32_12_15.13_HMA_for_Airfields.pdf

USACE / NAVFAC / AFCEC / NASA UFGS-32 12 15.13 (November 2015) Preparing Activity: USACE Superseding UFGS-32 12 15.13 (November 2012)

UNIFIED FACILITIES GUIDE SPECIFICATIONS

References are in agreement with UMRL dated October 2015

SECTION TABLE OF CONTENTS

DIVISION 32 - EXTERIOR IMPROVEMENTS

SECTION 32 12 15.13

HOT-MIX ASPHALT AIRFIELD PAVING

11/15

PART 1 GENERAL

1.1 FULL PAYMENT

1.1.1 Method of Measurement

1.1.2 Basis of Payment

1.2 PERCENT PAYMENT

1.2.1 Mat and Joint Densities

1.2.2 Pay Factor Based on In-place Density

1.2.3 Payment Adjustment for Smoothness (Final Wearing Surface Only)

1.2.4 Laboratory Air Voids and Theoretical Maximum Density

1.2.5 Mean Absolute Deviation

1.2.6 Pay Adjustment Based on Grade

1.3 REFERENCES

1.4 SUBMITTALS

1.5 QUALITY ASSURANCE[ AND QUALITY CONTROL]

1.5.1 Sublot Sampling

1.5.2 Additional Sampling and Testing

1.5.3 In-place Density

1.5.4 Surface Smoothness

1.5.4.1 Smoothness Requirements

1.5.4.1.1 Straightedge Testing

1.5.4.1.2 Profilograph Testing

1.5.4.2 Testing Method

1.5.4.2.1 Straightedge Testing

1.5.4.2.2 Profilograph Testing

1.5.4.2.3 Bumps ("Must Grind" Areas)

1.6 ENVIRONMENTAL REQUIREMENTS

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

2.1.1 Asphalt Mixing Plant

2.1.1.1 Truck Scales

2.1.1.2 Inspection of Plant

2.1.1.3 Storage Bins

2.1.2 Hauling Equipment

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2.1.3 Material Transfer Vehicle (MTV)

2.1.4 Asphalt Pavers

2.1.4.1 Receiving Hopper

2.1.4.2 Automatic Grade Controls

2.1.5 Rollers

2.1.6 Diamond Grinding

2.2 AGGREGATES

2.2.1 Coarse Aggregate

2.2.2 Fine Aggregate

2.2.3 Mineral Filler

2.2.4 Aggregate Gradation

2.3 ASPHALT CEMENT BINDER

2.4 MIX DESIGN

2.4.1 JMF Requirements

2.4.2 Adjustments to JMF

2.5 RECYCLED HOT MIX ASPHALT

2.5.1 RAP Aggregates and Asphalt Cement

2.5.2 RAP Mix

PART 3 EXECUTION

3.1 CONTRACTOR QUALITY CONTROL

3.1.1 General Quality Control Requirements

3.1.2 Testing Laboratory

3.1.3 Quality Control Testing

3.1.3.1 Asphalt Content

3.1.3.2 Aggregate Properties

3.1.3.3 Temperatures

3.1.3.4 Aggregate Moisture

3.1.3.5 Moisture Content of Mixture

3.1.3.6 Laboratory Air Voids, VMA, Marshall Stability and Flow

3.1.3.7 In-Place Density

3.1.3.8 Grade and Smoothness

3.1.3.9 Additional Testing

3.1.3.10 QC Monitoring

3.1.4 Sampling

3.1.5 Control Charts

3.2 PREPARATION OF ASPHALT BINDER MATERIAL

3.3 PREPARATION OF MINERAL AGGREGATE

3.4 PREPARATION OF HOT-MIX ASPHALT MIXTURE

3.5 PREPARATION OF THE UNDERLYING SURFACE

3.6 TEST SECTION

3.6.1 Sampling and Testing for Test Section

3.6.2 Additional Test Sections

3.7 TESTING LABORATORY

3.8 TRANSPORTING AND PLACING

3.8.1 Transporting

3.8.2 Placing

3.9 COMPACTION OF MIXTURE

3.9.1 General

3.9.2 Segregation

3.10 JOINTS

3.10.1 Transverse Joints

3.10.2 Longitudinal Joints

3.10.3 HMA-Portland Cement Concrete Joints

-- End of Section Table of Contents --

SECTION 32 12 15.13 Page 2

USACE / NAVFAC / AFCEC / NASA UFGS-32 12 15.13 (November 2015) Preparing Activity: USACE Superseding UFGS-32 12 15.13 (November 2012)

UNIFIED FACILITIES GUIDE SPECIFICATIONS

References are in agreement with UMRL dated October 2015

SECTION 32 12 15.13

HOT-MIX ASPHALT AIRFIELD PAVING

11/15

NOTE: This guide specification covers the requirements for bituminous intermediate and wearing courses (central-plant hot-mix) for airfields using Marshall or Gyratory compaction method.

Adhere to UFC 1-300-02 Unified Facilities Guide Specifications (UFGS) Format Standard when editing this guide specification or preparing new project specification sections. Edit this guide specification for project specific requirements by adding, deleting, or revising text. For bracketed items, choose applicable items(s) or insert appropriate information.

Remove information and requirements not required in respective project, whether or not brackets are present. Do not edit or rewrite the unbracketed text without the express consent of the Corps of Engineers Transportation Systems Center (TSMCX), the Air Force Civil Engineer Center (AFCEC) pavement subject matter expert (SME), or the Naval Facilities Engineering Command (NAVFAC).

Comments, suggestions and recommended changes for this guide specification are welcome and should be submitted as a Criteria Change Request (CCR) .

PART 1 GENERAL

NOTE: Modifications must be made to this guide specification during conversion to a project specification in accordance with the NOTES which are located throughout the document. These NOTES are instructions to the designer, and will not appear in the project specification.

This guide specification only pertains to the hot-mix asphalt aspects of the project and not to

SECTION 32 12 15.13 Page 3 any surface preparation requirements dealing with aggregate base courses, milling, or tack and prime coats. Cover surface preparation requirements by either including them in this guide specification or by adding pertinent sections to the project documents.

This specification utilizes a Quality Assurance and Quality Control (QA/QC) construction management philosophy. Quality Assurance refers to the actions performed by the Government or designated representative Engineer to assure the final product meets the job requirements (see paragraph QUALITY ASSURANCE). Results of QA testing are the basis for pay. Quality Control refers to the actions of the Contractor to monitor the construction and production processes and to correct these processes when out of control. Results of QC testing are reported daily on the process control charts maintained by the Contractor. Quality Control is covered in paragraph CONTRACTOR QUALITY CONTROL.

1.1 FULL PAYMENT

1.1.1 Method of Measurement

NOTE: For unit-price contracts, include first bracketed statements and delete the second set. For lump sum contracts, delete the first bracketed statements and include the second set.

[The amount paid for will be the number of metric short tons of hot-mix asphalt mixture used in the accepted work. Hot-mix asphalt mixture shall be weighed after mixing, and no separate payment will be made for weight of asphalt cement material incorporated herein.] [Measurement of the quantity of hot-mix asphalt, per ton placed and accepted, shall be made for the purposes of assessing the pay factors stipulated below.]

1.1.2 Basis of Payment

NOTE: For unit-price contracts, include first bracketed statements and delete the second set. For lump sum contracts, delete the first bracketed statements and include the second set. Include prescriptive unit price based on the Government/Engineer estimate for payment adjustment. lump sum contracts should not be used when the job exceeds 1000 metric tons tons.

[Quantities of hot-mix asphalt, determined as specified above, will be paid for at respective contract unit prices or at reduced prices adjusted in accordance with paragraphs PERCENT PAYMENT and QUALITY ASSURANCE. Payment will constitute full compensation for furnishing all materials, equipment, plant, and tools; and for all labor and other incidentals necessary to

SECTION 32 12 15.13 Page 4 complete work required by this section of the specification.] [The measured quantity of hot-mixed asphalt will be paid for and included in the lump sum contract price. If less than 100 percent payment is due based on the pay factors stipulated in paragraph QUALITY ASSURANCE, a unit price of [_____] per ton will be used for purposes of calculating the payment reduction.]

1.2 PERCENT PAYMENT

When a lot of material fails to meet the specification requirements for 100 percent pay as outlined in the following paragraphs, that lot shall be removed and replaced, or accepted at a reduced price which will be computed by multiplying the unit price by the lot's pay factor. The lot pay factor is determined by taking the lowest computed pay factor based on either laboratory air voids, in-place density, grade or smoothness (each discussed below). Pay factors based on different criteria (i.e., laboratory air voids and in-place density) of the same lot will not be multiplied together to get a lower lot pay factor. At the end of the project, an average of all lot pay factors will be calculated. If this average lot pay factor exceeds 95.0 percent and no individual lot has a pay factor less than 75.1 percent, then the percent payment for the entire project will be 100 percent of the unit bid price. If the average lot pay factor is less than

95.0 percent, then each lot will be paid for at the unit price multiplied by the lot's pay factor. For any lots which are less than 2000 metric short tons, a weighted lot pay factor will be used to calculate the average lot pay factor.

1.2.1 Mat and Joint Densities

The average in-place mat and joint densities are expressed as a percentage of the average theoretical maximum density (TMD) for the lot. The average TMD for each lot will be determined as the average TMD of the two random samples per lot. The average in-place mat density and joint density for a lot are determined and compared with Table 1 to calculate a single pay factor per lot based on in-place density, as described below. First, a pay factor for both mat density and joint density are determined from Table 1.

The area associated with the joint is then determined and will be considered to be 3 m 10 feet wide times the length of completed longitudinal construction joint in the lot. This area will not exceed the total lot size. The length of joint to be considered will be that length where a new lane has been placed against an adjacent lane of hot-mix asphalt pavement, either an adjacent freshly paved lane or one paved at any time previously. The area associated with the joint is expressed as a percentage of the total lot area. A weighted pay factor for the joint is determined based on this percentage (see example below). The pay factor for mat density and the weighted pay factor for joint density is compared and the lowest selected. This selected pay factor is the pay factor based on density for the lot. When the TMD on both sides of a longitudinal joint is different, the average of these two TMD will be used as the TMD needed to calculate the percent joint density. Rejected lots shall be removed and replaced. Rejected areas adjacent to longitudinal joints shall be removed 100 mm 4 inches into the cold (existing) lane. All density results for a lot will be completed and reported within 24 hours after the construction of that lot.

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Table 1. Pay Factor Based on In-place Density

Average Mat Density (4 cores)

Pay Factor, percent Average Joint Density (4 cores)

94.0 - 96.0 100.0 Above 92.5

93.9 100.0 92.4

93.8 or 96.1 99.9 92.3

93.7 99.8 92.2

93.6 or 96.2 99.6 92.1

93.5 99.4 92.0

93.4 or 96.3 99.1 91.9

93.3 98.7 91.8

93.2 or 96.4 98.3 91.7

93.1 97.8 91.6

93.0 or 96.5 97.3 91.5

92.9 96.3 91.4

92.8 or 96.6 94.1 91.3

92.7 92.2 91.2

92.6 or 96.7 90.3 91.1

92.5 87.9 91.0

92.4 or 96.8 85.7 90.9

92.3 83.3 90.8

92.2 or 96.9 80.6 90.7

92.1 78.0 90.6

92.0 or 97.0 75.0 90.5 below 92.0, above 97.0 0.0 (reject) below 90.5

1.2.2 Pay Factor Based on In-place Density

An example of the computation of a pay factor (in I-P units only) based on in-place density, is as follows: Assume the following test results for field density made on the lot: (1) Average mat density = 93.2 percent (of lab TMD). (2) Average joint density = 91.5 percent (of lab TMD). (3)

SECTION 32 12 15.13 Page 6

Total area of lot = 30,000 square feet. (4) Length of completed longitudinal construction joint = 2,000 feet.

a. Step 1: Determine pay factor based on mat density and on joint density, using Table 1:

Mat density of 93.2 percent = 98.3 pay factor.

Joint density of 91.5 percent = 97.3 pay factor.

b. Step 2: Determine ratio of joint area (length of longitudinal joint x 10 feet) to mat area (total paved area in the lot): Multiply the length of completed longitudinal construction joint by the specified 10 feet width and divide by the mat area (total paved area in the lot).

(2,000 feet x 10 feet)/30000 square feet = 0.6667 ratio of joint area to mat area (ratio).

c. Step 3: Weighted pay factor (wpf) for joint is determined as indicated below:

wpf = joint pay factor + (100 - joint pay factor) (1 - ratio) wpf =

97.3 + (100-97.3) (1-.6667) = 98.2 percent

d. Step 4: Compare weighted pay factor for joint density to pay factor for mat density and select the smaller:

Pay factor for mat density: 98.3 percent. Weighted pay factor for joint density: 98.2 percent

Select the smaller of the two values as pay factor based on density:

98.2 percent

1.2.3 Payment Adjustment for Smoothness (Final Wearing Surface Only)

Profilograph Testing. Record the location and data from all profilograph measurements. When the Profile Index of a lot exceeds the tolerance specified in paragraph SMOOTHNESS REQUIREMENTS by 16 mm per km 1.0 inch per mile, but less than 32 mm per km 2.0 inches per mile, after any reduction of high spots or removal and replacement, the computed pay factor for that lot based on surface smoothness will be 95 percent. When the Profile Index exceeds the tolerance by 32 mm per km 2.0 inches per mile, but less than 47 mm perkm 3.0 inches per mile, the computed pay factor will be 90 percent.

When the Profile Index exceeds the tolerance by 47 mm per km 3.0 inches per mile, but less than 63 mm per km 4.0 inches per mile, the computed pay factor will be 75 percent. Remove and replact the lot when the Profile Index exceeds the tolerance by 63 mm per km 4.0 inches per mile or more, at no additional cost to the Government Owner. Regardless of the above, correct any small individual area with surface deviation which exceeds the tolerance given above by more than 79 mm per km 5.0 inches per mile or more, by grinding to meet the specification requirements above or remove and replace at no additional cost to the Government Owner.

1.2.4 Laboratory Air Voids and Theoretical Maximum Density

Laboratory air voids will be calculated in accordance with ASTM D3203/D3203M by determining the density of each lab compacted specimen using the laboratory-prepared, thoroughly dry method in ASTM D2726/D2726M and determining the theoretical maximum density (TMD) of two of the sublots

SECTION 32 12 15.13 Page 7 using ASTM D2041/D2041M . Laboratory air void calculations for each lot will use the average theoretical maximum density values obtained for the lot. The mean absolute deviation of the four laboratory air void contents (one from each sublot) from the JMF air void content will be evaluated and a pay factor determined from Table 2. All laboratory air void tests will be completed and reported within 24 hours after completion of construction of each lot. The TMD is also used for computation of compaction, as required in paragraph MAT AND JOINT DENSITIES above.

1.2.5 Mean Absolute Deviation

An example of the computation of mean absolute deviation for laboratory air voids is as follows: Assume that the laboratory air voids are determined from 4 random samples of a lot (where 3 specimens were compacted from each sample). The average laboratory air voids for each sublot sample are determined to be 3.5, 3.0, 4.0, and 3.7. Assume that the target air voids from the JMF is 4.0. The mean absolute deviation is then:

Mean Absolute Deviation = (|3.5 - 4.0| + |3.0 - 4.0| + |4.0 - 4.0| + |3.7 - 4.0|)/4

= (0.5 + 1.0 + 0.0 + 0.3)/4 = (1.8)/4 = 0.45

The mean absolute deviation for laboratory air voids is determined to be

0.45. It can be seen from Table 2 that the lot's pay factor based on laboratory air voids, is 100 percent.

Table 2. Pay Factor Based on Laboratory Air Voids

Mean Absolute Deviation of Lab Air Voids from JMF Pay Factor, Percent

O.60 or less 100

0.61 - 0.80 98

0.81 - 1.00 95

1.01 - 1.20 90

Above 1.20 reject (0)

1.2.6 Pay Adjustment Based on Grade

NOTE: The grade and surface smoothness requirements specified below are for the final wearing surface only. If there is a requirement to test and control the grade and smoothness for the intermediate courses, for example, when the intermediate courses will be exposed to traffic, slight modifications to this specification will be required.

Within 5 working days after completion of a particular lot incorporating the final wearing course, test the final wearing surface of the pavement for conformance with specified plan grade requirements. Perform all testing in the presence of the Governmentr Engineer . Provide a final wearing surface of pavement conforming to the elevations and cross sections

SECTION 32 12 15.13 Page 8 shown and not vary more than 9 mm 0.03 foot for runways or 15 mm 0.05 foot for taxiways and aprons from the plan grade established and approved at site of work. Match finished surfaces at juncture with other pavements with finished surfaces of abutting pavements. Deviation from the plan elevation will not be permitted in areas of pavements where closer conformance with planned elevation is required for the proper functioning of drainage and other appurtenant structures involved. The grade will be determined by running lines of levels at intervals of 7.6 m 25 feet, or less, longitudinally and transversely, to determine the elevation of the completed pavement surface. Maintain detailed notes of the results of the testing and provide a copy to the Government Engineer immediately after each day's testing. When more than 5 percent of all measurements made within a lot are outside the 9 or 15 mm 0.03 or 0.05 foot tolerance, the pay factor based on grade for that lot will be 95 percent. In areas where the grade exceeds the tolerance by more than 50 percent, remove the surface lift full depth; and replace the lift with hot-mix asphalt to meet specification requirements, at no additional cost to the Government Owner. Diamond grinding may be used to remove high spots to meet grade requirements. Skin patching for correcting low areas or planing or milling for correcting high areas will not be permitted.

1.3 REFERENCES

NOTE: This paragraph is used to list the publications cited in the text of the guide specification. The publications are referred to in the text by basic designation only and listed in this paragraph by organization, designation, date, and title.

Use the Reference Wizard's Check Reference feature when you add a RID outside of the Section's Reference Article to automatically place the reference in the Reference Article. Also use the Reference Wizard's Check Reference feature to update the issue dates.

References not used in the text will automatically be deleted from this section of the project specification when you choose to reconcile references in the publish print process.

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

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

AASHTO M 156 (2013) Standard Specification for Requirements for Mixing Plants for Hot-Mixed, Hot-Laid Bituminous Paving Mixtures

AASHTO M 320 (2010; 2015) Standard Specification for Performance-Graded Asphalt Binder

SECTION 32 12 15.13 Page 9

AASHTO T 304 (2011; R 2015) Standard Method of Test for Uncompacted Void Content of Fine Aggregate

AASHTO T 308 (2010; R 2015) Standard Method of Test for Determining the Asphalt Binder Content of Hot Mix Asphalt (HMA) by the Ignition Method

AASHTO T 329 (2015) Standard Test Method for Moisture Content of Hot Mix Asphalt (HMA) by Oven Method

ASPHALT INSTITUTE (AI)

AI MS-2 (2015) Asphalt Mix Design Methods

ASTM INTERNATIONAL (ASTM)

ASTM C117 (2013) Standard Test Method for Materials Finer than 75-um (No. 200) Sieve in Mineral Aggregates by Washing

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

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

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

ASTM C136/C136M (2014) Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates

ASTM C142/C142M (2010) Standard Test Method for Clay Lumps and Friable Particles in Aggregates

ASTM C29/C29M (2009) Standard Test Method for Bulk Density ("Unit Weight") and Voids in Aggregate

ASTM C566 (2013) Standard Test Method for Total Evaporable Moisture Content of Aggregate by Drying

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

ASTM D140/D140M (2015) Standard Practice for Sampling Bituminous Materials

ASTM D1461 (2011) Moisture or Volatile Distillates in Bituminous Paving Mixtures

SECTION 32 12 15.13 Page 10

ASTM D2041/D2041M (2011) Theoretical Maximum Specific Gravity and Density of Bituminous Paving Mixtures

ASTM D2172/D2172M (2011) Quantitative Extraction of Bitumen from Bituminous Paving Mixtures

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

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

ASTM D2489/D2489M (2008) Estimating Degree of Particle Coating of Bituminous-Aggregate Mixtures

ASTM D2726/D2726M (2014) Bulk Specific Gravity and Density of Non-Absorptive Compacted Bituminous Mixtures

ASTM D3203/D3203M (2011) Percent Air Voids in Compacted Dense and Open Bituminous Paving Mixtures

ASTM D3665 (2012) Random Sampling of Construction Materials

ASTM D3666 (2013) Standard Specification for Minimum Requirements for Agencies Testing and Inspecting Road and Paving Materials

ASTM D4125/D4125M (2010) Asphalt Content of Bituminous Mixtures by the Nuclear Method

ASTM D4791 (2010) Flat Particles, Elongated Particles, or Flat and Elongated Particles in Coarse Aggregate

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

ASTM D5444 (2015) Mechanical Size Analysis of Extracted Aggregate

ASTM D6307 (2010) Asphalt Content of Hot Mix Asphalt by Ignition Method

ASTM D6925 (2014) Standard Test Method for Preparation and Determination of the Relative Density of Hot Mix Asphalt (HMA) Specimens by Means of the Superpave Gyratory Compactor

ASTM D6926 (2010) Standard Practice for Preparation of Bituminous Specimens Using Marshall Apparatus

ASTM D6927 (2015) Standard Test Method for Marshall Stability and Flow of Bituminous Mixtures

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ASTM D75/D75M (2014) Standard Practice for Sampling Aggregates

ASTM D946/D946M (2009a) Penetration-Graded Asphalt Cement for Use in Pavement Construction

ASTM D979/D979M (2015) Sampling Bituminous Paving Mixtures

ASTM E1274 (2003; R 2012) Standard Test Method for Measuring Pavement Roughness Using a Profilograph

U.S. ARMY CORPS OF ENGINEERS (USACE)

COE CRD-C 171 (1995) Standard Test Method for Determining Percentage of Crushed Particles in Aggregate

1.4 SUBMITTALS

NOTE: Review submittal description (SD) definitions in Section 01 33 00 SUBMITTAL PROCEDURES and edit the following list to reflect only the submittals required for the project.

The Guide Specification technical editors have designated those items that require Government approval, due to their complexity or criticality, with a "G." Generally, other submittal items can be reviewed by the Contractor's Quality Control System. Only add a “G” to an item, if the submittal is sufficiently important or complex in context of the project.

For submittals requiring Government approval on Army projects, a code of up to three characters within the submittal tags may be used following the "G" designation to indicate the approving authority.

Codes for Army projects using the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO" for District Office (Engineering Division or other organization in the District Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project Office. Codes following the "G" typically are not used for Navy, Air Force, and NASA projects.

An "S" following a submittal item indicates that the submittal is required for the Sustainability Notebook to fulfill federally mandated sustainable requirements in accordance with Section 01 33 29

SUSTAINABILITY REPORTING.

Choose the first bracketed item for Navy, Air Force and NASA projects, or choose the second bracketed item for Army projects.

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Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for [Contractor Quality Control approval.] [information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.] Submittals with an "S" are for inclusion in the Sustainability Notebook, in conformance to Section 01 33 29 SUSTAINABILITY REPORTING. Submit the following in accordance with Section 01 33 00

SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Placement Plan; G [, [_____]]

SD-03 Product Data

Diamond Grinding Plan; G [, [_____]] Mix Design; G [, [_____]] Contractor Quality Control; G [, [_____]]

SD-04 Samples

Aggregates Asphalt Cement Binder

SD-06 Test Reports

Aggregates; G [, [_____]] QC Monitoring

SD-07 Certificates

Asphalt Cement Binder; G [, [_____]] Testing Laboratory

1.5 QUALITY ASSURANCE[ AND QUALITY CONTROL]

NOTE: It is highly recommended to keep the Government Engineer's QA acceptance testing separate and distinct from the Contractor's QC testing for all runway, taxiway, and apron projects. However, it is recognized that in-house testing capability to provide the QA acceptance testing required by this section will not always be available; in this case, it is recommended that an independent material testing company be hired to provide the QA testing for the project. The cost of this testing to assure good long-term performance is very small relative to the overall cost of the construction, and especially compared to the cost of a pavement failure.

QA acceptance testing for projects consisting only of shoulder or overrun areas can be performed by either the Government or Contractor. Although not recommended, this guide specification may be modified to require the Contractor to hire an independent material testing laboratory to perform the QA testing listed in this section. The results would need to be forwarded daily to the Contracting

SECTION 32 12 15.13 Page 13

Officer Engineer as the basis for acceptance and pay.

Based on the above, delete the appropriate bracketed statement below.

The QA acceptance testing program includes material tests to determine laboratory air voids and in-place density, which are needed to determine percent payment. The project engineer may choose to have additional tests conducted by the QA acceptance test agency to monitor aggregate gradation, asphalt content, and volumetric properties. These tests would serve as a check to the Contractor's QC testing.

For projects with less than 2000 total metric tons tons, the entire project can be considered as a single lot. In this case, sublot sampling could occur over several days' production, which could lead to higher sublot variability.

[The Government Engineer's quality assurance (QA) program for this project is separate and distinct from the Contractor's quality control (QC) program specified in Part 3. Testing for acceptability of work will be performed by the Government Engineer or by an independent laboratory hired by the Contracting Officer Engineer , except for grade and smoothness testing which shall be performed by the Contractor.][ Aquire the services of an independent commercial laboratory to perform acceptance testing.] Acceptance of the plant produced mix and in-place requirements will be on a lot to lot basis. A standard lot for all requirements will be equal to 2000 metric short tons. Where appropriate, adjustment in payment for individual lots of hot-mix asphalt will be made based on in-place density, laboratory air voids, grade and smoothness in accordance with the following paragraphs. Grade and surface smoothness determinations will be made on the lot as a whole. Exceptions or adjustments to this will be made in situations where the mix within one lot is placed as part of both the intermediate and surface courses, thus grade and smoothness measurements for the entire lot cannot be made. In order to evaluate laboratory air voids and in-place (field) density, each lot will be divided into four equal sublots.

1.5.1 Sublot Sampling

One random mixture sample for determining laboratory air voids, theoretical maximum density, and for any additional testing the Government Engineer desires, will be taken from a loaded truck delivering mixture to each sublot, or other appropriate location for each sublot. All samples will be selected randomly, using commonly recognized methods of assuring randomness conforming to ASTM D3665 and employing tables of random numbers or computer programs. Laboratory air voids will be determined from three laboratory compacted specimens of each sublot sample in accordance with ASTM D3203/D3203M . The specimens will be compacted within 2 hours of the time the mixture was loaded into trucks at the asphalt plant. Samples will not be reheated prior to compaction and insulated containers will be used as necessary to maintain the temperature.

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1.5.2 Additional Sampling and Testing

The Contracting Officer Engineer reserves the right to direct additional samples and tests for any area which appears to deviate from the specification requirements. The cost of any additional testing will be paid for by the Government Owner. Testing in these areas will be treated as a separate lot. Payment will be made for the quantity of HMA represented by these tests in accordance with the provisions of this section.

1.5.3 In-place Density

NOTE: Retain the bracketed text when editing for Government Engineer's QA acceptance testing separate and distinct from the Contractor's QC testing as described in the above Designer Note (all runway, taxiway, and apron projects). Delete the bracketed text when specification is edited for Contractor QA testing.

For determining in-place density, obtain one random core (100 mm 4 inches or 150 mm 6 inches in diameter) at locations [identified by the Government Engineer ]from the mat (interior of the lane and at least 300 mm 12 inches from longitudinal joint or pavement edge) of each sublot, and one random core taken from the joint (immediately over joint) of each sublot, in accordance with ASTM D979/D979M. Fill all core holes with hot-mix and compact using a standard Marshall hammer to a mat density as specified.

Tack coat dry core holes before filling. Each random core will be full thickness of the layer being placed. When the random core is less than 25 mm 1 inch thick, it will not be included in the analysis. In this case, another random core will be taken. After air drying to meet the requirements for laboratory-prepared, thoroughly dry specimens, cores obtained from the mat and from the joints will be used for in-place density determination in accordance with ASTM D2726/D2726M .

1.5.4 Surface Smoothness

Use a straightedge and profilograph for measuring surface smoothness of runway pavements. Use a straightedge for measuring surface smoothness of all other pavement surfaces. Perform all testing in the presence of the Government Engineer . Maintain detailed notes of the testing results and provide a copy to the Government Engineer immediately after each day's testing. Where drawings show required deviations from a plane surface (for instance crowns, drainage inlets), finish the surface to meet the approval of the Government Engineer .

1.5.4.1 Smoothness Requirements

1.5.4.1.1 Straightedge Testing

Provide finished surfaces of the pavements withe no abrupt change of 3 mm 1/8 inch or more, and all pavements within the tolerances specified in Table 3 when checked with an approved 4 m 12 foot straightedge.

SECTION 32 12 15.13 Page 15

Table 3. Straightedge Surface Smoothness--Pavements

Pavement Category Direction of Testing Tolerance, mm inch

Runways and taxiway Longitudinal 31/8

Transverse 61/4

Shoulders (outside edge stripe)

Longitudinal 61/4

Transverse 61/4

Calibration hardstands and compass swinging bases

Longitudinal 31/8

Transverse 31/8

All other airfields and helicopter paved areas

Longitudinal 61/4

Transverse 61/4

1.5.4.1.2 Profilograph Testing

Provide finished surfaces of runways with a Profile Index not greater than 110 mm per km 7 inches per mile when tested with an approved California-type profilograph.

1.5.4.2 Testing Method

After the final rolling, but not later than 24 hours after placement, test the surface of the pavement in each entire lot in a manner to reveal surface irregularities exceeding the tolerances specified above. If any pavement areas are diamond ground, retest these areas immediately after diamond grinding. The maximum area allowed to be corrected by diamond grinding is 10 percent of the total area of the lot. Test the entire area of the pavement with a profilograph. Check a number of random locations along with any observed suspicious locations primarily at transverse and longitudinal joints with the straightedge.

1.5.4.2.1 Straightedge Testing

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

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

1.5.4.2.2 Profilograph Testing

Perform profilograph testing using an approved California profilograph and procedures described in ASTM E1274. Provide equipment that utilizes electronic recording and automatic computerized reduction of data to

SECTION 32 12 15.13 Page 16 indicate "must-grind" bumps and the Profile Index for the pavement. Use a "blanking band" that is 5 mm 0.2 inch wide and the "bump template" span ning 25 mm 1 inch with an offset of 10 mm 0.4 inch. Provide profilograph operated by an approved, factory-trained operator on the alignments specified above. Provide a copy of the reduced tapes to the Government Engineer at the end of each day's testing.

1.5.4.2.3 Bumps ("Must Grind" Areas)

Reduce any bumps ("must grind" areas) shown on the profilograph trace which exceed 10 mm 0.4 inch in height by diamond grinding until they do not exceed

7.5 mm 0.3 inch when retested. Taper diamond grinding in all directions to provide smooth transitions to areas not requiring diamond grinding. The following will not be permitted: (1) skin patching for correcting low areas, (2) planing or milling for correcting high areas. [ At the Contractor's option, pavement areas, including diamond ground areas, can be rechecked with the profilograph in order to record a lower Profile Index.][ Perform additional profilograph testing in all areas corrected by diamond grinding.]

1.6 ENVIRONMENTAL REQUIREMENTS

NOTE: The temperature requirements in Table 5 are included to avoid problems with the Contractor achieving density because the mix cools too fast.

Waivers to these requirements, for isolated incidences during production, are applicable if the density requirements are still met.

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

The temperature requirements may be waived by the Government Engineer , if requested; provided all other requirements, including compaction, are met.

Table 4. Surface Temperature Limitations of Underlying Course

Mat Thickness, mm inches Degrees C F

75 3 or greater 440

Less than 75 3 745

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

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

SECTION 32 12 15.13 Page 17

2.1.1 Asphalt Mixing Plant

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

2.1.1.1 Truck Scales

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

2.1.1.2 Inspection of Plant

Provide access to the Contracting Officer Engineer at all times, to all areas of the plant for checking adequacy of equipment; inspecting operation of the plant; verifying weights, proportions, and material properties;

checking the temperatures maintained in the preparation of the mixtures and for taking samples. Provide assistance as requested, for the Government Engineer to procure any desired samples.

2.1.1.3 Storage Bins

The asphalt mixture may be stored in non-insulated storage bins for a period of time not exceeding 3 hours. The asphalt mixture may be stored in insulated storage bins for a period of time not exceeding 8 hours. Provide the mix drawn from bins that meets the same requirements as mix loaded directly into trucks.

2.1.2 Hauling Equipment

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

2.1.3 Material Transfer Vehicle (MTV)

NOTE: A Material Transfer Vehicle (MTV) is required for runway and taxiway construction. The use of an MTV is optional for shoulder construction.

Provide Material transfer Vehicles for placement of the hot mix asphalt.

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

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

SECTION 32 12 15.13 Page 18

2.1.4 Asphalt Pavers

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

2.1.4.1 Receiving Hopper

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

2.1.4.2 Automatic Grade Controls

NOTE: Delete information on automatic grade control if not needed. Automatic grade control is needed when the design requires elevations for the hot-mix asphalt surface. Many maintenance and rehabilitation projects require an overlay thickness and do not specify actual grades.

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

a. Ski-type device of not less than 9.14 m 30 feet in length.

b. Taut stringline set to grade.

c. Short ski or shoe for joint matching.

d. Laser control.

2.1.5 Rollers

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

2.1.6 Diamond Grinding

Those performing diamond grinding are required to have a minimum of three

SECTION 32 12 15.13 Page 19 years experience in diamond grinding of airfield pavements. In areas not meeting the specified limits for surface smoothness and plan grade, reduce high areas to attain the required smoothness and grade, except as depth is limited below. Reduce high areas by diamond grinding the hardened concrete with an approved equipment after the concrete is at a minimum age of 14 days. Perform diamond grinding by sawing with an industrial diamond abrasive which is impregnated in the saw blades. Assemble the saw blades in a cutting head mounted on a machine designed specifically for diamond grinding that produces the required texture and smoothness level without damage to the concrete pavement or joint faces. Provide diamond grinding equipment with saw blades that are 3 mm 1/8-inch wide, a minimum of 60 blades per 300 mm 12 inches of cutting head width, and capable of cutting a path a minimum of 0.9 m 3 ft wide. Diamond grinding equipment that causes ravels, aggregate fractures, spalls or disturbance to the joints is not be permitted. The maximum area corrected by diamond grinding the surface of the hardened concrete is 10 percent of the total area of any sublot. The maximum depth of diamond grinding is 6 mm 1/4 inch. Provide diamond grinding machine equipped to flush and vacuum the pavement surface.

Dispose of all debris from diamond grinding operations off Government property. Prior to diamond grinding, submit a Diamond Grinding Plan for review and approval. At a minimum, include the daily reports for the deficient areas, the location and extent of deficiencies, corrective actions, and equipment. Remove and replace all pavement areas requiring plan grade or surface smoothness corrections in excess of the limits specified above in conformance with paragraph REPAIR, REMOVAL AND REPLACEMENT OF NEWLY CONSTRUCTED SLABS. [Retexture pavement areas given a wire comb or tined texture, areas exceeding 2 square meters 25 square feet that have been corrected by diamond grinding by transverse grooving using an approved grooving machine of standard manufacture. Provide grooves that are 6 mm 1/4 inch deep by 6 mm 1/4 inch wide on 37 mm 1-1/2 inch centers and carried into, and tapered to zero depth within the non-corrected surface, or match any existing grooves in the adjacent pavement. ]All areas in which diamond grinding has been performed will be subject to the thickness tolerances specified in paragraph THICKNESS, above.

Prior to production diamond grinding operations, perform a test section at the approved location, consisting of a minimum of two adjacent passes with a minimum length of 12 m 40 feet to allow evaluation of the finish, transition between adjacent passes, and the results of crossing a transverse joint. Production diamond grinding operations cannot be performed prior to approval.

2.2 AGGREGATES

Sample aggregates in the presence of a Government Representative. Obtain samples in accordance with ASTM D75/D75M and be representative of the materials to be used for the project. Provide aggregates consisting of crushed stone, crushed gravel, crushed slag, screenings, natural sand and mineral filler, as required. The portion of material retained on the 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 kg 200 pounds of blended mixture for mix design verification. Submit all aggregate test results and samples to the Government Engineer at least 14 days prior to start of construction. Perform job aggregate testing no earlier than 6 months before contract award.

SECTION 32 12 15.13 Page 20

2.2.1 Coarse Aggregate

NOTE: The requirement for sulfate soundness (requirement b., below) may be deleted in climates where freeze-thaw does not occur. However, in those areas where freeze-thaw does not occur, requirement

b. must remain if experience has shown that this test separates good performing aggregates from bad performing aggregates. Retain this requirement for all Navy projects.

Percentage of Wear (ASTM C131/C131M) must not exceed

40. Aggregates with a higher percentage of wear may be specified, provided a satisfactory record under similar conditions of service and exposure has been demonstrated.

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

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

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

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

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

e. Slag consisting of air-cooled, blast furnace slag, with a compacted weight of not less than 1200 kg per cubic meter 75 pounds per cubic foot when tested in accordance with ASTM C29/C29M.

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

2.2.2 Fine Aggregate

NOTE: Set the lower limit for uncompacted void content (requirement c., below) at 45 for fine aggregate angularity unless local experiences indicate that a lower value can be used. There are some aggregates which have a good performance record and have an uncompacted void content less than 45.

In no case set the limit at less than 43.

SECTION 32 12 15.13 Page 21

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

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

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

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

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

2.2.3 Mineral Filler

Provide mineral filler consisting of a nonplastic material meeting the requirements of ASTM D242/D242M.

2.2.4 Aggregate Gradation

NOTE: Delete from Table 5, the gradations that will not be used as a part of this project..

Use of gradation 1 must be limited to intermediate courses. Gradation 2 is suitable for intermediate and surface courses. Use of gradation 3 must be limited to shoulders and leveling courses. Do not use gradation 1 for surface courses.

Generally, the layer thickness for gradation No. 1 would be at least 57 mm 2.25 inches, the thickness for gradation No. 2 would be at least 37.5 mm 1.5 inches, and thickness for gradation No. 3 would be at least 25 mm 1.0 inch. The preferred thickness of the surface layer is 50 mm 2 inches. The surface layer should not be less than 37 mm 1.5 inches. The thickness of the underlying layers can be up to 75 mm 3 inches depending on the total designed thickness of the asphalt mixture.

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

SECTION 32 12 15.13 Page 22

Table 5. Aggregate Gradations

Gradation 1 Gradation 2 Gradation 3

Sieve Size, mm inch Percent Passing by Mass

Percent Passing by Mass

Percent Passing by Mass

25.01 100 --- ---

19.03/4 90-100 100 ---

12.51/2 68-88 90-100 100

9.53/8 60-82 69-89 90-100

4.75No. 4 45-67 53-73 58-78

2.36No. 8 32-54 38-60 40-60

1.18No. 16 22-44 26-48 28-48

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

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

0.15No. 100 6-18 6-18 6-18

0.075No. 200 3-6 3-6 3-6

2.3 ASPHALT CEMENT…