TE-05 Materials Manual of Instruction.pdf

United States Army Garrison Dugway Proving Ground

Technical Exhibit 05 Paving IDIQ Contract – Materials Manual of Instruction

Directorate of Public Works [Date]

Part 8 – Materials Manual July 2003

Quality Assurance – Appendix C 1

Part 8 – Materials Manual Materials Acceptance Program

January 2017 Terminology Page 1 of 9

TERMINOLOGY

Many of the terms listed below are defined differently by various agencies or organizations. The definitions of the American Association of State Highway and Transportation Officials (AASHTO) are the ones most commonly used in this document.

Absorbed Water – Water drawn into a solid by absorption, and having physical properties similar to ordinary water.

Absorption – The increase in the mass of aggregate due to water being absorbed into the pores of the material, but not including water adhering to the outside surface of the particles, expressed as a percentage of the dry mass.

Acceptance Program – All factors that comprise the State Transportation Department’s (STD) determination of the quality of the product as specified in the contract requirements. These factors include verification sampling, testing, and inspection and may include results of quality control sampling and testing.

Admixture – Material other than water, cement, and aggregates in Portland cement concrete (PCC).

Adsorbed Water – Water attached to the surface of a solid by electrochemical forces and having physical properties substantially different from ordinary water.

Aggregate – Hard granular material of mineral composition, including sand, gravel, slag or crushed stone, used in roadway base and in Portland cement concrete (PCC) and asphalt cement concrete (ACC).

Angular aggregate – Aggregate possessing well defined edges at the intersection of roughly planar faces

Coarse aggregate – Aggregate retained on or above the 4.75 mm (No. 4) sieve.

Coarse‐graded aggregate – Aggregate having a predominance of coarse sizes.

Dense‐graded aggregate – Aggregate having a particle size distribution such that voids occupy a relatively small percentage of the total volume.

Fine aggregate – Aggregate passing the 4.75 mm (No. 4) sieve.

Fine‐graded aggregate – Aggregate having a predominance of fine sizes.

Mineral filler – A fine mineral product at least 70 percent of which passes a 75 µm (No. 200) sieve.

Open‐graded / gap‐graded aggregate – Aggregate having a particle size distribution such that voids occupy a relatively large percentage of the total volume.

Well‐Graded Aggregate – Aggregate having an even distribution of particle sizes.

Agitation (Portland Cement Concrete) – The application of gentle motion in concrete sufficient to prevent segregation and loss of plasticity.

Air Voids – Total volume of the small air pockets between coated aggregate particles in asphalt cement concrete (ACC); expressed as a percentage of the bulk volume of the compacted paving mixture.

Ambient Temperature – Temperature of the surrounding air.

Angle of Internal Friction – The angle whose tangent is the ratio between the resistance offered to sliding along any plane in the soil and the component of the applied force acting normal to that plane.

Apparent Specific Gravity – The ratio of the mass, in air, of a volume of the impermeable portion of aggregate to the mass of an equal volume of water.

Asphalt – A dark brown to black cementitious material in which the predominate constituents are bitumens occurring in nature or obtained through petroleum processing. Asphalt is a constituent of most crude petroleums.

Asphalt Cement – An asphalt specially prepared in quality and consistency for use in the manufacture of asphalt cement concrete (ACC).

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Asphalt Cement Concrete (ACC) – A controlled mix of aggregate and asphalt cement, typically Hot‐Mix asphalt

(HMA).

Base – A layer of selected material constructed on top of subgrade or subbase and below the paving on a roadway.

Batch Plant – A manufacturing facility for producing asphalt cement concrete or Portland cement concrete from defined single batch proportions of aggregates and other materials.

Bias – The offset or skewing of data or information away from its true or accurate position as the result of systematic error.

Binder – Asphalt cement or modified asphalt cement that binds the aggregate particles into a dense mass.

Borrow – Construction material that must be imported from outside the roadway limits for the construction of the roadbed embankments, subgrade, shoulders, etc.

Boulders – Rock fragment, often rounded, with an average dimension larger than 300 mm (12 in.).

Bulk Specific Gravity – The ratio of the mass, in air, of a volume of aggregate or compacted HMA mix (including the permeable and impermeable voids in the particles, but not including the voids between particles) to the mass of an equal volume of water.

Bulk Specific Gravity (SSD) – The ratio of the mass, in air, of a volume of aggregate or compacted HMA mix, including the mass of water within the voids (but not including the voids between particles), to the mass of an equal volume of water. (See saturated surface dry.)

Capillary Water – Water held in a soil by the capillaries in the soil. It is free water, but it can he removed from the soil only after the water table is lowered or when evaporation takes place at a faster rate than the rate of capillary flow.

Cementitious Materials – Cement and pozzolans used in concrete including, but not limited to, Portland cement, fly ash, silica fume, & blast‐furnace slag.

Clay – Fine‐grained soil that exhibits plasticity over a range of water contents and that exhibits considerable strength when dry. Also, that portion of the soil finer than 2 µm.

Cobble – Rock fragment, often rounded, with an average dimension between 75 and 300 mm (3 and 12 in.).

Cohesion – The mutual attraction of particles due to molecular forces and the presence of moisture films.

Cohesionless Soil – Soil with little or no strength when dry and unconfined or when submerged, such as sand.

Cohesive soil – Soil with considerable strength when dry and that has significant cohesion when unconfined or submerged.

Compaction – Densification of a soil or hot mix asphalt (HMA) by mechanical means.

Compaction Curve (proctor curve or moisture‐density curve) – The curve showing the relationship between the dry unit weight or density and the water content of a soil for a given compactive effort.

Compaction Test (proctor or moisture‐density test) – Laboratory compaction procedure in which a soil of known water content is placed in a specified manner into a mold of given dimensions, subjected to a compactive effort of controlled magnitude, and the resulting density determined.

Compressibility – Property of a soil or rock relating to susceptibility to decrease in volume when subject to load.

Consistency of Concrete – The relative mobility of fresh‐mixed concrete or mortar, commonly measured by its slump.

Consolidation – The decrease in thickness of a soil stratum due to an increase in load.

January 2017 Terminology Page 3 of 9

Construction Joint – A joint made necessary by a prolonged interruption in the placing of concrete or asphalt.

Contraction Joint – A joint at the ends of a rigid slab to control the location of transverse cracks.

Continuous Mix Plant – A manufacturing facility for producing asphalt cement concrete (ACC) that proportions aggregate and asphalt by a continuous volumetric proportioning system without specific batch intervals.Creep – Continuous deformation of a material under steady load.

Deflocculating Agent – A chemical that destroys or prevents the formation of flocs (a loose mass of particles).

Degree of Saturation – The ratio of the volume of water to the volume of voids, usually expressed as a percentage.

Density – The ratio of mass to volume of a material. Usually expressed in lb/ft3.

Disintegration – Deterioration into small fragments.

Dispute Resolution – The procedure for resolving conflicts that may impact payment between the owner and Contractor.

Durability – The property of a material that describes its ability to resist disintegration by weathering and traffic.

Included under weathering are changes in the pavement and aggregate due to the action of water, including freezing and thawing.

Elasticity – The property of a material which enables it to rebound after compaction or after removal of a load.

Embankment – Controlled, compacted material between the subgrade and subbase or base in a roadway.

Emulsified Asphalt – An emulsion of asphalt cement and water which contains a small amount of an emulsifying agent. Water forms the continuous phase of the emulsion, and minute globules of asphalt form the discontinuous phase.

Erosion – The loosening and transporting of rock debris and soil by moving agents operation on the earth's surface.

The four main moving agents include the wind, waves and currents in the ocean or other bodies of water, glaciers, and running water.

Expansion Joint – A joint located to provide for expansion of a rigid slab without damage to itself, adjacent slabs or structures.

Faulting – Differential vertical displacement of material adjacent to a joint or crack.

Field Operating Procedure (FOP) – Procedure used in field testing on a construction site or in a field laboratory.

(Based on AASHTO or WAQTC test methods.)

Fineness Modulus – The sum of the cumulative percentages of aggregates retained on each of a specified series of sieves, divided by 100. AASHTO T 27

Fines – Portion of a soil or aggregate finer than a 75 µm (No. 200) sieve, also silts and clays.

Flexible Pavement – A pavement constructed of Hot‐Mix Asphalt (HMA).

Fog Coat – A very light application of asphalt without aggregate cover.

Free Water – Water on aggregate available for reaction with hydraulic cement. Mathematically, the difference between total moisture content and absorbed moisture content.

Friable – Easy to break or crumble.

Geologic Map – A map that shows the distribution of the different rock masses that underlie the ground surface plotted accurately to scale in relation to the topographic features and other control points on the map.

Gilsonite – A solid variety of asphalt that occurs in nature in the Uintah Basin, Utah.

January 2017 Terminology Page 4 of 9

Glacial Till – Material deposited by glaciation, usually composed of a wide range of particle sizes, which has not been subjected to the sorting action of water.

Gradation (grain‐size distribution) – The proportions, by mass, of a soil or fragmented rock distributed by particle size.

Gradation analysis (grain size analysis or sieve analysis) – The process of determining grain‐size distribution by separation of sieves with different size openings.

Gravel – Rounded particles of rock which will pass a 3 inch sieve and be retained on a No. 10 sieve.

Ground Water – Water that saturates the pores and cracks in the soil and rock beneath the land surface

Heave – Upward movement of soil caused by expansion or displacement resulting from phenomena such as moisture absorption, removal of overburden, driving of piles, frost action etc.

Homogeneous Mass – A mass that exhibits essentially the same physical properties at every point throughout the mass.

Honeycomb – A surface of interior defect in a concrete mass characterized by the lack of mortar between the coarse aggregate particles.

Hot‐Mix Asphalt (HMA) – High quality, thoroughly controlled, hot mixture of asphalt cement and well‐graded, high quality aggregate.

Hydraulic Cement – Cement that sets and hardens by chemical reaction with water.

Hydrophilic Aggregate – An aggregate that exhibits a greater affinity for water than for asphalt.

Hydrophobic Aggregate – An aggregate that exhibits a greater affinity for asphalt than for water.

Hydrostatic Pressure – The pressure in a liquid under static conditions; the product of the unit weight of the liquid and the difference in elevation between the given point and the free water elevation.

Hygroscopic Moisture – Water retained by soil after gravitational and capillary moisture is removed. It is held by each soil grain in the form of a very thin film and has both a physical and chemical affinity for the soil grain. It is also referred to as the air‐dry moisture content. This film is in equilibrium with the moisture content of the air and increases or decreases as the humidity of the air increases or decreases. The hygroscopic moisture content of a soil also varies with the grain size. As the grain size increases, the hygroscopic moisture content increases.

Independent Assurance (IA) – Unbiased and independent evaluation of all the sampling and testing procedures, equipment, and technicians involved with Quality Control (QC) and Verification/Acceptance.

Independent Sample – An individual material sample drawn at random, separate and independent from quality control and/or verification samples.

In‐situ – In its original place.

Internal Friction – The resistance to sliding within a soil mass due to particle interlock and particle friction.

Leaching – The removal of soluble salts or other soluble materials by percolating water.

Leveling Course – A course of variable thickness used to eliminate irregularities in contour of an existing surface prior to superimposed treatment or construction.

Liquid Limit (LL) – Water content corresponding to the boundary between the liquid and plastic states.

Loam – A mixture of sand, silt and/or clay with organic matter.

Load‐Transfer Device – A mechanical means designed to carry loads across a joint, typically a steel dowel.

January 2017 Terminology Page 5 of 9

Longitudinal Joint – A full‐depth or weakened‐plane type joint placed between traffic lanes to control longitudinal cracking.

Materials Acceptance Program (MAP) – All factors that UDOT uses to determine the quality of the highway products specified in a contract. These factors include verification sampling, testing, and inspection. This program is intended to meet the requirements of 23CFR637.

Maximum Density – The laboratory determined dry weight per cubic foot of a soil compacted at the optimum moisture content under a given compactive effort.

Maximum size – One sieve larger than nominal maximum size.

Moisture content – The ratio, expressed as a percentage, of the mass of water in a material to the dry mass of the material.

Nominal maximum size – One sieve larger than the first sieve to retain more than 10 percent of the material using an agency specified set of sieves based on cumulative percent retained. Where large gaps in specification sieves exist, intermediate sieve(s) may be inserted to determine nominal maximum size.

Nuclear Gauge – Instruments used to measure in‐place density, moisture content, or both through the measurement of nuclear emissions.

Optimum moisture content (optimum water content) – The water content at which a soil can be compacted to a maximum density by a given compactive effort.

Paste – Mix of water and hydraulic cement that binds aggregate in Portland cement concrete (PCC).

Pavement Structure – The combination of subbase, base, and surface courses placed on a subgrade to support the traffic load and distribute it to the roadbed.

Penetration – The consistency of a bituminous material, expressed as the distance in tenths of a millimeter (0.1

mm) that a standard needle vertically penetrates a sample of the material under specified conditions of loading, time, and temperature.

Percent Compaction – The ratio of density of a soil, aggregate, or HMA mix in the field to maximum density determined by a standard compaction test, expressed as a percentage.

Permeability – The measure of a materials ability to transmit water through its internal structure.

Plastic Limit (PL) – Water content corresponding to the boundary between the plastic and the semisolid states.

Plasticity – Property of a material to continue to deform indefinitely while sustaining a constant stress.

Plasticity Index (PI) – Numerical difference between the liquid limit and the plastic limit and, thus, the range of water content over which the soil is plastic.

Pore‐water Pressure – Stress transmitted through the pore water of a soil (water filling the voids of the soil).

Porosity – The ratio of the volume of void space (pores) of a material to the total volume of its mass, usually expressed as a percent.

Portland Cement – Hydraulic cement produced by pulverizing Portland cement clinker consisting mainly of hydraulic calcium silicates.

Portland Cement Concrete (PCC) – A controlled mix of Portland cement, aggregates, water, and possibly other admixtures.

Pozzolan – A material which, when combined with calcium hydroxide, exhibits cementitious properties.

Prime Coat – An application of a liquid asphalt to a surface.

January 2017 Terminology Page 6 of 9

Proficiency Samples – Homogeneous samples that are distributed and tested by two or more laboratories. The test results are compared to assure that the laboratories are obtaining the same results.

Pugmill – A shaft mixer designed to mix aggregate and cement.

Quality Assurance – Planned and systematic actions necessary to provide confidence that a product or service will satisfy given requirements for quality.

Quality Control (QC) – All contractor/vendor operational techniques and activities that are performed or conducted to fulfill contract requirements.

Random Sample – A sample drawn from a lot in which each increment in the lot has an equal probability of being chosen. All samples used for quality control and verification sampling and testing will be random samples.

Raveling – Progressive disintegration of a pavement surface by dislodgment of aggregate particles.

Rigid Pavement – Portland cement concrete pavement (PCCP).

Riprap – Broken rock used for the protection of embankments, cut slopes, structures, etc, against agents of erosion, primarily water.

Roadbed – The graded portion of a highway between top and side slopes, prepared as a foundation for the pavement structure and shoulders.

Road‐Mix – A mixture of aggregate and asphalt cement mixed in place.

Rutting – The formation of longitudinal depressions by the lateral displacement of soils or surfaces under traffic.

Sand – Particles of rock passing the 4.75 mm (No. 4) sieve and retained on the 75 µm (No. 200) sieve.

Saturated Surface Dry (SSD) – Condition of an aggregate particle, asphalt cement concrete (ACC) or portland cement concrete (PCC) core, or other porous solid when the permeable voids are filled with water, but no water is present on exposed surfaces. (See bulk specific gravity.)

Screeding – The process of striking off excess material to bring the top surface to proper contour and elevation.

Seal Coat – A thin asphaltic surface treatment used to improve the texture of and waterproof an asphalt surface.

Segregation – The separation of aggregate by size resulting in a non‐uniform material.

Settlement – The reduction in elevation of short sections of pavement or structures due to compressibility of underlying soils.

Silt – Material passing the 75 µm (No. 200) sieve that is non‐plastic or very slightly plastic, and exhibits little or no strength when dry and unconfined. Also, that portion of the soil finer than 75 µm and coarser than 2 µm.

Slaking – The process of breaking up or sloughing.

Slump – Measurement related to the consistency and workability of concrete.

Soil – Sediments or unconsolidated accumulations of solid particles produced by the physical and chemical disintegration or rocks, and which may or may not contain organic matter.

Soil Profile – A vertical cross‐section of soil layers.

Soil Structure – The arrangement and state of aggregation of soil particles in a soil mass.

Soil Support Value – An index number that expresses the relative ability of a soil or aggregate mixture to support traffic loads through the pavement structure.

Soil Texture – The relative proportion of the various particle‐size groups of small, individual grains, contained in a soil; the coarseness or fineness of the soil.

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Soundness – Resistance to both physical and chemical weathering.

Spalling – The breaking away of smaller fragments of material from a larger solid body as the result of a variety of mechanisms such as weathering, loading, and corrosion.

Specific Gravity – The ratio of the mass, in air, of a volume of a material to the mass of an equal volume of water.

Split Sample: A sample drawn, at random, from a given material which is then split in equal portions and tested by separate and independent personnel and laboratories. Split samples are used in the IA process to validate the testing personnel, test procedures and testing equipment.

Stability – The ability of an asphalt cement concrete (ACC) to resist deformation from imposed loads. Stability is dependent upon internal friction, cohesion, temperature, and rate of loading.

Stripping – Separation of bituminous films from aggregate particles due to the presence of moisture.

Structural Number – An index number derived from an analysis of traffic and roadbed soil conditions, which may be converted to pavement thickness through the use of suitable factors related to the type of material being used in the pavement structure.

Subbase – A layer of selected material constructed between the subgrade and the base coarse in a flexible HMA roadway, or between the subgrade and Portland cement concrete (PCC) pavement in a rigid PCC roadway.

Subgrade – Natural soil prepared and compacted to support a structure or roadway pavement.

Superpave™ – Superpave™ is a product of the SHRP asphalt research. Superpave HMA mixtures are a dense graded mix using high quality aggregates and asphalt binder used for the construction of surface courses of flexible pavements.

Surcharge – Additional fill material placed on a fill already built to grade. The additional fill material accelerates the rate of consolidation of compressible foundation soils.

Surface Course – One or more layers of a pavement structure designed to accommodate the traffic load, the top layer of which resists skidding, traffic abrasion, and the disintegrating effects of climate. This top layer is sometimes referred to as the wearing course.

Tack Coat – A very light application of liquid asphalt, or an asphalt emulsion diluted with water.

Theoretical Maximum Specific Gravity (Rice) – The ratio of the mass of a given volume of asphalt cement concrete (ACC) with no air voids to the mass of an equal volume of water, both at a stated temperature.

Topsoil – Surface soil, usually containing organic matter.

Transverse Joint – A joint running across the pavement.

Unconfined Compressive Strength – The load per unit area at which an unconfined cylindrical specimen will fail in simple compression.

Undisturbed Sample – A soil sample that has been obtained by methods which minimize disturbance of the sample.

Uniformity Coefficient (Cu) – A value employed to quantify how uniform or well‐graded an aggregate is, defined as Cu = D60/D10, where D60 equals the diameter of which 60 percent of the material is smaller and D10 equals the diameter of which 10 percent of the material is smaller.

Unit weight – The ratio of weight to volume of a substance. The term “density” is more commonly used.

Vendor – Supplier of project‐produced material that is other than the constructor.

Verification Sampling and Testing – Sampling and testing performed to validate the quality of the product.

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Viscosity – A measure of the resistance to flow; one method of measuring the consistency of asphalt cement.

Absolute viscosity – A method of measuring viscosity using the “poise” as the basic measurement unit.

This method is used at a temperature of 60°C, typical of hot pavement.

Kinematic viscosity – A method of measuring viscosity using the stoke as the basic measurement unit.

This method is used at a temperature of 135°C, typical of hot asphalt at a plant.

Void – The space in a soil mass or other material not occupied by solid mineral matter.

Void Ratio – The ratio of the volume of voids to the volume of solid particles.

Void in the Mineral Aggregate (VMA) – The volume of inter‐granular void space between aggregate particles of compacted asphalt cement concrete (ACC) that includes air and asphalt; expressed as a percentage of the bulk volume of the compacted paving mixture.

Voids filled with asphalt – The portion of the void in the mineral aggregate (VMA) that contains asphalt; expressed as a percentage of the bulk volume of mix or the VMA.

Volumetric Change – The decrease in volume of the soil mass when the water content is reduced from a given percentage to the shrinkage limit.

Water Table – The upper surface of a zone beneath the land surface where all the pores in the soil or rock are completely filled with water.

Wearing Course – The top portion of a surface course that takes direct wear from traffic.

Yield of Concrete – The volume of freshly mixed concrete from a known quantity of ingredients

January 2017 Terminology Page 9 of 9

Acronyms

AAP ‐ AASHTO Accreditation Program

AASHTO ‐ American Association of State Highway and Transportation Officials

AASHTO re:sourse – AASHTO Materials Reference Laboratory

ACC – Asphalt cement concrete

ACI – American Concrete Institute

ASTM – American Society for Testing and Materials

CCRL – Cement and Concrete Reference Laboratory

FHWA – Federal Highway Administration

HMA – Hot Mix Asphalt

IA – Independent Assurance

IAP – Independent Assurance Program

LQP – Laboratory Qualification Program

MAP – Materials Acceptance Program

QAP – Quality Assurance Program

QAS – Quality Assurance Section

STD – State Transportation Department

TTQP – Technician Training and Qualification Program

WAQTC – Western Alliance for Quality Transportation Construction

Part 8: Materials Manual July 2006

Open-Graded Surface Course

954- Page 1 of 3

Section 954

OPEN GRADED SURFACE COURSE

954.01 Scope

Provides guidelines to determine an Open Graded Surface Coarse (OGSC) Mix Design for Department projects. The Contractor will determine the aggregate gradation and submit the materials to the department to determine binder content. The department approves aggregate gradation according to specification and supplies the mix design.

REFERENCES:

UDOT MATERIALS MANUAL OF INSTRUCTION (MOI) PART 8

UDOT STANDARD SPECIFICATIONS

UDOT PROJECT SPECIAL PROVISIONS

954.02 Contractor Submittals To the Region Materials Laboratory

A minimum of 10 working days before paving, Contractor submits job mix gradation, aggregate quality test results, hydrated lime and pre-blended samples. Aggregate quality tests, asphalt binder, lime and job mix gradation must meet specification requirements.

Pre-blended samples are submitted as below:

Pre-Blended Samples: A pre-blended sample is a blend of the final aggregate structure, without lime and asphalt binder. The hydrated lime is submitted separately. The aggregate shall be batched such that it will meet the target gradation after lime induction.

If the gradation with the lime does not meet the target values within 1% for the #200 sieve and 2% for all other sieves, the submitted samples may be determined to be unacceptable by the Region Materials Engineer.

Samples for Bonding and Drainage Test

5 - 5300 g samples to be tested according to Appendix A of this section. (In the case of lightweight aggregate sample size may vary according to the volume of the aggregate)

Butter Batch

Samples to be submitted after the mix design is complete:

4 Asphalt Binder Correction Samples per ignition oven – AASHTO T 308 Samples are submitted at mix design asphalt binder content and gradation: blend the final aggregate structure with hydrated lime, RAP, and asphalt binder according to MOI 8-988 prior to submitting.

954.03 Determining Design Asphalt Binder Content

The Region Materials Engineer (RME) determines Design Asphalt Binder Content. The Region materials laboratory will obtain appropriate asphalt binder from the Central Materials Laboratory. The RME may require the Bonding and Drainage test be performed, Appendix A.

954.04 Changes in Job Mix Gradation

Contractor submits a written request for a change in job-mix gradation. The RME has five working days to review changes and determine adjustment to binder content if

954- Page 2 of 3 necessary.

954- Page 3 of 3

Appendix A – Bonding and Drainage of OGSC A.01 Scope

This method of test covers UDOT’s design procedure for the “determination of bonding” of Open Graded Seal Coats through the analysis of asphalt cement “drainage.”

A.02 Apparatus

Bonding Form – 12 x 12 in. metal frame, 1 in. deep

Double ply cardboard or equivalent - larger than the 12 x 12 in. bonding frame

Steel Pin Roller - 4 in. diameter, 14 in wide, 30 lb

Balance or Scale – sufficient capacity and readable to 0.1 g.

Miscellaneous – Metal pans, metal spatulas or spoons, timer and gloves, etc.

A.03 Procedure

Prepare and mix samples according to MOI 8-988, Guidelines for Laboratory Mixing with the following modification(s):

- Do not age mix according to AASHTO R 30.

- Proceed with the Bonding and Drainage procedure as listed below.

A.04 Bonding and Drainage Procedure

Prepare four samples in 0.5% asphalt binder increments such that they meet the following:

- Two samples less than final selected asphalt binder content

- One sample approximately equal to final selected asphalt binder content

- One sample higher than final selected asphalt binder content

(It is necessary to establish a minimum of two points below and one above to verify that no inconsistencies exist in the selection process of the optimum binder design content.)

Center Bonding Form over cardboard Place mix in Bonding Form, spread to level Compact mix – 10 passes (a pass is once in each direction)

Cool for 10 2 minutes Remove bonding form and mix Visually examine cardboard Verify sequentially larger amounts of drainage occur as the asphalt binder content is increased

A.05 Selecting Asphalt Binder Content

The asphalt binder content that provides 70-90 percent coverage of the cardboard surface is determined by visual examination. If desired an additional sample may be batched and the 70-90 percent coverage verified.

Part 8 - Materials Manual April 2004

Section 933

METHOD FOR DETERMINING AGGREGATE FLAKINESS INDEX

933.01 Objectives

The Flakiness Index of an aggregate is determined using a gauge with slots of appropriate dimensions. Individual size fractions are separated and each particle that passes through the appropriate slot is considered a flaky particle.

933.02 Definition

The Flakiness Index of an aggregate is the mass of particles in that aggregate which will pass the appropriate slot or slots for the individual size fraction expressed as a percentage of the total mass of that aggregate. The width of the slots is determined by multiplying the mean of upper and lower sieve size for the slot by 0.6.

933.03 Equipment

Gauge: metal 1/16” thick, with slots that comply with the tolerances given in columns 3 and 4 of Table 1, labeled to indicate individual size fraction appropriate to that slot

Scale or Balance of sufficient capacity and accurate to 0.1 percent of sample mass, or 0.1 gram conforming to the requirements of AASHTO M 231

Sieves conforming to the requirements of AASHTO M 92

Other apparatus as required by AASHTO T 27/T 11

933.04 Procedure

933.04.01 Preparation of test sample

Sample Size conforming to AASHTO T 27 Sieve Analysis of Fine and Coarse Aggregate.

Perform AASHTO T 11, Materials Finer than #200 Sieve in Mineral Aggregate by Washing in conjunction with AASHTO T 27. Separate aggregates into specified individual size fractions, Table 1. Material coarser than the 2 ½” sieve and finer than the ¼” sieve is discarded.

Note 1: If an individual size fraction mass exceeds the masses given in Table 1, the fraction may be reduced according to AASHTO T 248. The correction calculation, 933.04.04, is applied to proportionally determine the mass of flaky particles that would have been obtained had the whole of the original size fraction been gauged.

Determine and sum the masses of the individual size fractions, designate as M1.

Guidelines for Flakiness Index Calculation

933 - Page 2 of 3

933.04.02 Using the slot gauge

Select the slot appropriate to the individual size fraction under test (see Table 1). Gauge each particle by hand. A particle is considered flaky if it passes through the appropriate slot.

Combine and determine the mass of all particles passing through the slots and designate as M2.

Note 2: It is sometimes necessary to determine the flakiness of a particular fraction(s). In such cases the material larger and smaller than the fractions concerned is screened out and discarded. The test is then carried out as described above.

933.04.03 Calculation

Calculate the Flakiness Index as follows:

FI = (M2/M1) x 100

Where: FI = Flakiness Index M1= Total mass of all fractions M2= Total mass of particles passing the slots

933.04.04 Correction Calculation as per Note 1.

mi = mf x fr / mr

Where: mi = Corrected mass of flaky particles in fraction(i).

fr = Mass of flaky particles in reduced fraction mr = Mass of reduced fraction mf = Mass of fraction

All mi, are then added to the mass of particles passing through the slots from all uncorrected fractions in obtaining M1.

933.05 Reporting

Flakiness Index to the nearest whole number Sieve analysis percent passing according to AASHTO T 27

Guidelines for Flakiness Index Calculation

933 - Page 3 of 3

933.06 TABLE 1.

Dimensions of Thickness and Length Gauges

Aggregate Size-fraction

Minimum Length of Slot

Width of slot

Sample may be reduced if larger than: lbs. (kgs)

Test Sieve Size

100% Passing 100% Retained

2 ½” 2” 3 3/4” 1 1/3” ± 1/16” 100 (45)

2” 1 ½” 3 ½ ” 1 ± 1/16” 75 (35)

1 ½” 1” 3” ¾ ± 1/16” 25 (10)

1” ¾” 2 ¼ ” ½” ± 1/16” 10 (5)

¾” ½” 2” 3/8” ± 1/32” 5 (2)

½” 3/8” 1 ½ ” ¼” ± 1/32” 2 (1)

3/8” ¼” 1” 3/16” ± 1/32” 1 (0.5)

Part 8 - Materials Manual Revised: July 2002

Dynamic Stripping Test of Asphalt Material Aggregate Mixtures 945- Page 1 of 3

Section 945

DYNAMIC STRIPPING TEST OF ASPHALT MATERIAL AGGREGATE MIXTURES

945.01 Scope

This method covers an agitation test for measuring the retention of a bituminous film by an aggregate in the presence of water. This method shall be confined to Central and Region/District Laboratories.

945.02 Apparatus:

1. Metal cans - Disposable metal cans of 20 ounce capacity such as #303 commercial cans, and 2 quart cans with lids.

2. Balance - A balance with a capacity of 500 g and sensitive to 0.1 g.

3. Spatulas - Two steel spatulas with stiff blades, one approximately 1 inch in width and 4 inches in length, the other approximately 2.5 inches in width and 4 inches in length.

4. Screen - No. 10 sieve size, 6 inches square, to hold samples.

5. Two wooden strips, ½ inch wide, ½ inch thick, and 4 inches in length to support the screen.

6. Hard, nonabsorbent paper to receive drained asphalt material.

7. Soft-textured, absorbent paper, #202 filter paper or equivalent, to dry aggregate.

8. Containers - Glass or polystyrene containers of 17 ounces capacity, such as jars or beakers.

9. Drying Oven - A thermostatically-controlled oven capable of maintaining a temperature of 230 ± 41 F.

10. Paint shaker - Red Devil paint shaker, Model #30, or equivalent.

945.03 Materials

1. Aggregate - The aggregate used shall be unwashed and oven-dried to constant weight at a temperature of 230 ± 41 F. The aggregate shall pass a 3/4 inch sieve and be retained on the No. 4 sieve.

2. Asphalt Material - The bituminous material shall be that proposed for use on the project. If no type of asphalt material has as yet been designated for use, stripping tests shall be performed with PG58-22 asphalt binder.

945- Page 2 of 3

3. Water - The distilled or tap water used in conducting the stripping test shall have a ph of 6.0 to 8.0. No electrolytes of any kind shall be added to the water to obtain the required ph.

4. Hydrated lime, 1%.

945.04 Test Procedure

For each determination, one stripping test shall be performed. The asphalt shall contain no anti-stripping agent. Each test shall be performed as follows:

1. Place 150 g of the representative aggregate sample in a disposable metal can.

Add 50 g of asphalt binder or cut-back asphalt, which shall have been preheated to a temperature at which it will pour easily. PRECAUTION: If using asphalt emulsion, dampen the aggregate to a moisture content between 1 to 2 % and add 75 g of emulsified asphalt heated to 140 5 F.

2. Mix the asphalt material and aggregate with the narrow, stiff spatula until all aggregate particles are completely coated. The asphalt binder or cut-back asphalt–aggregate mixture may be heated in the oven to facilitate mixing. The temperature shall be approximately 125 F for cut-back asphalt and 200 F for asphalt cement. Do not heat emulsion-aggregate mixtures.

3. Place the sample on the elevated screen, and allow the excess asphalt material to drain off. Permit the sample to cure at room temperature (70 to 84 F) for 24 hours. PRECAUTION: Cure emulsion-aggregate mixtures for 48 hours.

4. After curing, scrape the sample off the screen with the wide, stiff unheated spatula, and place it in a glass or polystyrene container. Immerse the sample in water, and allow it to stand at room temperature for 24 hours.

5. Remove the sample from the glass container, being careful not to disturb the bond between the asphalt material and the aggregate, and place it in the 2 quart can.

For those samples that cannot be easily removed from the glass containers the following procedure shall be used:

(a) Invert the glass container with the sample.

(b) Allow a stream of warm water to run over the container until the sample is loosened from the glass.

6. Fill the 2 quart can, containing the sample, completely with tap or distilled water, and seal it with the lid. Place the can on the paint shaker, and allow it to be agitated for l0 minutes. After this time, remove the can from the paint shaker.

Let the water drain off, and decant the loose asphalt material from the sample.

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945.05 Addition of Lime to Aggregate:

The addition of hydrated lime may improve the stripping characteristics of some aggregates. The procedure shall be as follows:

1. Add one part of lime (by weight) to two parts of water (by weight), and mix thoroughly.

2. Add this mixture to the dry aggregate in the amount of 1% lime (by weight), and mix thoroughly. Allow the aggregate to cure in an open can for 24 hours.

3. After the curing period, test the aggregate as outlined in subsection 945.04, except anti-stripping agent.

945.06 Evaluation

Visually inspect the amount of stripped aggregate as passing at zero to ten percent.

945.07 Precaution:

Be sure the 2 quart can is filled completely with water and the lid is securely in place, before placing the can on the paint shaker. When filling the 2 quart can do not spray water directly on the mix.

Part 8 – Materials Manual February 2018

MOI Section 960 Superpave Volumetric Mix Design and Verification Page 1 of 6

Section 960

GUIDELINES FOR SUPERPAVE VOLUMETRIC MIX DESIGN AND VERIFICATION

960.01 Scope

This procedure provides guidelines to determine a Superpave Volumetric Mix Design for Hot/Warm-Mix Asphalt (HMA) for incorporation into Department projects. The Contractor will perform and submit the mix design according to specification; the Department will verify the mix design.

REFERENCES:

AASHTO STANDARDS:

M 323 Superpave Volumetric Mix Design

R 30 Standard Practice for Mixture Conditioning of Hot-Mix Asphalt (HMA)

R 35 Standard Practice for Superpave Volumetric Design for Hot Mix Asphalt (HMA)

T 30 Mechanical Analysis of Extracted Aggregate

T 84 Specific Gravity and Absorption of Fine Aggregate

T 85 Specific Gravity and Absorption of Coarse Aggregate

T 166 Bulk Specific Gravity of Compacted Hot-Mix Asphalt Mixtures Using Saturated-Surface Dry Specimens

T 209 Theoretical Maximum Specific Gravity and Density of Hot-Mix Paving Mixtures

T 308 Determining the Asphalt Binder Content of Hot-Mix Asphalt (HMA) by the Ignition Method

T 312 Standard Method for Preparing and Determining the Density of Hot Mix Asphalt (HMA) Specimens by Means of the Superpave Gyratory Compactor

T 319 Quantitative Extraction and Recovery of Asphalt Binder from Asphalt Mixtures

T 324 Hamburg Wheel-Track Testing of Compacted Hot Mix Asphalt (HMA)

UDOT MATERIALS MANUAL OF INSTRUCTION (MOI) PART 8

UDOT MINIMUM SAMPLING AND TESTING REQUIREMENTS

UDOT STANDARD SPECIFICATIONS

UDOT PROJECT SPECIAL PROVISIONS

960.02 Significance and Use

The objective of HMA mix design is to determine the combination of asphalt binder and aggregates that will give long lasting performance as part of the pavement structure. Mix design involves laboratory procedures developed to establish the necessary proportion of materials for use in HMA. Well-designed asphalt mixtures can be expected to serve successfully for many years.

The mix design of HMA is just the starting point to assure that an asphalt concrete pavement will perform as required. Together with proper construction practice, mix design is an important step in achieving well-performing asphalt pavements. In many cases, the cause of poor performing pavements has been attributed to poor or inappropriate mix design or to the production of a mixture other than what was designed in the laboratory. To that end, it is critical that the materials and proportions used in the design are representative of the materials and proportions that will be used in the pavement structure.

The purpose of the Mix Design Verification Process is to provide an independent review of the Contractor’s mix design. The verification process may consist of any, or all of the following:

A review of the Contractor’s design submittal documentation

MOI Section 960 Superpave Volumetric Mix Design and Verification Page 2 of 6

A review of the project history of a previously used HMA design A duplication of the Contractor’s laboratory effort to verify individual mix components and/or total mix properties

960.03 Superpave Volumetric Mix Design Guidelines

The mix design shall comply with AASHTO M 323: Standard Specification for Superpave Volumetric Mix Design with the following modifications:

Asphalt binder, aggregate and mix properties are defined by project specification, including, but not limited to:

Dust-to-binder ratio

VMA

VFA

Design air void content (Va) (% compaction @ Ndes) PG asphalt binder grade RAP asphalt binder recovered by AASHTO T 319 Hamburg Wheel-Track Testing (HWTT) (MOI 8-990) - (replaces Tensile Strength Ratio

(Lottman)) Flakiness Index (MOI 8-933)-(replaces Flat and Elongated Particles)

The laboratory performing the mix design will be qualified in HMA by the Laboratory Qualification Program.

Personnel must be qualified in Transportation Technician Qualification Program (TTQP) Asphalt (AsTT) and Superpave Mix Design (SMDTT)

The compactor will be approved as per MOI 8-961: Guidelines for Superpave Gyratory Compactor Protocol.

The HWTT lab will be approved by the Department, will be qualified by the Laboratory Qualification Program and will participate in all Department proficiency testing and inspections. AASHTO re:source accreditation in T-324 Hamburg Wheel-Track Testing of Hot Mix Asphalt (HMA) along with proficiency demonstration will be sufficient to obtain Department approval. Other means to approval will be considered on a case by case basis.

960.04 Standard Practice for Superpave Volumetric Mix Design

Mix Designs will be performed in accordance with AASHTO R 35: Standard Practice for Superpave Volumetric Design for Hot-Mix Asphalt with the following modifications:

Target air void content (Va) is by project specification.

The mix design will be performed using materials intended for use on the project. Materials used in the mix design will meet the following criteria:

Asphalt binder shall be obtained from a certified supplier meeting the requirements outlined in the UDOT Quality Management Plan 509: Asphalt Binder Management System. For mix design verifications, the Region Labs will obtain pre-qualified binder from the UDOT Binder Lab.

Chemical Warm Mix Asphalt - These chemical admixtures tend to reduce the viscosity of the binder and reduce the film thickness and corresponding mix design asphalt content slightly. Mix designs are verified without the warm mix additive to meet the project requirements. The Hamburg Test is run on the final material with the warm mix additive.

Hydrated lime shall be obtained from a certified supplier meeting the requirements outlined in Quality Management Plan 510: Hydrated Lime Management System. The hydrated lime will be accompanied by test results or will be pre-tested by the Central Materials Laboratory prior to use in the mix design verification

Requirements when using recycled asphalt pavement (RAP):

MOI Section 960 Superpave Volumetric Mix Design and Verification Page 3 of 6

Percentage of RAP/RAP Binder in the mix design will be expressed as a percentage of the final mix.

For mix designs that incorporate more that 15 percent RAP, a test report will be provided for each stockpile of RAP that includes: gradation, aggregate properties, asphalt binder content and PG grade of extracted asphalt binder (AASHTO M 323).

The final aggregate gradation is determined after the RAP and hydrated lime are added.

(AASHTO T 30)

The HMA is mixed according to MOI 8-988. Mixed material will be short term aged for “Volumetric Mix Designs” as per AASHTO R 30.

After the mix design parameters are determined, prepare and compact four sets of two gyratory specimens.

Compact three sets to Ndes to verify the target air voids, as defined by UDOT Standard Specification 02741, 0.5% at optimum asphalt binder content. Compact one set to Nmax to verify required relative density. AASHTO T 312

The laboratory performing the mix design or its subcontractor will perform Hamburg Wheel Track Testing of Compacted Bituminous Mixtures (MOI 8-990). Submit the complete test record in Standard Department format to the UDOT . Graph each wheel data showing the maximum rut depth and report the maximum impression for each wheel or test run. UDOT may verify the results by performing an additional test to be run on slabs or pucks at its discretion. Refer to 960.05 for material submittal.

960.05 Mix Design Verification Process

General:

The Department performs mix design verification; the verification process outlined in this document is intended to be complete. However, verification could include any or all tests identified in AASHTO M 323, project specifications, project special provisions, the current MOI, the current Minimum Sampling and Testing Requirements or other aggregate quality, volumetric, or mix performance tests that may be added in the future.

All materials submitted for use in the verification process are required to be representative of those used in the mix design.

The Contractor will submit the volumetric mix design data and materials samples for verification at least 10 working days before beginning paving. Paving will not begin until verification is complete. “Working days” refer to Monday through Friday, excluding state holidays, and begin when all the following are submitted to the Region Laboratory:

Mix Design Report All aggregate quality test results All pre-blended aggregate samples A sufficient quantity of the hydrated lime A sufficient quantity of the RAP used during the mix design process Test Report for RAP Test Report for hydrated lime Asphalt binder to Central Materials Lab Hamburg Wheel Tracker Test results

“Working days” end when the Region Materials Engineer (RME) provides a Mix Design Review Report to the Resident Engineer.

960.05.01 Contractor Submittals

Mix Design Report - The Contractor will submit the Mix Design Report to the RME. The Contractor will submit a Mix Design Report Summary and Transmittal Letter to the Resident Engineer (RE). The submittals should follow the outline and example in Appendix “A.”

MOI Section 960 Superpave Volumetric Mix Design and Verification Page 4 of 6

A verified mix design may be submitted for use on a project other than the project originally identified. The Contractor will submit the Verified Mix Design Report to the RME and a Mix Design Report Summary and Transmittal Letter to the RE for the new project. Both reports must include documentation regarding field changes made after original verification.

Pre-Blended Samples - The Contractor will prepare samples for use in the verification process. The pre-blended samples, RAP, and hydrated lime are submitted to the RME. The Contractor will provide additional samples upon request.

Note: Asphalt binder for mix design verification will be supplied to the Region Materials Lab from Central Materials Lab.

A pre-blended sample is a blend of the final aggregate structure, without RAP, hydrated lime, and asphalt binder. Pre-blended samples are made at the required sample size by recombining the aggregate portion that has been sieved into individual sieve size fractions. Larger samples split to sample size are not acceptable.

The final gradation of the mix includes the RAP and hydrated lime, as per specification. Mix design verification may include a sieve analysis of the virgin materials and/or of the post-ignition final gradation.

The following tolerances from target gradation for each sieve will be allowed:

1/2 inch ............................. 2% 3/8 inch ............................. 2% No. 4 ................................. 2% No. 8 ................................. 1% No. 16 ............................... 1% No. 30 ............................... 1% No. 50 ............................... 1% No. 100 ............................. 1% No. 200 ............................. 0.8%

Initial pre-blended samples to be submitted:

11 Samples – Gyratory Compaction – AASHTO T 312

5 Samples – Gmm Determination – AASHTO T 209

2 Samples – Hamburg Wheel Track Testing – MOI 8-990

Prepared as above (not mixed) Sufficient material for two 12”x12”x1.5” slabs

Samples to be submitted after the mix is verified:

4 Asphalt Binder Correction Samples per ignition oven, AASHTO T 308 Samples are submitted at mix design binder content and gradation: blend the final aggregate structure with hydrated lime, RAP, and asphalt binder according to MOI 8-988 prior to submitting.

Follow Method A of T 308;…