50 25 00 HotMix.pdf

Lower Rio Grande Flood Control Project – Interior Floodways Rehabilitation of North Floodway (North and South Levees) and Arroyo Colorado Floodway (North Levee) Hidalgo and Cameron Counties, Texas

HOT MIX ASPHALT CONCRETE PAVEMENT

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SPECIFICATION 50 25 00

This specification includes requirements for the construction of hot mix asphalt concrete pavement within the work area, and includes the following:

1.0 General

2.0 Materials & Equipment

3.0 Construction Methods

4.0 Measurement and Payment

PART 1 - GENERAL

1.1 RELATED DOCUMENTS, CONTRACT CLAUSES, & SPECIFICATIONS

The following may not include all related documents, contract clauses, & technical specifications, and does not relieve the Contractor of the responsibility of performing work associated with this specification in accordance with all terms of the Contract herein.

A. Related documents: As described in paragraph 1.2 of SPECIFICATION 01 01 00.

B. Contract: Section I, 52.236-21“Specifications and Drawings for Construction”

C. Technical Specifications:

• SPECIFICATION 50 22 00, “Asphalt Antistripping Agents”

• SPECIFICATION 50 23 00, “Equipment for Asphalt Concrete Pavement”

• SPECIFICATION 50 24 00, “Asphalt, Oils, And Emulsions”

D. References:

• Texas Department of Transportation Testing Standard (Tex)-406-A Material Finer Than 75 mm (No. 200) Sieve in Mineral Aggregates (Decantation Test For Concrete Aggregates), August 1999

• Tex-408-A Organic Impurities in Fine Aggregate for Concrete, August 1999

• Tex-460-A Determining Crushed Face Particle Count, August 1999

• Tex-530-C Effect of Water on Bituminous Paving Mixtures, August 2008

• Tex-100-E Surveying and Sampling Soils for Highways, August 1999

• Tex-106-E Calculating the Plasticity Index of Soils, August 1999

• Tex-107-E Determining the Bar Linear Shrinkage of Soils, August 1999

• Tex-200-F Sieve Analysis of Fine and Coarse Aggregates, August 2008

• Tex-207-F Determining Density of Compacted Bituminous Mixtures, April 2008

• Tex-227-F Theoretical Maximum Specific Gravity of Bituminous Mixtures, April 2008

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• Tex-236-F Determining Asphalt Content from Asphalt Paving Mixtures by the Ignition Method, May 2009

• Tex-280-F Determining Flat and Elongated Particles, February 2005

• Tex-914-K Calibrating Motorized Gyratory-Shear Molding Asphalt Press, August

• Texas Department of Transportation (TxDOT) Bituminous Rated Source Quality Catalog (BRSQC)

1.2 GENERAL

In general, the Contractor shall construct a pavement layer composed of a compacted, dense-graded mixture of aggregate and asphalt binder mixed hot in a mixing plant.

PART 2 – MATERIALS & EQUIPMENT

2.1 MATERIALS

The Contractor shall furnish uncontaminated materials of uniform quality that meet the requirements of the plans and specifications. Notify the Government of all material sources. Notify the Government before changing any material source or formulation. When the Contractor makes a source or formulation change, the Government will verify that the requirements of this Specification are met and may require a new laboratory mixture design, trial batch, or both. The Government may sample and test project materials at any time during the project to verify compliance.

A. Aggregate. Furnish aggregates from sources that conform to the requirements shown in Table 1, and as specified in this Specification, unless otherwise shown on the plans. Provide aggregate stockpiles that meet the definition in this Section for either coarse aggregate or fine aggregate.

When reclaimed asphalt pavement (RAP) is allowed by plan note, provide RAP stockpiles in accordance with this Specification. Aggregate from RAP is not required to meet Table 1 requirements unless otherwise shown on the plans. Supply mechanically crushed gravel or stone aggregates that meet the definitions in Tex-100-E. The Government will designate the plant or the quarry as the sampling location. Samples must be from materials produced for the project.

The Government will establish the surface aggregate classification (SAC) and perform Los Angeles abrasion, magnesium sulfate soundness, and Micro-Deval tests. Perform all other aggregate quality tests listed in Table 1. Document all test results on the mixture design report.

The Government may perform tests on independent or split samples to verify Contractor test results. Stockpile aggregates for each source and type separately. Determine aggregate gradations for mixture design and production testing based on the washed sieve analysis given in Tex-200-F, Part II. Do not add material to a compliance-confirmed stockpile from sources that do not meet the aggregate quality requirements of TxDOT’s BRSQC unless otherwise compliance-confirmed.

(1) Coarse Aggregate. Coarse aggregate stockpiles must have no more than twenty percent

(20%) material passing the No. 8 sieve. Provide aggregates from sources listed in the BRSQC. Provide aggregate from non-listed sources only when tested by the Government

USIBWC Contract No.: IBM09B0004 Page 50.25.00 - 3 and compliance-confirmed before use. Allow thirty (30) calendar days for the Government to sample, test, and report results for non-listed sources. Provide coarse aggregate with at least the minimum SAC shown on the plans. SAC requirements apply only to aggregates used on the surface of travel lanes, unless otherwise shown on the plans. The SAC for sources on TxDOT’s AQMP is listed in the BRSQC. Class B aggregate meeting all other requirements in Table 1 may be blended with a Class A aggregate in order to meet requirements for Class A materials. When blending Class A and B aggregates to meet a Class A requirement, ensure that at least fifty percent (50%) by weight of the material retained on the No. 4 sieve comes from the Class A aggregate source. Blend by volume if the bulk specific gravities of the Class A and B aggregates differ by more than 0.300. When blending, do not use Class C or D aggregates. For blending purposes, coarse aggregate from RAP will be considered as Class B aggregate.

(2) RAP. RAP is salvaged, milled, pulverized, broken, or crushed asphalt pavement. Crush or break RAP so that one hundred percent (100%) of the particles pass the two (2) inch sieve. When RAP is used, determine asphalt content and gradation for mixture design purposes. Perform other tests on RAP when shown on the plans. When RAP is allowed by plan note, use no more than thirty percent (30%) RAP in Type A or B mixtures unless otherwise shown on the plans. For all other mixtures, use no more than twenty percent (20%) RAP unless otherwise shown on the plans. Do not use RAP contaminated with dirt or other objectionable materials. Do not use the RAP if the decantation value exceeds five percent (5%) and the plasticity index is greater than 8. Test the stockpiled RAP for decantation in accordance with the laboratory method given in Tex-406-A, Part I. Determine the plasticity index using Tex-106-E if the decantation value exceeds five percent (5%). The decantation and plasticity index requirements do not apply to RAP samples with asphalt removed by extraction.

(3) Fine Aggregate. Fine aggregates consist of manufactured sands, screenings, and field sands. Fine aggregate stockpiles must meet the gradation requirements in Table 2.

Supply fine aggregates that are free from organic impurities. The Government may test the fine aggregate in accordance with Tex-408-A to verify the material is free from organic impurities. At most fifteen percent (15%) of the total aggregate may be field sand or other uncrushed fine aggregate. With the exception of field sand, use fine aggregate from coarse aggregate sources that meet the requirements shown in Table 1, unless otherwise compliance-confirmed. If ten percent (10%) or more of the stockpile is retained on the No. 4 sieve, test the stockpile and verify that it meets the requirements in Table 1 for coarse aggregate angularity (Tex-460-A) and flat and elongated particles (Tex-280-F).

B. Mineral Filler. Mineral filler consists of finely divided mineral matter such as agricultural lime, crusher fines, hydrated lime, cement, or fly ash. Mineral filler is allowed unless otherwise shown on the plans. Do not use more than two percent (2%) hydrated lime or cement, unless otherwise shown on the plans. The plans may require or disallow specific mineral fillers. When used, provide mineral filler that:

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(1) is sufficiently dry, free-flowing, and free from clumps and foreign matter;

(2) does not exceed 3% linear shrinkage when tested in accordance with Tex-107-E; and

(3) meets the gradation requirements in Table 3.

Table 1 Aggregate Quality Requirements

Property Test Method Requirement Coarse Aggregate SAC AQMP As shown on plans

Deleterious material, %, max Tex-217-F, Part I 1.5

Decantation, %, max Tex-217-F, Part II 1.5

Micro-Deval abrasion, %, max

Tex-461-A Note 1

Los Angeles abrasion, %, max

Tex-410-A 40

Magnesium sulfate soundness, 5 cycles, %, max

Tex-411-A 30

Coarse aggregate angularity, 2 crushed faces, %, min

Tex 460-A, Part I 852

Flat and elongated particles @ 5:1, %, max

Tex-280-F 10

Fine Aggregate Linear shrinkage, %, max

Tex-107-E 3

Combined Aggregate3 Sand equivalent, %, min Tex-203-F 45

1. Not used for acceptance purposes. Used by the COR as an indicator of the need for further investigation.

2. Only applies to crushed gravel.

3. Aggregates, without mineral filler, RAP, or additives, combined as used in the job-mix formula (JMF).

Table 2

Gradation Requirements for Fine Aggregate Sieve Size

% Passing by Weight or Volume

3/8" 100 #8 70–100

#200 0–30

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Table 3 Gradation Requirements for Mineral Filler

Sieve Size

% Passing by Weight or Volume

#8 100 #200 55–100

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

D. Asphalt Binder. Furnish the type and grade of performance-graded (PG) asphalt binder specified on the plans in accordance with SPECIFICATION 50 24 00, “Asphalt, Oils, and Emulsions.”

E. Tack Coat. Unless otherwise shown on the plans or compliance-confirmed, furnish CSS-1H, SS-

1H, or a PG binder with a minimum high-temperature grade of PG 58 for tack coat binder in accordance with SPECIFICATION 50 24 00, “Asphalt, Oils, and Emulsions.” Do not dilute emulsified asphalts at the terminal, in the field, or at any other location before use. If required, verify that emulsified asphalt proposed for use meets the minimum residual asphalt percentage specified in SPECIFICATION 50 24 00, “Asphalt, Oils, and Emulsions.” The Government will obtain at least 1 sample of the tack coat binder per project and test it to verify compliance with SPECIFICATION 50 24 00, “Asphalt, Oils, and Emulsions.” The Government will obtain the sample from the asphalt distributor immediately before use.

F. Additives. When shown on the plans, use the type and rate of additive specified. Other additives that facilitate mixing or improve the quality of the mixture may be allowed when compliance-confirmed. If lime or a liquid antistripping agent is used, add in accordance with SPECIFICATION 50 22 00, “Asphalt Antistripping Agents.” Do not add lime directly into the mixing drum of any plant where lime is removed through the exhaust stream unless the plant has a baghouse or dust collection system that reintroduces the lime back into the drum.

2.2 EQUIPMENT

The Contractor shall provide required or necessary equipment in accordance with SPECIFICATION 50 23 00, “Equipment for Asphalt Concrete Pavement.”

PART 3 – CONSTRUCTION METHODS

Design, produce, store, transport, place, and compact the specified paving mixture in accordance with the requirements of this Item. Unless otherwise shown on the plans, provide the mix design. The Government will perform quality assurance testing. The Contractor shall provide quality control testing as needed to meet the requirements of this Specification.

3.1 MIXTURE DESIGN

A. Design Requirements. Unless otherwise shown on the plans, use the typical weight design example given in Tex-204-F, Part I, to design a mixture meeting the requirements listed in Tables

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1 through 6. Use a compliance-confirmed laboratory to perform the Hamburg Wheel test and provide results with the mixture design. The Contractor shall submit mixture design and test results to the COR. The Contractor may submit a new mixture design at anytime during the project. The Contractor shall submit the mixture design to the COR for compliance confirmation prior to beginning production. The Contractor shall not begin production until mixture has been compliance-confirmed and shall re-submit mixture design if required. The Contractor shall provide the Government with a mixture design report. Include the following items in the report:

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

(2) results of all applicable tests;

(3) the mixing and molding temperatures;

(4) the signature of the engineer who performed the design;

(5) the date the mixture design was performed; and

(6) a unique identification number for the mixture design.

B. Job-Mix Formula Compliance-Confirmation. The job-mix formula (JMF) is the combined aggregate gradation and target asphalt percentage used to establish target values for mixture production. JMF is the original laboratory mixture design used to produce the trial batch. The Government and the Contractor will verify JMF based on plant-produced mixture from the trial batch unless otherwise compliance-confirmed. If the JMF is not verified by the Government from the trial batch, adjust the JMF or redesign the mix and produce as many trial batches as necessary to verify the JMF. Provide the Government with split samples of the mixtures and blank samples used to determine the ignition oven correction factors. The aggregate and asphalt correction factors will be determined from the ignition oven using Tex-236-F. A Texas gyratory compactor calibrated in accordance with Tex-914-K will be used in molding production samples. The Contractor will perform Tex-530-C and retain the tested sample for comparison purposes during production. The Government may waive the requirement for the boil test.

C. JMF Field Adjustments. Produce a mixture of uniform composition closely conforming to the compliance-confirmed JMF. If, during initial days of production, the Contractor or Government determines that adjustments to the JMF are necessary to achieve the specified requirements, or to more nearly match the aggregate production, the Government may allow adjustment of the JMF within the tolerances of Table 7 without a laboratory redesign of the mixture. The Government will adjust the asphalt content to maintain desirable laboratory density near the optimum value while achieving other mix requirements.

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Table 4 Master Gradation Bands (% Passing by Weight or Volume) and Volumetric Properties

Table 5 Laboratory Mixture Design Properties Property Test Method Requirement

Target laboratory-molded density, % Tex-207-F 96.01 Tensile strength (dry), psi (molded to 93% ±1% density) Tex-226-F 85–2002

Boil test3 Tex-530-C –

1Unless otherwise shown on the plans.

2May exceed 200 psi when compliance-confirmed and may be waived when compliance-confirmed.

3Used to establish baseline for comparison to production results. May be waived when compliance-confirmed.

Table 6 Hamburg Wheel Test Requirements

High-Temperature Binder Grade

Minimum # of Passes2 @ 0.5" Rut Depth, Tested @ 122°F

PG 64 or lower 10,000

PG 70 15,000

PG 76 or higher 20,000

1Tested in accordance with Tex-242-F.

2May be decreased or waived when shown on the plans.

Sieve Size A

Coarse Base

B Fine Base

C Coarse Surface

D Fine

Surface

F Fine

Mixture 1-1/2" 98.0–100.0 – – – –

1" 78.0–94.0 98.0–100.0 – – – 3/4" 64.0–85.0 84.0–98.0 95.0–100.0 – – 1/2" 50.0–70.0 – – 98.0–100.0 – 3/8" – 60.0–80.0 70.0–85.0 85.0–100.0 98.0–100.0 #4 30.0–50.0 40.0–60.0 43.0–63.0 50.0–70.0 80.0–86.0 #8 22.0–36.0 29.0–43.0 32.0–44.0 35.0–46.0 38.0–48.0 #30 8.0–23.0 13.0–28.0 14.0–28.0 15.0–29.0 12.0–27.0 #50 3.0–19.0 6.0–20.0 7.0–21.0 7.0–20.0 6.0–19.0 #200 2.0–7.0 2.0–7.0 2.0–7.0 2.0–7.0 2.0–7.0

Design Voids in Mineral Aggregates (VMA), % Minimum

– 12.0 13.0 14.0 15.0 16.0 Plant-Produced VMA, % Minimum

– 11.0 12.0 13.0 14.0 15.0

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Table 7 Operational Tolerances

Description Test Method Allowable

Difference from JMF Target

Individual % retained for #8 sieve and larger ±5.01 Individual % retained for sieves smaller than #8 and larger than #200

Tex-200-F or Tex-236-F ±3.01

% passing the #200 sieve ±2.01 Asphalt content, % Tex-236-F ±0.31 Laboratory-molded density, % Tex-207-F ±1.0 VMA, %, min Note 2

1When within these tolerances, mixture production gradations may fall outside the master grading limits; however, the percent passing the #200 sieve will be considered out of tolerance when outside the master grading limits.

2Test and verify that Table 4 requirements are met.

D. Production Operations. Perform a new trial batch when the plant or plant location is changed.

The COR may suspend production for noncompliance with this Item. Take corrective action and obtain compliance-confirmation to proceed after any production suspension for noncompliance.

(1) Operational Tolerances. During production, do not exceed the operational tolerances in

Table 7. Stop production if testing indicates tolerances are exceeded on:

(a) Three (3) consecutive tests on any individual sieve,

(b) Four (4) consecutive tests on any of the sieves, or

(c) Two (2) consecutive tests on asphalt content.

Begin production only when test results or other information indicate, to the satisfaction of the Government, that the next mixture produced will be within Table 7 tolerances.

(2) Storage and Heating of Materials. Do not heat the asphalt binder above the temperatures specified in SPECIFICATION 50 24 00, “Asphalts, Oils, and Emulsions” or outside the manufacturer’s recommended values. On a daily basis, provide the Government with the records of asphalt binder and hot-mix asphalt discharge temperatures in accordance with SPECIFICATION 50 23 00, “Equipment for Asphalt Concrete Pavement.” Unless otherwise compliance-confirmed, do not store mixture for a period long enough to affect the quality of the mixture, nor in any case longer than twelve (12) hours.

(3) Mixing and Discharge of Materials. Notify the Government of the target discharge temperature and produce the mixture within 25°F of the target. Monitor the temperature of the material in the truck before shipping to ensure that it does not exceed 350°F. The Government will not pay for or allow placement of any mixture produced at more than 350°F. Control the mixing time and temperature so that substantially all moisture is removed from the mixture before discharging from the plant.

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E. Hauling Operations. Before use, clean all truck beds to ensure mixture is not contaminated.

When a release agent is necessary to coat truck beds, use a release agent on the compliance-confirmed list maintained by TxDOT.

F. Placement Operations. Prepare the surface by removing raised pavement markers and objectionable material such as moisture, dirt, sand, leaves, and other loose impediments from the surface before placing mixture. Remove vegetation from pavement edges. Place the mixture to meet the typical section requirements and produce a smooth, finished surface with a uniform appearance and texture. Offset longitudinal joints of successive courses of hot mix by at least 6

in. Place mixture so longitudinal joints on the surface course coincide with lane lines. Ensure that all finished surfaces will drain properly. Place mixture within the compacted lift thickness shown in Table 8, unless otherwise shown on the plans or allowed.

Table 8

Compacted Lift Thickness and Required Core Height Compacted Lift Thickness

Mixture Type Minimum (in.)

Maximum (in.)

A 3.00 6.00 B 2.50 5.00 C 2.00 4.00 D 1.50 3.00 F 1.25 2.50

(1) Weather Conditions. Place mixture when the roadway surface temperature is 60°F or higher unless otherwise compliance-confirmed. Measure the roadway surface temperature with a handheld infrared thermometer. Unless otherwise shown on the plans, place mixtures only when weather conditions and moisture conditions of the roadway surface are suitable in the opinion of the Government.

(2) Tack Coat. Clean the surface before placing the tack coat. Unless otherwise compliance-confirmed, apply tack coat uniformly. The Government will set the rate between four-hundredths (0.04) and one-tenth (0.10) gallon of residual asphalt per square yard of surface area. Apply a thin, uniform tack coat to all contact surfaces of curbs, structures, and all joints. Prevent splattering of tack coat when placed adjacent to curb, gutter, and structures.

Roll the tack coat with a pneumatic-tire roller. Tex-243-F may be used to verify that the tack coat has adequate adhesive properties. The Government may suspend paving operations until there is adequate adhesion.

G. Lay-Down Operations.

(1) Minimum Mixture Placement Temperatures. Use Table 9 for minimum mixture placement temperatures.

(2) Windrow Operations. When hot mix is placed in windrows, operate windrow pickup equipment so that substantially all the mixture deposited on the roadbed is picked up and loaded into the paver.

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Table 9 Suggested Minimum Mixture Placement Temperature

High-Temperature Binder Grade

Minimum Placement Temperature (Before

Entering Paver) PG 64 or lower 260°F

PG 70 270°F

PG 76 280°F

PG 82 or higher 290°F

H. Compaction. Use air void control unless ordinary compaction control is specified on the plans.

Avoid displacement of the mixture. If displacement occurs, correct to the satisfaction of the Government. Ensure pavement is fully compacted before allowing rollers to stand on the pavement. Use only water or a compliance-confirmed release agent on rollers, tamps, and other compaction equipment. Keep diesel, gasoline, oil, grease, and other foreign matter off the mixture. Operate vibratory rollers in static mode when not compacting, when changing directions, or when the plan depth of the pavement mat is less than one and one-half (1 ½ ) inch.

Use tamps to thoroughly compact the edges of the pavement along curbs, headers, and similar structures and in locations that will not allow thorough compaction with the rollers. The Government may require rolling with a trench roller on widened areas, in trenches, and in other limited areas. Allow the compacted pavement to cool to 160°F or lower before opening to traffic.

Sprinkle the finished mat with water or limewater to expedite opening the roadway to traffic.

(1) Air Void Control. Compact dense-graded hot-mix asphalt to contain from five percent

(5%) to nine percent (9%) in-place air voids. Do not increase the asphalt content of the mixture to reduce pavement air voids.

(a) Rollers. Furnish the type, size, and number or rollers required for compaction, as compliance-confirmed. Use a pneumatic-tire roller to seal the surface, unless otherwise shown on the plans. Use additional rollers as required to remove any roller marks.

(b) Air Void Determination. Unless otherwise shown on the plans, obtain two (2) roadway specimens at each location selected by the Government for in-place air void determination. Air voids will be measured in accordance with Tex-207-F and Tex- 227-F. Before drying to a constant weight, cores may be pre-dried using a Corelok or similar vacuum device to remove excess moisture. The average air void content of the two (2) cores will be used to calculate the in-place air voids at the selected location.

(c) Air Voids Out of Range. If the in-place air void content in the compacted mixture is below five percent (5%) or greater than nine percent (9%), change the production and placement operations to bring the in-place air void content within requirements. The Government may suspend production until the in-place air void content is brought to the required level, and may require a test section as described in “Test Section” below. The COR may request additional air void determination specimens and if shown to be out-of-range, the COR may require the Contractor to remove / replace

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(d) Test Section. Construct a test section of one (1) lane-width and at most two-tenths (0.2) mile in length to demonstrate that compaction to between five percent (5%) and nine percent (9%) in-place air voids can be obtained. Continue this procedure until a test section with five percent (5%) to nine percent (9%) in-place air voids can be produced. The Government will allow only two (2) test sections per day. When a test section producing satisfactory in-place air void content is placed, resume full production.

(2) Ordinary Compaction Control. Furnish the type, size, and number or rollers required for compaction, as compliance-confirmed. Furnish at least one (1) medium pneumatic-tire roller (minimum 12-ton weight). Use the control strip method given in Tex-207-F, Part IV, to establish rolling patterns that achieve maximum compaction. Follow the selected rolling pattern unless changes that affect compaction occur in the mixture or placement conditions.

When such changes occur, establish a new rolling pattern. Compact the pavement to meet the requirements of the plans and specifications. When rolling with the three (3)-wheel, tandem or vibratory rollers, start by first rolling the joint with the adjacent pavement and then continue by rolling longitudinally at the sides. Proceed toward the center of the pavement, overlapping on successive trips by at least one (1) foot. Make alternate trips of the roller slightly different in length. On superelevated curves, begin rolling at the low side and progress toward the high side.

I. Irregularities. Immediately take corrective action if surface irregularities, including but not limited to segregation, rutting, raveling, flushing, fat spots, mat slippage, color, texture, roller marks, tears, gouges, streaks, or uncoated aggregate particles, are detected. The Government may suspend production or placement operations until the problem is corrected. At the expense of the Contractor and to the satisfaction of the Government, remove and replace any mixture that does not bond to the existing pavement or that has other surface irregularities identified above.

PART 4 – MEASUREMENT AND PAYMENT

4.1 MEASUREMENT

For this project, hot mix will be measured by the ton of composite hot mix complete in place, which includes asphalt, aggregate, and additives. This is a plans quantity measurement bid item; the quantity to be paid is the quantity shown in the proposal.

4.2 PAYMENT

The work performed and materials furnished in accordance with this Specification and measured as provided under “Measurement” will be paid for at the unit price bid for “Hot Mix Asph Surf” of the depth specified. This price is full compensation for surface preparation, materials including tack coat, placement, equipment, labor, tools, and incidentals. Trial batches will not be paid for unless they are incorporated into pavement work compliance-confirmed by the Government.

- END OF SPECIFICATION -

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