Attachment_2_-_Asphalt_Mix_Specification.pdf

TABLE OF CONTENTS

SECTION 32 12 15.13

ASPHALT PAVING FOR AIRFIELDS

PART 1 - GENERAL

1.1 NOT USED

1.2 PERCENT PAYMENT

1.2.1 Mat and Joint Densities

1.2.2 Surface Smoothness

1.2.3 Lab Air Densities and Theoretical Maximum Density

1.2.4 Grade

1.3 REFERENCES

1.4 SUBMITTALS

1.5 QUALITY ASSURANCE

1.5.1 Sublot Sampling

1.5.2 Not Used

1.5.3 In-place Density

1.5.4 Surface Smoothness

1.5.4.1 Smoothness Requirements

1.5.4.1.1 Straightedge Testing

1.5.4.1.2 Profilograph Testing

1.5.4.2 Testing Method

1.5.4.2.1 Straightedge Testing

1.5.4.2.2 Profilograph Testing

1.5.4.2.3 Bumps ("Must Grind" Areas)

1.6 ENVIRONMENTAL REQUIREMENTS

PART 2 - PRODUCTS

2.1 SYSTEM DESCRIPTION

2.1.1 Asphalt Mixing Plant

2.1.1.1 Truck Scales

2.1.1.2 Inspection of Plant

2.1.1.3 Storage Bins

2.1.2 Hauling Equipment Material

2.1.3 Transfer Vehicle (MTV)

2.1.4 Asphalt Pavers

2.1.4.1 Receiving Hopper

2.1.5 Rollers

5 April 2018

2.1.6 Diamond Grinding

2.2 AGGREGATES

2.2.1 Coarse Aggregate

2.2.2 Fine Aggregate

2.2.3 Mineral Filler

2.2.4 Aggregate Gradation

2.3 ASPHALT CEMENT BINDER

2.4 NOT USED

2.5 MIX DESIGN

2.5.1 JMF Requirements

2.5.2 Adjustments to JMF

PART 3 - EXECUTION

3.1 CONTRACTOR QUALITY CONTROL

3.1.1 General Quality Control Requirements

3.1.2 Testing Laboratory

3.1.3 Quality Control Testing

3.1.3.1 Asphalt Content

3.1.3.2 Aggregate Properties

3.1.3.3 Temperatures

3.1.3.4 Aggregate Moisture

3.1.3.5 Moisture Content of Mixture

3.1.3.6 Laboratory Air Voids, VMA, Marshall Stability and Flow

3.1.3.7 In-Place Density

3.1.3.8 Grade and Smoothness

3.1.3.9 Additional Testing

3.1.3.10 QC Monitoring

3.1.4 Sampling

3.1.5 Control Charts

3.2 PREPARATION OF ASPHALT BINDER MATERIAL

3.3 PREPARATION OF MINERAL AGGREGATE

3.4 PREPARATION OF HOT-MIX ASPHALT MIXTURE

3.5 PREPARATION OF THE UNDERLYING SURFACE

3.6 TEST SECTION

3.7 TESTING LABORATORY

3.8 TRANSPORTING AND PLACING

3.8.1 Transporting

3.8.2 Placing

3.9 COMPACTION OF MIXTURE

3.9.1 General

3.9.2 Segregation

3.10 JOINTS

3.10.1 Transverse Joints

3.10.2 Longitudinal Joints

3.10.3 Asphalt Pavement-Portland Cement Concrete Joints

-- End of Table of Contents --

PART 1 - GENERAL

1.1 NOT USED.

1.2 PERCENT PAYMENT

The Contractor will receive full payment as long as the following requirements are met.

1.2.1 Mat and Joint Densities

The average in-place mat and joint densities are expressed as a percentage of the average theoretical maximum density (TMD) for the lot.

The average TMD for each lot will be determined as the average TMD of the four random samples per lot.

The Contractor shall aim for an average mat density of between 93.9 and

96.0 percent. However, the Government will accept an average mat density of between 92.0 and 97.0 percent. Any lots that have an average mat density of less than 92.0 percent, or higher than 97.0 percent, will be rejected.

The Contractor shall aim for an average joint density of at least 92.4 percent. However, the Government will accept an average joint density of at least 90.5 percent. Any lots that have an average joint density less than 90.5 percent will be rejected. The area associated with the joint will considered to be 10 feet wide times the length of completed longitudinal construction joint.

Rejected lots shall be removed and replaced. Rejected areas adjacent to longitudinal joints shall be removed 4 inches into the cold (existing) lane. All density results for a lot will be completed and reported within 24 hours after the construction of that lot.

1.2.2 Surface Smoothness

Profilograph Testing. The Contractor shall aim for a Profile Index of not more than 7 inches per mile. However, the Government will accept a Profile Index of up to 11 inches per mile. Any lot that has a Profile Index of greater than 11 inches per mile will be rejected and must be replaced. Regardless of the above, correct any small individual area with a surface deviation that exceeds the tolerance given above by more than 5.0 inches per mile. This can be done by grinding or removal and replacement.

1.2.3 Laboratory Air Voids and Theoretical Maximum Density

Laboratory air voids will be calculated in accordance with ASTM D3203/D3203M by determining the density of each lab compacted specimen using the laboratory-prepared, thoroughly dry method in ASTM D2726/D2726M and determining the theoretical maximum density (TMD) of four of the sublots using ASTM D2041/D2041M. Laboratory air void calculations for each lot will use the average theoretical maximum density values obtained for the lot. The mean absolute deviation of the four laboratory air void contents (one from each sublot) from the JMF air void content will be evaluated. All laboratory air void tests will be completed and reported within 24 hours after completion of construction of each lot. The TMD is also used for computation of compaction, as required in paragraph MAT AND

JOINT DENSITIES above.

1.2.3.1 Mean Absolute Deviation of Lab Air Voids from JMF: The Contractor shall aim for a deviation of 0.60 or less. However, the Government will accept a deviation of up to 1.20. Any lot that has a deviation of greater than 1.20 will be rejected and must be replaced.

1.2.4 Grade

Match finished surfaces at juncture with other pavements with finished surfaces of abutting pavements. Diamond grinding may be used to remove high spots to meet grade requirements. Skin patching for correcting low areas or planing or milling for correcting high areas will not be permitted.

1.3 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

AASHTO M 156 (2013; R 2017) Standard Specification for

Requirements for Mixing Plants for Hot-Mixed, Hot-Laid Bituminous Paving Mixtures

AASHTO M 320 (2017) Standard Specification for

Performance-Graded Asphalt Binder

AASHTO T 304 (2011; R 2015) Standard Method of Test for

Uncompacted Void Content of Fine Aggregate

AASHTO T 308 (2016) Standard Method of Test for

Determining the Asphalt Binder Content of Hot Mix Asphalt (HMA) by the Ignition Method

AASHTO T 329 (2015) Standard Test Method for Moisture

Content of Hot Mix Asphalt (HMA) by Oven

ASPHALT INSTITUTE (AI)

AI MS-2 (2015) Asphalt Mix Design Methods

ASTM INTERNATIONAL (ASTM)

ASTM C117 (2017) Standard Test Method for Materials Finer than 75-um (No. 200) Sieve in Mineral Aggregates by Washing

ASTM C127 (2015) Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Coarse Aggregate

ASTM C128 (2015) Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Fine Aggregate

ASTM C131/C131M (2014) Standard Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

ASTM C136/C136M (2014) Standard Test Method for Sieve

Analysis of Fine and Coarse Aggregates

ASTM C142/C142M (2017) Standard Test Method for Clay Lumps and Friable Particles in Aggregates

ASTM C29/C29M (2017a) Standard Test Method for Bulk

Density ("Unit Weight") and Voids in Aggregate

ASTM C566 (2013) Standard Test Method for Total

Evaporable Moisture Content of Aggregate by Drying

ASTM C88 (2013) Standard Test Method for Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate

ASTM D140/D140M (2016) Standard Practice for

Sampling Asphalt Materials

ASTM D1461 (2017) Standard Test Method for Moisture or Volatile Distillates in Asphalt Mixtures

ASTM D2041/D2041M (2011) Theoretical Maximum Specific

Gravity and Density of Bituminous Paving Mixtures

ASTM D2172/D2172M (2017) Standard Test Methods for

Quantitative Extraction of Asphalt Binder from Asphalt Mixtures

ASTM D2419 (2014) Sand Equivalent Value of Soils and Fine Aggregate

ASTM D242/D242M (2009; R 2014) Mineral Filler for Bituminous Paving Mixtures

ASTM D2489/D2489M (2016) Standard Test Method for

Estimating Degree of Particle Coating of Asphalt Mixtures

ASTM D2726/D2726M (2017) Standard Test Method for

Bulk Specific Gravity and Density of Non-Absorptive Compacted Bituminous Mixtures

ASTM D3203/D3203M (2017) Standard Test Method for Percent Air Voids in Compacted Asphalt

ASTM D3665 (2012; R 2017) Standard Practice for

Random Sampling of Construction Materials

ASTM D3666 (2016) Standard Specification for

Minimum Requirements for Agencies Testing and Inspecting Road and Paving Materials

ASTM D4125/D4125M (2010) Asphalt Content of

Bituminous Mixtures by the Nuclear

ASTM D4791 (2010) Flat Particles, Elongated

Particles, or Flat and Elongated Particles in Coarse Aggregate

ASTM D4867/D4867M (2009; R 2014) Effect of Moisture on Asphalt Concrete Paving Mixtures

ASTM D5444 (2015) Mechanical Size Analysis of Extracted Aggregate ASTM D5821 (2013; R 2017) Standard Test Method for

Determining the Percentage of Fractured Particles in Coarse Aggregate

ASTM D6307 (2016) Standard Test Method for

Asphalt Content of Hot Mix Asphalt by Ignition Method

ASTM D6925 (2014) Standard Test Method for

Preparation and Determination of the Relative Density of Hot Mix Asphalt (HMA) Specimens by Means of the Superpave Gyratory Compactor

ASTM D6926 (2016) Standard Practice for

Preparation of Asphalt Mixture Specimens Using Marshall Apparatus

ASTM D6927 (2015) Standard Test Method for Marshall

Stability and Flow of Bituminous

ASTM D75/D75M (2014) Standard Practice for

Sampling Aggregates

ASTM D946/D946M (2015) Penetration-Graded Asphalt

Cement for Use in Pavement Construction

ASTM D979/D979M (2015) Sampling Bituminous Paving

ASTM E1274 (2003; R 2017) Standard Test Method for Measuring Pavement Roughness Using a Profilograph

1.4 SUBMITTALS

Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES: Mix Design and QC Monitoring

1.5 QUALITY ASSURANCE

The Contractor shall hire an independent testing laboratory to perform all of the QA testing specified in this paragraph. This is separate and distinct from the Contractor's quality control (QC) program specified in Part 3. Acceptance of the plant produced mix and in-place requirements will be on a lot to lot basis. A standard lot for all requirements will be equal to 2000 metric short tons. Grade and surface smoothness determinations will be made on the lot as a whole. In order to evaluate laboratory air voids and in-place (field) density, each lot will be divided into four equal sublots.

1.5.1 Sublot Sampling

One random mixture sample for determining laboratory air voids and theoretical maximum density will be taken from a loaded truck delivering mixture to each sublot, or other appropriate location for each sublot.

All samples will be selected randomly, using commonly recognized methods of assuring randomness conforming to ASTM D3665 and employing tables of random numbers or computer programs. Laboratory air voids will be determined from three laboratory compacted specimens of each sublot sample in accordance with ASTM D3203/D3203M. The specimens will be compacted within 2 hours of the time the mixture was loaded into trucks at the asphalt plant. Samples will not be reheated prior to compaction and insulated containers will be used as necessary to maintain the temperature.

1.5.2 Not Used

1.5.3 In-place Density

For determining in-place density, obtain one random core 4 or 6 inches in diameter from the mat (at least 12 inches away from longitudinal joint) of each sublot, and one random core taken from the joint (immediately over joint) of each sublot, in accordance with ASTM D979/D979M. Fill all core holes with asphalt pavement and compact using a standard Marshall hammer to a mat density as specified. Tack coat dry core holes before filling. Each random core will be full thickness of the layer being placed. After air drying to meet the requirements for laboratory-prepared, thoroughly dry specimens, cores obtained from the mat and from the joints will be used for in-place density determination in accordance with ASTM D2726/D2726M.

1.5.4 Surface Smoothness

Use a straightedge and profilograph for measuring surface smoothness of runway pavements. Perform all testing in the presence of the Government Engineer. Maintain detailed notes of the testing results and provide a copy to the Government Engineer immediately after each day's testing.

1.5.4.1 Smoothness Requirements

1.5.4.1.1 Straightedge Testing

Provide finished surfaces of the pavements with no abrupt change of 1/8 inch or more, and all pavements within the tolerances specified in Table 3 when checked with an approved 12 foot straightedge.

Table 3. Straightedge Surface Smoothness--Pavements

Pavement Category Direction of Testing Tolerance, inch

Runways Longitudinal 1/8

Transverse 1/4

1.5.4.1.2 Profilograph Testing

Provide finished surfaces of runways with a Profile Index not greater than 7 inches per mile when tested with an approved California-type profilograph.

1.5.4.2 Testing Method

After the final rolling, but not later than 24 hours after placement, test the surface of the pavement in each entire lot in a manner to reveal surface irregularities exceeding the tolerances specified above.

If any pavement areas are diamond ground, retest these areas immediately after diamond grinding. The maximum area allowed to be corrected by diamond grinding is 10 percent of the total area of the lot. Test the entire area of the pavement with a profilograph. Check a number of random locations along with any observed suspicious locations primarily at transverse and longitudinal joints with the straightedge.

1.5.4.2.1 Straightedge Testing

Hold the straightedge in contact with the pavement surface and measure the maximum distance between the straightedge and the pavement surface.

Determine the amount of surface irregularity by placing the freestanding (unleveled) straightedge on the pavement surface and allowing it to rest upon the two highest spots covered by its length, and measuring the maximum gap between the straightedge and the pavement surface in the area between these two high points. Use the straightedge to measure abrupt changes in surface grade.

1.5.4.2.2 Profilograph Testing

Perform profilograph testing using an approved California profilograph and procedures described in ASTM E1274. Provide equipment that utilizes electronic recording and automatic computerized reduction of data to indicate "must-grind" bumps and the Profile Index for the pavement. Use a "blanking band" that is 0.2 inch wide and the "bump template" spanning 1 inch with an offset of 0.4 inch. Provide profilograph operated by an approved, factory-trained operator on the alignments specified above. Provide a copy of the reduced tapes to the Government Engineer at the end of each day's testing.

1.5.4.2.3 Bumps ("Must Grind" Areas)

Reduce any bumps ("must grind" areas) shown on the profilograph trace which exceed 0.4 inch in height by diamond grinding until they do not exceed 0.3 inch when retested. Taper diamond grinding in all directions to provide smooth transitions to areas not requiring diamond grinding.

The following will not be permitted: (1) skin patching for correcting low areas, (2) planing or milling for correcting high areas. Perform additional profilograph testing in all areas corrected by diamond grinding.

1.6 ENVIRONMENTAL REQUIREMENTS

Do not place asphalt pavement upon a wet surface or when the surface temperature of the underlying course is less than specified in Table 4.

Table 4. Surface Temperature Limitations of Underlying Course

Mat Thickness, inches Degrees F

Less than 3 45

PART 2 - PRODUCTS

2.1 SYSTEM DESCRIPTION

Perform the work consisting of pavement courses composed of mineral aggregate and asphalt material heated and mixed in a central mixing plant and placed on a prepared course. Provide hot-mix asphalt (HMA) pavement designed and constructed in accordance with this section.

2.1.1 Asphalt Mixing Plant

Provide plants used for the preparation of asphalt mixture conforming to the requirements of AASHTO M 156 with the following changes:

2.1.1.1 Truck Scales

Weigh the asphalt mixture on approved scales, or on certified public scales at no additional expense to the Government. Inspect and seal scales at least annually by an approved calibration laboratory.

2.1.1.2 Inspection of Plant

Provide access to the Contracting Officer Engineer at all times, to all areas of the plant for checking adequacy of equipment; inspecting operation of the plant; verifying weights, proportions, and material properties; checking the temperatures maintained in the preparation of the mixtures and for taking samples. Provide assistance as requested, for the Government Engineer to procure any desired samples.

2.1.1.3 Storage Bins

The asphalt mixture may be stored in non-insulated storage bins for a period of time not exceeding 3 hours. The asphalt mixture may be stored in insulated storage bins for a period of time not exceeding 8 hours.

Provide the mix drawn from bins that meets the same requirements as mix loaded directly into trucks.

2.1.2 Hauling Equipment

Provide trucks used for hauling asphalt mixture that have tight, clean, and smooth metal beds. To prevent the mixture from adhering to them, lightly coat the truck beds with a minimum amount of paraffin oil, lime solution, or other approved material. Do not use petroleum based products as a release agent. Provide each truck with a suitable cover to protect the mixture from adverse weather. When necessary to ensure that the mixture is delivered to the site at the specified temperature, provide insulated or heated truck beds with covers (tarps) that are securely fastened.

2.1.3 Material Transfer Vehicle (MTV)

Provide Material Transfer Vehicles for placement of the asphalt mixture.

To transfer the material from the hauling equipment to the paver, use a self-propelled, material transfer vehicle with a swing conveyor that delivers material to the paver from outside the paving lane and without making contact with the paver. Provide MTV capable to move back and forth between the hauling equipment and the paver providing material transfer to the paver, while allowing the paver to operate at a constant speed.

Provide Material Transfer Vehicle with remixing and storage capability to prevent physical and thermal segregation.

2.1.4 Asphalt Pavers

Provide mechanical spreading and finishing equipment consisting of a self-powered paver, capable of spreading and finishing the mixture to the specified line, grade, and cross section. Provide paver screed capable of laying a uniform mixture to meet the specified thickness, smoothness, and grade without physical or temperature segregation, the full width of the material being placed. Provide a screed equipped with a compaction device to be used during all placement.

2.1.4.1 Receiving Hopper

Provide paver with a receiving hopper of sufficient capacity to permit a uniform spreading operation and a distribution system to place the mixture uniformly in front of the screed without segregation. Provide a screed that effectively produces a finished surface of the required evenness and texture without tearing, shoving, or gouging the mixture.

2.1.5 Rollers

Provide rollers in good condition and operated at slow speeds to avoid displacement of the asphalt mixture. Provide sufficient number, type, and weight of rollers to compact the mixture to the required density while it is still in a workable condition. Do not use equipment which causes excessive crushing of the aggregate.

2.1.6 Diamond Grinding

Those performing diamond grinding are required to have a minimum of three years of experience in diamond grinding of airfield pavements. In areas not meeting the specified limits for surface smoothness, reduce high areas to attain the required smoothness and grade, except as depth is limited below. Reduce high areas by diamond grinding the asphalt pavement with approved equipment after the asphalt pavement is at a minimum age of 14 days. Perform diamond grinding by sawing with saw blades impregnated with an industrial diamond abrasive. Assemble the saw blades in a cutting head mounted on a machine designed specifically for diamond grinding that produces the required texture and smoothness level without damage to the asphalt pavement or joint faces. Provide diamond grinding equipment with saw blades that are 1/8-inch wide, a minimum of 60 blades per 12 inches of cutting head width, and capable of cutting a path a minimum of 3 feet wide. Diamond grinding equipment that causes raveling, fracturing of aggregate, or disturbance to the underlying material will not be allowed. The maximum area corrected by diamond grinding the surface of the asphalt pavement is 10 percent of the total area of any sublot. The maximum depth of diamond grinding is 1/2 inch.

Provide diamond grinding machine equipped to flush and vacuum the pavement surface. Dispose of all debris from diamond grinding operations off base. Prior to diamond grinding, submit a Diamond Grinding Plan for review and approval. At a minimum, include the daily reports for the deficient areas, the location and extent of deficiencies, corrective actions, and equipment. Remove and replace all pavement areas requiring plan grade or surface smoothness corrections in excess of the limits specified.

Prior to production diamond grinding operations, perform a test section at the approved location, consisting of a minimum of two adjacent passes with a minimum length of 40 feet to allow evaluation of the finish and transition between adjacent passes. Production diamond grinding operations cannot be performed prior to approval.

2.2 AGGREGATES

Obtain samples in accordance with ASTM D75/D75M and be representative of the materials to be used for the project. Provide aggregates consisting of crushed stone, crushed gravel, crushed slag, screenings, natural sand and mineral filler, as required. The portion of material retained on the No. 4 sieve is coarse aggregate. The portion of material passing the No.

4 sieve and retained on the No. 200 sieve is fine aggregate. The portion passing the No. 200 sieve is defined as mineral filler. Submit sufficient materials to produce 200 pounds of blended mixture for mix design verification. Submit all aggregate test results and samples to the Government Engineer at least 14 days prior to start of construction.

2.2.1 Coarse Aggregate

Provide coarse aggregate consisting of sound, tough, durable particles, free from films of material that would prevent thorough coating and bonding with the asphalt material and free from organic matter and other deleterious substances. Provide coarse aggregate particles meeting the following requirements:

a. The percentage of loss not be greater than 40 percent after 500 revolutions when tested in accordance with ASTM C131/C131M.

b. The sodium sulfate soundness loss not exceeding 12 percent, or the magnesium sulfate soundness loss not exceeding 18 percent after five cycles when tested in accordance with ASTM C88.

c. At least 75 percent by weight of coarse aggregate contain at least two or more fractured faces when tested in accordance with ASTM D5821 with fractured faces produced by crushing.

d. The particle shape essentially cubical and the aggregate containing not more than 20 percent, by weight, of flat particles and elongated particles (3:1 ratio of maximum to minimum) when tested in accordance with ASTM D4791.

e. Slag consisting of air-cooled, blast furnace slag, with a compacted weight of not less than 75 pounds per cubic foot when tested in accordance with ASTM C29/C29M.

f. Clay lumps and friable particles not exceeding 0.3 percent, by weight, when tested in accordance with ASTM C142/C142M.

2.2.2 Fine Aggregate

Provide fine aggregate consisting of clean, sound, tough, durable particles. Provide aggregate particles that are free from coatings of clay, silt, or any objectionable material, contain no clay balls, and meet the following requirements:

a. Quantity of natural sand (noncrushed material) added to the aggregate blend not exceeding 15 percent by weight of total aggregate.

b. Individual fine aggregate sources with a sand equivalent value greater than 45 when tested in accordance with ASTM D2419.

c. Fine aggregate portion of the blended aggregate with an uncompacted void content greater than 45.0 percent when tested in accordance with AASHTO T 304 Method A.

d. Clay lumps and friable particles not exceeding 0.3 percent, by weight, when tested in accordance with ASTM C142/C142M.

2.2.3 Mineral Filler

Provide mineral filler consisting of a non-plastic material meeting the requirements of ASTM D242/D242M.

2.2.4 Aggregate Gradation

Provide a combined aggregate gradation that conforms to gradations specified in Table 5, when tested in accordance with ASTM C136/C136M and ASTM C117, and does not vary from the low limit on one sieve to the high limit on the adjacent sieve or vice versa, but grades uniformly from coarse to fine. Provide a JMF within the specification limits. However, the gradation can exceed the limits when the allowable deviation from the JMF shown in Tables 8 and 9 are applied.

Table 5 – Aggregate Gradation

Gradation 2

Sieve Size, inch Percent Passing by Mass

1 ---

3/4 100

1/2 90-100

3/8 69-89

No. 4 53-73

No. 8 38-60

No. 16 26-48

No. 30 18-38

No. 50 11-27

No. 100 6-18

No. 200 3-6

2.3 ASPHALT CEMENT BINDER

Provide asphalt cement binder that conforms to AASHTO M 320 Performance Grade (PG) 70-22. Provide test data indicating grade certification by the supplier at the time of delivery of each load to the mix plant.

Submit copies of these certifications to the Government Engineer.

2.4 NOT USED

2.5 MIX DESIGN

Develop the mix design. Provide an asphalt mixture composed of well-graded aggregate, mineral filler if required, and asphalt material.

Provide aggregate fractions sized, handled in separate size groups, and combined in such proportions that the resulting mixture meets the grading requirements of Table 5. Do not produce asphalt pavement for payment until a JMF has been approved. Design the asphalt mixture using hand-held hammer procedures contained in AI MS-2 and the criteria shown in Table 6.

Use laboratory compaction temperatures for Polymer Modified Asphalts as recommended by the asphalt cement manufacturer. If the Tensile Strength Ratio (TSR) of the composite mixture, as determined by ASTM D4867/D4867M is less than 75, reject the aggregates or the asphalt mixture treated with an anti-stripping agent. Add a sufficient amount of anti-stripping agent to produce a TSR of not less than 75. If an antistrip agent is required, provide it at no additional cost to the Government.

2.5.1 JMF Requirements

Submit the proposed JMF in writing, for approval, at least 14 days prior to the start of the test section, including as a minimum:

a. Percent passing each sieve size.

b. Percent of asphalt cement.

c. Percent of each aggregate and mineral filler to be used.

d. Asphalt viscosity grade, penetration grade, or performance grade.

e. Number of blows of hammer per side of molded specimen.

f. Laboratory mixing temperature.

g. Lab compaction temperature.

h. Temperature-viscosity relationship of the asphalt cement.

i. Plot of the combined gradation on the 0.45 power gradation chart, stating the nominal maximum size.

j. Graphical plots and summary tabulation of stability, flow, air voids, voids in the mineral aggregate, and unit weight versus asphalt content as shown in AI MS-2. Include summary tabulation that includes individual specimen data for each specimen tested. Specific gravity and absorption of each aggregate.

k. Specific gravity and absorption of each aggregate.

l. Percent natural sand.

m. Percent particles with two or more fractured faces (in coarse aggregate).

n. Fine aggregate angularity.

o. Percent flat or elongated particles (in coarse aggregate).

p. Tensile Strength Ratio and wet/dry specimen test results.

q. Antistrip agent (if required).

r. List of all modifiers.

Table 6 - Marshall Design Criteria

Test Property 75 Blow Mix

Stability, pounds minimum 2150(1)

Flow, 0.01 inch 8-16(2)

Air voids, percent 4(4)

Percent Voids in mineral aggregate (minimum)

See Table 7

Dust Proportion(3) 0.8-1.2

TSR, minimum percent 75

TSR Conditioned Strength (minimum psi)

(1) This is a minimum requirement. Provide significantly higher average during construction to ensure compliance with the specifications.

(2) The flow requirement is not applicable for Polymer Modified Asphalts

(3) Dust Proportion is calculated as the aggregate content, expressed as a percent of mass, passing the No. 200 sieve, divided by the effective asphalt content, in percent of total mass of the mixture.

4) Select the JMF asphalt content corresponding to an air void content of 4 percent. Verify the other properties of Table 6 meet the specification requirements at this asphalt content.

Table 7. Minimum Percent Voids in Mineral Aggregate (VMA)(1)

Aggregate (See Table 5) Minimum VMA, percent

Gradation 2 14

(1) Calculate VMA in accordance with AI MS-2, based on ASTM D2726/D2726M bulk specific gravity for the aggregate.

2.5.2 Adjustments to JMF

The JMF for each mixture is in effect until a new formula is approved in writing by the Government Engineer. Should a change in sources of any materials be made, perform a new mix design and a new JMF approved before the new material is used. Make minor adjustments within the specification limits to the JMF to optimize mix volumetric properties.

Adjustments to the original JMF are limited to plus or minus 4 percent on the No. 4 and coarser sieves; plus or minus 3 percent on the No. 8 to No. 50 sieves; and plus or minus 1 percent on the No. 100 sieve.

Adjustments to the JMF are limited to plus or minus 1.0 percent on the No. 200 sieve. Asphalt content adjustments are limited to plus or minus

0.40 from the original JMF. If adjustments are needed that exceed these limits, develop a new mix design.

PART 3 - EXECUTION

3.1 CONTRACTOR QUALITY CONTROL

3.1.1 General Quality Control Requirements

Submit the Quality Control Plan. Do not produce hot-mix asphalt pavement for payment until the quality control plan has been approved. In the quality control plan, address all elements which affect the quality of the pavement including, but not limited to:

a. Mix Design and unique JMF identification code

b. Aggregate Grading

c. Quality of Materials

d. Stockpile Management and procedures to prevent contamination

e. Proportioning including percent of warm-mix additive

f. Mixing and Transportation

g. Correlation of mechanical hammer to hand hammer. Determine the number of blows of the mechanical hammer required to provide the same density of the JMF as provided by the hand hammer. Use the average of three specimens per trial blow application.

h. Mixture Volumetrics

i. Moisture Content of Mixtures

j. Placing and Finishing

k. Joints

l. Compaction, including Asphalt Pavement-Portland Cement Concrete joints

m. Surface Smoothness

n. Truck bed release agent

3.1.2 Testing Laboratory

Provide a fully equipped asphalt laboratory located at the plant or job site that is equipped with heating and air conditioning units to maintain a temperature of 75 plus or minus 5 degrees F. Provide laboratory facilities that are kept clean and all equipment maintained in proper working condition. Provide the Government Engineer with unrestricted access to inspect the laboratory facility, to witness quality control activities, and to perform any check testing desired.

3.1.3 Quality Control Testing

Perform all quality control tests applicable to these specifications and as set forth in the Quality Control Program. Required elements of the testing program include, but are not limited to, tests for the control of asphalt content, aggregate gradation, temperatures, aggregate moisture, moisture in the asphalt mixture, laboratory air voids, stability, flow, in-place density, grade and smoothness. Develop a Quality Control Testing Plan as part of the Quality Control Program.

3.1.3.1 Asphalt Content

A minimum of two tests to determine asphalt content will be performed per lot (a lot is defined in paragraph QUALITY ASSURANCE) by one of the following methods: extraction method in accordance with ASTM D2172/D2172M, Method A or B, the ignition method in accordance with the AASHTO T 308, ASTM D6307, or the nuclear method in accordance with ASTM D4125/D4125M, provided each method is calibrated for the specific mix being used. For the extraction method, determine the weight of ash, as described in ASTM D2172/D2172M, as part of the first extraction test performed at the beginning of plant production; and as part of every tenth extraction test performed thereafter, for the duration of plant production. Use the last weight of ash value in the calculation of the asphalt content for the mixture.

3.1.3.2 Aggregate Properties

Determine aggregate gradations a minimum of twice per lot from mechanical analysis of recovered aggregate in accordance with ASTM D5444 or ASTM D6307. For batch plants, test aggregates in accordance with ASTM C136/C136M using actual batch weights to determine the combined aggregate gradation of the mixture. Determine the specific gravity of each aggregate size grouping for each 20,000 tons in accordance with ASTM C127 or ASTM C128. Determine fractured faces for gravel sources for each 20,000 tons in accordance with ASTM D5821. Determine the uncompacted void content of manufactured sand for each 20,000 tons in accordance with AASHTO T 304 Method A.

3.1.3.3 Temperatures

Check temperatures at least four times per lot, at necessary locations, to determine the temperature at the dryer, the asphalt cement in the storage tank, the asphalt mixture at the plant, and the asphalt mixture at the job site.

3.1.3.4 Aggregate Moisture

Determine the moisture content of aggregate used for production a minimum of once per lot in accordance with ASTM C566.

3.1.3.5 Moisture Content of Mixture

Determine the moisture content of the mixture at least once per lot in accordance with AASHTO T 329.

3.1.3.6 Laboratory Air Voids, VMA, Marshall Stability and Flow

Obtain mixture samples at least four times per lot and compacted into specimens, using 75 blows per side with the Marshall hand-held hammer as described in ASTM D6926. After compaction, determine the laboratory air voids and VMA of each specimen, as well as the Marshall stability and flow, as described in ASTM D6927. Provide VMA within the limits of Table 7.

3.1.3.7 In-Place Density

Conduct any necessary testing to ensure the specified density is achieved.

A nuclear gauge or other non-destructive testing device may be used to monitor pavement density.

3.1.3.8 Grade and Smoothness

Conduct the necessary checks to ensure the grade and smoothness requirements are met in accordance with paragraph QUALITY

ASSURANCE.

3.1.3.9 Additional Testing

Perform any additional testing, deemed necessary to control the process.

3.1.3.10 QC Monitoring

Submit all QC test results to the Government Engineer on a daily basis as the tests are performed.

3.1.4 Sampling

When directed by the Government Engineer, sample and test any material which appears inconsistent with similar material being produced, unless such material is voluntarily removed and replaced or deficiencies corrected. Perform all sampling in accordance with standard procedures specified.

3.1.5 Control Charts

For process control, establish and maintain linear control charts on both individual samples and the running average of last four samples for the parameters listed in Table 8, as a minimum. Post the control charts as directed by the Government Engineer and maintain current at all times. Identify the following on the control charts, the project number, the test parameter being plotted, the individual sample numbers, the Action and Suspension Limits listed in Table 8 applicable to the test parameter being plotted, and the test results. Also show target values (JMF) on the control charts as indicators of central tendency for the cumulative percent passing, asphalt content, and laboratory air voids parameters. When the test results exceed either applicable Action Limit, take immediate steps to bring the process back in control. When the test results exceed either applicable Suspension Limit, halt production until the problem is solved. When the Suspension Limit is exceeded for individual values or running average values, the Government Engineer has the option to require removal and replacement of the material represented by the samples or to leave in place and base acceptance on mixture volumetric properties and in place density.

Use the control charts as part of the process control system for identifying trends so that potential problems can be corrected before they occur. Make decisions concerning mix modifications based on analysis of the results provided in the control charts. In the Quality Control Plan, indicate the appropriate action to be taken to bring the process into control when certain parameters exceed their Action Limits.

Table 8. Action and Suspension Limits for the Parameters to be Plotted on Individual and Running Average Control Charts

Individual Samples Running Average of Last Four Samples

Parameter to be Plotted Action Limit

Suspension Limit

Action Limit Suspension Limit

No. 4 sieve, Cumulative Percent Passing, deviation from JMF target; plus or minus values

6 8 4 5

No. 30 sieve, Cumulative Percent Passing, deviation from JMF target; plus or minus values

4 6 3 4

No. 200 sieve, Cumulative Percent Passing, deviation from JMF target; plus or minus values

1.4 2.0 1.1 1.5

Asphalt content, percent deviation from JMF target;

plus or minus value

0.4 0.5 0.2 0.3

Laboratory Air Voids, percent deviation from JMF target value

No specific action and suspension limits set since this parameter is used to determine percent payment

In-place Mat Density, percent of TMD

No specific action and suspension limits set since this parameter is used to determine percent payment

In-place Joint Density, percent of TMD

No specific action and suspension limits set since this parameter is used to determine percent payment

VMA

Gradation 2 14.3 14.0 14.5 14.0

Marshall Compaction

Stability, pounds (minimum)

75 blow JMF 1760 1640 2150 2030

Flow, 0.01 inch

75 blow JMF 8 min. 7 min. 9 min. 8 min.

16 max. 17 max. 15 max. 16 max.

3.2 PREPARATION OF ASPHALT BINDER MATERIAL

Heat the asphalt cement material while avoiding local overheating and providing a continuous supply of the asphalt material to the mixer at a uniform temperature. Maintain the temperature of unmodified asphalts to no more than 325 degrees F when added to the aggregates. The temperature of modified asphalts is not to exceed 350 degrees F.

3.3 PREPARATION OF MINERAL AGGREGATE

Heat and dry the aggregate for the mixture prior to mixing. No damage to the aggregates due to the maximum temperature and rate of heating used is allowed. Maintain the temperature no lower than is required to obtain complete coating and uniform distribution on the aggregate particles and to provide a mixture of satisfactory workability.

3.4 PREPARATION OF HOT-MIX ASPHALT MIXTURE

Weigh or meter the aggregates and the asphalt cement and introduce into the mixer in the amount specified by the JMF. Limit the temperature of the asphalt mixture when the asphalt cement is added. Mix the combined materials until the aggregate obtains a thorough and uniform coating of asphalt binder, and is thoroughly distributed throughout the mixture.

The moisture content of all asphalt mixture upon discharge from the plant is not to exceed 0.5 percent by total weight of mixture as measured by ASTM D1461.

3.5 PREPARATION OF THE UNDERLYING SURFACE

Immediately before placing asphalt pavement, clean the underlying course of dust and debris. Apply a tack coat in accordance with the contract specifications.

3.6 TEST SECTION

A test section will not be required for this project.

3.7 TESTING LABORATORY

Laboratories used to develop the JMF, perform Contractor Quality Control testing, and Quality Assurance and acceptance testing are required to meet the requirements of ASTM D3666. Perform all required test methods by an accredited laboratory. Submit a certification of compliance signed by the manager of the laboratory stating that it meets these requirements to the Government Engineer prior to the start of construction. At a minimum, include the following certifications:

a. Qualifications of personnel; laboratory manager, supervising technician, and testing technicians.

b. A listing of equipment to be used in developing the job mix.

c. A copy of the laboratory's quality control system.

d. Evidence of participation in the AASHTO Materials Reference Laboratory (AMRL) program.

3.8 TRANSPORTING AND PLACING

3.8.1 Transporting

Transport asphalt mixture from the mixing plant to the site in clean, tight vehicles. Schedule deliveries so that placing and compacting of mixture is uniform with minimum stopping and starting of the paver.

Provide adequate artificial lighting for night placements. Hauling over freshly placed material is not permitted until the material has been compacted as specified, and allowed to cool to 140 degrees F.

3.8.2 Placing

Do not broadcast waste mixture onto the mat or recycled into the paver hopper. Collect waste mixture and dispose off site. Regulate the speed of the paver to eliminate pulling and tearing of the asphalt mat. Begin placement of the mixture along the centerline of a crowned section or on the high side of areas with a one-way slope. Place the mixture in consecutive adjacent strips having a minimum width of 10 feet. Locate the longitudinal joint in the surface course at the centerline of the pavement.

3.9 COMPACTION OF MIXTURE

3.9.1 General

a. After placing, thoroughly and uniformly compact the mixture by rolling. Compact the surface as soon as possible without causing displacement, cracking or shoving. Determine the sequence of rolling operations and the type of rollers used, except as specified in paragraph ASPHALT PAVEMENT-PORTLAND CEMENT CONCRETE JOINTS and with the exception that application of more than three passes with a vibratory roller in the vibrating mode is prohibited. Maintain the speed of the roller, at all times, sufficiently slow to avoid displacement of the asphalt mixture and be effective in compaction.

Correct at once any displacement occurring as a result of reversing the direction of the roller, or from any other cause.

b. Furnish sufficient rollers to handle the output of the plant.

Continue rolling until the surface is of uniform texture, true to grade and cross section, and the required field density is obtained.

To prevent adhesion of the mixture to the roller, keep the wheels properly moistened, but excessive water is not permitted. Remove the full depth of any mixture that becomes loose and broken, mixed with dirt, contains check-cracking, or is in any way defective, replace with fresh asphalt mixture, and immediately compact to conform to the surrounding area. Skin patching is not allowed.

3.9.2 Segregation

When the in-place material appears to be segregated, the Government Engineer may direct the Contractor, at no additional cost, to sample the material and have it tested and compared to the aggregate gradation, asphalt content, and in-place density requirements in Table 9. If the material fails to meet these specification requirements, remove and replace the extent of the segregated material the full depth of the layer of asphalt mixture at no additional cost to the Government. When segregation occurs in the mat, take appropriate action to correct the process so that additional segregation does not occur.

3.10 JOINTS

Construct joints to ensure a continuous bond between the courses and to obtain the required density. Provide all joints with the same texture as other sections of the course and meet the requirements for smoothness and grade.

3.10.1 Transverse Joints

Do not pass the roller over the unprotected end of the freshly laid mixture, except when necessary to form a transverse joint. When necessary to form a transverse joint, construct by means of placing a bulkhead or by tapering the course. Utilize a dry saw cut on the transverse joint full depth and width on a straight line to expose a vertical face prior to placing the adjacent lane. Cutting equipment that uses water as a cooling or cutting agent nor milling equipment is permitted. Remove the cutback material from the project. In both methods, provide a light tack coat of asphalt material to all contact surfaces before placing any fresh mixture against the joint.

3.10.2 Longitudinal Joints

Cut back longitudinal joints which are irregular, damaged, uncompacted, cold (less than 175 degrees F at the time of placing the adjacent lane), or otherwise defective, a maximum of 3 inches from the top edge of the lift with a cutting wheel to expose a clean, sound, near vertical surface for the full depth of the course. Remove all cutback material from the project. Cutting equipment that uses water as a cooling or cutting agent nor milling equipment is permitted. Provide a light tack coat of asphalt material to all contact surfaces prior to placing any fresh mixture against the joint.

3.10.3 Asphalt Pavement-Portland Cement Concrete Joints

Joints between asphalt pavement and Portland Cement Concrete (PCC) require specific construction procedures for the asphalt pavement. The following criteria are applicable to the first 10 feet or paver width of asphalt pavement adjacent to the PCC.

a. Place the asphalt pavement side of the joint in a direction parallel to the joint.

b. Place the asphalt pavement side sufficiently high so that when fully compacted the asphalt pavement is greater than 1/8 inch but less than 1/4 inch higher than the PCC side of the joint.

c. Compact with steel wheel rollers and at least one rubber tire roller. Compact with a rubber tire roller that weights at least tons 20 tons with tires inflated to at least 90 psi. Avoid spalling the PCC during placement and compaction of the asphalt pavement.

Operate steel wheel rollers in a way that prevents spalling the PCC. Repair any damage to PCC edges or joints as directed by the Government Engineer. If damage to the PCC joint or panel edge exceeds a total of 3 feet, remove and replace the PCC panel at no additional expense to the Government.

d. NOTE: The Government Engineer will determine if diamond grinding will be required. If the joint meets the smoothness requirement specified below, and there are no complaints after two weeks of use, diamond grinding will not be required.

After compaction is finished, diamond grind a minimum width of 3 feet of the asphalt pavement so that the asphalt pavement side is less than 1/8 inch higher than the PCC side. Perform diamond grinding in accordance with subparagraph DIAMOND GRINDING above. The asphalt pavement immediately adjacent to the joint is not allowed to be lower than the PCC after the grinding operation. Transition the grinding into the asphalt pavement in a way that ensures good smoothness and provides drainage of water. The joint and adjacent materials when completed is required to meet all of the requirements for smoothness. Measure smoothness across the asphalt pavement-PCC joint using a 12 feet straightedge. The acceptable tolerance is 1/8 inch.

e. Consider the asphalt pavement next to the PCC as a separate lot for evaluation. Take four cores for each lot of material placed adjacent to the joint. The size of lot is 10 feet wide by the length of the joint being paved. Locate the center of each of the four cores 6 inches from the edge of the concrete. Take each core at a random location along the length of the joint. The requirements for joint density for this lot, adjacent to the PCC joint, are the same as those for the mat density.

f. All procedures, including repair of damaged PCC, are required to be in accordance with the approved Quality Control Plan.

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