Attachment_1_-__SOW_Repair_Taxiway_Alpha.pdf

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ECES/ECEC DATE Page 1 of 24

Project: ##-#### Project Name

STATEMENT OF WORK

PROJECT NUMBER 12-1026

30 October 2012

Ali Al Salem AB

USAF MILL & OVERLAY TAXIWAY ALPHA

386 ECES/CEC 30 OCT 2012 Page 2 of 24

Attachment 1 Repair Taxiway Alpha FA5703-13-R-0004

1. SECTION I – GENERAL REQUIREMENTS

1.1. GENERAL SCOPE OF WORK

1.1.1. The Contractor shall provide all engineering, supervision, labor, parts, equipment, tools, supplies and all incidentals required to perform pavement repair to 80,190 square feet of pavement on Taxiway Alpha and ALL associated site work and improvements necessary in accordance with this Scope of Work (SOW) on Ali Al Salem Airbase (ASAB) at the location(s) indicated by the Contracting Officer (CO) and Base Civil Engineer (BCE).

1.2. PERIOD OF PERFORMANCE

1.2.1. The Contractor shall follow the Period of Performance (PoP) which will be established by the Government. The CO will incorporate the agreed upon PoP in the terms and conditions of the contract. The Government reserves the right to negotiate an acceptable PoP. The

PoP for this project shall be no longer than 72 calendar days. If the contract is longer than the established PoP, unless determined not to be the contractors fault, the government will assess liquidated damages. Contractor shall provide any necessary evidence that pertains to reasons for not following the PoP.

1.3. DESIGNATION OF AUTHORITY AND GOVERNMENT REQUIREMENTS

1.3.1. The Base Civil Engineer (BCE) or his authorized representative is designated as the representative of the CO for the purpose of technical surveillance of the workmanship and inspection of materials for work being performed under this contract. This designation in no way authorizes anyone other than the CO to commit the Government to changes in the terms and conditions of the contract.

1.3.2. The U.S. Government will not provide materials, equipment or labor for demolition or construction unless specifically mentioned in the scope of work.

1.4. CONTRACTOR REQUIREMENTS

1.4.1. Qualifications: The Contractor awarded this project shall have a supervisor and/or foreman qualified, experienced and fluent in English in ALL project tasks required by this

SOW. The supervisor and/or foreman will be on site at all times to oversee and supervise qualified experienced technicians in all phases of work. The Contractor shall submit similar project and personnel qualifications in writing to the CO for review and approval. If more than one supervisor/foreman is required for various phases or if the supervisor/foreman is to be replaced, the Contractor shall provide the necessary documentation for EACH supervisor/foreman required. The BCE shall have the right to determine whether the proposed supervisor/foreman has sufficient technical and language capabilities and the

Contractor shall immediately replace any individual not deemed acceptable to the

Government.

Qualifications and experience of the design engineer, if applicable, will similarly need to be submitted prior to the commencement of the design. A degreed, licensed professional engineer is required to supervise and review all designs requiring structural, mechanical, 386 ECES/CEC 30 OCT 2012 Page 3 of 24 civil or electrical calculations, prior to submission to the CO. All calculations and final drawings must be signed and stamped by the professional engineer.

1.4.2. Contractor Base Access: The Contractor is responsible for ensuring proper documentation is received for personnel, vehicle, equipment, material and tool passes in time to avoid any delay in project start of performance. This includes personnel attainment of Kuwaiti

Ministry of Defense badges and proper advance notification to the EA for scheduling of escort support. Any additional time required for obtaining badges and passes as required for access to the base will not necessarily be grounds for additional time granted to complete the project, if passes are delayed due to the Contractor.

1.4.2.1 The Contractor shall anticipate working hours between 0700-1630 HRS Monday through Sunday, excluding Friday’s and Kuwaiti Holiday’s. With CO approval, working hours may vary on a day to day basis.

1.4.3. Pre-construction Meeting: The Contractor shall be required to meet with the CO, BCE, Airfield Manager, and other members as required prior to the commencement of any work in order to coordinate the project construction. Topics of discussion will include: Hours of work, lay-down and storage areas, work area limits, safety compliance, emergency and routine evacuation of the work area and any other topics deemed necessary by the CO or

BCE representative.

1.4.4. Site Measurements: The Contractor shall perform a physical survey of the actual site to verify locations of existing objects and buildings, as well as existing power cables, communication cables, water and sanitary sewer line conditions prior to the start of construction. Utilities that are shown in any attachments or plans are approximate locations; contractor shall verify conflict locations prior to construction. Also, the

Contractor shall submit a list of items that will need to be moved to accommodate the construction work to the BCE and CO for review.

1.4.5. Standard Material & Workmanship: All materials and supplies shall be new and standard products regularly used for commercial construction and of similar size, style and complexity in Kuwait. Workmanship shall be comparable to commercial construction performed in Kuwait and comply with standards contained in this SOW. The CO and BCE representative shall review materials and inspect work for compliance with these standards.

Low quality work will be rejected at the discretion of either the CO or BCE or both representatives.

1.4.6. Material & Equipment Storage: The Contractor shall stockpile and place materials and equipment only in areas specifically approved by the BCE. All materials stored on base are at the risk of the Contractor and not the responsibility of the Government.

1.4.7. Safety: The Contractor personnel shall work in a safe manner in accordance with

Government standards. Determination of what constitutes unsafe practices is at the discretion of Government personnel. Failure of the site supervisor to ensure Contractor personnel work safely and with the proper gear may require a stoppage of work and/or removal of the workers at no cost or delay charged to the Government. All Contractor personnel shall have appropriate clothing and Personal Protective Equipment (PPE) worn at all times. At a minimum, this includes wearing work pants and shirts, work boots and yellow or orange bright reflective safety vests. Loose fitting clothing and open toed shoes are not allowed on the work site. Additionally, some tasks require additional protection:

i.e., safety glasses, hearing protection, masks, etc. that shall be required for certain tasks.

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Safety harnesses shall be required for workers performing work two (2) meters or more above ground or floor level.

1.4.8. Accident Prevention: The Contractor shall comply with the following safety requirements while performing work under this contract:

1.4.8.1 Use diligent care not to damage the facility or government assets in the project area and Ali Al Salem Air Base (ASAB) while in performance of this contract.

Damage caused by Contractor negligence will be repaired to pre-existing condition and no additional cost to the Government.

1.4.8.2 Traffic Control Devices: The Contractor will be responsible for signaling, lighting and barricading the immediate work area as determined by the CO or

BCE.

1.4.8.3 All vehicles operated by the Contactor will obey all traffic signs and laws while operating on the compound.

1.4.8.4 Electrical extension cords may be used on a temporary basis to provide power to tools and equipment. Do not overload extension cords. Any frayed or spliced extension cords are prohibited.

1.4.8.5 Unexploded Ordinance: If any item is discovered that may be unexploded ordinance, immediately alert the Government escort. The Government escort will contact appropriate agencies.

1.4.8.6 Fire Prevention: The prevention of fire is imperative during construction projects.

The Contractor is responsible for enforcing fire safety in his work area. The

Contractor shall have serviceable fire extinguishers readily available at all times.

Extinguishers shall be supplied by the Contractor.

1.4.8.6.1. Smoking is prohibited inside buildings and within 15 meters (50 feet) of flammable and combustible liquids. Smoking is permitted only in designated areas.

1.4.8.6.2. The Contractor shall report all fires to the Government escort. Upon discovery of a fire, yell “Fire, Fire, Fire”, notify the Government escort and evacuate the area.

1.4.9. Environmental Protection: The Contractor shall comply with the following environmental requirements while performing work under this contract:

1.4.9.1 In the event the Contractor brings any hazardous material on to ASAB, the

Contractor shall notify 386 ECES/CEAV of the approximate quantities of the material to be used on the project and will supply a Material Safety Data Sheet

(MSDS) of those materials in English.

1.4.9.2 The Contractor shall be responsible for maintaining the work site to prevent the spread of contamination, provide for the safety of all individuals in the vicinity of the work site areas and prevent the release of any contaminants into the environment. Any tanks or drum containers used by the Contractor on ASAB to store hazardous materials including petroleum products will be stored within

386 ECES/CEC 30 OCT 2012 Page 5 of 24 secondary containment structures capable of holding a volume of 110% of the largest container.

1.4.9.3 The Contractor shall be responsible for the covering of open bodied vehicles transporting any material likely to create air pollution or become debris while on base.

1.4.9.4 All mud, dirt, debris, foreign objects, trash, or spills (including Sub-Contractors and suppliers) on a street or parking lot, used as access to the work site or staging area shall be cleaned off the same day or as soon as practicable or requested by the CO.

1.4.9.5 The Contractor shall immediately report to the CO to discuss any issues or incidents which may indicate potential imminent risk to Government personnel or the environment. Following the notification, the Contractor shall be available to the CO for instructions regarding remediation of the release. Contractor should be aware of “you spill, you dig” policies related to working on ASAB and be prepared to respond to a release caused by the Contractor’s personnel. To report a release or spill, contact the Government escort immediately.

1.4.9.6 To report a release or spill, contact the CO as soon as possible.

1.4.9.6.1.1.1. Report the following:

1.4.9.6.1.1.1.1. a. Your name, location, organization, and telephone number

1.4.9.6.1.1.1.2. b. Name and address of the party responsible for the incident

1.4.9.6.1.1.1.3. c. Date and time of the incident

1.4.9.6.1.1.1.4. d. Location of the incident

1.4.9.6.1.1.1.5. e. Source and cause of the release or spill

1.4.9.6.1.1.1.6. f. Types of material(s) released or spilled

1.4.9.6.1.1.1.7. g. Quantity of materials released or spilled

1.4.9.6.1.1.1.8. h. Danger or threat posed by the release or spill

1.4.9.6.1.1.1.9. I .Number and types of injuries (if any)

2. SECTION II – TECHNICAL REQUIREMENTS

2.1. PROJECT TASK LIST

2.1.1. The following is a list of the major tasks included in this SOW:

Section 2.2.1. Site Investigation

Section 2.2.2. Site Prep

Section 2.2.3. Mobilization

Section 2.2.4. Mill and Overlay AC Pavement

Section 2.2.5. Site Cleanup

2.2. EXPANDED DESCRIPTION OF PROJECT TASK LIST

2.2.1. Site Investigation: All dimensions within this scope of work and on any attachments are estimates. The Contractor shall field verify all measurements and configurations prior to the start of work. If the site is insufficient in any way, mitigation of these deficiencies shall be included in the Contractor’s proposal.

2.2.1.1 For all projects requiring excavation, the Contractor’s proposal shall acknowledge that the soil conditions on Ali Al Salem Air Base are primarily rock. The

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Contractor’s proposal shall include all necessary equipment, labor, and materials required to excavate through rock, remove surplus material and provide CO approved backfill material as directed.

2.2.1.2 Note: Contractor shall be responsible to perform core-drilled samples of the pavement areas to be repaired and confirm in writing that the proposed improvements may be performed as indicated. Depths of pavements shown on the drawings are assumed based upon available data and may not represent actual conditions. It is the responsibility of the Contractor to verify existing depths and condition of pavements in the area of work and notify the Contracting Officer and

Base Civil Engineer (BCE) representative of any discrepancies prior to commencement of any work. There may be geotextile fabric under the existing overlay at various points.

2.2.2. Site Prep:

2.2.2.1 Contractor shall be responsible for locating all existing utilities by test pit (hand digging) or pot-holing prior to the commencement of work within existing roadways.

2.2.2.2 Contractor shall perform a full site layout and staking by a licensed Professional

Land Surveyor and Licensed Professional Civil Engineer.

2.2.2.3 Contractor shall provide to the BCE a complete set of “Existing Conditions” Land

Survey Drawings the 2011 or newer editions of AutoCAD and PDF saved on either a CD or DVD disk.

2.2.2.4 Survey shall Include a topographic survey depicting minor contours at 30 cm (1 foot Contours) and major contours at 150 cm (5 foot Contours). Elevation points at 25’ grid will be required.

2.2.2.5 Survey shall include and identify all visible objects above ground, and all known, unknown, or detectible underground utilities.

2.2.2.6 All Drawings shall be to scale, and displayed in Universal Transverse Mercator

Zone 38 North (UTM Zone 38N, Kuwait), with World Geodetic System 1984

(WGS84) and the elevation should be height above ellipsoid (WGS84) and sea level (EGM96). If there has been gravitational surveys performed nearby, these shall be noted. A survey database file for all features should show both ellipsoid height and Geiod height and WGS84 as well as UTM coordinates. WGS84 data shall be corrected to WGS84 (G1150) datum reference. GPS benchmarks shall be documented at ITRF2000 coordinates referenced to epoch 1997. Basic project control surveys will be performed using precise differential carrier-phase tracking

Navstar GPS measurement procedures or electronic data collection total stations.

2.2.2.7 All of the control points established at the site shall be plotted at the correct coordinate point and shall be identified by name or number, and adjusted elevations.

2.2.2.8 This site survey will be coordinated with the Base Civil Engineer, and the

Contractor to develop Technical Details and drawings that meet the approval of the BCE.

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2.2.3. Mobilization: Contractor shall mobilize the required forces to perform the work and set up a staging area and stockpile area in coordination with the Contracting Officer and Airfield

Manager. Only locations approved by the CO and Airfield Manager shall be used for the storage of materials, equipment and debris. All materials and debris must be secured daily against winds and prop/jet wash while on the airfield.

2.2.3.1 A pre-construction meeting must be performed prior to the commencement of work on each phase with representatives of the Contractor, Airfield Management, Contracting Officer, Construction Inspector and 386 ECES Project Manager.

2.2.3.2 Lighted low profile barricades shall be installed for each phase as indicated on the

Safety Plan. Airfield Management shall be responsible for placing and replacing the low-profile barricades. The Contractor shall ensure that the barricades are maintained and in place at all times during the performance of the work.

2.2.4. Mill and Overlay AC Pavement:

2.2.4.1 Mill Ex. Pavement: Contractor shall mill the area indicated on the plans for the indicated phase. Contractor shall take care to mill to a depth not to exceed 2.0 inches or 51 mm on Taxiway Alpha, without damaging the existing pavement or base below. The mill shall remain level such that a 2” overlay will produce a level grade surface. Damage to the areas which might be milled more than 2” will be repaired at the Contractor’s expense. If the sub base must be built up to support new pavement the repair will be accomplished by the contractor. All repairs will be reported to the BCE before commencing. Milling will terminate before contact with the taxiway lighting system. Lights damaged by Contractor will be repaired at the Contractor’s expense.

2.2.4.2 Disposal of Millings: Contractor shall dispose of the millings either off base in accordance with local Host Nation (State of Kuwait) regulations and requirements for disposal of hazardous and/or waste materials or alternatively stockpile the millings at a location on base as directed by the Contracting Officer. Special care shall be taken so as to not leave debris including asphalt millings loose on the airfield which can damage aircraft or inhibit Airfield Operations.

2.2.4.3 Milling stockpile will not exceed 36” in height and remain in place no longer than

48 hrs.

2.2.4.4 Apply Tack Coat: Contractor shall apply a tack coat to all surfaces, horizontal and vertical, to which new AC paving will be placed. Tack coat shall be of a material approved by the BCE representative Project Manager and CO prior to placement. Contractor will be required to coordinate with the CO at least one week prior for a Force Protection “GACT” inspection at the loading site prior to transport of tack coat material on Ali Al Salem Airbase.

2.2.4.5 Place One (1) 2.0 inch or 51 mm lift of Asphalt Pavement: Contractor shall place one (1) 2.0 inch or 51 mm lift of hot mix asphalt concrete (AC) pavement over

Taxiway Alpha as shown on the drawings. The pavement shall meet the specifications included with this SOW for airfield asphalt pavement. Contractor shall place the lift over the entire area indicated at one time without additional seams to better ensure the integrity of the placed asphalt and reduce the potential for cracking or separation at joints. Contractor will be required to coordinate with

386 ECES/CEC 30 OCT 2012 Page 8 of 24 the CO at least one week prior for a Force Protection “GACT” inspection at the loading site prior to transport of hot mix asphalt material on Ali Al Salem

Airbase. At the discretion of the BCE representative Project Manager or

Construction Inspector, the Government may require 386 ECES personnel to be present at the batch plant and/or asphalt testing laboratory to observe batch mixing and testing required of the Contractor of the Hot Mix Asphalt (HMA) materials.

A minimum of 98% maximum density of the HMA shall be achieved by rolling and compacting of the placed asphalt lift. New asphalt pavement shall be precisely at grade with any adjacent pavement, smooth and free of any local depressions that could retain water puddles.

2.2.4.6 Restore Taxiway Striping: Contractor shall restore striping to pre-milling locations in each area with glass-bead reflective paint specifically approved for airfield striping. Contractor shall submit specifications for reflective taxiway paint specifically approved for airfield applications and a striping plan to the

Contracting Officer and Airfield Manager for approval prior to purchase.

Minimum standards based upon UFGS specifications, the UFCs and Air Force

ETL’s for airfield marking will be required. Specifications for airfield stripping are attached at the end of this document.

2.2.5. Site Cleanup: The Contractor shall be responsible for any cleanup and repair required to restore site to the preconstruction condition or any improved conditions called for in this

SOW. Additionally, the site must be clear of all debris at the end of each working day.

2.3. SUBMITTALS: All materials and articles requiring approval shall be submitted by the Contractor using the AF Form 3000. Any material used without or before Government approval is subject to removal, at no additional cost to the Government. The Contractor shall submit material samples, design drawings, and related calculations to the CO for approval a minimum of five (5) calendar days prior to procurement and placement of that particular material and construction respectively.

This is to preclude approval of a completed design package preceding any construction placement thereby completing delivery orders expeditiously. Upon review by the Government, the submittal along with any comments will be returned to the Contractor within five (5) calendar days. If required, the Contractor shall modify the submittal per Government’s comments and resubmit within five (5) calendar days. Upon final approval, the Contractor shall commence with the procurement and construction accordingly. The Contractor shall submit the following to the

Government for review and approval prior to performing the associated work:

2.3.1. AF Form 3064 or similar schedule (in calendar days) that includes minimal milestones detailing various stages of construction and phasing, lead time of new materials and installation. Weekly updates shall be provided to CO. The contractors schedule shall clearly state the proposed project start, substantial completion and final completion dates. If the contractor fails to meet the final completion date, liquidated damages shall be assessed according the contract documents and this SOW. Substantial completion is a date at which the work is sufficiently complete, in accordance with the contract documents and this SOW, so that the owner may use or occupy the work originally designed and intended for.

Substantial completion does not in any way exclude the contractor from finishing the remainder of the required work for final completion. This schedule must be submitted before any work begins

2.3.2. Contractor will provide a Taxiway striping plan to the Airfield Manager for review and approval before painting. The striping will not be limited to the overlay area exclusively

(see attached drawings).

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2.3.3. Notification of any Government property the Contractor plans to move or relocate. The

Government may elect to move these items in lieu of the Contractor.

2.3.4. Product Data Sheets. All products being submitted for approval shall include a technical data sheet. In the submittal it must be clear which product will be used if more than one product is shown on the page. Do NOT submit entire photocopied catalog unless every page is relevant to the product being considered. The Government may require physical material samples of some items at no additional cost to the Government.

2.3.5. Hot mix asphalt mix design proposed for the project. HMA design shall meet the minimum specifications provided with this SOW.

2.3.6. Specifications for proposed base course including a gradation curve or table of aggregate sizes to be used, type/source of soil and aggregates and relative percentages of each.

2.3.7. Specifications for tack coat material to be used.

2.3.8. List of equipment to be used on each phase of the project including concrete saw dimensions and maximum depth of cut achievable as well as other demolition and placement equipment to be used

2.3.9. A detailed statement of the technical approach to perform each task including methods of demolition, placement and transitions between phases.

2.3.10. The Contractor shall submit, before final payment, a complete set of As-Built and Land

Survey drawings including but not limited to: site layout and construction details, civil, mechanical, electrical and architectural drawings. The survey shall include spot elevations on 25’ grid of new pavement and shoulders. The Contractor shall provide these as-built drawings in the most recent editions of Auto CAD, Esri, & PDF saved on either a CD or

DVD disk. The Contractor shall include any operation and maintenance manuals and information for any material that requires further maintenance beyond the one (1) year warranty period.

2.4. MILESTONE INSPECTIONS

2.4.1. The Contractor shall abide by the following schedule of inspections by the BCE representative. The Contractor shall be responsible for notifying the CO when work is ready to be inspected at each milestone noted below. Also, the CO or BCE representative may inspect any work at any time. Inspections by the Government do not in any way absolve the Contractor from his obligation to provide materials and construction free from defects and in accordance with the required specifications.

2.4.1.1 Demolition, Milling, and Sub base repair – To be performed when any demolition, milling, and sub base work is to begin, during and after for each phase.

2.4.1.2 Tack Coat Application – To be performed before and after tack coat is applied

2.4.1.3 Asphalt Pavement: To be performed before and after each lift of asphalt. Also, a

Government inspector may request to be present at the batch plant and during any asphalt mix testing.

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2.4.1.4 Taxiway Marking

2.4.1.5 Pre-Final Inspection: To be performed when the Contractor has completed/installed all civil, electrical/HVAC/plumbing, etc. Any electrical outlets and switches shall NOT be mounted to the walls to allow inspection of wiring. Panels shall be left open for inspection and drop ceiling tiles shall NOT be installed for the pre-final inspection if they were moved during construction.

2.4.1.6 Final Inspection: To be performed after the Contractor has resolved all punchlist items identified during the pre-final inspection.

2.5. GRAVEL MATERIALS

2.5.1. Graded-Crushed Aggregate (GCA) Base Course: GCA shall consist of clean, sound, durable particles of crushed stone, crushed slag, crushed gravel, angular sand, or other approved material. GCA shall be free of silt and clay as defined by ASTM D 2487, organic matter, and other objectionable materials or coatings. The portion retained on the 4.75 mm sieve shall be known as coarse aggregate; that portion passing the 4.75 mm sieve shall be known as fine aggregate.

2.5.2. Coarse Aggregate: Shall be angular particles of uniform density. When the coarse aggregate is supplied from more than one source, aggregate from each source shall meet the specified requirements and shall be stockpiled separately.

2.5.3. Crushed Gravel: Crushed gravel shall be manufactured by crushing gravels, and shall meet all the requirements specified below.

2.5.4. Crushed Stone shall consist of freshly mined quarry rock, and shall meet all the requirements specified below.

2.5.5. GCA Coarse Aggregate shall not show more than 40 percent loss when subjected to the

Los Angeles abrasion test in accordance with ASTM C 131. GCA coarse aggregate shall 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 C 88. The amount of flat and elongated particles shall not exceed 20 percent for the fraction retained on the 12.5 mm sieve or 20 percent for the fraction passing the 12.5 mm 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 shall 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 midsection area of the piece. 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.

Crushed gravel shall be manufactured from gravel particles 90 percent of which by weight are retained on the maximum size sieve listed in the following table.

2.5.6. Fine Aggregate shall be angular particles of uniform density. When the fine aggregate is supplied from more than one source, aggregate from each source shall meet the specified requirements. GCA fine aggregate shall consist of angular particles produced by crushing stone, slag, or gravel that meets the requirements for wear and soundness specified for GCA coarse aggregate. Fine aggregate shall be produced by crushing only particles larger than

4.75 mm sieve in size. The fine aggregate shall contain at least 90 percent by weight of

386 ECES/CEC 30 OCT 2012 Page 11 of 24 particles having two or more freshly fractured faces in the portion passing the 4.75 mm sieve and retained on the 2 mm sieve, and in the portion passing the 2 mm sieve and retained on the 0.425 mm sieve.

2.5.7. GCA Gradation Requirements: The specified gradation requirements shall apply to the completed base course. The aggregates shall be continuously well graded within the limits specified in the contract using the following table for the specified material. Percentage by

Weight Passing Square-Mesh Sieve:

SIEVE SIZE

PERCENT PASSING BY WEIGHT

3-INCH 1 1/4-INCH 3/4-INCH

3-inch (75 mm) 90 – 100 -- --

1 1/2 inch (37.5 mm) 60 – 85 -- --

1 1/4 inch (31.5 mm) -- 95 – 100 --

1 inch (25 mm) -- -- 100

3/4 inch (19 mm) 40 – 65 70 – 93 95 – 100

3/8 inch (9.5 mm) -- 42 – 80 50 – 90

No. 4 (4.75 mm) 15 – 40 25 – 63 35 – 70

No. 10 (2.00 mm) 10 – 30 16 – 48 15 – 55

No. 40 (0.425 mm) 5 – 20 8 – 28 10 – 35

No. 200 (0.075 mm) 2.0 – 12.0 2.0 – 12.0 5.0 – 15.0

Note 1: Particles having diameters less than 0.02 mm shall not be in excess of 3 percent by weight of the total sample tested.

Note 2: The values are based on aggregates of uniform specific gravity. If materials from different sources are used for the coarse and fine aggregates, they shall be tested in accordance with ASTM C 127 and ASTM C 128 to determine their specific gravities. If the specific gravities vary by more than 10 percent, the percentages passing the various sieves shall be corrected as directed by the Contracting Officer.

2.5.7.1 Contractor shall provide a sample meeting the above specifications of the material for approval prior to any acceptable deliver and placement on the project site.

2.5.8. Contractor shall provide a material sample meeting the above specifications of the material for approval prior to any acceptable deliver and placement on the project site.

2.6. GATCH MATERIALS

2.6.1. This section describes furnishing processed or selected materials (GATCH) for backfilling or fill sections where the plans designate, as follows:

2.6.1.1 Material shall be free of lumps of rocks, clay, organic matter (weeds, wood, paper, etc), and other objectionable materials as. Unless otherwise allowed, the maximum particle size shall not exceed 25 mm.

2.6.1.2 Excavations for rock or other unstable materials.

2.6.1.3 Trenches for pipe culverts, storm sewers, sanitary sewers, underdrains, electrical lines, communication lines and similar structures.

2.6.1.4 Furnish natural sand or a mixture of sand with gravel, crushed gravel, crushed stone, or other broken or fragmented material.

386 ECES/CEC 30 OCT 2012 Page 12 of 24

2.6.1.5 For backfill for trench excavation, use a maximum size of any gravel, stone, or other broken or fragmented material so that 100 percent passes a 6-inch sieve, not less than 85 percent by weight passes a 3-inch sieve, and not less than 25 percent by weight passes a No. 4 sieve. For bedding under, around and 6-inches above a water, sanitary sewer, electrical or communication line, use granular backfill that consists substantially of sand with all particles retained on a one inch sieve removed. Use grade 1, unless the contract specifies otherwise.

2.6.1.6 Gradation for Grade 1 backfill:

2.6.1.7 Contractor shall provide a sample meeting the above specifications of the

GATCH for approval prior to any acceptable deliver and placement on the project site.

2.6.2. Before placing embankment materials, complete any required clearing and grubbing of the site and prepare the foundation as required for project, unless the contract specifies otherwise.

2.6.3. Construct an embankment starting at the lowest point of the fill, below the grade at the bottom of ravines. Construct the embankment in layers by spreading and leveling the material during placement. Spread individual layers evenly to uniform thickness throughout and approximately parallel with the finished grade for the full width of the embankment, unless directed otherwise. Place the material in layers generally no thicker than 200 millimeters (8 inches), to secure the required compaction. On side hills too steep to operate hauling equipment, over low wet ground, in marshes, or if filling in water, provide a single layer, just thick enough to support the hauling equipment while placing subsequent layers.

2.6.3.1 Deposit, spread, and level, as specified above, the embankment material in layers generally no thicker than 8 inches before compaction. Compact each layer of the embankment until the compaction equipment achieves no further significant consolidation. Provide the required compaction for each layer before placing any material for a succeeding layer.

2.6.3.2 Use specialized compaction equipment supplemented by routing, hauling, and leveling equipment over each layer of the fill to make use of the compaction capabilities of this equipment..

2.6.3.3 Specialized compaction equipment includes tamping rollers, pneumatic-tire rollers, vibratory rollers, or other alternate compaction equipment that produces the required results. Obtain the engineer’s approval before using alternate compaction equipment.

SIEVE SIZE

MAXIMUM PERCENT

PASSING BY WEIGHT

GRADE 1

1-inch (25 mm) 95 – 100

1/2 inch (12.5 mm) 85 – 90

No. 4 (4.75 mm) 45 – 85

No. 40 (0.425 mm) 5 – 30

No. 100 (0.150 mm) 0 – 10

386 ECES/CEC 30 OCT 2012 Page 13 of 24

2.6.3.4 For tamping rollers, use equipment that exerts at least 150 pounds per square inch of pressure on the tamping surface of each tamping foot in a transverse row.

2.6.3.5 Use pneumatic-tire rollers or other equipment that have a weight of not less than

150 pounds per linear inch of overall rolling width

2.7. ASPHALT MATERIALS (References: Unified Facilities Guide Specifications, Division 32 –

Exterior Improvements, Section 32 12 15 Hot-Mix Asphalt (HMA) for Airfields.)

2.7.1. General: 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. HMA designed and constructed in accordance with this section shall conform to the lines, grades, thicknesses, and typical cross sections shown on the drawings. Construct each course to the depth, section, or elevation required by the drawings and rolled, finished, and approved before the placement of the next course. Submit proposed Placement Plan, indicating lane widths, longitudinal joints, and transverse joints for each course or lift.

Contractor shall prepare an asphalt mix design for submittal.

2.7.2. Asphalt Mixing Plant: Plants used for the preparation of hot-mix asphalt shall conform to the requirements of AASHTO M 156 with the following changes:

2.7.2.1 Truck Scales. Weigh the asphalt mixture on approved scales furnished by the

Contractor, or on certified public scales at the Contractor's expense. Scales shall be inspected and certified at least annually by an approved calibration laboratory.

2.7.2.2 Testing Facilities. Provide laboratory facilities at the plant for the use of the

Government's Engineer's acceptance testing and the Contractor's quality control testing.

2.7.2.3 Inspection of Plant. The Contracting Officer Engineer or representative shall have access 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.

2.7.2.4 Storage Bins. The asphalt mixture may be stored in non-insulated storage bins for a period of time not exceeding three (3) hours. The asphalt mixture may be stored in insulated storage bins for a period of time not exceeding eight (8) hours. The mix drawn from bins shall meet the same requirements as mix loaded directly into trucks.

2.7.3. Hauling Equipment: Well maintained trucks used for hauling hot-mix asphalt shall have tight, clean, and smooth metal beds. To prevent the mixture from adhering to them, the truck beds shall be lightly coated with a minimum amount of paraffin oil, lime solution, or other approved material. Petroleum based products shall not be used as a release agent.

Each truck shall have a suitable cover to protect the mixture from adverse weather. When necessary to ensure that the mixture will be delivered to the site at the specified temperature, truck beds shall be insulated or heated and covers (tarps) shall be securely fastened.

2.7.4. Material Transfer Vehicle (MHV): Material transfer Vehicles shall be required due to the improvement in smoothness and decrease in both physical and thermal segregation. To

386 ECES/CEC 30 OCT 2012 Page 14 of 24 transfer the material from the hauling equipment to the paver, use a self-propelled, material transfer vehicle that can deliver material to the paver without making contact with the paver. The MTV shall be able 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. The Material Transfer Vehicle will have remixing and storage capability to prevent physical and thermal segregation.

2.7.5. Asphalt Pavers: Mechanical spreading and finishing equipment shall consist of a self-powered paver, capable of spreading and finishing the mixture to the specified line, grade, and cross section. The screed of the paver shall be 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. The screed will be equipped with a compaction device and it will be used during all placement.

2.7.6. Receiving Hopper: The paver shall have a receiving hopper of sufficient capacity to permit a uniform spreading operation. The hopper shall be equipped with a distribution system to place the mixture uniformly in front of the screed without segregation. The screed shall effectively produce a finished surface of the required evenness and texture without tearing, shoving, or gouging the mixture.

2.7.7. Automatic Grade Controls: If an automatic grade control device is used, the paver shall be equipped with a control system capable of automatically maintaining the specified screed elevation. The control system shall be automatically actuated from either a reference line and/or through a system of mechanical sensors or sensor-directed mechanisms or devices which will maintain the paver screed at a predetermined transverse slope and at the proper elevation to obtain the required surface. The transverse slope controller shall be capable of maintaining the screed at the desired slope within plus or minus 0.1 percent. A transverse slope controller shall not be used to control grade. The controls shall be capable of working in conjunction with any of the following attachments:

2.7.7.1 Ski-type device of not less than 9.14 meter (30 feet) in length

2.7.7.2 Taut string line set to grade.

2.7.7.3 Short ski or shoe for joint matching.

2.7.7.4 Laser control.

2.7.8. Rollers: Rollers shall be in good condition and shall be operated at slow speeds to avoid displacement of the asphalt mixture. The number, type, and weight of rollers shall be sufficient to compact the mixture to the required density while it is still in a workable condition. Equipment which causes excessive crushing of the aggregate shall not be used.

2.7.9. Smoothness Requirements: The finished surfaces of the pavement shall have no abrupt change of 3 mm (1/8 inch) or more, and all pavements shall be within a 6 mm (1/4 inch) tolerance in any direction when checked with an approved 4 meter (12 foot) straightedge.

2.7.10. Aggregates: Aggregates shall consist of crushed stone, crushed gravel, crushed slag, screenings, natural sand and mineral filler, as required. The portion of material retained on the 4.75 mm (No. 4) sieve is coarse aggregate. The portion of material passing the 4.75 mm

(No. 4) sieve and retained on the 0.075 mm (No. 200) sieve is fine aggregate. The portion passing the 0.075 mm (No. 200) sieve is defined as mineral filler. Submit sufficient materials to produce 90 kilogram (200 pound) of blended mixture for mix design verification. All aggregate test results and samples shall be submitted to the Contracting

Officer Engineer at least 14 days prior to start of construction. Aggregate testing shall have been performed within 90 days of performing the mix design.

386 ECES/CEC 30 OCT 2012 Page 15 of 24

2.7.11. Coarse Aggregate: Coarse aggregate shall consist 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. The coarse aggregate particles shall meet the following requirements:

2.7.11.1 The percentage of loss shall not be greater than 40 percent after 500 revolutions when tested in accordance with ASTM C 131.

2.7.11.2 The sodium sulfate soundness loss shall not exceed 12 percent, or the magnesium sulfate soundness loss shall not exceed 18 percent after five cycles when tested in accordance with ASTM C 88.

2.7.11.3 At least 75 percent by weight of coarse aggregate shall have at least two or more fractured faces when tested in accordance with COE CRD-C 171. Fractured faces shall be produced by crushing.

2.7.11.4 The particle shape shall be essentially cubical and the aggregate shall not contain more than 20 percent, by weight, of flat and elongated particles (3:1 ratio of maximum to minimum) when tested in accordance with ASTM D 4791.

2.7.11.5 Slag shall be air-cooled, blast furnace slag, and shall have a compacted weight of not less than 1200 kilogram/cubic meter (75 pound/cubic foot) when tested in accordance with ASTM C 29/C 29M.

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

2.7.12. Fine Aggregate: Fine aggregate shall consist of clean, sound, tough, durable particles. The aggregate particles shall be free from coatings of clay, silt, or objectionable material and shall contain no clay balls. The fine aggregate particles shall meet the following requirements:

2.7.12.1 The quantity of natural sand (non-crushed material) added to the aggregate blend shall not exceed 15 percent by weight of total aggregate.

2.7.12.2 The individual fine aggregate sources shall have a sand equivalent value greater than 45 when tested in accordance with ASTM D 2419.

2.7.12.3 The fine aggregate portion of the blended aggregate shall have an uncompacted void content greater than 45.0 percent when tested in accordance with ASTM C

1252 Method A.

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

2.7.13. Aggregate Gradation: The combined aggregate gradation shall conform to gradations specified in the following Table , when tested in accordance with ASTM C 136 and ASTM

C 117, and shall not vary from the low limit on one sieve to the high limit on the adjacent sieve or vice versa, but grade uniformly from coarse to fine. The JMF shall be within the specification limits; however, the gradation can exceed the limits when the allowable deviation from the JMF shown in the section 2.6.15. Contractor shall provide an asphalt mix design showing the following gradations as specified by the contract.

Gradation 1* Gradation 2*

Percent Passing Percent Passing

Sieve Size, mm by Mass by Mass

25.0 (1 inch) 100 ---

19.0 (3/4 inch) 76 - 96 100

12.5 (1/2 inch) 68 - 88 76 - 96

9.5 (3/8 inch) 60 - 82 69 - 89

4.75 (No.4) 45 - 67 53 - 73

386 ECES/CEC 30 OCT 2012 Page 16 of 24

2.36 (No.8) 32 - 54 38 - 60

1.18 (No.16) 22 - 44 26 - 48

0.60 (No.30) 15 - 35 18 - 38

0.30 (No.50) 9 - 25 11 - 27

0.15 (No.100) 6 - 18 6 - 18

0.75 (No.200) 3 - 6 3 - 6

*Use of gradation 1 must be limited to binder or intermediate courses. Gradation

2 is suitable for surface course.

2.7.14. Asphalt cement binder: Shall conform to AASHTO M 320 Performance Grade (PG) 70-

22. Test data indicating grade certification shall be provided by the supplier at the time of delivery of each load to the mix plant. Copies of these certifications shall be submitted to the Contracting Officer Engineer. The supplier is defined as the last source of any modification to the binder. The Contracting Officer Engineer may sample and test the binder at the mix plant at any time before or during mix production. Samples for this verification testing shall be obtained in accordance with ASTM D 140/D 140M and in the presence of the Contracting Officer Engineer. These samples shall be furnished to the

Contracting Officer Engineer for the verification testing, which shall be at no cost to the

Contractor. Submit sample information (data) of the asphalt cement specified for mix design verification and approval not less than 14 days before start of the test section.

2.7.15. Mix Design: Develop the mix design. The Job Mix formula (JMF)shall have been developed and aggregates tested no earlier than six (6) months before contract award. The asphalt mix shall be composed of a mixture of well-graded aggregate, mineral filler if required, and asphalt material. The aggregate fractions shall be sized, handled in separate size groups, and combined in such proportions that the resulting mixture meets the grading requirements contained hearwithin. No hot-mix asphalt for payment shall be produced until a JMF has been approved. The hot-mix asphalt shall be designed using the Superpave gyratory compactor set at [50] [75] gyrations. Samples shall be prepared at various asphalt contents and compacted in accordance with ASTM D 6925.] Laboratory compaction temperatures for Polymer Modified Asphalts shall be as recommended by the asphalt cement manufacturer. If the Tensile Strength ratio (TSR) of the composite mixture, as determined by ASTM D 4867/D 4867M is less than 75, the aggregates shall be rejected or the asphalt mixture treated with an anti-stripping agent. The amount of anti-stripping agent added shall be sufficient to produce a TSR of not less than 75. If an antistrip agent is required, it shall be provided at no additional cost to the Government. Sufficient materials to produce 90 kilogram (200 pound) of blended mixture shall be provided to the

Contracting Officer Engineer for verification of mix design at least 14 days prior to construction of test section.

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

2.7.16.1 Percent passing each sieve size.

2.7.16.2 Percent of asphalt cement.

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

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

2.7.16.5 [Number of blows of hammer per side of molded specimen.] [Number of

Superpave gyratory compactor gyrations.]

2.7.16.6 Laboratory mixing temperature.

2.7.16.7 Lab compaction temperature.

2.7.16.8 Temperature-viscosity relationship of the asphalt cement.

386 ECES/CEC 30 OCT 2012 Page 17 of 24

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

2.7.16.10 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-02.

Summary tabulation shall include individual specimen data for each specimen tested.

2.7.16.11 Specific gravity and absorption of each aggregate.

2.7.16.12 Percent natural sand.

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

2.7.16.14 Fine aggregate angularity.

2.7.16.15 Percent flat or elongated particles (in coarse aggregate).\

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

2.7.16.17 Antistrip agent (if required).

2.7.16.18 List of all modifiers.

2.7.17. Transporting: The hot-mix asphalt shall be transported using well maintained vehicles from the mixing plant to the site in clean, tight vehicles. Deliveries shall be scheduled so that placing and compacting of mixture is uniform with minimum stopping and starting of the paver. Adequate artificial lighting shall be provided for night placements. Hauling over freshly placed material will not be permitted until the material has been compacted as specified, and allowed to cool to 60 degrees C (140 degrees F).

2.7.18. Preparation of the Underlying Surface: Immediately before placing the hot mix asphalt, the underlying course shall be cleaned of dust and debris. A prime coat and tack coat shall be applied in accordance with the contract specifications.

2.7.19. Placing: The mix shall be placed in lifts of adequate thickness and compacted at a temperature suitable for obtaining density, surface smoothness, and other specified requirements. Upon arrival, the mixture shall be placed to the full width by an asphalt paver; it shall be struck off in a uniform layer of such depth that, when the work is completed, it shall have the required thickness and conform to the grade and contour indicated. Waste mixture shall not be broadcast onto the mat or recycled into the paver hopper. Collect waste mixture and dispose off site. The speed of the paver shall be regulated to eliminate pulling and tearing of the asphalt mat.