ESBD_515561_1778768475270_Attachment B - 2024 TxDOT Specifications.pdf

2024 Specifications 341

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Item 341 Dense-Graded Hot-Mix Asphalt

1. DESCRIPTION

Construct a hot-mix asphalt (HMA) pavement layer composed of a compacted, dense-graded mixture of aggregate, asphalt binder, and additives 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 341.4.9.4., “Exempt Production.”

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 and document all material source changes when the Contractor makes a source or formulation change. The Engineer may sample and test project materials anytime during the project to verify specification compliance in accordance with Item 6, “Control of Materials.”

2.1. Aggregate. Furnish aggregates from sources that conform to the requirements shown in Table 1 and 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 shown in Table 1. Document all test results in 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 in accordance with Tex-200-F, Part II.

2.1.1. Coarse Aggregate. Coarse aggregate stockpiles must have no more than 20% material passing the No. 8 sieve.

Aggregates from sources listed in the Department’s Bituminous Rated Source Quality Catalog (BRSQC) are preapproved for use. Use only the rated values for HMA listed in the BRSQC. Rated values for surface treatment (ST) do not apply to coarse aggregate sources used in HMA.

For sources not listed in the Department’s BRSQC:

build an individual stockpile for each material;

request the Department test the stockpile for specification compliance;

allow 30 calendar days for the Engineer to sample, test, and report results;

use only when tested and approved; and once approved, do not add additional material to the stockpile unless otherwise allowed by the

Engineer.

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Provide coarse aggregate with at least the minimum SAC shown on the plans. SAC requirements apply only to aggregates used on the surface of travel lanes, unless otherwise shown on the plans. The SAC for sources in the Department’s 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 shown in Table 1 may be blended with a Class A aggregate to meet requirements for Class A materials, unless otherwise shown on the plans. When blending Class A and Class B aggregates to meet a Class A requirement, 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, unless otherwise shown on the plans. Blend by volume if the bulk specific gravities of the Class A and Class 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 anytime during production, when the Contractor blends Class A and Class B aggregates to meet a Class A requirement. The Engineer will use the Department’s mix design template, when electing to verify conformance, to calculate the percent of Class 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 to verify the percent of Class A aggregate retained on the No. 4 sieve. The Engineer will use the gradations supplied by the Contractor in the mixture design report as an input for the template. 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 at least 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 anytime 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 RSSM = rated source soundness magnesium 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 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 of 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).

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2.1.3. Fine Aggregate. Fine aggregates consist of manufactured sands, screenings, and field sands. Fine aggregate stockpiles must meet the fine aggregate properties in accordance with Table 1 and the gradation requirements in accordance with Table 2. Supply fine aggregates that are free of organic impurities. The Engineer may test the fine aggregate in accordance with Tex-408-A to verify the material is free of organic impurities. Unless otherwise shown on the plans, at most 10% of the total aggregate may be field sand or other uncrushed fine aggregate. Use fine aggregate, except 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 1.5 Decantation, %, Max Tex-217-F, Part II 1.5 Micro-Deval abrasion, % Tex-461-A Note 1 Los Angeles abrasion, %, Max Tex-410-A 40 Magnesium sulfate soundness, 5 cycles, %, Max Tex-411-A 30

Crushed face count,2 %, 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 453

Organic impurities Tex-408-A Note 4

1. Used to estimate the magnesium sulfate soundness loss in accordance with Section 341.2.1.1.2., “Micro-

Deval Abrasion.”

2. Only applies to crushed gravel.

3. The Department may perform Tex-252-F on fine aggregates not meeting this minimum requirement. Fine aggregates with a methylene blue value of 10.0 mg/g or less may be used.

4. Optional test.

Table 2

Gradation Requirements for Fine Aggregate Sieve Size % Passing by Wt. 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 dry enough, free-flowing, and free of 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 shown in Table 3, unless otherwise shown on the plans.

http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/400-A_series/pdfs/cnn408.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/400-A_series/pdfs/cnn460.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit280.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/400-A_series/pdfs/cnn499.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit217.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit217.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/400-A_series/pdfs/cnn461.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/400-A_series/pdfs/cnn410.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/400-A_series/pdfs/cnn411.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/400-A_series/pdfs/cnn460.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit280.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/100-E_series/pdfs/soi107.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit203.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/400-A_series/pdfs/cnn408.pdf chrome-extension://efaidnbmnnnibpcajpcglclefindmkaj/https:/ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit252.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/100-E_series/pdfs/soi107.pdf https://ftp.txdot.gov/pub/txdot-info/cst/TMS/100-E_series/pdfs/soi107.pdf

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Table 3 Gradation Requirements for Mineral Filler

Sieve Size % Passing by Wt. 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.

2.4. Asphalt Binder. Furnish the type and grade of performance-graded (PG) asphalt binder shown on the plans that meets the requirements of Item 300, “Asphalts, Oils, and Emulsions.”

2.5. Tack Coat. Furnish CSS-1H, SS-1H, EBL, or a PG binder with a minimum high-temperature grade of PG 58 for tack coat binder in accordance with Item 300. Specialized tack coat materials on the MPL for Tracking Resistant Asphalt Interlayer (TRAIL) will be 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, unless required in conformance with the manufacturer’s recommendation for approved TRAIL products on the MPL.

2.6. Additives. Use the type of additive specified when shown on the plans. Use the rate of additive specified in conformance with the manufacturer’s recommendation. Additives that facilitate mixing and 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. Lime or liquid antistripping agent is required when shown on the plans.

When lime or a liquid antistripping agent is used, add in accordance with Item 301, “Asphalt Antistripping Agents.” Do not add lime directly into the mixing drum of any plant 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). 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 MPL.

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 at or 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 Department-approved chemical warm-mix additive, denoted as “chemical additive” on the MPL, that is used to facilitate mixing and compaction of HMA at a discharge temperature greater than 275°F.

Compaction aid is allowed for use on all projects. Compaction aid is required when shown on the plans or as required in Section 341.4.7.1., “Weather Conditions.”

Warm-mix foaming processes, denoted as “foaming process” on the MPL, may be used to facilitate mixing and compaction of HMA at target discharge temperatures greater than 275°F; however, warm-mix foaming processes are not defined as a compaction aid.

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 in accordance with Table 4. The allowable percentages in accordance with 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 anytime during http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit236.pdf

5 - 32 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 in accordance with 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 Table 4 and Table 5 are defined as follows, unless otherwise shown on the plans.

Surface. The final HMA lift placed at the top of the pavement structure.

Intermediate. Mixtures placed below an HMA surface mix and less than or equal to 8.0 in. below the riding surface.

Base. Mixtures placed greater than 8.0 in. below 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 at least 95.0% passing the 1/2-in. sieve, before burning in the ignition oven, unless otherwise approved. The Engineer may allow the Contractor to use an alternate to the 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-owned RAP stockpiles are available for the Contractor’s use when the stockpile locations are shown on the plans. If Department-owned RAP is available for the Contractor’s use, the Contractor may use Contractor-owned fractionated RAP and replace it with an equal quantity of Department-owned RAP.

Department-owned RAP generated by required work on the Contract is available for the Contractor’s 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 8. 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

Max Allowable Amounts of RAP1 Max 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. RAS is defined as processed asphalt shingle material from manufacturing of asphalt roofing shingles or from re-roofing residential structures. Post-manufactured RAS is processed manufacturer’s shingle scrap byproduct. Post-consumer RAS is processed shingle scrap removed from residential structures. 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 may be used separately or in conjunction with RAP. Comply with all regulatory requirements stipulated for RAS by TCEQ.

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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, “Evaluating and Using Nonhazardous Recyclable Materials Guidelines.” Treat RAS as an established nonhazardous recyclable material if it has not come into contact with any hazardous materials. Use RAS from shingle sources on the MPL. Remove all materials that are not part of the shingle, such as wood, paper, metal, plastic, and felt paper, before use. 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 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. No binder substitution will be allowed when shown on the plans. The Contractor may use a substitute PG binder shown 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 300.2.11., “Performance-Graded Binders.”

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 be allowed only at the discretion of the Engineer if the Hamburg wheel test results are between 10.0 mm and 12.5 mm.

Table 5 Allowable PG Binders and Max 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

76-22 70-22 70-22 15.0 25.0 30.0 70-22 Note 2 64-22 15.0 25.0 30.0 64-22 Note 2 Note 2 15.0 25.0 30.0 76-28 70-28 70-28 15.0 25.0 30.0 70-28 Note 2 64-28 15.0 25.0 30.0 64-28 Note 2 Note 2 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. No binder substitution is allowed.

3. EQUIPMENT

Provide required or necessary equipment in accordance with Item 320, “Equipment for Asphalt Concrete Pavement.”

4. CONSTRUCTION

Produce, haul, place, and compact the specified paving mixture. In addition to tests required in accordance with the Specification, the Contractor may perform other QC tests as necessary. Anytime during the project, the Engineer may perform production and placement tests as 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.

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4.1. Certification. Personnel certified by the Department-approved HMA 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 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 Level AGG101-certified specialists for aggregate testing.

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

Test Description Test Method Contractor Engineer Level1 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, Part I and Part III AGG101

Decantation Tex-217-F, Part II AGG101 Los Angeles abrasion Tex-410-A – Department Magnesium sulfate soundness Tex-411-A – Department 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 Methylene blue test Tex-252-F – Department Bulk-specific gravity Tex-201-F AGG101 Organic impurities Tex-408-A AGG101

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

Mix Design and Verification Design and job-mix formula (JMF) changes Tex-204-F 2

Mixing Tex-205-F 2 Molding (Superpave gyratory compactor [SGC]) Tex-241-F 1A

Laboratory-molded density Tex-207-F, Part I and Part VI 1A

Rice gravity Tex-227-F, Part II 1A Ignition oven correction factors2 Tex-236-F, Part II 1A Indirect tensile strength Tex-226-F 1A Hamburg wheel test Tex-242-F 1A Witnessing mixing of correction factors Tex-236-F, Part III – Department

Boil test Tex-530-C 1A 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, Part I and Part VI 1A

Rice gravity Tex-227-F, Part II 1A Gradation and 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 – Department http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit221.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit200.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit200.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit217.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit217.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/400-A_series/pdfs/cnn410.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/400-A_series/pdfs/cnn411.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/400-A_series/pdfs/cnn461.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/400-A_series/pdfs/cnn460.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit280.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/100-E_series/pdfs/soi107.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit203.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit252.pdf https://ftp.txdot.gov/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit201.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/400-A_series/pdfs/cnn408.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/500-C_series/pdfs/aph500.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/500-C_series/pdfs/aph500.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit204.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit205.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit241.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit207.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit227.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit236.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit226.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit242.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit236.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/500-C_series/pdfs/aph530.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit225.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit222.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit241.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit207.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit227.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit236.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit233.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit212.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit242.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/400-A_series/pdfs/cnn461.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/500-C_series/pdfs/aph530.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit211.pdf

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Test Description Test Method Contractor Engineer Level1 Placement Testing

Selecting placement random numbers Tex-225-F, Part II – 1B

Trimming roadway cores Tex-251-F, Part I and Part II 1A/1B

In-place air voids Tex-207-F, Part I and Part 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 Note3 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 – Department

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

2. Refer to Section 341.4.9.2.3., “Production Testing,” for exceptions to using an ignition oven.

3. Profiler and operator are required to be certified at the Texas A&M Transportation Institute facility when surface test Type B is specified.

4.2. Reporting and Responsibilities. Use Department-provided templates to record and calculate all test data, including mixture design, production and placement QC and QA, control charts, thermal profiles, segregation density profiles, and longitudinal joint density. Obtain the current version of the templates from the Department’s website 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 shown 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, or 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 5.3., “Conformity with Plans, Specifications, and Special Provisions.”

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 test4 Production Quality Assurance

Gradation3

Engineer Contractor 1 working day of completion of the sublot

Asphalt binder content3 Laboratory-molded density1 Hamburg wheel test5 Boil test4 Binder tests5 http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit225.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit251.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit207.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit207.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit207.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit233.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/1000-S_series/pdfs/spe1001.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit207.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit207.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit244.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit249.pdf

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Description Reported By Reported To To Be Reported Within 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 cores6

Segregation3 1 working day of completion of the lot Longitudinal joint density3 Thermal profile3

Aging ratio5

Shear bond strength test5 5 working days after receiving the cores

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 shown in Table 16 or as shown on the plans.

4. When shown on the plans.

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

6. 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 QC and QA testing. Update the control charts as soon as test results for each sublot become available. 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 with material requirements before mixture production; and procedure for monitoring the quality and variability of asphalt binder.

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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, compaction aid, foaming process, and 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., production rate, 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 physical and thermal 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., speed, operation of wings, and 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.

4.4. Mixture Design.

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

Design the mixture using an SGC, and 50 gyrations as the design number of 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 shown in Table 9. The Ndesign level may be reduced to at least 35 gyrations at the Contractor’s discretion.

Use a Department-approved laboratory on the MPL to perform the Hamburg wheel test and provide results with the mixture design, or provide the laboratory mixture and request that the Department perform the Hamburg wheel test. Upon receiving the sample from the Contractor, 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 anytime during the project. The Engineer will verify and approve all mixture designs (JMF1) before the Contractor can begin production.

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;

the binder source and optimum design asphalt content;

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

the Ndesign level used on the SGC;

http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit204.pdf https://ftp.dot.state.tx.us/pub/txdot-info/cmd/mpl/hamburgs.pdf

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the mixing and molding temperatures;

the signature of the Level 2 person or persons who 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 Wt. or Volume) and Void in Mineral Aggregate (VMA) Requirements

Sieve Size

DG-B

Fine Base

DG-C

Coarse Surface

DG-D

Fine

Surface

DG-F

Fine

Mixture 2″ – – – –

1-1/2″ 100.01 – – – 1″ 98.0–100.0 100.01 – –

3/4″ 84.0–98.0 95.0–100.0 100.01 – 1/2″ — — 98.0–100.0 100.01 3/8″ 60.0–80.0 70.0–85.0 85.0–100.0 98.0–100.0 #4 40.0–60.0 43.0–63.0 50.0–70.0 70.0–90.0 #8 29.0–43.0 32.0–44.0 35.0–46.0 38.0–48.0 #30 13.0–28.0 14.0–28.0 15.0–29.0 12.0–27.0 #50 6.0–20.0 7.0–21.0 7.0–20.0 6.0–19.0

#200 2.0–7.0 2.0–7.0 2.0–7.0 2.0–7.0 Design (VMA), % Min

– 13.0 14.0 15.0 16.0 Production (Plant-Produced) (VMA), % Min

– 12.5 13.5 14.5 15.5

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

Table 9

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 Boil test3 Tex-530-C –

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

2. The Engineer may allow the indirect tensile test strength to exceed 200 psi if the corresponding Hamburg wheel rut depth is >2.5 mm and <12.5 mm.

3. When shown on the plans. Used to establish baseline for comparison to production results.

Table 10

Hamburg Wheel Test Requirements

High-Temperature Binder Grade Test Method Min # of Passes at 12.5-mm1 Rut Depth, Tested at 50°C PG 64 or lower

Tex-242-F 10,0002

PG 70 15,0003

PG 76 or higher 20,000

1. The Hamburg wheel test will have a minimum rut depth of 2.5 mm.

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 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 http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit207.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit241.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit226.pdf

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Engineer without including the WMA additive, foaming process, or compaction aid. When WMA or a compaction aid is used, document the additive or process used and recommended rate in 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. Contractor’s Responsibilities.

4.4.2.1.1. Providing Superpave Gyratory Compactor. Provide an SGC in accordance with Item 504, “Field Office and Laboratory,” and make the SGC available to the Engineer for use in molding production samples.

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 25 lb. 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. Notify the Engineer before performing Tex-236-F, Part II. Allow the Engineer to witness the mixing of ignition oven correction factor sample. Determine the aggregate and asphalt correction factors from the ignition oven in accordance with Tex-236-F, Part II.

If the Engineer witnesses the mixing of the ignition oven correction factor samples, provide the Engineer with identically prepared 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. Correction factors must be performed every 12 mo.

4.4.2.1.7. Boil Test. When shown on the plans, 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.

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. If applicable, include the WMA additive, foaming process, or compaction aid for verification testing of JMF1 and development of JMF2. Produce a trial batch mixture that meets the requirements shown in Tables 4, 5, and 11. 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.

http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit206.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit236.pdf

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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 three equal portions in accordance with Tex-222-F. Label these portions as “Contractor,” “Engineer,” and “Referee.” Deliver samples 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 shown in Table 11. Ensure the trial batch mixture is also in compliance with the Hamburg wheel requirement shown in Table 10. Use a Department-approved laboratory listed on the MPL to perform the Hamburg wheel test on the trial batch mixture, or request that the Department perform the Hamburg wheel test. Provide approximately 25 lb. of the trial batch mixture if opting to have the Department perform the Hamburg wheel test, and request that the Department perform the test. Upon receiving the sample from the Contractor, 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. After the Engineer grants full approval of JMF1, evaluate the trial batch test results, determine the optimum mixture proportions, and submit as JMF2. 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 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 shown in Table 4 and Table 5.

4.4.2.1.15. Mixture Production. Use JMF2 to produce Lot 1 in accordance with Section 341.4.9.3.1.1., “Lot 1 Placement,” after receiving approval for JMF2 and a passing Hamburg wheel result on the trial batch from a laboratory listed on the MPL. Once JMF2 is approved, and without receiving the results from the Department’s Hamburg wheel test on the trial batch, the Contractor may proceed to Lot 1 production at their own risk.

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 removed and replaced at the Contractor’s expense.

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 adjustments 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 accordance with Table 4 and Table 5, meet the master gradation limits in accordance with Table 8, and be within the operational tolerances of JMF2 in accordance with Table 11.

4.4.2.1.18. Requesting Referee Testing. Use referee testing, if needed, in accordance with Section 341.4.9.1., “Referee Testing,” to resolve testing differences with the Engineer.

http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit222.pdf http://ftp.dot.state.tx.us/pub/txdot-info/cst/TMS/200-F_series/pdfs/bit226.pdf

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Table 11 Operational Tolerances

Description Test Method Allowable

Difference Between JMF2 and JMF1

Target1

Allowable Difference Between Current JMF and JMF22

Allowable Difference Between Contractor and Engineer3

Individual % retained on #8 sieve and larger Tex-200-F or

Tex-236-F

Must be Within Master Gradation Limits in Table 8

±5.04 ±5.0 Individual % retained on sieves smaller than #8 and larger than #200 ±3.04 ±3.0

% passing the #200 sieve ±2.04 ±1.6 Asphalt binder content, % Tex-236-F ±0.5 ±0.3 ±0.3 Laboratory-molded density, %

Tex-207-F ±1.0 ±1.0 ±1.0

In-place air voids, % – – ±1.0 Laboratory-molded bulk specific gravity – – ±0.020 VMA, %, Min Tex-204-F Note5 Note5 – Theoretical maximum specific (Rice) gravity Tex-227-F – – ±0.020

1. JMF1 is the approved laboratory mixture design used for producing the trial batch. JMF2 is the approved mixture design developed from the trial batch used to produce Lot 1.

2. Current JMF is JMF3 or higher. JMF3 is the approved mixture design used to produce Lot 2.

3. Contractor may request referee testing when values exceed these tolerances.

4. When within these tolerances, mixture production gradations may fall outside the master gradation limits; however, the % passing the

#200 will…