32_12_16_(HMA_for_Roads).pdf

SECTION 32 12 16 Page 1

JOINT BASE LEWIS-MCCHORD (JBLM) DESIGN STANDARDS

SECTION 32 12 16 - HOT-MIX ASPHALT (HMA) FOR ROADS

Design Requirements Pavement Marking: Paving done adjacent to a fire hydrant shall include the addition of a blue double sided reflectorized raised pavement marker in the roadway at the location shown in "Typical Fire Hydrant Location Pavement Markers , available on the JBLM Design Standards.

Detailed specifications for the pavement markers can be found in the Washington State Department of Transportation Standard Specification for Bridge and Road Construction, Sections 8-09 & 9-21.

SECTION 32 12 16

HOT-MIX ASPHALT (HMA) FOR ROADS

08/09

PART 1 GENERAL

1.1 UNIT PRICES

1.2 REFERENCES

1.3 SUBMITTALS

1.4 ENVIRONMENTAL REQUIREMENTS

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

2.2 AGGREGATES

2.3 ASPHALT CEMENT BINDER

2.4 MIX DESIGN

2.5 RECYCLED HOT MIX ASPHALT

PART 3 EXECUTION

3.1 PREPARATION OF ASPHALT BINDER MATERIAL

3.2 PREPARATION OF MINERAL AGGREGATE

3.3 PREPARATION OF HOT-MIX ASPHALT MIXTURE

3.4 PREPARATION OF THE UNDERLYING SURFACE

3.5 TEST SECTION

3.6 TESTING LABORATORY

3.7 TRANSPORTING AND PLACING

3.8 COMPACTION OF MIXTURE

3.9 JOINTS

3.10 QUALITY CONTROL

3.11 MATERIAL ACCEPTANCE

http://lewic2pw075:8092/doc_files/Fronts/HydrantPavementMarkers.pdf

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PART 1 GENERAL

1.1 REFERENCES

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 320 (2010; 2015) Performance-Graded Asphalt binder

ASPHALT INSTITUTE (AI)

AI MS-02 (2015) Mix Design Methods for Asphalt

AI MS-22 (2nd Edition; 2001) Construction of Hot-Mix

Asphalt Pavements

AI SP-2 (2001; 3rd Ed) Superpave Mix Design

ASTM INTERNATIONAL (ASTM)

ASTM C 117 (2013) Standard Test Method for Materials

Finer than 75-um (No. 200) Sieve in Mineral Aggregates by Washing

ASTM C 1252 (2006) Standard Test Methods for Uncompacted

Void Content of Fine Aggregate (as Influenced by Particle Shape, Surface Texture, and Grading)

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 C 29/C 29M (2009) Standard Test Method for Bulk Density

("Unit Weight") and Voids in Aggregate

ASTM C 566 (2013) Standard Test Method for Total

Evaporable Moisture Content of Aggregate by Drying

ASTM C 88 (2013) Standard Test Method for Soundness of

Aggregates by Use of Sodium Sulfate or Magnesium Sulfate

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ASTM D140/D140M (2015) Sampling Bituminous Materials

ASTM D 1461 (2011) Moisture or Volatile Distillates in

Bituminous Paving Mixtures

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

ASTM D 2419 (2014) Standard Test Method for 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 D2950/D2950M (2014) Density of Bituminous Concrete in

Place by Nuclear Methods

ASTM D 3665 (2012) Random Sampling of Construction

Materials

ASTM D 3666 (2013) 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 D 4791 (2010) Flat Particles, Elongated Particles, or Flat and Elongated Particles in Coarse Aggregate

ASTM D 4867/D 4867M (2009; R 2014) Effect of Moisture on Asphalt

Concrete Paving Mixtures

ASTM D 5444 (2015) Mechanical Size Analysis of Extracted

Aggregate

ASTM D 6307 (2010) Asphalt Content of Hot Mix Asphalt by

Ignition Method

ASTM D 6926 (2010) Preparation of Bituminous Specimens

Using Marshall Apparatus

ASTM D 6927 (2015) Standard Test Method for Marshall

Stability and Flow of Bituminous Mixtures

STATE OF CALIFORNIA DEPARTMENT OF TRANSPORTATION (CALTRANS)

CTM 526 (2002) Operation of California Profilograph and Evaluation of Profiles

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U.S. ARMY CORPS OF ENGINEERS (USACE)

COE CRD-C 171 (1995) Standard Test Method for Determining

Percentage of Crushed Particles in Aggregate

1.2 SYSTEM DESCRIPTION

The work shall consist of pavement courses composed of mineral aggregate and asphalt material heated and mixed in a central mixing plant and placed on a prepared course. HMA designed and constructed in accordance with this section shall conform to the lines, grades, thicknesses, and typical cross sections indicated in the delivery order or task order. Each course shall be constructed to the depth, section, or elevation required by the drawings and shall be rolled, finished, and approved before the placement of the next course.

1.2.1 Asphalt Mixing Plant

Plants used for the preparation of hot-mix asphalt shall conform to the requirements of ASTM D 995 with the following changes:

a. Truck Scales. The asphalt mixture shall be weighed on approved certified scales at the Contractor's expense. Scales shall be inspected and sealed at least annually by an approved calibration laboratory.

b. Testing Facilities. The Contractor shall provide laboratory facilities at the plant for the use of the Government's acceptance testing and the Contractor's quality control testing.

c. Inspection of Plant. The Contracting Officer shall have access at all times, to all areas of the plant for checking adequacy of equipment; inspecting operation of the plant; verifying weights, proportions, and material properties; checking the temperatures maintained in the preparation of the mixtures and for taking samples.

The Contractor shall provide assistance as requested, for the Government to procure any desired samples.

d. Storage Bins. Use of storage bins for temporary storage of hot-mix asphalt will be permitted as follows:

(1) The asphalt mixture may be stored in non-insulated storage bins for a period of time not exceeding 3 hours.

(2) The asphalt mixture may be stored in insulated storage bins for a period of time not exceeding 8 hours. The mix drawn from bins shall meet the same requirements as mix loaded directly into trucks.

1.2.2 Hauling Equipment

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

SECTION 32 12 16 Page 5 the mixture from adverse weather. When necessary to ensure that the mixture will be delivered to the site at the specified temperature, truck beds shall be insulated or heated and covers (tarps) shall be securely fastened.

1.2.3 Asphalt Pavers

Asphalt pavers shall be self-propelled, with an activated screed, heated as necessary, and shall be capable of spreading and finishing courses of hot-mix asphalt which will meet the specified thickness, smoothness, and grade.

The paver shall have sufficient power to propel itself and the hauling equipment without adversely affecting the finished surface.

1.2.3.1 Receiving Hopper

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

1.2.3.2 Automatic Grade Controls

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

The controls shall be capable of working in conjunction with any of the following attachments:

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

b. Taut stringline set to grade.

c. Short ski or shoe for joint matching.

d. Laser control.

1.2.4 Rollers

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

1.3 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-03 Product Data

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Mix Design; G

Proposed JMF.

Contractor Quality Control; G

Quality control plan.

Material Acceptance; G

Acceptance test results.

SD-04 Samples

Asphalt Cement Binder

A 5 gallon sample for mix design verification.

Aggregates

Sufficient materials to produce 200 lb of blended mixture for mix design verification.

SD-06 Test Reports

Aggregates; G QC Monitoring

Aggregate and QC test results.

SD-07 Certificates

Asphalt Cement Binder; G

Copies of certified test data.

Amount, type and description of any modifiers blended into the asphalt cement binder

Testing Laboratory

Certification of compliance.

Plant Scale Calibration Certification

1.4 ENVIRONMENTAL REQUIREMENTS

The hot-mix asphalt shall not be placed upon a wet surface or when the surface temperature of the underlying course is less than specified in Table

3. The temperature requirements may be waived by the Contracting Officer, if requested; however, all other requirements, including compaction, shall be met.

Table 3. Surface Temperature Limitations of Underlying Course Mat Thickness, inches Degrees F

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3 or greater 40 Less than 3 45

PART 2 PRODUCTS

2.1 AGGREGATES

Aggregates shall consist of crushed stone, crushed gravel, crushed slag, screenings, natural sand and mineral filler, as required. The portion of material retained on the No. 4 sieve is coarse aggregate. The portion of material passing the No. 4 sieve and retained on the No. 200 sieve is fine aggregate. The portion passing the No. 200 sieve is defined as mineral filler. All aggregate test results and samples shall be submitted to the Contracting Officer at least 14 days prior to start of construction.

2.1.1 Coarse Aggregate

Coarse aggregate shall consist of sound, tough, durable particles, free from films of material that would prevent thorough coating and bonding with the asphalt material and free from organic matter and other deleterious substances. All individual coarse aggregate sources shall meet the following requirements:

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

b. The percentage of loss shall not be greater than 18 percent after five cycles when tested in accordance with ASTM C 88 using magnesium sulfate.

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

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

e. Slag shall be air-cooled, blast furnace slag, and shall have a compacted weight of not less than 75 lb/cu ft when tested in accordance with ASTM C 29/C 29M.

f. Clay lumps and friable particles shall not exceed 0.3 percent, by weight, when tested in accordance with ASTM C 142.

2.1.2 Fine Aggregate

Fine aggregate shall consist of clean, sound, tough, durable particles. The aggregate particles shall be free from coatings of clay, silt, or any objectionable material and shall contain no clay balls.

a. All individual fine aggregate sources shall have a sand equivalent value not less than 45 when tested in accordance with ASTM D 2419.

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b. The fine aggregate portion of the blended aggregate shall have an uncompacted void content not less than 45.0 percent when tested in accordance with ASTM C 1252 Method A.

c. The quantity of natural sand (noncrushed material) added to the aggregate blend shall not exceed 25 percent by weight of total aggregate.

d. Clay lumps and friable particles shall not exceed 0.3 percent, by weight, when tested in accordance with ASTM C 142

2.1.3 Mineral Filler

Mineral filler shall be nonplastic material meeting the requirements of ASTM D 242.

2.1.4 Aggregate Gradation

The combined aggregate gradation shall conform to gradations specified in Table 2, when tested in accordance with ASTM C 136 and ASTM C 117, and shall not vary from the low limit on one sieve to the high limit on the adjacent sieve or vice versa, but grade uniformly from coarse to fine.

Table 4. Aggregate Gradations

Gradation 1 Gradation 2 Gradation 3 Percent Passing Percent Passing Percent Passing Sieve Size, inch by Mass by Mass by Mass

1 100 --- --- 3/4 76-96 100 --- 1/2 68-88 76-96 100 3/8 60-82 69-89 76-96 No. 4 45-67 53-73 58-78 No. 8 32-54 38-60 40-60 No. 16 22-44 26-48 28-48 No. 30 15-35 18-38 18-38 No. 50 9-25 11-27 11-27 No. 100 6-18 6-18 6-18 No. 200 3-6 3-6 3-6

2.2 ASPHALT CEMENT BINDER

Asphalt cement binder shall conform to AASHTO M 320 Performance Grade (PG)

64.22. Test data indicating grade certification shall be provided by the supplier at the time of delivery of each load to the mix plant. Copies of these certifications shall be submitted to the Contracting Officer. The supplier is defined as the last source of any modification to the binder.

The Contracting Officer may sample and test the binder at the mix plant at any time before or during mix production. Samples for this verification testing shall be obtained by the Contractor in accordance with ASTM D 140 and in the presence of the Contracting Officer. These samples shall be furnished to the Contracting Officer for the verification testing, which shall be at no cost to the Contractor. Samples of the asphalt cement specified shall be submitted for approval not less than 14 days before start of the test section.

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2.3 MIX DESIGN

a. The Contractor shall develop the mix design. The asphalt mix shall be composed of a mixture of well-graded aggregate, mineral filler if required, and asphalt material. The aggregate fractions shall be sized, handled in separate size groups, and combined in such proportions that the resulting mixture meets the grading requirements of the job mix formula (JMF). No hot-mix asphalt for payment shall be produced until a JMF has been approved.

The hot-mix asphalt shall be designed using procedures contained in AI MS-02 and the criteria shown in Table 5. The hand-held hammer shall be used to compact the specimens. If the Tensile Strength Ratio (TSR) of the composite mixture, as determined by ASTM D 4867/D 4867M is less than 75, the aggregates shall be rejected or the asphalt mixture treated with an approved anti-stripping agent. The amount of anti-stripping agent added shall be sufficient to produce a TSR of not less than 75. If an antistrip agent is required, it shall be provided by the Contractor at no additional cost.

Sufficient materials to produce 200 pound of blended mixture shall be provided to the Contracting Officer for verification of mix design at least 14 days prior to construction of test section.

b. At the option of the Contractor a currently used DOT Superpave hot mix may be used in lieu of developing a Marshall hot mix design as described herein. The Superpave volumetric mix shall be designed in accordance with

AI SP-2.

2.3.1 JMF Requirements

The job mix formula shall be submitted in writing by the Contractor for approval at least 14 days prior to the start of the test section and shall include as a minimum:

a. Percent passing each sieve size.

b. Percent of asphalt cement.

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

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

e. Number of blows of hand-held hammer per side of molded specimen.

f. Laboratory mixing temperature.

g. Lab compaction temperature.

h. Temperature-viscosity relationship of the asphalt cement.

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

j. Graphical plots of stability, flow, air voids, voids in the mineral aggregate, and unit weight versus asphalt content as shown in AI MS-02.

k. Specific gravity and absorption of each aggregate.

l. Percent natural sand.

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m. Percent particles with 2 or more fractured faces (in coarse aggregate).

n. Fine aggregate angularity.

o. Percent flat or elongated particles (in coarse aggregate).

p. Tensile Strength Ratio (TSR).

q. Antistrip agent (if required) and amount.

r. List of all modifiers and amount.

s. Correlation of hand-held hammer with mechanical hammer.

t. Percentage and properties (asphalt content, binder properties, and aggregate properties) of reclaimed asphalt pavement (RAP) in accordance with paragraph RECYCLED HOT-MIX ASPHALT, if RAP is used.

Table 5. Marshall Design Criteria

Test Property 50 Blow Mix 75 Blow Mix

Stability, pounds minimum *1000 *1800

Flow, 0.01 inch 8-18 8-16

Air voids, percent 3-5 3-5

Percent Voids in mineral aggregate VMA, (minimum)

Gradation 1 13.0 13.0 Gradation 2 14.0 14.0 Gradation 3 15.0 15.0

TSR, minimum percent 75 75

* This is a minimum requirement. The average during construction shall be significantly higher than this number to ensure compliance with the specifications.

** Calculate VMA in accordance with AI MS-02, based on ASTM D 2726 bulk specific gravity for the aggregate.

2.3.2 Adjustments to Field JMF

The Laboratory JMF for each mixture shall be in effect until a new formula is approved in writing by the Contracting Officer. Should a change in sources of any materials be made, a new laboratory jmf design shall be performed and a new JMF approved before the new material is used. The Contractor will be allowed to adjust the Laboratory JMF within the limits

SECTION 32 12 16 Page 11 specified below to optimize mix volumetric properties with the approval of the Contracting Officer. Adjustments to the Laboratory JMF shall be applied to the field (plant) established JMF and limited to those values as shown.

Adjustments shall be targeted to produce or nearly produce 4 percent voids total mix (VTM).

TABLE 6. Field (Plant) Established JMF Tolerances Sieves Adjustments (plus or minus), percent

1/2 inch 3 No. 4 3 No. 8 3 No. 200 1 Binder Content 0.40

If adjustments are needed that exceed these limits, a new mix design shall be developed. Tolerances given above may permit the aggregate grading to be outside the limits shown in Table 4; while not desirable, this is acceptable, except for the No. 200 sieve, which shall remain within the aggregate grading of Table 4.

2.4 RECYCLED HOT MIX ASPHALT

Recycled HMA shall consist of reclaimed asphalt pavement (RAP), coarse aggregate, fine aggregate, mineral filler, and asphalt cement. The RAP shall be of a consistent gradation and asphalt content and properties. When RAP is fed into the plant, the maximum RAP chunk size shall not exceed 2 inches. The recycled HMA mix shall be designed using procedures contained in AI MS-02 and AI MS-22. The job mix shall meet the requirements of paragraph MIX DESIGN. The amount of RAP shall not exceed 30 percent.

2.4.1 RAP Aggregates and Asphalt Cement

The blend of aggregates used in the recycled mix shall meet the requirements of paragraph AGGREGATES. The percentage of asphalt in the RAP shall be established for the mixture design according to ASTM D 2172 using the appropriate dust correction procedure.

2.4.2 RAP Mix

The blend of new asphalt cement and the RAP asphalt binder shall meet the dynamic shear rheometer at high temperature and bending beam at low temperature requirements in paragraph ASPHALT CEMENT BINDER. The virgin asphalt cement shall not be more than two standard asphalt material grades different than that specified in paragraph ASPHALT CEMENT BINDER.

PART 3 EXECUTION

3.1 PREPARATION OF ASPHALT BINDER MATERIAL

The asphalt cement material shall be heated avoiding local overheating and providing a continuous supply of the asphalt material to the mixer at a uniform temperature. The temperature of unmodified asphalts shall be no more than 325 degrees F when added to the aggregates. Performance-Graded (PG) asphalts shall be within the temperature range of 325 degrees F when added to the aggregate.

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3.2 PREPARATION OF MINERAL AGGREGATE

The aggregate for the mixture shall be heated and dried prior to mixing. No damage shall occur to the aggregates due to the maximum temperature and rate of heating used. The temperature of the aggregate and mineral filler shall not exceed 350 degrees F when the asphalt cement is added. The temperature shall not be lower than is required to obtain complete coating and uniform distribution on the aggregate particles and to provide a mixture of satisfactory workability.

3.3 PREPARATION OF HOT-MIX ASPHALT MIXTURE

The aggregates and the asphalt cement shall be weighed or metered and introduced into the mixer in the amount specified by the JMF. The combined materials shall be mixed until the aggregate obtains a uniform coating of asphalt binder and is thoroughly distributed throughout the mixture. Wet mixing time shall be the shortest time that will produce a satisfactory mixture, but no less than 25 seconds for batch plants. The wet mixing time for all plants shall be established by the Contractor, based on the procedure for determining the percentage of coated particles described in ASTM D 2489, for each individual plant and for each type of aggregate used.

The wet mixing time will be set to at least achieve 95 percent of coated particles. The moisture content of all hot-mix asphalt upon discharge from the plant shall not exceed 0.5 percent by total weight of mixture as measured by ASTM D 1461.

3.4 PREPARATION OF THE UNDERLYING SURFACE

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

3.5 TEST SECTION

Prior to full production, the Contractor shall place a test section for each JMF used. The Contractor shall construct a test section 250 - 500 feet long and two paver passes wide placed for two lanes, with a longitudinal cold joint. The test section shall be of the same thickness as the course which it represents. The underlying grade or pavement structure upon which the test section is to be constructed shall be the same as the remainder of the course represented by the test section. The equipment and personnel used in construction of the test section shall be the same equipment to be used on the remainder of the course represented by the test section. The test section shall be placed as part of the project pavement as approved by the Contracting Officer.

3.5.1 Sampling and Testing for Test Section

Sampling and testing shall comply with WSDOT Standard Specification Section 5-04.3(8) A.

3.5.2 Additional Test Sections

If the initial test section should prove to be unacceptable, the necessary adjustments to the JMF, plant operation, placing procedures, and/or rolling procedures shall be made. A second test section shall then be placed.

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Additional test sections, as required, shall be constructed and evaluated for conformance to the specifications. Full production shall not begin until an acceptable section has been constructed and accepted.

3.6 TESTING LABORATORY

The laboratory used to develop the JMF shall meet the requirements of ASTM D 3666. The Government will inspect the laboratory equipment and test procedures prior to the start of hot mix operations for conformance to ASTM D 3666. The laboratory shall maintain the Corps certification for the duration of the project. A statement signed by the manager of the laboratory stating that it meets these requirements or clearly listing all deficiencies shall be submitted to the Contracting Officer prior to the start of construction. The statement shall contain as a minimum:

a. Qualifications of personnel; laboratory manager, supervising technician, and testing technicians.

b. A listing of equipment to be used in developing the job mix.

c. A copy of the laboratory's quality control system.

d. Evidence of participation in the AASHTO Materials Reference Laboratory (AMRL) program.

3.7 TRANSPORTING AND PLACING

3.7.1 Transporting

The hot-mix asphalt shall be transported from the mixing plant to the site in clean, tight vehicles. Deliveries shall be scheduled so that placing and compacting of mixture is uniform with minimum stopping and starting of the paver. Adequate artificial lighting shall be provided for night placements.

Hauling over freshly placed material will not be permitted until the material has been compacted as specified, and allowed to cool to 140 degrees F. To deliver mix to the paver, the Contractor shall use a material transfer vehicle which shall be operated to produce continuous forward motion of the paver.

3.7.2 Placing

The mix shall be placed and compacted at a temperature suitable for obtaining density, surface smoothness, and other specified requirements.

Upon arrival, the mixture shall be placed to the full width by an asphalt paver; it shall be struck off in a uniform layer of such depth that, when the work is completed, it shall have the required thickness and conform to the grade and contour indicated. The speed of the paver shall be regulated to eliminate pulling and tearing of the asphalt mat. Unless otherwise permitted, placement of the mixture shall begin along the centerline of a crowned section or on the high side of areas with a one-way slope. The mixture shall be placed in consecutive adjacent strips having a minimum width of 10 feet. The longitudinal joint in one course shall offset the longitudinal joint in the course immediately below by at least 1 foot;

however, the joint in the surface course shall be at the centerline of the pavement. Transverse joints in one course shall be offset by at least 10 feet from transverse joints in the previous course. Transverse joints in adjacent lanes shall be offset a minimum of 10 feet. On isolated areas

SECTION 32 12 16 Page 14 where irregularities or unavoidable obstacles make the use of mechanical spreading and finishing equipment impractical, the mixture may be spread and luted by hand tools.

3.8 COMPACTION OF MIXTURE

After placing, the mixture shall be thoroughly and uniformly compacted by rolling. The surface shall be compacted as soon as possible without causing displacement, cracking or shoving. The sequence of rolling operations and the type of rollers used shall be at the discretion of the Contractor. The speed of the roller shall, at all times, be sufficiently slow to avoid displacement of the hot mixture and be effective in compaction. Any displacement occurring as a result of reversing the direction of the roller, or from any other cause, shall be corrected at once. Sufficient rollers shall be furnished to handle the output of the plant. Rolling shall continue until the surface is of uniform texture, true to grade and cross section, and the required field density is obtained. To prevent adhesion of the mixture to the roller, the wheels shall be kept properly moistened but excessive water will not be permitted. In areas not accessible to the roller, the mixture shall be thoroughly compacted with hand tampers. Any mixture that becomes loose and broken, mixed with dirt, contains check-cracking, or is in any way defective shall be removed full depth, replaced with fresh hot mixture and immediately compacted to conform to the surrounding area. This work shall be done at the Contractor's expense.

Skin patching will not be allowed.

3.9 JOINTS

The formation of joints shall be made ensuring a continuous bond between the courses and to obtain the required density. All joints shall have the same texture as other sections of the course and meet the requirements for smoothness and grade.

3.9.1 Transverse Joints

The roller shall not pass over the unprotected end of the freshly laid mixture, except when necessary to form a transverse joint. When necessary to form a transverse joint, it shall be made by means of placing a bulkhead or by tapering the course. The tapered edge shall be cut back to its full depth and width on a straight line to expose a vertical face prior to placing material at the joint. The cutback material shall be removed from the project. In both methods, all contact surfaces shall be given a light tack coat of asphalt material before placing any fresh mixture against the joint.

3.9.2 Longitudinal Joints

Longitudinal joints which are irregular, damaged, uncompacted, cold (less than 175 degrees F at the time of placing adjacent lanes), or otherwise defective, shall be cut back a maximum of 3 inches from the top of the course with a cutting wheel to expose a clean, sound vertical surface for the full depth of the course. All cutback material shall be removed from the project. All contact surfaces shall be given a light tack coat of asphalt material prior to placing any fresh mixture against the joint. The Contractor will be allowed to use an alternate method if it can be demonstrated that density, smoothness, and texture can be met.

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3.10 CONTRACTOR QUALITY CONTROL

3.10.1 General Quality Control Requirements

The Contractor shall develop an approved Quality Control Plan. Hot-mix asphalt for payment shall not be produced until the quality control plan has been approved. The plan shall address all elements which affect the quality of the pavement including, but not limited to:

a. Mix Design

b. Aggregate Grading

c. Quality of Materials

d. Stockpile Management

e. Proportioning

f. Mixing and Transportation

g. Mixture Volumetrics

h. Moisture Content of Mixtures

i. Placing and Finishing

j. Joints

k. Compaction

l. Surface Smoothness

3.10.2 Testing Laboratory

The Contractor shall provide a fully equipped asphalt laboratory located at the plant or job site. The laboratory shall meet the requirements as required in ASTM D 3666. Laboratory facilities shall be kept clean and all equipment maintained in proper working condition. The Contracting Officer shall be permitted unrestricted access to inspect the Contractor's laboratory facility, to witness quality control activities, and to perform any check testing desired. The Contracting Officer will advise the Contractor in writing of any noted deficiencies concerning the laboratory facility, equipment, supplies, or testing personnel and procedures. When the deficiencies are serious enough to adversely affect test results, the incorporation of the materials into the work shall be suspended immediately and will not be permitted to resume until the deficiencies are corrected.

3.10.3 Quality Control Testing

The Contractor shall perform all quality control tests applicable to these specifications and as set forth in the Quality Control Program. The testing program shall include, but shall not be limited to, tests for the control of asphalt content, aggregate gradation, temperatures, aggregate moisture, moisture in the asphalt mixture, laboratory air voids, stability, flow, in-place density, grade and smoothness. A Quality Control Testing Plan shall be developed as part of the Quality Control Program.

3.10.3.1 Asphalt Content

A minimum of two tests to determine asphalt content will be performed per lot (a lot is defined in paragraph MATERIAL ACCEPTANCE) by one of the following methods: the extraction method in accordance with ASTM D 2172, Method A or B, the ignition method in accordance with ASTM D 6307, or the nuclear method in accordance with ASTM D 4125. Calibrate the ignition oven or the nuclear gauge for the specific mix being used. For the extraction method, the weight of ash, as described in ASTM D 2172, shall be determined as part of the first extraction test performed at the beginning of plant

SECTION 32 12 16 Page 16 production; and as part of every tenth extraction test performed thereafter, for the duration of plant production. The last weight of ash value obtained shall be used in the calculation of the asphalt content for the mixture.

3.10.3.2 Gradation

Aggregate gradations shall be determined a minimum of twice per lot from mechanical analysis of recovered aggregate in accordance with ASTM D 5444.

When asphalt content is determined by the ignition oven or nuclear method, aggregate gradation shall be determined from hot bin samples on batch plants, or from the cold feed on drum mix plants. For batch plants, aggregates shall be tested in accordance with ASTM C 136 using actual batch weights to determine the combined aggregate gradation of the mixture.

3.10.3.3 Temperatures

Temperatures shall be checked at least four times per lot, at necessary locations, to determine the temperature at the dryer, the asphalt cement in the storage tank, the asphalt mixture at the plant, and the asphalt mixture at the job site.

3.10.3.4 Aggregate Moisture

The moisture content of aggregate used for production shall be determined a minimum of once per lot in accordance with ASTM C 566.

3.10.3.5 Moisture Content of Mixture

The moisture content of the mixture shall be determined at least once per lot in accordance with ASTM D 1461 or an approved alternate procedure.

3.10.3.6 Laboratory Air Voids, Marshall Stability and Flow

Mixture samples shall be taken at least four times per lot and compacted into specimens, using 50 blows per side with the hand-held Marshall hammer as described in ASTM D 6926. Hot-mix provided under the DOT Superpave option shall be compacted in accordance with the DOT requirements. After compaction, the laboratory air voids of each specimen shall be determined.

Stability and flow shall be determined for the Marshall-compacted specimens, in accordance with ASTM D 6927.

3.10.3.7 In-Place Density

The Contractor shall conduct any necessary testing to ensure the specified density is achieved. A nuclear gauge may be used to monitor pavement density in accordance with ASTM D 2950.

3.10.3.8 Grade and Smoothness

The Contractor shall conduct the necessary checks to ensure the grade and smoothness requirements are met in accordance with paragraph MATERIAL

ACCEPTANCE.

3.10.3.9 Additional Testing

Any additional testing, which the Contractor deems necessary to control the process, may be performed at the Contractor's option.

SECTION 32 12 16 Page 17

3.10.3.10 QC Monitoring

The Contractor shall submit all QC test results to the Contracting Officer on a daily basis as the tests are performed. The Contracting Officer reserves the right to monitor any of the Contractor's quality control testing and to perform duplicate testing as a check to the Contractor's quality control testing.

3.10.4 Sampling

When directed by the Contracting Officer, the Contractor shall sample and test any material which appears inconsistent with similar material being produced, unless such material is voluntarily removed and replaced or deficiencies corrected by the Contractor. All sampling shall be in accordance with standard procedures specified.

3.10.5 Control Charts

For process control, the Contractor shall establish and maintain linear control charts on both individual samples and the running average of last four samples for the parameters listed in Table 8, as a minimum. These control charts shall be posted as directed by the Contracting Officer and shall be kept current at all times. The control charts shall identify the project number, the test parameter being plotted, the individual sample numbers, the Action and Suspension Limits listed in Table 8 applicable to the test parameter being plotted, and the Contractor's test results. Target values from the JMF shall also be shown on the control charts as indicators of central tendency for the cumulative percent passing, asphalt content, and laboratory air voids parameters. When the test results exceed either applicable Action Limit, the Contractor shall take immediate steps to bring the process back in control. When the test results exceed either applicable Suspension Limit, the Contractor shall halt production until the problem is solved. The Contractor shall use the control charts as part of the process control system for identifying trends so that potential problems can be corrected before they occur. Decisions concerning mix modifications shall be made based on analysis of the results provided in the control charts.

The Quality Control Plan shall indicate the appropriate action which shall be taken to bring the process into control when certain parameters exceed their Action Limits.

SECTION 32 12 16 Page 18

Table 8. Action and Suspension Limits for the Parameters to be Plotted on

Individual and Running Average Control Charts

Running Average of Individual Samples Last Four Samples

Action Suspension Action Suspension Parameter to be Plotted Limit Limit Limit Limit

No. 4 sieve, Cumulative % 6 8 4 5 Passing, deviation from JMF target; plus or minus values

No. 30 sieve, Cumulative % 4 6 3 4 Passing, deviation from JMF target; plus or minus values

No. 200 sieve, Cumulative % 1.4 2.0 1.1 1.5 Passing, deviation from JMF target; plus or minus values

Stability, pounds (minimum) 75 Blow JMF 1800 1700 1900 1800 50 Blow JMF 1000 900 1100 1000 Flow, 0.01 inches 75 Blow 8 min. 7 min. 9 min. 8 min.

16 max. 17 max. 15 max. 16 max.

50 Blow 8 min. 7 min. 9 min. 8 min.

18 max. 19 max. 17 max. 18 max.

Asphalt content, % deviation 0.4 0.5 0.2 0.3 from JMF target; plus or minus value

Laboratory Air Voids, % No specific action and suspension deviation from JMF target limits set value

In-place Mat Density, No specific action and suspension % of TMD limits set

In-place Joint Density, No specific action and suspension % of TMD limits set

3.11 MATERIAL ACCEPTANCE

Testing for acceptability of work will be performed by an independent laboratory hired by the Contractor. Test results and payment calculations shall be forwarded daily to the Contracting Officer. 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 8 hours of production.

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.

SECTION 32 12 16 Page 19

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.

3.11.1 Sublot Sampling

One random mixture sample for determining laboratory air voids, theoretical maximum density, and for any additional testing the Contracting Officer 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 D 3665 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 D 6926.

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.

3.11.2 Additional Sampling and Testing

The Contracting Officer 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. Testing in these areas will be in addition to the lot testing, and the requirements for these areas will be the same as those for a lot.

3.11.3 Grade

The final wearing surface of pavement shall conform to the elevations and cross sections shown and shall vary not more than 0.05 foot from the plan grade established and approved at site of work. Finished surfaces at juncture with other pavements shall coincide 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 25 feet, or less, longitudinally and transversely, to determine the elevation of the completed pavement surface. Within 5 working days, after the completion of a particular lot incorporating the final wearing surface, the Contractor shall test the final wearing surface of the pavement for conformance with the specified plan grade. 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.

3.11.4 Surface Smoothness

The Contractor shall use one of the following methods to test and evaluate surface smoothness of the pavement. All testing shall be performed in the presence of the Contracting Officer. Detailed notes of the results of the testing shall be kept and a copy furnished to the Government immediately after each day's testing. The profilograph method shall be used for all longitudinal testing, except where the runs would be less than 200 feet in length and the ends where the straightedge shall be used. Where drawings

SECTION 32 12 16 Page 20 show required deviations from a plane surface (crowns, drainage inlets, etc.), the surface shall be finished to meet the approval of the Contracting Officer.

3.11.4.1 Smoothness Requirements

a. Straightedge Testing: The finished surfaces of the pavements shall have no abrupt change of 1/4 inch or more, and all pavements shall be within the tolerances of 1/4 inch in both the longitudinal and transverse directions, when tested with an approved 12 feet straightedge.

b. Profilograph Testing: The finished surfaces of the pavements shall have no abrupt change of 1/8 inch or more, and each 0.1 mile segment of each pavement lot shall have a Profile Index not greater than 9 inches/mile when tested with an approved California-type profilograph.

If the extent of the pavement in either direction is less than 200 feet, that direction shall be tested by the straightedge method and shall meet requirements specified above.

3.11.4.2 Testing Method

After the final rolling, but not later than 24 hours after placement, the surface of the pavement in each entire lot shall be tested by the Contractor in such a manner as to reveal all surface irregularities exceeding the tolerances specified above. Separate testing of individual sublots is not required. If any pavement areas are ground, these areas shall be retested immediately after grinding. Each lot of the pavement shall be tested in both a longitudinal and a transverse direction on parallel lines. The transverse lines shall be 15 feet or less apart, as directed. The longitudinal lines shall be at the centerline of each paving lane for lanes less than 20 feet wide and at the third points for lanes 20 feet or wider.

Other areas having obvious deviations shall also be tested. Longitudinal testing lines shall be continuous across all joints.

a. Straightedge Testing. The straightedge shall be held in contact with the surface and moved ahead one-half the length of the straightedge for each successive measurement. The amount of surface irregularity shall be determined 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.

b. Profilograph Testing. Profilograph testing shall be performed using approved equipment and procedures described in CDT Test 526. The equipment shall utilize electronic recording and automatic computerized reduction of data to indicate "must-grind" bumps and the Profile Index for each 0.1 mile segment of each pavement lot. Grade breaks on parking lots shall be accommodated by breaking the profile segment into shorter sections and repositioning the blanking band on each segment.

The "blanking band" shall be 0.2 inches wide and the "bump template" shall span 1 inch with an offset of 0.3 inch. The Profile Index shall be computed for each pass of the profilograph in each 0.1 mile segment.

The Profile Index for each segment shall be the average of the Profile Indices for each pass in each segment. The profilograph shall be

SECTION 32 12 16 Page 21 operated by a DOT approved operator. A copy of the reduced tapes shall be furnished the Government at the end of each day's testing.

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1.2.4 Rollers