Attachment 2 Airfield Specifications (rev. 1).pdf

673 CIVIL ENGINEERING

SQUADRON

CES/CENM

STANDARD

SPECIFICATIONS

FOR

AIRFIELD CONSTRUCTION

A SUPPLEMENT TO THE 2020 SSRC

Edition

Contents

SECTION 106 DEFINITIONS AND TERMS

SECTION 302 AGGREGATE and/or GRADED-CRUSHED AGGREGATE BASE COURSE

SECTION 306 ASPHALT TREATED BASE COURSE

SECTION 308 CRUSHED ASPHALT BASE COURSE

SECTION 309 AGGREGATE DRAINAGE LAYER

SECTION 403 JOINT SEALING FILLER, BITUMINOUS PAVEMENT

SECTION 404 SEAL COAT AND BITUMINOUS SURFACE TREATMENT

SECTION 409 ASPHALT PAVING FOR AIRFIELDS

SECTION 502 CONCRETE PAVING FOR AIRFIELDS AND OTHER HEAVY DUTY PAVEMENTS

SECTION 504 RESEALING OF JOINTS IN RIGID PAVEMENT

SECTION 601 PAVEMENT GROOVING

SECTION 602 AIRCRAFT TIE-DOWN AND GROUNDING

SECTION 605 AIRFIELD MANHOLES AND INLETS

SECTION 612 JET BLAST DEFLECTOR

SECTION 643 TRAFFIC MAINTENANCE

SECTION 661 AIRFIELD LIGHTING AND VISUAL NAVIGATION AIDS

SECTION 670 TRAFFIC MARKINGS

Revision Date Type 1 2/22/2021 Addendum 1- Correct Set Issued

NOTE TO USERS

These Specifications are a supplement to the 2020 Standard Specifications for Road Construction, 2020 Edition (SSRC). Descriptions, scope of work, and materials in the SSRC will be the same for work and materials used in airfield construction unless otherwise amended here.

When using these Specifications for airfield work, replace references to “roadways” with “airfield”, “taxiway”, “runway”, etc. as appropriate.

Work items required for use on airfields, but which are not contained in this Supplement are located in, and will be paid for using, the Standard Specifications for Road Construction.

SECTION 106

DEFINITIONS AND TERMS

Add the following Subsections:

106-1.18 AIRFIELD WORK REQUIREMENTS AND RESTRICTIONS. The Contractor shall coordinate all airfield work thru the Project Manager to the Chief, Airfield Manager and the Airfield Manager at least 30 days in advance to plan the airfield work schedule. Notify the Airfield Manager again 10 days prior to starting work.

The Contractor will be required to immediately move his equipment and personnel a minimum of 500 feet from the edge of the runway or taxiway or parking apron at times of aircraft emergencies, ground movement of heavy cargo aircraft, or operational exercises. Such removals, when required, will be given on 5 minutes notice, usually by the control tower, and expedient action by the Contractor is required.

The Contractor shall be aware of the restricted areas on the airfield and shall not enter these areas unless approved by the Airfield Manager and Security Forces. Delay time should be expected for work in these areas.

The Contractor’s Superintendent and each work crew shall have a 2-way radio when working on the airfield to maintain radio contact with the control tower at all times. The frequency required shall be arranged with the Chief of Airfield Management.

“No closure” runway work shall be accomplished on the weekends from 1800 hours on Friday to 0600 hours on Monday, and on week nights from 1800 hours to 0600 hours, unless approved otherwise by the Government. This runway work typically involves spall repairs, concrete joint and crack resealing, and AC crack sealing. “No closure” means that take-offs and landings are occurring on the runway being worked on but on a limited basis.

The runway will remain open during “no closure” times for landings and takeoffs and the Contractor will be required to vacate described above. The Contractor should expect long delays in getting on the runways and several interruptions requiring vacating the runways. The Contractor shall coordinate all runway work with the Government as described above. The Chief of Airfield Management will attempt to provide a partial or complete closure of the runway or re-route air traffic to the other runway.

When aircraft are arriving or departing an active runway, the Contractor will be restricted from operations 1,000 feet beyond the threshold and 300 feet from the centerline of the active runway. Additionally, the Contractor shall have no equipment, workers or other obstacles that extend above a line that has a 1:35 slope along the longitudinal axis of the runway centerline and a 1:7 slope perpendicular to the runway centerline. The Contractor may return his equipment and/or workers to this restricted area upon clearance from the Elmendorf Ground Control after the aircraft has taxied and taken off or landed.

Excavate for trenches only when material is on hand and ready for placing. Immediately after material has been placed and work approved, trenches shall be backfilled and compacted as required by the Contract. During the work, all hazardous conditions shall be marked and lighted in accordance with these Specifications.

Any stockpile area within the airfield will require approval from the Government. Only approved clean fill, asphalt, and concrete shall be placed stored there.

106-1.19 SCHEDULE OF WORK ON AIRFIELD. Construction work hours on the airfield other than the runways shall be limited to Monday thru Saturday from 0600 to 2100 hours, excluding federal holidays, unless approved otherwise by the Government. However, the Contractor may have to schedule work on the airfield to conform to aircraft operating schedules which may differ from the above work hours.

The Contractor shall request permission from the Airfield Manager thru the Project Manager at least 72 hours in advance when the Contractor plans on working after 1800 hours on weekdays and on Saturdays and Sundays for accomplishing runway work or to work outside of permitted hours in other areas of the airfield.

Submit to the Government a schedule and work plan for airfield work. The work plan shall include: the location of the work; distances from the ends of runways, taxiways, buildings, and other structures as necessary; and dates and hours during which the work will be performed. Notify the Government of any changes prior to beginning each day's work.

The Government will attempt to schedule and route aircraft so as to permit the maximum amount of time for the Contractor's activities. However, in the event of an emergency, intense operational demands, adverse wind conditions and other such unforeseen difficulties, the Contractor shall discontinue operations at the specified work locations of the airfield.

It is estimated that approximately 50 flights per day between the hours of 0700 to 1600, and approximately 5 flights between 1600 to 0700 will occur.

The Contractor shall not perform any work within the airfield or surrounding roads (as defined by the Government) during the JBER Air Show. The work restriction begins at 1200 on Thursday and ends at 0600 on Monday. The Contractor will be notified as soon as possible after an established date is confirmed.

The Contractor may experience construction delays in accomplishing work on the airfield during military exercises. Some work areas will not be available to the Contractor during military exercises and some work areas during military exercises will be available to the Contractor only from 1800 to 0600 hours on weeknights and on weekends from 1800 hours on Friday to 0600 hours on Monday. The Contractor should plan on four 10-day to 14-day military exercises on the airfield between the months of May thru September. The Contractor will be notified as soon as possible after established dates are confirmed.

The Contractor may experience construction delays of up to 4 hours in performing work on the airfield during Military Distinguished Visitor (DV) Visits, Change of Command Ceremonies, and other Special Events. Some work areas will not be available to the Contractor during these events. The Contractor should plan for delays or shutdowns of four delays on the airfield between the months of May thru September. The Contractor will be notified as soon as possible after established dates are confirmed.

106-1.20 WORK IN LANDING AREAS. The Contractor shall place nothing upon the landing areas without authorization of the Airfield Manager.

Unless otherwise authorized by the Airfield Manager, the Contractor shall outline those landing areas hazardous to aircraft, with red flags by day, & with electric, battery-operated, low-intensity red flasher lights by night.

Each time before entering any landing area, additional permission must be obtained from the Elmendorf Ground Control, unless the landing area is marked as hazardous to aircraft in accordance with the preceding paragraph.

All vehicles which the Contractor operates in landing areas shall be identified by means of a flag on a staff attached to and flying above the vehicle. The flag shall be three feet square and shall consist of a checkered pattern of international orange and white squares of one foot on each side (except that the flag may vary up to 10 percent from each of these dimensions).

Unless otherwise authorized by the Airfield Manager, all other equipment and materials in the landing areas shall be marked with red flags by day, and with electric, battery-operated, low-intensity red flasher lights by night.

Work shall be carried on so as to leave that portion of the landing area which is available to aircraft free from hazards, holes, piles of material and projecting shoulders that might damage an airplane tire.

Add the following Section:

SECTION 302

AGGREGATE and/or GRADED-CRUSHED AGGREGATE BASE COURSE

302-1.01 DESCRIPTION. Construct a base layer under the pavements, as indicated on drawings, consisting of Aggregate Base Course (ABC) or Graded-Crushed Aggregate Base Course (GCA).

For the purpose of this Specification, ABC is defined as well graded, durable aggregate uniformly moistened and mechanically stabilized by compaction and having a California Bearing Ration (CBR) of 80.

Additionally, GCA is defined as well graded, crushed, durable aggregate uniformly moistened and mechanically stabilized by compaction and having a CBR of 100.

MATERIALS

302-2.01 AGGREGATES. Provide ABC and GCA consisting of clean, sound, durable particles of crushed stone, crushed gravel, angular sand, or other approved material. Provide ABC that is free of lumps of clay, organic matter, and other objectionable materials or coatings. Provide GCA that is free of silt and clay as defined by ASTM D2487, organic matter, and other objectionable materials or coatings.

The portion retained on the No. 4 sieve is known as coarse aggregate; that portion passing the No. 4 sieve is known as fine aggregate. When the coarse and fine aggregate is supplied form more than one source, provide aggregate from each source that meets the specified requirements.

302-2.02 COARSE AGGREGATE. Provide coarse aggregates with angular particles of uniform density.

Separately stockpile coarse aggregate supplied from more than one source.

Crushed Gravel: Provide crushed gravel that has been manufactured by crushing gravels and that meets all the requirements of this Subsection.

Crushed Stone: Provide crushed stone consisting of freshly mined quarry rock, meeting all the requirements of this Subsection.

1. Aggregate Base Course. The percentage of loss of ABC coarse aggregate must not exceed 50 percent when tested in accordance with ASTM C131. Provide aggregate that contains no more than 30 percent flat and elongated particles. A flat particle is one having a ratio of width to thickness greater than 3; an elongated particle is one having a ratio of length to width greater than 3. In the portion retained on each sieve specified, the crushed aggregates must contain at least 50 percent by weight of crushed pieces having three or more freshly fractured faces determined in accordance with ASTM D5821. When two fractures are contiguous, the angle between planes of the fractures must be at least 30 degrees in order to count as two fractured faces. Manufacture crushed gravel from gravel particles 50 percent of which, by weight, are retained on the maximum size sieve listed in Table 302.1.

2. Graded-Crushed Aggregate Base Course. The percentage of loss of GCA coarse aggregate must not exceed 40 percent loss when tested in accordance with ASTM C131. Provide GCA coarse aggregate that does not exhibit a loss greater than 18 percent weighted average, at five cycles, when tested for soundness in magnesium sulfate, or 12 percent weighted average, at five cycles, when tested in sodium sulfate in accordance with ASTM C88. Provide aggregate that contains no more than 20 percent flat and elongated particles for the fraction retained on the 1/2 inch sieve nor 20 percent for the fraction passing the 1/2 inch sieve. A flat particle is one having a ratio of width to thickness greater than 3; an elongated particle is one having a ratio of length to width greater than 3. In the portion retained on each sieve specified, the crushed aggregate must contain at least 90 percent by weight of crushed pieces having three or more freshly fractured faces determined in accordance with ASTM D5821. When two fractures are contiguous, the angle between planes of the fractures must be at least 30 degrees in order to count as two fractured faces. Manufacture crushed gravel from gravel particles 90 percent of which by weight are retained on the maximum size sieve listed in Table 302.1.

302-2.03 FINE AGGREGATE. Provide GCA fine aggregate consisting of angular particles produced by crushing stone, slag, or gravel that meets the requirements for wear and soundness specified for GCA coarse aggregate.

Produce fine aggregate by crushing only particles larger than No.4 sieve in size. Provide fine aggregate that contains at least 90 percent by weight of particles having two or more freshly fractured faces in the portion passing the No. 4 sieve and retained on the No. 10 sieve, and in the portion passing the No. 10 sieve and retained on the No. 40 sieve.

302-2.04 GRADATION REQUIREMENTS. Apply the specified gradation requirements to the completed base course. Provide aggregates that are continuously well graded within the limits specified in Table 302-1. Use sieves that conform to ASTM E11.

Table 302-1 Gradation of Aggregates.

Sieve Designation No. 1 No. 2 No. 3

2 inch 100 - - 1-1/2 inch 70-100 100 -

1 inch 45-80 60-100 100 ½ inch 30-60 30-65 40-70 No. 4 20-50 20-50 20-50 No. 10 15-40 15-40 15-40 No. 40 5-25 5-25 5-25 No. 200 0-6 0-6 0-6

Particles having diameters less than 0.02 mm must not be in excess of 3 percent by weight of the total sample tested as determined in accordance with AASHTO T 88.

The above values are based on aggregates of uniform specific gravity. If materials from different sources are used for the coarse and fine aggregates, test the materials in accordance with ASTM C127 and ASTM C128 to determine their specific gravities. Correct the percentages passing the various sieves as directed by the Government if the specific gravities vary by more than 10 percent.

302-2.05 LIQUID LIMIT AND PLASTICITY INDEX. Apply liquid limit and plasticity index requirements to the completed course and to any component that is blended to meet the required gradation. The portion of any component or of the completed course passing the No. 40 sieve must be either nonplastic or have a liquid limit not greater than 25 and a plasticity index not greater than 5.

302-2.06 INITIAL MATERIAL ACCEPTANCE. Provide the Government with the results from each of the following tests, on the proposed material prior to commencing construction, to demonstrate that the proposed material meets all specified requirements when furnished. Complete this testing for each source if materials from more than one source are proposed.

1. Sieve Analysis including 0.02 mm material.

2. Liquid limit and plasticity index.

3. Moisture-density relationship.

4. Wear.

5. Soundness.

6. CBR.

Submit certified copies of test results for approval not less than 30 days before material is required for the work.

Tentative approval of material will be based on initial test results.

CONSTRUCTION

302-3.01 GENERAL REQUIREMENTS. When the ABC or GCA is constructed in more than one layer, clean the previously constructed layer of loose and foreign matter by sweeping with power sweepers or power brooms, except that hand brooms may be used in areas where power cleaning is not practicable. Provide adequate drainage during the entire period of construction to prevent water from collecting or standing on the working area.

302-3.02 STOCKPILING MATERIAL. Clear and level storage sites prior to stockpiling of material. Stockpile all materials, including approved material available from excavation and grading, in the manner and at the locations designated. Stockpile aggregates on the cleared and leveled areas designated by the Government to prevent segregation. Stockpile materials obtained from different sources separately.

302-3.03 PREPARATION OF UNDERLYING COURSE OR SUBGRADE. Clean the underlying course or subgrade of all foreign substances prior to constructing the base course(s). Do not construct base course(s) on underlying course or subgrade that is frozen. Construct the surface of the underlying course or subgrade to meet specified compaction and surface tolerances. Correct ruts or soft yielding spots in the underlying courses, areas having inadequate compaction, and deviations of the surface from the specified requirements set forth herein by loosening and removing soft or unsatisfactory material and adding approved material, reshaping to line and grade, and recompacting to specified density requirements. For cohesionless underlying courses or subgrades containing sands or gravels, as defined in ASTM D2487, stabilize the surface prior to placement of the base course(s). Stabilize by mixing ABC or GCA into the underlying course and compacting by approved methods.

Consider the stabilized material as part of the underlying course and meet all requirements of the underlying course. Do not allow traffic or other operations to disturb the finished underlying course and maintain in a satisfactory condition until the base course is placed.

302-3.04 GRADE CONTROL. Provide a finished and completed base course conforming to the lines, grades, and cross sections shown. Place line and grade stakes as necessary for control.

302-3.05 MIXING AND PLACING MATERIALS. Mix the coarse and fine aggregates in a stationary plant. Make adjustments in mixing procedures or in equipment, as directed, to obtain true grades, to minimize segregation or degradation, to obtain the required water content, and to ensure a satisfactory base course meeting all requirements of this Subsection. Place the mixed material on the prepared subgrade or subbase in layers of uniform thickness with an approved spreader. Place the layers so that when compacted they will be true to the grades or levels required with the least possible surface disturbance. Where the base course is placed in more than one layer, clean the previously constructed layers of loose and foreign matter by sweeping with power sweepers, power brooms, or hand brooms, as directed.

Make adjustments in placing procedures or equipment as may be directed by the Government to obtain true grades, to minimize segregation and degradation, to adjust the water content, and to ensure an acceptable base course.

302-3-06 LAYER THICKNESS. Compact the completed base course to the thickness indicated. No individual layer may be thicker than 6 inches nor be thinner than 3 inches in compacted thickness. Compact the base course(s) to a total thickness that is within 1/2 inch of the thickness indicated. Where the measured thickness is more than 1/2 inch deficient, correct such areas by scarifying, adding new material of proper gradation, reblading, and recompacting as directed. Where the measured thickness is more than 1/2 inch thicker than indicated, the course will be considered as conforming to the specified thickness requirements. The average job thickness will be the average of all thickness measurements taken for the job and must be within 1/4 inch of the thickness indicated. Measure the total thickness of the base course at intervals of one measurement for each 500 square yards of base course. Measure total thickness using 3 inch diameter test holes penetrating the base course.

302-3.07 COMPACTION. Compact each layer of the base course, as specified, with approved compaction equipment. Maintain water content during the compaction procedure to within plus or minus 2 percent of the optimum water content determined from laboratory tests.

Begin rolling at the outside edge of the surface and proceed to the center, overlapping on successive trips at least one-half the width of the roller. Slightly vary the length of alternate trips of the roller. Adjust speed of the roller as needed so that displacement of the aggregate does not occur. Compact mixture with hand-operated power tampers in all places not accessible to the rollers. Continue compaction until each layer is compacted through the full depth to at least 100 percent of laboratory maximum density. Make such adjustments in compacting or finishing procedures as may be directed by the Government to obtain true grades, to minimize segregation and degradation, to reduce or increase water content, and to ensure a satisfactory base course.

Remove any materials found to be unsatisfactory and replace with satisfactory material or rework, as directed, to meet the requirements of this Specification.

302-3.08 PROOF ROLLING. In addition to the compaction specified, proof roll the top of each layer of base course of primary taxiways and the center 75 feet of runways with 30 coverages. Proof roll top of completed subbase course on center 40 feet of taxiways that are not Type A (primary) traffic. Apply 4 coverages to all other paved areas, exclusive of runway overrun and blast protection areas.

Use a heavy pneumatic-tired roller having four or more tires abreast, each tire loaded to a minimum of 30,000 pounds and inflated to a minimum of 125 psi. A coverage is defined as the application of one tire print over the designated area. In the areas designated, apply proof rolling to the top of the underlying material on which the base course is laid and to the top of each layer of the completed base course. Maintain water content of the underlying material and each layer of the base course as specified in Subsection 302-3.07 from start of compaction to completion of proof rolling of that layer. Remove any base course materials or any underlying materials that produce unsatisfactory results by proof rolling and replace with satisfactory materials. Then recompact and proof roll to meet these specifications.

302-3.09 EDGES OF BASE COURSE. Place the base course(s) so that the completed section will be a minimum of 2 feet wider, on all sides, than the next layer that will be placed above it. Place approved material along the outer edges of the base course in sufficient quantity to compact to the thickness of the course being constructed. When the course is being constructed in two or more layers, simultaneously roll and compact at least a 2 foot width of this shoulder material with the rolling and compacting of each layer of the base course, as directed.

302-3.10 FINISHING. Finish the surface of the top layer of base course after final compaction and proof rolling by cutting any overbuild to grade and rolling with a steel-wheeled roller. Do not add thin layers of material to the top layer of base course to meet grade. If the elevation of the top layer of base course is 1/2 inch or more below grade, scarify the top layer to a depth of at least 3 inches and blend new material in and compact and proof roll to bring to grade. Make adjustments to rolling and finishing procedures as directed by the Government to minimize segregation and degradation, obtain grades, maintain moisture content, and ensure an acceptable base course. Should the surface become rough, corrugated, uneven in texture, or traffic marked prior to completion, scarify the unsatisfactory portion and rework and recompact it or replace as directed.

Construct the top layer so that the surface shows no deviations in excess of 3/8 inch when tested with a 12 foot straightedge. Take measurements in successive positions parallel to the centerline of the area to be paved. Also take measurements perpendicular to the centerline at 50 foot intervals. Correct deviations exceeding this amount by removing material and replacing with new material, or by reworking existing material and compacting it to meet these specifications.

Maintain the base course in a satisfactory condition until the full pavement section is completed and accepted.

Immediately repair any defects and repeat repairs as often as necessary to keep the area intact. Retest any base course that was not paved over prior to the onset of winter to verify that it still complies with the requirements of this specification. Rework or replace any area of base course that is damaged as necessary to comply with this Subsection.

302-4.01 CONTRACTOR’S QUALITY CONTROL. At a minimum, perform each of the following tests on samples taken from the placed and compacted ABC and GCA. Provide the Government with copies of test results within 24 hours of test completion. Take samples and test at the rates indicated.

1. Perform density tests on every lift of material placed and at a frequency of one set of tests for every 250 square yards, or portion thereof, of completed area.

2. Perform sieve analysis including 0.02 mm size material on every lift of material placed and at a frequency of one sieve analysis for every 500 square yards, or portion thereof, of material placed.

3. Perform liquid limit and plasticity index tests at the same frequency as the sieve analysis.

4. Measure the thickness of the base course at intervals providing at least one measurement for each 500 square yards of base course or part thereof. Measure the thickness using test holes, at least 3 inch in diameter through the base course.

The above tests are separate from tests that the Government may choose to perform using Section 685.

Final approval of the materials will be based on Contractor and/or Section 685 tests for gradation, liquid limit, and plasticity index performed on samples taken from the completed and fully compacted course(s).

302-5.01 METHOD OF MEASUREMENT. Section 109 by the ton. The tonnage of ABC and GCA material will be the number of tons of aggregate, placed and accepted in the completed course as determined by the Government. Deductions will be made for any material wasted, unused, rejected, or used for convenience of the Contractor, and for water exceeding specified amount at time of weighing.

Submit copies of scale tickets during progress of the work in accordance with Section 109.

302-6.01 BASIS OF PAYMENT. Quantities of ABC and GCA, determined as specified above, will be paid for at the respective contract unit prices, which will constitute full compensation for the construction and completion of the ABC and GCA.

Payment will be made under:

Pay Item Pay Unit 302(1) Graded Crushed-Aggregate Base Course Ton 302(2) Aggregate Base Course Ton

SECTION 306

ASPHALT TREATED BASE COURSE

306-6.01 BASIS OF PAYMENT. Add the following Pay Item:

306(2) Asphalt Treated Base (ATB) Course for Airfields Ton

SECTION 308

CRUSHED ASPHALT BASE COURSE

308-5.01 BASIS OF PAYMENT. Add the following Pay Items:

308(3) Crushed Asphalt Base Course for Airfields Cubic Yard 308(4) CSS-1 Asphalt for Base Course on Airfields Ton

SECTION 309

AGGREGATE DRAINAGE LAYER

309-1.01 DESCRIPTION. Construct a drainage layer under the pavements, as indicated on drawings, consisting of Rapid Draining Material (RDM) or Open Graded Material (OGM) stabilized with cement or bituminous material.

309-2.01 MATERIALS. Asphalt or cement stabilized material will require Government notification and approval in accordance with this Section.

309-2.02 AGGREGATE. If a JBER gravel extraction site is not used, select the aggregate source at least 60 days prior to field use in the test section. Tentative approval of the source will be based on certified test results to verify that materials proposed for use meet the contract requirements. Final approval of both the source and the material will be based on test section performance and tests for gradation, soundness, wear, flat and/or elongated particles tests and fractured faces tests. For aggregate drainage layer materials, perform these tests on samples taken from the completed and compacted drainage layer course within the test section. For bituminous or cement stabilized drainage layer material, perform these tests on aggregate samples taken prior to addition of bituminous or cementitious material and subsequent placement in the test section.

Provide aggregates consisting of clean, sound, hard, durable, angular particles of crushed stone, crushed slag, or crushed gravel which meet the specification requirements. Slag must be an air-cooled, blast-furnace product having a dry weight of not less than 65 pcf determined by ASTM C29. Provide aggregates free of silt and clay as defined by ASTM D2487, vegetable matter, and other objectionable materials or coatings.

Provide aggregate with a soundness loss not greater than 18 percent weighted averaged at 5 cycles when tested in magnesium sulfate in accordance with ASTM C88 and a percentage of loss on abrasion not exceeding 40after 500 revolutions as determined by ASTM C131. Determine the percentage of flat and/or elongated particles by ASTM D4791 with the following modifications:

1) Separate the aggregates into two size fractions, particles greater than 1/2 inch sieve and particles passing the 1/2 inch sieve and retained on the No. 4 sieve.

2) The percentage of flat and/or elongated particles in either fraction must not exceed 20.

3) A flat particle is one having a ratio of width to thickness greater than 3; an elongated particle is one having a ratio of length to width greater than 3.

4) When the aggregate is supplied from more than one source, aggregate from each source must meet the specified requirements.

When the aggregate is supplied from crushed gravel it must be manufactured from gravel particles, 90 percent of which by weight are retained on the maximum-size sieve listed in Table 1. In the portion retained on each sieve specified, the crushed gravel must contain at least 90 percent by weight of crushed pieces having two or more freshly fractured faces with the area of each face being at least equal to 75 percent of the smallest midsectional area of the face. When two fractures are contiguous, the angle between planes of the fractures must be at least 30 degrees in order to count as two fractured faces.

Provide drainage layer aggregates that are well graded within the limits specified in Table 1.

Table 1 – Gradation of Drainage Layer Material – Percent by Weight Passing Sieve Designation Rapid Draining Material (RDM) Open Grated Material (OGM)

1-1/2 inch 100 100 1 inch 70-100 95-100 ¾ inch 55-100 - ½ inch 40-80 25-80 3/8 inch 30-65 -

No. 4 10-50 0-10 No. 8 0-25 0-5

No. 16 0-5 -

The values are based on aggregates of uniform specific gravity, and the percentages passing the various sieves may require appropriate correction by the Government when aggregates of varying specific gravities are used.

For RDM, the coefficient of uniformity (CU) must be greater than 3.5. (CU = D60/D10). The Contractor is responsible for adjusting the RDM gradation within the ranges listed in Table 1 to provide a stable construction surface for the proposed equipment and method of transporting materials. The drainage layer may be stabilized with Portland cement or asphalt at no additional cost to the government, if approved during the test section.

Asphalt cement or Portland cement is required to stabilize the OGM.

309-2.03 BITUMINOUS MATERIAL. Asphalt cement to be mixed with aggregates must conform to Performance Grade 52-28. In addition, the asphalt cement must show a negative spot when subjected to the spot test in accordance with AASHTO T 102, using the standard naphtha specified.

Submit bituminous or cementitious sources and certified material test results for approval not less than 60 days prior to field use in the test section.

309-2.04 CEMENTITIOUS MATERIAL. Portland cement to be mixed with aggregates must conform to ASTM C150 Type I, IA, II or IIA.

309-2.05 BITUMINOUS OR CEMENT STABILIZED JOB-MIX FORMULA. The bituminous stabilized mix consists of a mixture of OGM and a minimum of 2 percent asphalt cement by weight. Maintain tolerances for bituminous stabilized material for field production at plus or minus 0.25 percent for asphalt cement and plus or minus 25 degrees F for mixing temperatures. Provide cement stabilized mix consisting of OGM and a minimum of 200 pounds of Portland cement per cubic yard with a water/cement ratio of 0.37. Based on the test section performance, the Contractor will be responsible for adjustments (increases) in asphalt cement or Portland cement quantities to ensure the stabilized drainage layer will not rut or be disturbed by the Contractor's proposed paving method. Submit a job-mix formula (JMF) with the test section report for Government approval.

309-3.01 SAMPLING AND TESTING. Sampling and testing are the responsibility of the Contractor. Perform sampling and testing using a laboratory approved in accordance with these Specifications. Test the materials to establish compliance with the specified requirements and perform testing at the specified frequency. The Government may specify the time and location of the tests. Furnish copies of test results to the Government within 24 hours of completion of the tests.

Take aggregate samples in accordance with ASTM D75. Take bituminous samples in accordance with ASTM D140. Take bituminous or cement stabilized mixture samples using methods approved by the Government.

At a minimum, the Contractor shall perform the following tests:

1. Sieve Analysis. Perform sieve analyses in accordance with ASTM C117 and ASTM C136 using sieves conforming to ASTM E11.

2. Field Density Tests. Perform field density tests for RDM drainage layers in accordance with ASTM

D6938 by Direct Transmission Method for the full depth of the lift, use ASTM D6938 to determine the moisture content of the aggregate drainage layer material. Check the calibration curves furnished with the moisture gauges along with density calibration checks as described in ASTM D6938. Make the calibration checks of both the density and moisture gauges using the prepared containers of material method, as described in paragraph "Calibration" of ASTM D6938, on each different type of material being tested at the beginning of a job and at intervals as directed by the Government. Submit copies of field test results within 24 hours after the tests are performed.

3. Soundness Test. Perform soundness tests in accordance with ASTM C88.

4. Wear Test. Perform wear tests in conformance with ASTM C131.

5. Flat or Elongated Particles Test. Perform flat and/or elongated particles tests in accordance with ASTM D4791.

6. Fractured Faces Test. When aggregates are supplied from crushed gravel, use approved test methods to ensure the aggregate meets the requirements for fractured faces.

7. Bitumen Content. Perform bitumen extraction tests in accordance with ASTM D2172 or ignition tests in accordance with ASTM D6307.

309-3.02 INITIAL TESTS. Perform one of each of the following tests (309-3.01.1, 3, 4, 5, 6) on the proposed material, prior to commencing construction, to demonstrate that the proposed material meets all specified requirements when furnished. If the material source changes during the life of the Task Order, perform the tests again on the material from the new source. Submit material sources and material test results prior to field use.

309-3.03 IN-PLACE TESTS.

1. Aggregate Layer. Perform field density and moisture content tests at a rate of at least one test for every 2,000 square yards of completed area and not less than one test for each day's production.

Perform sieve analyses at a rate of at least one test for every 6,000 square yards of completed area.

Perform soundness tests, wear tests, fractured faces tests and flat and/or elongated particles tests at the rate of one test for every 12,000 square yards of production.

2. Stabilized Layer. Perform sieve analyses on aggregates prior to addition of asphalt or Portland cement, at a rate of at least one test for every 6,000 square yards of completed area and not less than one test for each days production. Make extraction tests on bituminous stabilized material at the same frequency.

Perform soundness tests, Los Angeles abrasion tests, fractured faces tests, and flat and/or elongated particles tests at the rate of one test for every 12,000 square yards of production.

309-4.01 SURFACE PREPARATION. Clean the underlying course of all foreign materials prior to constructing the drainage layer. Do not construct the drainage layer on underlying course that is frozen. Construct the underlying course in accordance with the Specifications and Drawings. Correct ruts or soft yielding spots in the underlying courses having inadequate compaction and deviations of the surface from the requirements set forth herein by loosening and removing soft or unsatisfactory material and by adding approved material, reshaping to line, and grade, and recompacting to specified density. Do not allow traffic or other operations to disturb the finished underlying course and maintain in a satisfactory condition until the drainage layer is placed.

309-4.02 TRANSPORTING MATERIAL. Transport aggregate drainage layer material to the site in a manner which prevents segregation and contamination of materials.

Transport bituminous stabilized material from the mixing plant to the site in trucks having tight, clean, smooth beds lightly coated with an approved releasing agent to prevent adhesion of the stabilized material to the truck beds. Drain excessive releasing agent prior to loading. Cover each load with canvas or other approved material of ample size to protect the stabilized material from the weather and to prevent loss of heat. Loads that have crusts of cold, unworkable material or have become wet will be rejected. Hauling over freshly placed material will not be permitted.

Transport cement stabilized material from the mixing plant to the site in trucks equipped with protective covers.

Loads that have crusts of unworkable material or have become excessively wet will be rejected. Hauling over freshly placed material will not be permitted.

309-4.03 PLACEMENT. Place drainage layer material when the atmospheric temperature is above 35 degrees F. Correct areas of completed drainage layer or underlying courses that are damaged by freezing, rainfall, or other weather conditions or by contamination from sediments, dust, dirt, or foreign material to meet specified requirements.

Place drainage layer material on the underlying course in lifts of uniform thickness using equipment meeting the requirements listed below. When a compacted layer 6 inches or less in thickness is required, place the material in a single lift. When a compacted layer in excess of 6 inches is required, place the material in lifts of equal thickness. No lift may be thicker than 6 inches nor be thinner than 3 inches in compacted thickness. Place and compact lifts true to the grades or levels required with the least possible surface disturbance. Where the drainage layer is placed in more than one lift, clean the previously constructed lift of loose and foreign material.

Make adjustments in placing procedures or equipment as needed to obtain true grades and minimize segregation and degradation of the drainage layer material.

1. Placement Equipment. Use an asphalt paving machine to place drainage layer material. Alternate methods may be used if it can be demonstrated in the test section that these methods obtain the specified results.

2. Compaction Equipment. Use a dual or single smooth 2000 lb (min.) vibratory drum roller, which provides a maximum compactive effort without crushing the drainage layer aggregate, to compact drainage layer material.

3. Bituminous Mixing Plant. Use a bituminous mixing plant that is an automatic or semiautomatic controlled, commercially manufactured unit capable of producing a bituminous stabilized aggregate mixture consistent with the job-mix formula (JMF).

4. Cementitious Mixing Plant. Use a cementitious mixing plant that is an automatic or semiautomatic controlled, commercially manufactured unit capable of producing a cement stabilized aggregate mixture consistent with the approved job mix formula. Dry mix aggregate and cement sufficiently to prevent cement balls from forming when water is added.

Bituminous stabilized material having temperatures less than 175 degrees F when dumped into the asphalt paving machine will be rejected. Adjust the paving machine so that the surface of the lift being laid will be smooth and continuous without tears and pulls. Correct irregularities in alignment of the lift left by the paving machine by trimming directly behind the machine. Immediately after trimming, thoroughly compact the edges of the lift by a method approved by the Government. Distortion of the lift during tamping will not be permitted. If more than one lift is required, offset the longitudinal joint in one lift over that in the lift immediately below by at least 1 foot;

however, construct the joint in the top layer at the centerline of the pavement. Offset transverse joints in one layer by at least 2 feet from transverse joints in the previous layer. Offset transverse joints in adjacent strips by a minimum of 10 feet. At the end of each day's construction, form a straight transverse construction joint by cutting back into the completed work to form a true vertical face free of loose or shattered material. Remove material along construction joints not properly compacted.

Place drainage layer material when the atmospheric temperature is above 35 degrees F. Correct areas of completed drainage layer or underlying courses that are damaged by freezing, rainfall, or other weather conditions or by contamination from sediments, dust, dirt, or foreign material to meet specified requirements.

309-4.04 PLACING ADJACENT STABILIZED STRIPS. Place the stabilized material in consecutive adjacent strips having a minimum width of 10 feet, except where edge lanes require strips less than 10 feet to complete the area. When placing adjacent strips, operate the paving machine so that the screed overlaps the previously placed strip 3 to 4 inches and is sufficiently high so that compaction will produce a smooth, dense joint. Push back the stabilized material placed on the edge of the previously placed strip by the paver to the edge of the strip being placed. Remove and waste excess stabilized material.

309-4.05 HAND SPREADING. Spread by hand drainage layer material in areas where machine spreading is impractical. Spread the material uniformly in a loose layer to prevent segregation. Construct the layer so that the compacted material conforms to the required grade and thickness after compaction.

309-5.01 TEST SECTION. Construct a test section to evaluate the ability to carry traffic, including placement of overlaying material and the constructability of the drainage layer including required mixing, placement, and compaction procedures. Test section data will be used by the Government to validate the required number of compaction passes given in this Section and the field dry density requirements for full scale production.

One test section will be required each year regardless of the number of drainage layers contained in the Task Orders for that year. Construct the test section a minimum of 30 days prior to the start of full scale production of the first drainage layer contained in the Task Order for that year to provide sufficient time for an evaluation of the proposed materials, equipment and procedures including Government QA testing.

Provide certified test results, approved by the Government prior to the start of the test section, to verify that the materials proposed for use in the test section meet the Contract requirements.

Place the test section inside the production paving limits. Do not construct the drainage layer in the test section until the underlying courses and subgrade preparation, required for the pavement section, have been completed, inspected and approved. Place the test section a minimum of 100 feet long and two full paving lanes wide side by side.

Perform mixing, placement, and compaction using equipment described in this Section. Operate compaction equipment at speeds no greater than 1.5 mph. Start compaction from the outside edges of the paving lane and proceed to the centerline of the lift being placed. Keep the roller a minimum of one half the roller width from the outside edge of the drainage layer being placed until the desired density is obtained. Then roll the outside edge.

309-5.02 RDM AGGREGATE DRAINAGE LAYER TESTS. Construct the test section with aggregate in a wet state so as to establish a correlation between number of roller passes and dry density achievable during field production. Designate three separate areas within the test section, test each area for density, moisture, and gradation. Complete all testing in the middle third of the test section being placed. Conduct density and moisture content tests in accordance with ASTM D6938. Conduct sieve analysis tests on samples, taken adjacent to the density test locations. Take one set of tests (i.e. density, moisture, and sieve analysis) before the third compaction pass and after each subsequent compaction pass at three separate locations as directed by the Government. Define a pass as the movement of a roller over the drainage layer area for one direction only.

Compact the RDM using a maximum of 5 passes in the vibrating state and one final pass in the static state.

Continue compaction passes and density readings until the difference between the average dry densities of any two consecutive passes is less than or equal to 1.0 pcf.

309-5.03 BITUMINOUS/CEMENT STABILIZED DRAINAGE LAYER. Construct the test section with the same equipment used for production. Designate three separate areas within the test section for sampling. Complete all testing in the middle third of the test section being placed. The Government will perform visual examination of each sample to determine if and when crushing of aggregate occurs. Take one sample before compaction and after each subsequent compaction pass at three separate locations as directed by the Government. Continue compaction for a maximum of 6 passes. A pass is defined as the movement of a roller over the drainage layer area for one direction only. Use placement procedures and equipment as described herein. The Contractor shall determine the number of passes required for compaction from the test section.

309-5.04 EVALUATION. Within 10 days of completion of the test section, submit to the Government a Test Section Construction Report complete with all required test data, correlations, and recommendations. The Report shall include an evaluation of the data, validate the required number of passes of the roller, the need for a final static pass of the roller, and the dry density for field density control during construction.

309-6.01 COMPACTION. Base field compaction requirements on the results of the test section, using the materials, methods, and equipment proposed for use in the work.

Perform compaction using rollers meeting the requirements of this Section and operating at a rolling speed of no greater than 1.5 miles per hour. Compact each lift of drainage material, including shoulders when specified under the shoulders, with the number of passes of the roller as follows: for RDM material use 4 passes in the vibratory state and one in the static. For cement or Bituminous stabilized OGM material use 3 passes in the vibratory state and one in the static state. The Government will validate the number of roller passes after the test section is evaluated and before production starts.

Maintain a minimum field dry density as specified by testing. If the required field dry density is not obtained, adjust the number of roller passes in accordance with this Section. Compact aggregate in a moisture state as determined in the test section. Avoid crushing of aggregate particles by excessive rolling. Begin compaction of bituminous stabilized material immediately when the material has cooled to 170 degrees F. Not more than 30 minutes may elapse between the start of moist mixing of cement stabilized material and the start of field compaction. Complete field compaction within 60 minutes. In all places not accessible to the rollers, compact the drainage layer material with mechanical hand operated tampers.

Place shoulder material along the edges of the drainage layer course in a quantity that will compact to the thickness of the layer being constructed. Roll and compact at least a 3 feet width of the shoulder simultaneously with the rolling and compacting of each lift of the drainage layer.

Compact the drainage layer to a thickness that is within 1/2 inch of the thickness indicated. Measure thickness at intervals providing at least one measurement for each 500 square yards of drainage layer. Make measurements in test holes at least 3 inches in diameter unless the Contractor can demonstrate, for Government approval, that a steel rod pushed through the drainage layer clearly stops at the material interface. Where the measured thickness is more than 1/2 inch deficient, correct such areas in accordance with this Section. Where the measured thickness is 1/2 inch more than indicated, it will be considered as conforming to the requirements provided the surface of the drainage layer is within 1/2 inch of established grade. The average job thickness will be the average of all job measurements as specified above but within 1/4 inch of the thickness shown on the drawings.

309-7.01 FINISHING. Finish the top surface of the drainage layer after final compaction, as determined from the test section.