Attachment5-UFGSSect321215.pdf

SECTION 32 12 15

HOT-MIX ASPHALT (HMA) FOR AIRFIELDS

01/11

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 156 (1997: R 2009) Standard Specification for Requirements for Mixing Plants for Hot-Mixed, Hot-Laid Bituminous Paving Mixtures

AASHTO M 320 (2009) Standard Specification for Performance-Graded Asphalt Binder

AASHTO T 308 (2009) Standard Method of Test for Determining the Asphalt Binder Content of Hot Mix Asphalt (HMA) by the Ignition Method

AASHTO T 329 (2008) Standard Test Method for Moisture Content of Hot Mix Asphalt (HMA) by Oven Method

ASPHALT INSTITUTE (AI)

AI MS-02 (1997 6th Ed) Mix Design Methods

ASTM INTERNATIONAL (ASTM)

ASTM C 117 (2004) 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 C 127 (2007) Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Coarse Aggregate

ASTM C 128 (2007a) Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Fine Aggregate

ASTM C 131 (2006)Standard Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

ASTM C 136 (2006) Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates

ASTM C 142 (1997; R 2004) 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 (1997; R 2004) Standard Test Method for Total Evaporable Moisture Content of Aggregate by Drying

ASTM C 88 (2005) Standard Test Method for Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate

ASTM D 140/D 140M (2009) Standard Practice for Sampling Bituminous Materials

ASTM D 1461 (1985; R 2006) Moisture or Volatile Distillates in Bituminous Paving Mixtures

ASTM D 2041 (2003a) Theoretical Maximum Specific Gravity and Density of Bituminous Paving Mixtures

ASTM D 2172 (2005) Quantitative Extraction of Bitumen from Bituminous Paving Mixtures

ASTM D 2419 (2009) Sand Equivalent Value of Soils and Fine Aggregate

ASTM D 242/D 242M (2009) Mineral Filler for Bituminous Paving Mixtures

ASTM D 2489/D 2489M (2008) Estimating Degree of Particle Coating of Bituminous-Aggregate Mixtures

ASTM D 2726 (2010) Bulk Specific Gravity and Density of Non-Absorptive Compacted Bituminous Mixtures

ASTM D 3203 (2005) Percent Air Voids in Compacted Dense and Open Bituminous Paving Mixtures

ASTM D 3381 (2009a) Viscosity-Graded Asphalt Cement for Use in Pavement Construction

ASTM D 3665 (2007) Random Sampling of Construction

Materials

ASTM D 3666 (2009a) Minimum Requirements for Agencies Testing and Inspecting Road and Paving Materials

ASTM D 4125 (2005) Asphalt Content of Bituminous Mixtures by the Nuclear Method

ASTM D 4791 (2005e1) Flat Particles, Elongated Particles, or Flat and Elongated Particles in Coarse Aggregate

ASTM D 4867/D 4867M (2009) Effect of Moisture on Asphalt Concrete Paving Mixtures

ASTM D 5444 (2008) Mechanical Size Analysis of Extracted Aggregate

ASTM D 6307 (2005; R 2010) Asphalt Content of Hot Mix Asphalt by Ignition Method

ASTM D 6925 (2009) 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 D 6926 (2004) Standard Practice for Preparation of Bituminous Specimens Using Marshall Apparatus

ASTM D 6927 (2006) Standard Test Method for Marshall Stability and Flow of Bituminous Mixtures

ASTM D 946 (2009a) Penetration-Graded Asphalt Cement for Use in Pavement Construction

ASTM D 979 (2001; R 2006e1) Sampling Bituminous Paving Mixtures

STATE OF CALIFORNIA DEPARTMENT OF TRANSPORTATION (CDT)

CDT Test 526 (2002) Operation of California Profilograph and Evaluation of Profiles

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

Perform the work consisting of pavement courses composed of mineral aggregate and asphalt material heated and mixed in a central mixing plant and placed on a prepared course. HMA designed and constructed in accordance with this section shall conform to the lines, grades, thicknesses, and typical cross sections shown on the drawings. Construct each course to the depth, section, or elevation required by the drawings and rolled, finished, and approved before the placement of the next course. Submit proposed Placement Plan, indicating lane widths, longitudinal joints, and transverse joints for each course or lift.

1.2.1 Asphalt Mixing Plant

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

a. Truck Scales. Weigh the asphalt mixture on approved scales furnished by the Contractor, or on certified public scales at the Contractor's expense. Scales shall be inspected and sealed at least annually by an approved calibration laboratory.

b. Testing Facilities. 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 Government shall have access at all times, to all areas of the plant for checking adequacy of equipment;

inspecting operation of the plant; verifying weights, proportions, and material properties; checking the temperatures maintained in the preparation of the mixtures and for taking samples. Provide assistance as requested, for the Government to procure any desired samples.

d. 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. 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 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 Material Transfer Vehicle (MTV)

Material transfer Vehicles shall be required due to the improvement in smoothness and decrease in both physical and thermal segregation. To transfer the material from the hauling equipment to the paver, use a self-propelled, material transfer vehicle that can deliver material to the paver without making contact with the paver. The MTV shall be able to move back and forth between the hauling equipment and the paver providing material transfer to the paver, while allowing the paver to operate at a constant speed. The Material Transfer Vehicle will have remixing and storage capability to prevent physical and thermal segregation.

1.2.4 Asphalt Pavers

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

1.2.4.1 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.

1.2.4.2 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.

1.2.5 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-02 Shop Drawings

Placement Plan; G, EDB

SD-03 Product Data

Mix Design; G, EDB

Contractor Quality Control; G, EDB

SD-04 Samples

Asphalt Cement Binder Aggregates

SD-06 Test Reports

Aggregates; G, CM QC Monitoring

SD-07 Certificates

Asphalt Cement Binder; G, CM Testing Laboratory

1.4 QUALITY ASSURANCE

The Government'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 Contractor or by an independent laboratory hired by the Contractor, including grade and smoothness testing which shall be performed by the Contractor. 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 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.

1.4.1 Sublot Sampling

One random mixture sample for determining laboratory air voids, theoretical maximum density, and for any additional testing the 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 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.

1.4.2 Additional Sampling and Testing

The Government 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 contractor.

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.

1.4.3 In-place Density

For determining in-place density, one random core (4 inches or 6 inches in diameter) will be taken by the Engineer from the mat (interior of the lane) of each sublot, and one random core will be taken from the joint (immediately over joint) of each sublot, in accordance with ASTM D 979.

Each random core will be full thickness of the layer being placed. When the random core is less than 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 D 2726.

1.4.4 Surface Smoothness

Use the following method to test and evaluate surface smoothness of the finished surface of the pavement final grade. All testing shall be performed in the presence of the Government. Detailed notes of the results of the testing shall be kept and a copy furnished to the Government immediately after each day's testing. Where drawings show required deviations from a plane surface (crowns, drainage inlets, etc.), the surface shall be finished to meet the approval of the Government.

1.4.4.1 Smoothness Requirements

a. Straightedge Testing: The finished surfaces of the pavements shall have no abrupt change of 1/8 inch or more, and all pavements shall be within the tolerances specified in Table 3 when checked with an approved 12 foot straightedge.

Table 3. Straightedge Surface Smoothness--Pavements

Pavement Category Direction of Testing Tolerance, inches

Runways and taxiways Longitudinal 1/8 Transverse 1/4

Calibration hardstands and Longitudinal 1/8 compass swinging bases Transverse 1/8

All other airfields and Longitudinal 1/4 helicopter paved areas Transverse 1/4

1.4.4.2 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 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 diamond ground, these areas shall be retested immediately after grinding. The area corrected by grinding shall not exceed 10 percent of the total area of the lot. The entire area 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 lines less than 20 feet and at the third points for lanes 20 feet or greater. 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. Bumps ("Must Grind" Areas). Any bumps ("must grind" areas) shown on the profilograph trace which exceed 0.4 inch in height shall be reduced by diamond grinding until they do not exceed 0.3 inch when retested. Such grinding shall be tapered in all directions to provide smooth transitions to areas not requiring 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 ground areas, may be rechecked with the profilograph in order to record a lower Profile Index.

1.5 ENVIRONMENTAL REQUIREMENTS

The hot-mix asphalt shall not be placed upon a wet surface or when the ambient air temperature is less than specified in Table 5. The temperature requirements may be waived by the Governments Design Engineer, if requested; however, all other requirements, including compaction, shall be met.

Table 5. Ambient Air Temperature Limitations

Mat Thickness, inches Degrees F

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. Submit sufficient materials to produce 200 lb of blended mixture for mix design verification. All aggregate test results and samples shall be submitted to the Government at least 14 days prior to start of construction. Aggregate testing shall have been performed within 90 days of performing the mix design.

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

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. The fine aggregate particles shall meet the following requirements:

a. The quantity of natural sand (noncrushed material) added to the aggregate blend shall not exceed 15 percent by weight of total aggregate.

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

c. The fine aggregate portion of the blended aggregate shall have an uncompacted void content greater than 45.0 percent when tested in accordance with ASTM C 1252 Method A.

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/D 242M.

2.1.4 Aggregate Gradation

The combined aggregate gradation shall conform to gradations specified in Table 6, when tested in accordance with ASTM C 136 and ASTM C 117, and shall not vary from the low limit on one sieve to the high limit on the adjacent sieve or vice versa, but grade uniformly from coarse to fine. The JMF shall be within the specification limits; however, the grdation can exceed the limits when the allowable devaliation form the JMF shown in Tables 9 and 10 are applied.

Table 6. 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) 67-22. . 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 Government. The supplier is defined as the last source of any modification to the binder.

The Government may sample and test the binder at the mix plant at any time before or during mix production. Samples for this verification testing shall be obtained in accordance with ASTM D 140/D 140M and in the presence of the Government. These samples shall be furnished to the Engineer for the verification testing, which shall be at no cost to the Contractor.

Submit 5 gallon sample of the asphalt cement specified for mix design verification and approval not less than 14 days before start of the test section.

2.3 MIX DESIGN

Develop the mix design. The Job Mix formula (JMF)shall have been developed and aggregates tested no earlier than 6 monnths before contract award. The asphalt mix shall be composed of a mixture of well-graded aggregate, mineral filler if required, and asphalt material. The aggregate fractions shall be sized, handled in separate size groups, and combined in such proportions that the resulting mixture meets the grading requirements of Table 6. No hot-mix asphalt for payment shall be produced until a JMF has been approved. The hot-mix asphalt shall be designed using hand-held hammer procedures contained in AI MS-02 and the criteria shown in Table 7.

Laboratory compaction temperatures for Polymer Modified Asphalts shall be as recommended by the asphalt cement manufacturer. If the Tensile Strength Ratio (TSR) of the composite mixture, as determined by ASTM D 4867/D 4867M is less than 75, the aggregates shall be rejected or the asphalt mixture treated with an anti-stripping agent. The amount of anti-stripping agent added shall be sufficient to produce a TSR of not less than 75. If an antistrip agent is required, it shall be provided at no additional cost to the Government. Sufficient materials to produce 200 pound of blended mixture shall be provided to the Governments Design Engineer for verification of mix design at least 14 days prior to construction of test section.

2.3.1 JMF Requirements

Submit the proposed JMF in writing, for approval, at least 14 days prior to the start of the test section, including 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 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 and summary tabulation of air voids, voids in the mineral aggregate, and unit weight versus asphalt content as shown in AI MS-02. Summary tabulation shall include individual specimen data for each specimen tested.

k. Specific gravity and absorption of each aggregate.

l. Percent natural sand.

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

n. Fine aggregate angularity.

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

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

q. Antistrip agent (if required).

r. List of all modifiers.

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

Table 8. Minimum Percent Voids in Mineral Aggregate (VMA)(4)

Aggregate (See Table 6) Minimum VMA, percent Gradation 1 13.0 Gradation 2 14.0 Gradation 3 15.0

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

2.3.2 Adjustments to JMF

The JMF for each mixture shall be in effect until a new formula is approved in writing by the Governments Design Engineer. Should a change in sources of any materials be made, a new mix design shall be performed and a new JMF approved before the new material is used. The Contractor will be allowed to make minor adjustments within the specifcation limits to the JMF to optimize mix volumetric properties. Adjustments to the original JMF shall be limited to plus or minus 4 percent on the No. 4 and coarser sieves; plus or minus 3 percent on the No. 8 to No. 50 sieves; and plus or minus 1 percent on the No. 100 sieve. Adjustments to the JMF shall be limited to plus or minus 1.0 percent on the No. 200 sieve. Asphalt content adjustments shall be limited to plus or minus 0.40 from the original JMF.

If adjustments are needed that exceed these limits, a new mix design shall be developed.

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. RAP stockpiles shall be free from contamination, including coal-tar sealers.

When RAP is fed into the plant, the maximum RAP chunk size shall not exceed 2 inches. The individual aggregates in a RAP chunk shall not exceed the maximum size aggregate of the gradation specified in Table 6. The recycled HMA mix shall be designed using procedures contained in AI MS-02. The job mix shall meet the requirements of paragraph MIX DESIGN. RAP shall only be used for shoulder surface course mixes and for any intermediate courses.

The amount of RAP shall be limited to 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 penetration 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 CONTRACTOR QUALITY CONTROL

3.1.1 General Quality Control Requirements

Submit the 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 and unique JMF identification code

b. Aggregate Grading

c. Quality of Materials

d. Stockpile Management and procedures to prevent contamination

e. Proportioning

f. Mixing and Transportation

g. Correlation of mechanical hammer to hand hammer. Determine the number of blows of the mechanical hammer required to provide the same density of the JMF as provided by the hand hammer. Use the average of three specimens per trial blow application.

h. Mixture Volumetrics

i. Moisture Content of Mixtures

j. Placing and Finishing

k. Joints

l. Compaction, including HMA-PCC joints

m. Surface Smoothness

n. Truck bed release agent

3.1.2 Testing Laboratory

Provide a fully equipped asphalt laboratory located at the plant or job site. It shall be equipped with heating and air conditioning units to maintain a temperature of 75 plus or minus 5 degrees F. Laboratory facilities shall be kept clean and all equipment shall be maintained in proper working condition. The Engineer 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 Engineer 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.

3.1.3 Quality Control Testing

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.

3.1.3.1 Asphalt Content

A minimum of two tests to determine asphalt content will be performed per lot (a lot is defined in paragraph QUALITY ASSURANCE) by one of the following methods: extraction method in accordance with ASTM D 2172, Method A or B, the ignition method in accordance with the AASHTO T 308, ASTM D 6307, or the nuclear method in accordance with ASTM D 4125, provided each method is calibrated 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 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.

3.1.3.2 Aggregate Properties

Aggregate gradations shall be determined a minimum of twice per lot from mechanical analysis of recovered aggregate in accordance with ASTM D 5444 or ASTM D 6307. 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. The specifc gravity of each aggregate size grouping shall be determined for each 20,000 tons in accordance with ASTM C 127 or ASTM C 128. Fractured faces for gravel sources shall be determined for each 18,000 20,000 tons in accordance with COE CRD-C 171.

The uncompacted void content of manufactured sand shall be determined for each 20,000 tons in accordance with ASTM C 1252 Method A.

3.1.3.3 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.

3.1.3.4 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.

3.1.3.5 Moisture Content of Mixture

The moisture content of the mixture shall be determined at least once per lot in accordance with AASHTO T 329.

3.1.3.6 Laboratory Air Voids, VMA

Mixture samples shall be taken at least four times per lot and compacted into specimens, using 75 blows per side with the Marshall hand-held hammer as described in ASTM D 6926. After compaction, the laboratory air voids and VMA of each specimen shall be determined.. The VMA shall be within the limits of Table 8.

3.1.3.7 In-Place Density

Conduct any necessary testing to ensure the specified density is achieved.

A nuclear gauge or other non-destructive testing device may be used to monitor pavement density.

3.1.3.8 Grade and Smoothness

Conduct the necessary checks to ensure the grade and smoothness requirements are met in accordance with paragraph QUALITY ASSURANCE.

3.1.3.9 Additional Testing

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

3.1.3.10 QC Monitoring

Submit all QC test results to the Governments Contract Management Representitive on a daily basis as the tests are performed. The Governments Contract Management Representitive 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.

3.1.4 Sampling

When directed by the Government, 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.

3.1.5 Control Charts

For process control, establish and maintain linear control charts on both individual samples and the running average of last four samples for the parameters listed in Table 9, as a minimum. These control charts shall be posted as directed by the Government 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 9 applicable to the test parameter being plotted, and the Contractor's test results. Target values (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, take immediate steps to bring the process back in control. When the test results exceed either applicable Suspension Limit, halt production until the problem is solved. When the Suspension Limit is exceeded for individual values or running average values, the Contracting Officer Engineer has the option to require the Contractor to remove and replace the material represented by the samples or to leave in place and base acceptance on mixture volumetric properties and in place density. 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.

Table 9. Action and Suspension Limits for the Parameters to be Plotted on

Individual and Running Average Control Charts

Individual Samples Running Average of 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

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 since this parameter is value used to determine percent payment

In-place Mat Density, % of No specific action and suspension TMD limits set since this parameter is used to determine percent payment

In-place Joint Density, % of No specific action and suspension TMD limits set since this parameter is used to determine percent payment

3.2 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.

3.3 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.

3.4 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 thorough and uniform coating of asphalt binder (testing in accordance with ASTM D 2489/D 2489M may be required by the Contracting Officer) and is thoroughly distributed throughout the mixture. 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.

3.5 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 or tack coat shall be applied in accordance with the contract specifications.

3.6 TEST SECTION

Prior to full production, place a test section for each JMF used.

Construct a test section consisting of a maximum of 250 tons and two paver passes wide placed in two lanes, with a longitudinal cold joint. The test section shall be of the same depth 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 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 Government.

3.6.1 Sampling and Testing for Test Section

One random sample shall be taken at the plant, triplicate specimens compacted, and tested for stability, flow, laboratory air voids, and Tensile Strength Ratio (TSR). A portion of the same sample shall be tested for theoretical maximum density (TMD), aggregate gradation and asphalt content. Four randomly selected cores shall be taken from the finished pavement mat, and four from the longitudinal joint, and tested for density. Random sampling shall be in accordance with procedures contained in ASTM D 3665. The test results shall be within the tolerances or exceed the minimum values shown in Table 10 for work to continue. If all test results meet the specified requirements, the test section shall remain as part of the project pavement. If test results exceed the tolerances shown, the test section shall be removed and replaced at no cost to the Government and another test section shall be constructed.

Table 10. Test Section Requirements for Material and Mixture Properties

Property Specification Limit

Aggregate Gradation-Percent Passing (Individual Test Result)

No. 4 and larger JMF plus or minus 8

No. 8, No. 16, No. 30, and No. 50 JMF plus or minus 6

No. 100 and No. 200 JMF plus or minus 2.0

Asphalt Content, Percent JMF plus or minus 0.5 (Individual Test Result)

Laboratory Air Voids, Percent (Average of 3 specimens) JMF plus or minus 1.0

VMA, Percent (Average of 3 specimens) See Table 8

Tensile Strength Ratio (TSR) 75% minimum

Mat Density, Percent of TMD (Average of 4 Random Cores) 92.0 - 96.0

Joint Density, Percent of TMD (Average of 4 Random Cores) 90.5 minimum

3.6.2 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.

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.

3.7 TESTING LABORATORY

The laboratories used to develop the JMF, perform Contractor Quality Control testing, and for Government acceptance testing shall meet the requirements of ASTM D 3666. All required test methods shall be performed by an accredited laboratory. The Government may inspect the laboratory equipment and test procedures prior to the start of hot-mix operations for conformance with ASTM D 3666. The laboratory shall maintain this validation for the duration of the project. Submit a certification of compliance signed by the manager of the laboratory stating that it meets these requirements to the Government prior to the start of construction.

The certification 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.

3.8 TRANSPORTING AND PLACING

3.8.1 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.

3.8.2 Placing

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

Collect waste mixture and dispose off site. The speed of the paver shall be regulated to eliminate pulling and tearing of the asphalt mat.

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 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.

3.9 COMPACTION OF MIXTURE

3.9.1 General

a. 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 are at the discretion of the Contractor, with the exception that application of more than three passes with a vibratory roller in the vibrating mode is prohibited. The speed of the roller shall, at all times, be sufficiently slow to avoid displacement of the hot mixture and be effective in compaction. Correct at once any displacement occurring as a result of reversing the direction of the roller, or from any other cause.

b. Furnish sufficient rollers to handle the output of the plant.

Continue rolling 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, keep the wheels properly moistened, but excessive water will not be permitted. In areas not accessible to the roller, thoroughly compact the mixture with hand tampers. Remove the full depth of any mixture that becomes loose and broken, mixed with dirt, contains check-cracking, or is in any way defective, replace with fresh hot mixture and immediately compact to conform to the surrounding area. This work shall be done at the Contractor's expense. Skin patching will not be allowed.

3.9.2 Segregation

The Government can sample and test any material that looks deficient.

When the in-place material appears to be segregated, the Government has the option to sample the material and have it tested and compared to the aggregate gradation, asphalt content, and in-place density requirements in Table 10. If the material fails to meet these specification requirements, the extent of the segregated material will be removed and replaced the full depth of the layer of asphalt mixture at no additional cost to the Government. When segregation occurs in the mat, take appropriate action to correct the process so that additional segregation does not occur.

3.10 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.

3.10.1 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 the adjacent lane. 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.

3.10.2 Longitudinal Joints

Longitudinal joints which are irregular, damaged, uncompacted, cold (less than 175 degrees F at the time of placing the adjacent lane), or otherwise defective, shall be cut back a maximum of 3 inches from the top edge of the lift with a cutting wheel to expose a clean, sound, near vertical surface for the full depth of the course. All cutback material shall be removed from the project. Cutting equipment that uses water as a cooling or cutting agent shall not be permitted. All contact surfaces shall be given a light tack coat of asphalt material prior to placing any fresh mixture against the joint.

3.10.3 HMA-Portland Cement Concrete Joints

Avoid spalling portland cement concrete (PCC) pavement when compacting HMA at a HMA-PCC joint. Pneumatic-tire rollers should be used and the HMA shall be rolled parallel to the joint. All procedures, including repair of damaged PCC, shall be in accordance with the approved Quality Control Plan.

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