggregate quality tests listed in Table 1. Document all test results on the mixture design report. The Engineer may perform tests on independent or split samples to verify Contractor test results. Stockpile aggregates for each source and type separately. Determine aggregate gradations for mixture design and production testing based on the washed sieve analysis given in Tex-200-F, Part II.

2.1.1. Coarse Aggregate. Coarse aggregate stockpiles must have no more than 20% material passing the No. 8 Bituminous Rated Source Quality Catalog

(BRSQC) are preapproved for use. Use only the rated values for hot-mix listed in the BRSQC. Rated values for surface treatment (ST) do not apply to coarse aggregate sources used in hot-mix asphalt.

build an individual stockpile for each material;

request the Department test the stockpile for specification compliance; and once approved, do not add material to the stockpile unless otherwise approved.

Provide aggregate from non-listed sources only when tested by the Engineer and approved before use. Allow 30 calendar days for the Engineer to sample, test, and report results for non-listed sources.

2 - 32 10-19

Statewide

Provide coarse aggregate with at least the minimum SAC shown on the plans. SAC requirements only apply to aggregates used on the surface of travel lanes. SAC requirements apply to aggregates used on surfaces

Aggregate Quality Monitoring Program (AQMP) (Tex-499-A) is listed in the BRSQC.

2.1.1.1. Blending Class A and Class B Aggregates. Class B aggregate meeting all other requirements in Table 1 may be blended with a Class A aggregate to meet requirements for Class A materials, unless otherwise shown on the plans. Ensure that at least 50% by weight, or volume if required, of the material retained on the No. 4 sieve comes from the Class A aggregate source when blending Class A and B aggregates to meet a Class A requirement unless otherwise shown on the plans. Blend by volume if the bulk specific gravities of the Class A and B aggregates differ by more than 0.300. Coarse aggregate from RAP and Recycled Asphalt Shingles (RAS) will be considered as Class B aggregate for blending purposes.

The Engineer may perform tests at any time during production, when the Contractor blends Class A and B aggregates to meet a Class A requirement, to ensure that at least 50% by weight, or volume if required, of the material retained on the No. 4 sieve comes from the Class A aggregate source. The Engineer will use the

A aggregate retained on the No. 4 sieve by inputting the bin percentages shown from readouts in the control room at the time of production and stockpile gradations measured at the time of production. The Engineer may determine the gradations based on either washed or dry sieve analysis from samples obtained from individual aggregate cold feed bins or aggregate stockpiles. The Engineer may perform spot checks using the gradations supplied by the Contractor on the mixture design report as an input for the template; however, a failing spot check will require confirmation with a stockpile gradation determined by the Engineer.

2.1.1.2. Micro-Deval Abrasion. The Engineer will perform a minimum of one Micro-Deval abrasion test in accordance with Tex-461-A for each coarse aggregate source used in the mixture design that has a Rated Source Soundness Magnesium (RSSM) loss value greater than 15 as listed in the BRSQC. The Engineer will perform testing before the start of production and may perform additional testing at any time during production. The Engineer may obtain the coarse aggregate samples from each coarse aggregate source or may require the Contractor to obtain the samples. The Engineer may waive all Micro-Deval testing based on a satisfactory test history of the same aggregate source.

The Engineer will estimate the magnesium sulfate soundness loss for each coarse aggregate source, when tested, using the following formula:

Mgest. = (RSSM)(MDact./RSMD) where:

Mgest. = magnesium sulfate soundness loss MDact. = actual Micro-Deval percent loss RSMD = Rated Source Micro-Deval

When the estimated magnesium sulfate soundness loss is greater than the maximum magnesium sulfate soundness loss specified, the coarse aggregate source will not be allowed for use unless otherwise approved. The Engineer will consult the Soils and Aggregates Section of the Materials and Tests Division, and additional testing may be required before granting approval.

2.1.2. Intermediate Aggregate. Aggregates not meeting the definition of coarse or fine aggregate will be defined as intermediate aggregate. Supply intermediate aggregates, when used that are free from organic impurities.

The Engineer may test the intermediate aggregate in accordance with Tex-408-A to verify the material is free from organic impurities. Supply intermediate aggregate from coarse aggregate sources, when used that meet the requirements shown in Table 1 unless otherwise approved.

Test the stockpile if 10% or more of the stockpile is retained on the No. 4 sieve, and verify that it meets the requirements in Table 1 for crushed face count (Tex-460-A) and flat and elongated particles (Tex-280-F).

3 - 32 10-19

Statewide

2.1.3. Fine Aggregate. Fine aggregates consist of manufactured sands, screenings, and field sands. Fine aggregate stockpiles must meet the gradation requirements in Table 2. Supply fine aggregates that are free from organic impurities. The Engineer may test the fine aggregate in accordance with Tex-408-A to verify the material is free from organic impurities. Unless otherwise shown on the plans, up to 10% of the total aggregate may be field sand or other uncrushed fine aggregate. Use fine aggregate, with the exception of field sand, from coarse aggregate sources that meet the requirements shown in Table 1 unless otherwise approved.

Test the stockpile if 10% or more of the stockpile is retained on the No. 4 sieve and verify that it meets the requirements in Table 1 for crushed face count (Tex-460-A) and flat and elongated particles (Tex-280-F).

Table 1 Aggregate Quality Requirements

Property Test Method Requirement Coarse Aggregate

SAC Tex-499-A (AQMP) As shown on the plans Deleterious material, %, Max Tex-217-F, Part I 1.0 Decantation, %, Max Tex-217-F, Part II 1.5 Micro-Deval abrasion, % Tex-461-A Note 1 Los Angeles abrasion, %, Max Tex-410-A 352 Magnesium sulfate soundness, 5 cycles, %, Max Tex-411-A 253 Crushed face count,4 %, Min Tex-460-A, Part I 85 Flat and elongated particles @ 5:1, %, Max Tex-280-F 10

Fine Aggregate Linear shrinkage, %, Max Tex-107-E 3 Sand equivalent, %, Min Tex-203-F 45

1. Used to estimate the magnesium sulfate soundness loss in accordance with Section 3077 -Deval

Abrasion

2. For base mixtures defined in Section 3077.2.7 the Los Angeles abrasion may be increased to a maximum of 40%.

3. For base mixtures defined in Section 3077 magnesium sulfate soundness, five cycles, may be increased to a maximum of 30%.

4. Only applies to crushed gravel.

Table 2 Gradation Requirements for Fine Aggregate

Sieve Size % Passing by Weight or Volume 3/8 100 #8 70 100

#200 0 30

2.2. Mineral Filler. Mineral filler consists of finely divided mineral matter such as agricultural lime, crusher fines, hydrated lime, or fly ash. Mineral filler is allowed unless otherwise shown on the plans. Use no more than 2% hydrated lime or fly ash unless otherwise shown on the plans. Use no more than 1% hydrated lime if a substitute binder is used unless otherwise shown on the plans or allowed. Test all mineral fillers except hydrated lime and fly ash in accordance with Tex-107-E to ensure specification compliance. The plans may require or disallow specific mineral fillers. Provide mineral filler, when used, that:

is sufficiently dry, free-flowing, and free from clumps and foreign matter as determined by the Engineer;

does not exceed 3% linear shrinkage when tested in accordance with Tex-107-E; and meets the gradation requirements in Table 3, unless otherwise shown on the plans.

Table 3 Gradation Requirements for Mineral Filler

Sieve Size % Passing by Weight or Volume #8 100

#200 55 100

2.3. Baghouse Fines. Fines collected by the baghouse or other dust-collecting equipment may be reintroduced into the mixing drum.

4 - 32 10-19

Statewide

2.4. Asphalt Binder. Furnish the type and grade of performance-graded (PG) asphalt specified on the plans.

2.5. Tack Coat. Furnish CSS-1H, SS-1H, or a PG binder with a minimum high-temperature grade of PG 58 for tack coat binder in accordance with Item tack coat allowed or required when shown on the plans. Do not dilute emulsified asphalts at the terminal, in the field, or at any other location before use.

2.6. Additives. Use the type and rate of additive specified when shown on the plans. Additives that facilitate mixing, compaction, or improve the quality of the mixture are allowed when approved. Provide the Engineer with documentation such as the bill of lading showing the quantity of additives used in the project unless otherwise directed.

2.6.1. Lime and Liquid Antistripping Agent. When lime or a liquid antistripping agent is used, add in accordance with Item where lime is removed through the exhaust stream unless the plant has a baghouse or dust collection system that reintroduces the lime into the drum.

2.6.2. Warm Mix Asphalt (WMA). Warm Mix Asphalt (WMA) is defined as HMA that is produced within a target temperature discharge range of 215°F and 275°F using approved WMA additives or processes from the

WMA is allowed for use on all projects and is required when shown on the plans. When WMA is required, the maximum placement or target discharge temperature for WMA will be set at a value below 275°F.

Department-approved WMA additives or processes may be used to facilitate mixing and compaction of HMA produced at target discharge temperatures above 275°F; however, such mixtures will not be defined as

WMA.

2.6.3. Compaction Aid. Compaction Aid is defined as a chemical warm mix additive that is used to produce an asphalt mixture at a discharge temperature greater than 275°F.

Compaction Aid is allowed for use on all projects and is required when shown on the plans.

2.7. Recycled Materials. Use of RAP and RAS is permitted unless otherwise shown on the plans. Use of RAS is restricted to only intermediate and base mixes unless otherwise shown on the plans. Do not exceed the maximum allowable percentages of RAP and RAS shown in Table 4. The allowable percentages shown in Table 4 may be decreased or increased when shown on the plans. Determine the asphalt binder content and gradation of the RAP and RAS stockpiles for mixture design purposes in accordance with Tex-236-F, Part I.

The Engineer may verify the asphalt binder content of the stockpiles at any time during production. Perform other tests on RAP and RAS when shown on the plans. Asphalt binder from RAP and RAS is designated as recycled asphalt binder. Calculate and ensure that the ratio of the recycled asphalt binder to total binder does not exceed the percentages shown in Table 5 during mixture design and HMA production when RAP or RAS is used. Use a separate cold feed bin for each stockpile of RAP and RAS during HMA production.

Surface, intermediate, and base mixes referenced in Tables 4 and 5 are defined as follows:

Surface. The final HMA lift placed at the top of the pavement structure or placed directly below mixtures produced in accordance with Items 316, 342, 347, or 348;

Intermediate. Mixtures placed below an HMA surface mix and less than or equal to 8.0 in. from the riding surface; and Base. Mixtures placed greater than 8.0 in. from the riding surface. Unless otherwise shown on the plans, mixtures used for bond breaker are defined as base mixtures.

2.7.1. RAP. RAP is salvaged, milled, pulverized, broken, or crushed asphalt pavement. Fractionated RAP is defined as a stockpile that contains RAP material with a minimum of 95.0% passing the 3/8-in. or 1/2-in.

5 - 32 10-19

Statewide sieve, before burning in the ignition oven, unless otherwise approved. The Engineer may allow the Contractor to use an alternate to the 3/8-in. or 1/2-in. screen to fractionate the RAP.

Use of Contractor-owned RAP including HMA plant waste is permitted unless otherwise shown on the plans.

Department-shown on the plans. If Department-owned RAP is tractor may use Contractor-owned fractionated RAP and replace it with an equal quantity of Department-owned RAP.

Department-owned RAP generat use when shown on the plans. Perform any necessary tests to ensure Contractor- or Department-owned RAP is appropriate for use. The Department will not perform any tests or assume any liability for the quality of the Department-owned RAP unless otherwise shown on the plans. The Contractor will retain ownership of RAP generated on the project when shown on the plans.

Do not use Department- or Contractor-owned RAP contaminated with dirt or other objectionable materials.

Do not use Department- or Contractor-owned RAP if the decantation value exceeds 5% and the plasticity index is greater than eight. Test the stockpiled RAP for decantation in accordance with Tex-406-A, Part I.

Determine the plasticity index in accordance with Tex-106-E if the decantation value exceeds 5%. The decantation and plasticity index requirements do not apply to RAP samples with asphalt removed by extraction or ignition.

Do not intermingle Contractor-owned RAP stockpiles with Department-owned RAP stockpiles. Remove unused Contractor-owned RAP material from the project site upon completion of the project. Return unused Department-owned RAP to the designated stockpile location.

Table 4 Maximum Allowable Amounts of RAP1

Maximum Allowable Fractionated RAP (%)

Surface Intermediate Base

20.0 30.0 35.0

1. Must also meet the recycled binder to total binder ratio shown in Table 5.

2.7.2. RAS. Use of post-manufactured RAS or post-consumer RAS (tear-offs) is not permitted in surface mixtures unless otherwise shown on the plans. RAS may be used in intermediate and base mixtures unless otherwise shown on the plans. Up to 3% RAS may be used separately or as a replacement for fractionated RAP in accordance with Table 4 and Table 5. RAS is defined as processed asphalt shingle material from manufacturing of asphalt roofing shingles or from re-roofing residential structures. Post-manufactured RAS is

-product. Post-consumer RAS is processed shingle scrap removed from residential structures. Comply with all regulatory requirements stipulated for RAS by the TCEQ. RAS may be used separately or in conjunction with RAP.

Process the RAS by ambient grinding or granulating such that 100% of the particles pass the 3/8 in. sieve when tested in accordance with Tex-200-F, Part I. Perform a sieve analysis on processed RAS material before extraction (or ignition) of the asphalt binder.

Add sand meeting the requirements of Table 1 and Table 2 or fine RAP to RAS stockpiles if needed to keep the processed material workable. Any stockpile that contains RAS will be considered a RAS stockpile and be limited to no more than 3.0% of the HMA mixture in accordance with Table 4.

Certify compliance of the RAS with DMS-11000 with any hazardous materials. Use RAS from substantially all materials before use that are not part of the shingle, such as wood, paper, metal, plastic, and felt paper. Determine the deleterious content of RAS material for mixture design purposes in accordance with Tex-217-F, Part III. Do not use RAS if deleterious materials are more than 0.5% of the stockpiled RAS unless

6 - 32 10-19

Statewide otherwise approved. Submit a sample for approval before submitting the mixture design. The Department will perform the testing for deleterious material of RAS to determine specification compliance.

2.8. Substitute Binders. Unless otherwise shown on the plans, the Contractor may use a substitute PG binder listed in Table 5 instead of the PG binder originally specified if using recycled materials, and if the substitute PG binder and mixture made with the substitute PG binder meet the following:

the substitute binder meets the specification requirements for the substitute binder grade in accordance with Section -Graded Binders; and the mixture has less than 10.0 mm of rutting on the Hamburg Wheel test (Tex-242-F) after the number of passes required for the originally specified binder. Use of substitute PG binders may only be allowed at the discretion of the Engineer if the Hamburg Wheel test results are between 10.0 mm and 12.5 mm.

Table 5 Allowable Substitute PG Binders and Maximum Recycled Binder Ratios

Originally Specified PG Binder

Allowable Substitute PG Binder for Surface Mixes

Allowable Substitute PG Binder for

Intermediate and Base Mixes

Maximum Ratio of Recycled Binder1 to Total Binder (%)

Surface Intermediate Base

76-224,5 70-22 70-22 15.0 25.0 30.0

70-222,5 N/A 64-22 15.0 25.0 30.0

64-222,3 N/A N/A 15.0 25.0 30.0

76-284,5 70-28 70-28 15.0 25.0 30.0

70-282,5 N/A 64-28 15.0 25.0 30.0

64-282,3 N/A N/A 15.0 25.0 30.0

1. Combined recycled binder from RAP and RAS. RAS is not permitted in surface mixtures unless otherwise shown on the plans.

2. Binder substitution is not allowed for surface mixtures.

3. Binder substitution is not allowed for intermediate and base mixtures.

4. Use no more than 15.0% recycled binder in surface mixtures when using this originally specified PG binder.

5. Use no more than 25.0% recycled binder when using this originally specified PG binder for intermediate mixtures. Use no more than 30.0% recycled binder when using this originally specified PG binder for base mixtures.

3. EQUIPMENT

Provide required or necessary equipment in accordance with Item ent for Asphalt Concrete Pavement

4. CONSTRUCTION

Produce, haul, place, and compact the specified paving mixture. In addition to tests required by the specification, Contractors may perform other QC tests as deemed necessary. At any time during the project, the Engineer may perform production and placement tests as deemed necessary in accordance with Item 5, Control of the Work Schedule and participate in a mandatory pre-paving meeting with the Engineer on or before the first day of paving unless otherwise shown on the plans.

4.1. Certification. Personnel certified by the Department-approved hot-mix asphalt certification program must conduct all mixture designs, sampling, and testing in accordance with Table 6. Supply the Engineer with a list of certified personnel and copies of their current certificates before beginning production and when personnel

7 - 32 10-19

Statewide changes are made. Provide a mixture design developed and signed by a Level 2 certified specialist. Provide Level 1A certified specialists at the plant during production operations. Provide Level 1B certified specialists to conduct placement tests. Provide AGG101 certified specialists for aggregate testing.

8 - 32 10-19

Statewide

Table 6 Test Methods, Test Responsibility, and Minimum Certification Levels

Test Description Test Method Contractor Engineer Level1

1. Aggregate and Recycled Material Testing Sampling Tex-221-F 1A/AGG101 Dry sieve Tex-200-F, Part I 1A/AGG101 Washed sieve Tex-200-F, Part II 1A/AGG101 Deleterious material Tex-217-F, Parts I & III AGG101 Decantation Tex-217-F, Part II AGG101 Los Angeles abrasion Tex-410-A TxDOT Magnesium sulfate soundness Tex-411-A TxDOT Micro-Deval abrasion Tex-461-A AGG101 Crushed face count Tex-460-A AGG101 Flat and elongated particles Tex-280-F AGG101 Linear shrinkage Tex-107-E AGG101 Sand equivalent Tex-203-F AGG101 Bulk specific gravity Tex-201-F AGG101 Unit weight Tex-404-A AGG101 Organic impurities Tex-408-A AGG101

2. Asphalt Binder & Tack Coat Sampling Asphalt binder sampling Tex-500-C, Part II 1A/1B Tack coat sampling Tex-500-C, Part III 1A/1B

3. Mix Design & Verification Design and JMF changes Tex-204-F 2 Mixing Tex-205-F 2 Molding (SGC) Tex-241-F 1A Laboratory-molded density Tex-207-F, Parts I & VI 1A Rice gravity Tex-227-F, Part II 1A Ignition oven correction factors2 Tex-236-F, Part II 2 Indirect tensile strength Tex-226-F 1A Hamburg Wheel test Tex-242-F 1A Boil test Tex-530-C 1A

4. Production Testing Selecting production random numbers Tex-225-F, Part I 1A Mixture sampling Tex-222-F 1A/1B Molding (SGC) Tex-241-F 1A Laboratory-molded density Tex-207-F, Parts I & VI 1A Rice gravity Tex-227-F, Part II 1A Gradation & asphalt binder content2 Tex-236-F, Part I 1A Control charts Tex-233-F 1A Moisture content Tex-212-F, Part II 1A/AGG101 Hamburg Wheel test Tex-242-F 1A Micro-Deval abrasion Tex-461-A AGG101 Boil test Tex-530-C 1A Abson recovery Tex-211-F TxDOT

5. Placement Testing Selecting placement random numbers Tex-225-F, Part II 1B Trimming roadway cores Tex-251-F, Parts I & II 1A/1B In-place air voids Tex-207-F, Parts I & VI 1A In-place density (nuclear method) Tex-207-F, Part III 1B Establish rolling pattern Tex-207-F, Part IV 1B Control charts Tex-233-F 1A Ride quality measurement Tex-1001-S Note 3 Segregation (density profile) Tex-207-F, Part V 1B Longitudinal joint density Tex-207-F, Part VII 1B Thermal profile Tex-244-F 1B Shear Bond Strength Test Tex-249-F TxDOT

1. Level 1A, 1B, AGG101, and 2 are certification levels provided by the Hot Mix Asphalt Center certification program.

2. Refer to Section 3077.4.9.2

3. Profiler and operator are required to be certified at the Texas A&M Transportation Institute facility when Surface Test

Type B is specified.

9 - 32 10-19

Statewide

4.2. Reporting and Responsibilities. Use Department-provided templates to record and calculate all test data, including mixture design, production and placement QC/QA, control charts, thermal profiles, segregation density profiles, and longitudinal joint density. Obtain the current version of the templates at http://www.txdot.gov/inside-txdot/forms-publications/consultants-contractors/forms/site-manager.html or from the Engineer. The Engineer and the Contractor will provide any available test results to the other party when requested. The maximum allowable time for the Contractor and Engineer to exchange test data is as given in Table 7 unless otherwise approved. The Engineer and the Contractor will immediately report to the other party any test result that requires suspension of production or placement, a payment adjustment less than 1.000, or that fails to meet the specification requirements. Record and electronically submit all test results and pertinent information on Department-provided templates.

Subsequent sublots placed after test results are available to the Contractor, which require suspension of operations, may be considered unauthorized work. Unauthorized work will be accepted or rejected at the discretion of the Engineer in accordance with Article

Table 7

Reporting Schedule Description Reported By Reported To To Be Reported Within

Production Quality Control Gradation1

Contractor Engineer 1 working day of completion of the sublot Asphalt binder content1 Laboratory-molded density2 Moisture content3 Boil test3

Production Quality Assurance Gradation3

Engineer Contractor 1 working day of completion of the sublot

Asphalt binder content3 Laboratory-molded density1 Hamburg Wheel test4 Boil test3 Binder tests4

Placement Quality Control In-place air voids2

Contractor Engineer 1 working day of completion of the lot Segregation1 Longitudinal joint density1 Thermal profile1

Placement Quality Assurance

In-place air voids1

Engineer Contractor

1 working day after receiving the trimmed cores5

Segregation3

1 working day of completion of the lot Longitudinal joint density3 Thermal profile3 Aging ratio4

Payment adjustment summary

Engineer Contractor 2 working days of performing all required tests and receiving Contractor test data

1. These tests are required on every sublot.

2. Optional test. When performed on split samples, report the results as soon as they become available.

3. To be performed at the frequency specified in Table 17 or as shown on the plans.

4. To be reported as soon as the results become available.

5. Two days are allowed if cores cannot be dried to constant weight within 1 day.

The Engineer will use the Department-provided template to calculate all payment adjustment factors for the lot. Sublot samples may be discarded after the Engineer and Contractor sign off on the payment adjustment summary documentation for the lot.

Use the procedures described in Tex-233-F to plot the results of all quality control (QC) and quality assurance (QA) testing. Update the control charts as soon as test results for each sublot become available.

10 - 32 10-19

Statewide

Make the control charts readily accessible at the field laboratory. The Engineer may suspend production for failure to update control charts.

4.3. Quality Control Plan (QCP). Develop and follow the QCP in detail. Obtain approval for changes to the QCP made during the project. The Engineer may suspend operations if the Contractor fails to comply with the

QCP.

Submit a written QCP before the mandatory pre-paving meeting. Receive approval of the QCP before beginning production. Include the following items in the QCP:

4.3.1. Project Personnel. For project personnel, include:

a list of individuals responsible for QC with authority to take corrective action;

current contact information for each individual listed; and current copies of certification documents for individuals performing specified QC functions.

4.3.2. Material Delivery and Storage. For material delivery and storage, include:

the sequence of material processing, delivery, and minimum quantities to assure continuous plant operations;

aggregate stockpiling procedures to avoid contamination and segregation;

frequency, type, and timing of aggregate stockpile testing to assure conformance of material requirements before mixture production; and procedure for monitoring the quality and variability of asphalt binder.

4.3.3. Production. For production, include:

loader operation procedures to avoid contamination in cold bins;

procedures for calibrating and controlling cold feeds;

procedures to eliminate debris or oversized material;

procedures for adding and verifying rates of each applicable mixture component (e.g., aggregate, asphalt binder, RAP, RAS, lime, liquid antistrip, WMA);

procedures for reporting job control test results; and procedures to avoid segregation and drain-down in the silo.

4.3.4. Loading and Transporting. For loading and transporting, include:

type and application method for release agents; and truck loading procedures to avoid segregation.

4.3.5. Placement and Compaction. For placement and compaction, include:

proposed agenda for mandatory pre-paving meeting, including date and location;

proposed paving plan (e.g., paving widths, joint offsets, and lift thicknesses);

type and application method for release agents in the paver and on rollers, shovels, lutes, and other utensils;

procedures for the transfer of mixture into the paver, while avoiding segregation and preventing material spillage;

process to balance production, delivery, paving, and compaction to achieve continuous placement operations and good ride quality;

paver operations (e.g., operation of wings, height of mixture in auger chamber) to avoid physical and thermal segregation and other surface irregularities; and procedures to construct quality longitudinal and transverse joints.

11 - 32 10-19

Statewide

4.4. Mixture Design.

4.4.1. Design Requirements. Use the SP design procedure provided in Tex-204-F, unless otherwise shown on the plans. Design the mixture to meet the requirements listed in Tables 1, 2, 3, 4, 5, 8, 9, 10, and 11.

Design the mixture at 50 gyrations (Ndesign). Use a target laboratory-molded density of 96.0% to design the mixture; however, adjustments can be made to the Ndesign value as noted in Table 10. The Ndesign level may be reduced to at least results with the mixture design, or provide the laboratory mixture and request that the Department perform the Hamburg Wheel test. The Engineer will be allowed 10 working days to provide the Contractor with Hamburg Wheel test results on the laboratory mixture design.

The Engineer will provide the mixture design when shown on the plans. The Contractor may submit a new mixture design at any time during the project. The Engineer will verify and approve all mixture designs (JMF1) before the Contractor can begin production.

The aggregate gradation may pass below or through the reference zone shown in Table 9 unless otherwise shown on the plans. Design a mixture with a gradation that has stone-on-stone contact and passes below the reference zone shown in Table 9 when shown on the plans. Verify stone-on-stone contact using the method given in the SP design procedure in Tex-204-F, Part IV.

Provide the Engineer with a mixture design report using the Department-provided template. Include the following items in the report:

the combined aggregate gradation, source, specific gravity, and percent of each material used;

asphalt binder content and aggregate gradation of RAP and RAS stockpiles;

the Ndesign level used;

results of all applicable tests;

the mixing and molding temperatures;

the signature of the Level 2 person or persons that performed the design;

the date the mixture design was performed; and a unique identification number for the mixture design.

Table 8 Master Gradation Limits (% Passing by Weight or Volume) and VMA Requirements Sieve Size

SP-B

Intermediate

SP-C

Surface

SP-D

Fine Mixture

1-1/2 100.01

1 98.0 100.0 100.01 3/4 90.0 100.0 98.0 100.0 100.01 1/2 Note2 90.0 100.0 98.0 100.0 3/8 Note2 90.0 100.0 #4 23.0 90.0 28.0 90.0 32.0 90.0 #8 23.0 34.6 28.0 37.0 32.0 40.0

#16 2.0 28.3 2.0 31.6 2.0 37.6 #30 2.0 20.7 2.0 23.1 2.0 27.5 #50 2.0 13.7 2.0 15.5 2.0 18.7 #200 2.0 8.0 2.0 10.0 2.0 10.0

Design VMA, % Minimum

14.0 15.0 16.0

Production (Plant-Produced) VMA, % Minimum

13.5 14.5 15.5

1. Defined as maximum sieve size. No tolerance allowed.

2. Must retain at least 10% cumulative.

12 - 32 10-19

Statewide

Table 9 Reference Zones (% Passing by Weight or Volume)

Sieve Size

SP-B

Intermediate

SP-C

Surface

SP-D

Fine Mixture

1-

#4 #8 34.6 34.6 39.1 39.1 47.2 47.2

#16 22.3 28.3 25.6 31.6 31.6 37.6 #30 16.7 20.7 19.1 23.1 23.5 27.5 #50 13.7 13.7 15.5 15.5 18.7 18.7 #200

Table 10

Laboratory Mixture Design Properties Mixture Property Test Method Requirement

Target laboratory-molded density, % Tex-207-F 96.0 Design gyrations (Ndesign) Tex-241-F 501 Indirect tensile strength (dry), psi Tex-226-F 85 2002 Dust/asphalt binder ratio3 0.6 1.4 Boil test4 Tex-530-C

1. Adjust within a range of 35 100 gyrations when shown on the plans or specification or mutually agreed between the Engineer and Contractor.

2. The Engineer may allow the IDT strength to exceed 200 psi if the corresponding Hamburg

Wheel rut depth is greater than 3.0 mm and less than 12.5 mm.

3. Defined as % passing #200 sieve divided by asphalt binder content.

4. Used to establish baseline for comparison to production results. May be waived when approved.

Table 11

Hamburg Wheel Test Requirements High-Temperature

Binder Grade Test Method

Minimum # of Passes @ 12.5 mm1 Rut Depth, Tested @ 50°C

PG 64 or lower Tex-242-F

10,0002

PG 70 15,0003

PG 76 or higher 20,000

1. When the rut depth at the required minimum number of passes is less than 3 mm, the

Engineer may require the Contractor to lower the Ndesign level to at least 35 gyrations.

2. May be decreased to at least 5,000 passes when shown on the plans.

3. May be decreased to at least 10,000 passes when shown on the plans.

4.4.2. Job-Mix Formula Approval. The job-mix formula (JMF) is the combined aggregate gradation, Ndesign level, and target asphalt percentage used to establish target values for hot-mix production. JMF1 is the original laboratory mixture design used to produce the trial batch. When WMA is used, JMF1 may be designed and submitted to the Engineer without including the WMA additive. When WMA is used, document the additive or process used and recommended rate on the JMF1 submittal. The Engineer and the Contractor will verify JMF1 based on plant-produced mixture from the trial batch unless otherwise approved. The Engineer may accept an existing mixture design previously used on a Department project and may waive the trial batch to verify JMF1. The Department may require the Contractor to reimburse the Department for verification tests if more than two trial batches per design are required.

4.4.2.1. .

4.4.2.1.1. Providing Superpave Gyratory Compactor (SGC). Furnish an SGC calibrated in accordance with Tex-241-F SGC available to the Engineer for use in molding production samples.

13 - 32 10-19

Statewide

4.4.2.1.2. Gyratory Compactor Correlation Factors. Use Tex-206-F, Part II, to perform a gyratory compactor correlation when the Engineer uses a different SGC. Apply the correlation factor to all subsequent production test results.

4.4.2.1.3. Submitting JMF1. Furnish a mix design report (JMF1) with representative samples of all component materials and request approval to produce the trial batch. Provide approximately 10,000 g of the design mixture if opting to have the Department perform the Hamburg Wheel test on the laboratory mixture, and request that the Department perform the test.

4.4.2.1.4. Supplying Aggregates. Provide approximately 40 lb. of each aggregate stockpile unless otherwise directed.

4.4.2.1.5. Supplying Asphalt. Provide at least 1 gal. of the asphalt material and enough quantities of any additives proposed for use.

4.4.2.1.6. Ignition Oven Correction Factors. Determine the aggregate and asphalt correction factors from the ignition oven in accordance with Tex-236-F, Part II. Provide correction factors that are not more than 12 months old.

Provide the Engineer with split samples of the mixtures before the trial batch production, including all additives (except water), and blank samples used to determine the correction factors for the ignition oven used for QA testing during production. Correction factors established from a previously approved mixture design may be used for the current mixture design if the mixture design and ignition oven are the same as previously used, unless otherwise directed.

4.4.2.1.7. Boil Test. Perform the test and retain the tested sample from Tex-530-C until completion of the project or as directed. Use this sample for comparison purposes during production. The Engineer may waive the requirement for the boil test.

4.4.2.1.8. Trial Batch Production. Provide a plant-produced trial batch upon receiving conditional approval of JMF1 and authorization to produce a trial batch, including the WMA additive or process if applicable, for verification testing of JMF1 and development of JMF2. Produce a trial batch mixture that meets the requirements in Table 4, Table 5, and Table 12. The Engineer may accept test results from recent production of the same mixture instead of a new trial batch.

4.4.2.1.9. Trial Batch Production Equipment. Use only equipment and materials proposed for use on the project to produce the trial batch.

4.4.2.1.10. Trial Batch Quantity. Produce enough quantity of the trial batch to ensure that the mixture meets the specification requirements.

4.4.2.1.11. Number of Trial Batches. Produce trial batches as necessary to obtain a mixture that meets the specification requirements.

4.4.2.1.12. Trial Batch Sampling. Obtain a representative sample of the trial batch and split it into 3 equal portions in accordance with Tex-222-F to the appropriate laboratory as directed.

4.4.2.1.13. Trial Batch Testing. Test the trial batch to ensure the mixture produced using the proposed JMF1 meets the mixture requirements in Table 12. Ensure the trial batch mixture is also in compliance with the Hamburg Wheel requirement in Table 11. Use a Department-approved laboratory to perform the Hamburg Wheel test on the trial batch mixture or request that the Department perform the Hamburg Wheel test.

The Engineer will be allowed 10 working days to provide the Contractor with Hamburg Wheel test results on the trial batch. Provide the Engineer with a copy of the trial batch test results.

4.4.2.1.14. Development of JMF2. Evaluate the trial batch test results after the Engineer grants full approval of JMF1 based on results from the trial batch, determine the optimum mixture proportions, and submit as JMF2.

14 - 32 10-19

Statewide

Adjust the asphalt binder content or gradation to achieve the specified target laboratory-molded density. The asphalt binder content established for JMF2 is not required to be within any tolerance of the optimum asphalt binder content established for JMF1; however, mixture produced using JMF2 must meet the voids in mineral aggregates (VMA) requirements for production shown in Table 8. If the optimum asphalt binder content for JMF2 is more than 0.5% lower than the optimum asphalt binder content for JMF1, the Engineer may perform or require the Contractor to perform Tex-226-F on Lot 1 production to confirm the indirect tensile strength does not exceed 200 psi. Verify that JMF2 meets the mixture requirements in Table 4 and Table 5.

4.4.2.1.15. Mixture Production. Use JMF2 to produce Lot 1 as described in Section 3077 -approved d to Lot 1 production, once JMF2 is on the trial batch.

Notify the Engineer if electing to proceed without Hamburg Wheel test results from the trial batch. Note that the Engineer may require up to the entire sublot of any mixture failing the Hamburg Wheel test to be

4.4.2.1.16. Development of JMF3. Evaluate the test results from Lot 1, determine the optimum mixture proportions, and submit as JMF3 for use in Lot 2.

4.4.2.1.17. JMF Adjustments. If JMF adjustments are necessary to achieve the specified requirements, make the adjustment before beginning a new lot. The adjusted JMF must:

be provided to the Engineer in writing before the start of a new lot;

be numbered in sequence to the previous JMF;

meet the mixture requirements in Table 4 and Table 5;

meet the master gradation limits shown in Table 8; and be within the operational tolerances of JMF2 listed in Table 12.

4.4.2.1.18. Requesting Referee Testing. Use referee testing, if needed, in accordance with Section 3077.4.9.1., 15 - 32 10-19

Statewide

Table 12 Operational Tolerances

Description Test

Method

Allowable Difference Between Trial Batch and JMF1 Target

Allowable Difference from Current JMF Target

Allowable Difference between Contractor and Engineer1

Individual % retained for #8 sieve and larger

Tex-200-F or

Tex-236-F

Must be Within Master Grading Limits in

Table 8

±5.02,3 ±5.0

Individual % retained for sieves smaller than #8 and larger than #200

±3.02,3 ±3.0

% passing the #200 sieve ±2.02,3 ±1.6 Asphalt binder content, % Tex-236-F ±0.5 ±0.33 ±0.3 Dust/asphalt binder ratio4 Note 5 Note 5 N/A Laboratory-molded density, %

Tex-207-F

±1.0 ±1.0 ±0.5 In-place air voids, % N/A N/A ±1.0 Laboratory-molded bulk specific gravity

N/A N/A ±0.020

VMA, % min Tex-204-F Note 6 Note 6 N/A Theoretical maximum specific (Rice) gravity

Tex-227-F N/A N/A ±0.020

1. Contractor may request referee testing only when values exceed these tolerances.

2. When within these tolerances, mixture production gradations may fall outside the master grading limits; however, the % passing the #200 will be considered out of tolerance when outside the master grading limits.

3. Only applies to mixture produced for Lot 1 and higher.

4. Defined as % passing #200 sieve divided by asphalt binder content.

5. Verify that Table 10 requirement is met.

6. Verify that Table 8 requirements are met.

4.4.2.2. .

4.4.2.2.1. Gyratory Compactor. The Engineer will use a Department SGC, calibrated in accordance with Tex-241-F, to mold samples for laboratory mixture design verification. For molding trial batch and production specimens, the Engineer will use the Contractor-provided SGC at the field laboratory or provide and use a Department SGC at an alternate location. The Engineer will make the Contractor-provided SGC in the Department field laboratory available to the Contractor for molding verification samples.

4.4.2.2.2. Conditional Approval of JMF1 and Authorizing Trial Batch. The Engineer will review and verify conformance of the following information within two working days of receipt:

the Contractor-provided Hamburg Wheel test results;

all required materials including aggregates, asphalt, additives, and recycled materials; and the mixture specifications.

The Engineer will grant the Contractor conditional approval of JMF1 if the information provided on the paper does not provide Hamburg Wheel test results with laboratory mixture design, 10 working days are allowed for conditional approval of JMF1. The Engineer will base full approval of JMF1 on the test results on mixture from the trial batch.

Unless waived, the Engineer will determine the Micro-Deval abrasion loss in accordance with Section 3077 - two working days, conditional approval of JMF1 will still be granted within 2 working days of receiving JMF1. When the

After conditionally approving JMF1, including either Contractor- or Department-supplied Hamburg Wheel test results, the Contractor is authorized to produce a trial batch.

16 - 32 10-19

Statewide

4.4.2.2.3. Hamburg Wheel Testing of JMF1. If the Contractor requests the option to have the Department perform the Hamburg Wheel test on the laboratory mixture, the Engineer will mold samples in accordance with Tex-242-F to verify compliance with the Hamburg Wheel test requirement in Table 11.

4.4.2.2.4. Ignition Oven Correction Factors. The Engineer will use the split samples provided by the Contractor to determine the aggregate and asphalt correction factors for the ignition oven used for QA testing during production in accordance with Tex-236-F, Part II. Provide correction factors that are not more than 12 months old.

4.4.2.2.5. Testing the Trial Batch. Within 1 full working day, the Engineer will sample and test the trial batch to ensure that the mixture meets the requirements in Table 12. If the Contractor requests the option to have the Department perform the Hamburg Wheel test on the trial batch mixture, the Engineer will mold samples in accordance with Tex-242-F to verify compliance with the Hamburg Wheel test requirement in Table 11.

The Engineer will have the option to perform the following tests on the trial batch:

Tex-226-F, to verify that the indirect tensile strength meets the requirement shown in Table 10; and Tex-530-C, to retain and use for comparison purposes during production.

4.4.2.2.6. Full Approval of JMF1. The Engineer will grant full…