SECTION 02713 PAV 2008.doc

SECTION 02713

BITUMINOUS BASE COURSE

1. GENERAL

1.1 REFERENCES

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

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS (AASHTO)

AASHTO T 102

Spot Test of Asphaltic Materials

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM C 29/C 29M

Unit Weight and Voids in Aggregate

ASTM C 88

Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate

ASTM C 127

Specific Gravity and Absorption of Coarse Aggregate

ASTM C 128

Specific Gravity and Absorption of Fine Aggregate

ASTM C 131

Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

ASTM C 136

Sieve Analysis of Fine and Coarse Aggregates

ASTM C 183

Sampling and the Amount of Testing of Hydraulic Cement

ASTM D 5

Penetration of Bituminous Materials

ASTM D 75

Sampling Aggregates

ASTM D 140

Sampling Bituminous Materials

ASTM D 242

Mineral Filler for Bituminous Paving Mixtures

ASTM D 946

Penetration-Graded Asphalt Cement for Use in Pavement Construction

ASTM D 1250

Petroleum Measurement Tables

ASTM D 1856

Recovery of Asphalt From Solution by Abson Method

ASTM D 2172

Quantitative Extraction of Bitumen from Bituminous Paving Mixtures

ASTM D 2216

Laboratory Determination of Water (Moisture) Content of Soil and Rock

ASTM D 3381

Viscosity-Graded Asphalt Cement for Use in Pavement Construction

ASTM D 3515

Hot-Mixed, Hot-Laid Bituminous Paving Mixtures

ASTM D 4318

Liquid Limit, Plastic Limit, and Plasticity Index of Soils

NEW JERSEY STATE HIGHWAY DEPARTMENT (NJSHD)

Standard Specification for Road & Bridge Construction

1.2. UNIT PRICES

1.2.1 Measurement for Payment

1.2.1.1 Bituminous Base-Course Tonnage

The amount paid for will be the number of units measure as indicated in the Unit Price Schedule bituminous mixture used in the accepted work. Bituminous mixture shall be weighed after mixing, and no deductions will be made for the weight of bituminous material incorporated in the mix. No payment will be made for defective areas until corrected.

1.2.1.2 Correctional Factor for Aggregates Used

Quantities of paving mixtures called for in bid schedule are based on aggregates having a specific gravity of 2.65 as determined according to apparent specific gravity paragraphs in ASTM C 127 and ASTM C 128. Correction in the tonnage of bituminous base course mixtures shall be made to compensate for the difference in the tonnage of mixtures used in the project, when specific gravities of aggregates used are more than 2.70 and less than 2.60. The tonnage paid for shall be the number of tons used, proportionately corrected for specific gravities using 2.65 as the base correctional factor.

1.2.1.3 Basis for Payment

The quantities of bituminous base course and bituminous materials shall be paid for at the respective contract unit prices in the bid schedule. Payment shall constitute full compensation for preparing and reconditioning the underlying layer; for furnishing all material, equipment, plant, and tools; and for all labor and other incidentals necessary to complete the work required by this section.

1.3. SUBMITTALS

Government approval is required for submittals with a "GA" designation; submittals having an "FIO" designation are for information only. The following shall be submitted in accordance with Section 01330 SUBMITTAL PROCEDURES:

SD-01 Data

Job-Mix Formula (JMF); GA.

Mix design at least 30 days before it is to be used.

SD-09 Reports

Sources of Aggregates; GA. Bituminous Materials; GA. Sampling and testing; GA.

Copies of field tests results within 48 hours after the tests are performed. Certified copies of test results for approval not less than 30 days before material is required for the work.

SD-14 Samples

Sources of Aggregates; GA.

Samples of a new source of aggregates for approval; GA.

SD-18 Records

Waybills and delivery tickets; GA. Sources of Aggregates; GA.

Copies of waybills and delivery tickets during the progress of the work. Certified waybills and delivery tickets for all materials actually used. Plan for operation of a new source of aggregates well in advance of starting production.

1.4. SAMPLING AND TESTING

Sampling and testing shall be the responsibility of the Contractor. Sampling and testing shall be performed by an approved commercial testing laboratory or by facilities furnished by the Contractor. No work requiring testing shall be permitted until the facilities have been inspected and approved. The first inspection shall be at the expense of the Government. Cost incurred for any subsequent inspection required because of failure of the facilities to pass the first inspection will be charged to the Contractor. Tests shall be performed in sufficient numbers and at the locations and times directed to ensure that materials, mixtures and compaction meet specified requirements. Samples of finished pavement, including samples that span the longitudinal joint, shall be obtained by the Contractor. Sizes of samples shall be suitable to determine conformance to density, thickness, and other specified requirements. Samples shall be taken at start of paving operations and at intervals throughout paving operations as directed. Samples of plant mixtures will be taken and tested by the Contractor to determine conformance to specified requirements. Certified copies of the test results shall be furnished to the Contracting Officer.

1.4.1. Aggregates

Sampling shall be in accordance with ASTM D 75. Samples of aggregates shall be tested at the start of production and at intervals during production of the bituminous base course. Intervals and points of sampling will be as approved. Test results on these samples will be the basis for approval of specific lots of aggregates.

1.4.2. Mineral Filler

Sampling of mineral filler shall conform to ASTM C 183.

1.4.3. Bituminous Materials

Sampling of bituminous materials shall conform to ASTM D 140.

1.4.4. Field Sampling of Pavements and Mixtures

The type, size, and locations of samples will be approved. The Contractor shall furnish all tools, labor, and materials for cutting samples and will be responsible for replacing pavement to meet specified requirements. Samples of finished pavement shall be cut at the rate of one sample per 3,000 square yards, or fraction thereof, of finished pavement.

1.5. PLANT, EQUIPMENT, MACHINES, TOOLS, AND PERSONNEL

1.5.1. Bituminous Plant

The bituminous plant shall be of such capacity, as specified herein, to produce the quantities of bituminous mixtures required for the project within the completion time of the contract. Hauling equipment, paving machines, rollers, miscellaneous equipment, and tools shall be provided in sufficient numbers and capacity and in proper working condition to place the bituminous paving mixtures at a rate equal to the plant output. A sufficient number of adequately trained personnel shall be available during paving operations to produce a pavement meeting the requirements in this specification.

1.5.2. Mixing Plants

Mixing plants shall be an automatic or semiautomatic controlled, commercially manufactured unit designed, coordinated, and operated to consistently produce a mixture within the job-mix formula (JMF). The plant shall have a minimum capacity of 100 tons per hour. Drum mixers will be pre-qualified at the production rate to be used during actual mix production. The pre-qualification tests will include extraction in accordance with ASTM D 2172 and recovery of the asphalt cement in accordance with ASTM D 1856. The penetration of the recovered asphalt binder shall not be less than 60 percent of the original penetration in accordance with ASTM D 5.

1.6. WEATHER LIMITATIONS

Bituminous courses shall not be constructed when the underlying course contains free surface water. Unless otherwise directed, asphalt courses shall not be constructed when temperature of the surface of the underlying course is below 40 degrees F.

1.7. Waybills and Delivery Tickets

Copies of waybills and delivery tickets shall be submitted during progress of work. Before the final statement is allowed, the Contractor shall submit certified waybills and certified delivery tickets for all aggregates and bituminous materials actually used in construction covered by the contract. The Contractor shall not remove bituminous material from the tank cars or storage tanks until the initial outage and temperature measurements have been taken, nor shall the car or tank be released until the final outage has been taken by the Contracting Officer.

2. PRODUCTS

2.1. AGGREGATES

Aggregates shall consist of crushed stone, crushed slag, crushed gravel screenings, sand, and mineral filler, as required. The portion of these materials retained on the No. 4 sieve shall be known as coarse aggregate; the portion passing the No. 4 sieve and retained on the No. 200 sieve, as fine aggregate; and the portion passing the No. 200 sieve, as mineral filler.

2.1.1. Coarse Aggregates

Coarse aggregates shall consist of clean, sound, durable fragments of crushed stone, crushed slag, or crushed gravel meeting the following requirements:

2.1.1.1. Aggregate Wear

The percentage of wear shall not exceed 40 after 500 revolutions, as determined in accordance with ASTM C 131.

2.1.1.2. Aggregate Loss

The percentage of loss shall not exceed five percent after five cycles performed in accordance with ASTM C 88, using magnesium sulfate.

2.1.1.3 Dry Weight of Crushed Slag

The dry weight of crushed slag shall be not less than 75 pcf as determined in accordance with ASTM C 29/C 29M.

2.1.2. Fine Aggregates

Fine aggregates shall consist of clean, durable natural sands; manufactured sands prepared by crushing stone, slag, or gravel, or any combination of natural and manufactured sands. Natural sands shall consist of grains of clean, hard, durable rock.

2.1.3. Mineral Filler

Mineral filler shall conform to ASTM D 242.

2.1.4. Liquid Limit and Plasticity Index

Liquid limit and plasticity index shall be measured in accordance with ASTM D 4318. Requirements stated herein shall apply to any aggregate component that is blended to meet the required gradation and also to the aggregate in the completed base course. The portion of the aggregate passing the No. 40 sieve shall be either non-plastic or have a liquid limit not greater than 25 and a plasticity index not greater than 5.

2.1.5. Sources of Aggregates

Sources of aggregates shall be selected well in advance of the time the material will be required in the work. If a previously developed source is selected, test results shall be submitted with evidence that central plant hot-mix bituminous pavements constructed with the aggregates have had a satisfactory service record of at least 5 years under similar climatic conditions. An inspection of the producer's operation may be made. When new sources are developed, the Contractor shall indicate the sources and submit samples for approval and a plan for operation well in advance of starting production. Proposed sources may be inspected. The Contractor shall make such tests and other investigations as necessary to determine whether or not aggregates meeting the requirements specified can be produced from the proposed sources. Inspection of the source of aggregate does not relieve the Contractor of the responsibility for delivery at the jobsite of aggregates that meet requirements specified herein.

2.2. BITUMINOUS MATERIALS

Sources where bituminous materials are obtained shall be selected in advance of time when materials will be required in the work, and test results shall be submitted for approval not less than 30 days before such material is required for use in the work.

2.2.1. Asphalt Cement

Asphalt cement to be mixed with mineral aggregates shall conform to ASTM D 3381, Table 1 Grade. In addition, the asphalt cement shall show a negative spot when subjected to the spot test in accordance with AASHTO T 102, using the standard naphtha specified therein.

2.2.2. Quality Control

In addition to initial qualification testing of bituminous materials, samples shall be taken before and during construction when shipments of bituminous materials are received or when necessary to assure that some condition of handling or storage has not been detrimental to the bituminous material.

2.3. AGGREGATE GRADATION

Mineral aggregate shall be of such size that percentage composition by weight, as determined by ASTM C 136, will conform to the gradation specified in TABLE 1. The table is based on aggregates of uniform specific gravity; percentages passing various sieves may be changed by the Contracting Officer when aggregates of varying specific gravities are used.

TABLE 1. AGGREGATE GRADATION

Sieve Percent Percent Percent Percent

Size Passing Passing Passing Passing

1 1/2 inch 100 --- --- ---

1 inch 75-93 100 --- ---

3/4 inch 67-85 74-92 100 ---

1/2 inch 57-75 64-82 73-91 100

3/8 inch 50-68 55-73 63-81 74-92

No. 4 36-54 39-57 45-63 53-71

No. 8 26-44 28-46 32-50 38-56

No. 16 18-36 19-37 23-41 27-45

No. 30 11-29 12-30 15-33 19-37

No. 50 7-21 9-23 10-24 13-27

No. 100 4-14 6-16 7-17 9-19

No. 200 3-7 3-7 3-7 3-7

2.4. COMPOSITION OF MIXTURE

2.4.1. Job-Mix Formula (JMF)

No bituminous mixture shall be produced until a JMF has been approved by the Contracting Officer. The formula will indicate the percentage of each sieve fraction of aggregate, the percentage of bitumen, and the temperature of the completed mixture when discharged from the mixer. The JMF will be allowed tolerances given in TABLE 2 herein. Bitumen content and aggregate gradation may be adjusted within the limits of tables specified herein to improve the paving mixtures, as directed, without adjustments in contract prices.

TABLE 2. JOB-MIX FORMULA TOLERANCES

Tolerance, Material Plus or Minus

Aggregate passing No. 4 sieve or larger 5 percent

Aggregate passing Nos. 8, 16, 30, and 50 sieves 4 percent

Aggregate passing Nos. 100 and 200 sieves 2 percent

Bitumen 0.25 percent

Temperature of mixing 25 degrees F

2.4.2. Test Properties of Bituminous Mixtures

The finished mixture shall meet requirements described below when tested in accordance with the appropriate A.A.S.H.O. or A.S.T.M. testing method. All samples will be compacted with 75 blows of specified hammer on each side of sample.

2.4.2.1. Stability, Flow, and Voids

a. Non-absorptive Aggregate: When the water-absorption value of the entire blend of aggregate does not exceed 2.5 percent as determined by ASTM C 127 and ASTM C 128, aggregate is designated as non-absorptive. The apparent specific gravity shall be used in computing the voids total mix and voids filled with bitumen; the mixture shall meet the requirement in TABLE 3.

TABLE 3. NONABSORPTIVE AGGREGATE MIXTURE

Test Property Limits

Stability, minimum, pounds 1800

Flow, maximum, 1/100-inch units 16

Voids total mix, percent 4-6

Voids filled with bitumen, percent 65-75

b. Absorptive Aggregate: When the water-absorption value of the entire blend of aggregate exceeds 2.5 percent as determined in ASTM C 127 and ASTM C 128, the aggregate is designated as absorptive. Bulk-impregnated specific gravity, as determined from [_____], shall be used in computing the percentages of the voids total mix and voids filled with bitumen; the mixture shall meet the requirements in TABLE 4.

TABLE 4. ABSORPTIVE AGGREGATE MIXTURE

Test Property Limits

Stability, minimum, pounds 1800

Flow, maximum, 1/100-inch units 16

Voids total mix, percent 3-5

Voids filled with bitumen, percent 70-80

2.4.2.2. Reduction in Stability by Immersion

If the index of retained stability of specimens of composite mixture. as determined by the appropriate A.A.S.H.O. or A.S.T.M. testing method. is less than 75 percent, aggregates shall be rejected or the bitumen shall be treated with an approved anti-stripping agent. The quantity or type of anti-stripping agent to add to the bitumen shall be sufficient, as approved, to produce an index of retained stability of not less than 75 percent. Payment will not be made to the Contractor for the addition of the anti-stripping agent that may be required.

3. EXECUTION

3.1. CONDITIONING OF UNDERLYING COURSE

Prior to placing the bituminous base course, the underlying surface shall be cleaned of foreign or objectionable matter. The condition of the underlying course will be inspected and approved.

3.2. MIXING

3.2.1. Preparation of Mineral Aggregates

Each aggregate stockpile shall be placed and maintained in such a manner to prevent segregation. Rates of feed of aggregates shall be regulated so that the moisture content and temperature of aggregates will be within tolerances specified herein. Dry storage shall be provided for mineral filler.

3.2.2. Preparation of Bituminous Mixtures

Aggregates, mineral filler, and bitumen shall be conveyed into the mixer in proportionate quantities required to meet the JMF. The mixing time shall be as required to obtain a uniform coating of the aggregate with the bituminous material. The temperature of bitumen at time of mixing shall not exceed 300 degrees F. The temperature of aggregate and mineral filler in the mixer shall not exceed 325 degrees F when bitumen is added. Overheated and carbonized mixtures or mixtures that foam will be rejected.

3.2.3. Water Content of Aggregates

Drying operations shall reduce the water content of mixture to less than 0.75 percent. The water content test will be conducted in accordance with ASTM D 2216. If the water content is determined on hot bin samples, the water content will be a weighted average based on composition of blend.

3.2.4. Storage of Bituminous Paving Mixture

The mixture shall be stored according to the requirements of ASTM D 3515.

3.3. TRANSPORTATION OF BITUMINOUS MIXTURE

Transportation of bituminous mixture from the paving plant to the site shall be in trucks having tight, clean, smooth beds lightly coated with an approved releasing agent to prevent adhesion of mixture to truck bodies. Excessive releasing agent will be drained prior to loading. Each load shall be covered with canvas or other approved material of ample size to protect mixture from weather and prevent loss of heat. Loads that have crusts of cold, unworkable material or have become wet by rain will be rejected. Hauling over freshly placed material will not be permitted.

3.4. PLACING

Bituminous mixtures shall not be placed without ample time to complete spreading and rolling during daylight hours, unless satisfactory artificial lighting is provided.

3.4.1. Spraying of Contact Surfaces of Structures

Contact surfaces of previously constructed pavement, curbs, manholes, and similar structures shall be sprayed with a thin coat of bituminous material conforming to the requirements of Section 02748 BITUMINOUS TACK AND PRIME COATS.

3.4.2. Offsetting Joints in Bituminous Base Course

The bituminous base course shall be placed so that longitudinal joints will be offset from joints in the underlying course by at least 1 foot. Transverse joints shall be offset by at least 2 feet from transverse joints in the underlying course.

3.4.3. General Requirements for Use of Mechanical Spreader

The range of temperatures of mixtures, when dumped into the mechanical spreader, shall be as approved. Mixtures having temperatures less than 225 degrees F when dumped into the mechanical spreader will be rejected. The mechanical spreader shall be adjusted and speed regulated so that the surface of the course being laid will be smooth and continuous without tears and pulls, and of such depth that, when compacted, the surface will conform to the cross section, grade, and contour indicated. Placing with respect to the center line, areas with crowned sections, or the high side of areas with one-way slope shall be as directed. Placing of the mixture shall be as nearly continuous as possible, and the speed of placing shall be adjusted, as directed, to permit proper rolling. When segregation occurs in the mixture during placing, the spreading operation shall be suspended until the cause is determined and corrected. Irregularities in alignment of the course left by the mechanical spreader shall be corrected by trimming directly behind machine. Immediately after trimming, the edges of the course shall be thoroughly compacted by tamping laterally with a lute. Distortion of the course during tamping will not be permitted.

3.4.4. Special Requirements for Placing Strips Succeeding Initial Strips

In placing each succeeding strip after the initial strip has been spread and compacted as specified below, the screed of the mechanical spreader shall overlap previously placed strip 3 to 4 inches and shall be sufficiently high so that compaction will produce a smooth, dense joint. The mixture placed on the edge of the previously placed strip by the mechanical spreader shall be pushed back to the edge of the strip being placed by using a lute. Excess mixture shall be removed and wasted.

3.4.5. Handwork Behind Machine Spreading

A sufficient number of shovelers and rakers shall follow the spreading machine, adding or removing hot mixture and raking mixtures as required to obtain a course that, when completed, will conform to all requirements specified herein. Excessive handwork will not be permitted. Broadcasting or fanning of the mixture over areas being compacted will not be permitted.

3.4.6.Hand Spreading in Lieu of Machine Spreading

In areas where the use of machine spreading is impractical, the mixture shall be spread by hand. Spreading shall be in a manner to prevent segregation. The mixture shall be spread uniformly with hot rakes in a loose layer of thickness that, when compacted, will conform to the required grade and thickness.

3.5. GRADE AND SURFACE-SMOOTHNESS REQUIREMENTS

Finished surfaces of bituminous base courses, when tested as specified below, shall conform to the grade-line and elevations shown and to surface-smoothness requirements specified.

3.5.1. Plan Grade

Finished surfaces shall conform, within tolerances specified, to the lines, grades, and cross sections indicated. Finished surfaces of runways, taxiways, and aprons shall vary not more than 0.04 foot from the plan grade-line or elevation established and approved at the site of work. Finished surfaces of non-aircraft traffic areas, such as blast pads and stabilized shoulders, shall vary not more than 0.06 foot from the plan grade-line and elevation established and approved at the site. Finished surfaces at the juncture with other pavements shall coincide with finished surfaces of abutting pavements. The 0.04-and 0.06-foot deviations from the plan grade-line and elevation will not be permitted in areas of pavements where closer conformance with plan grade and elevation is required for the proper functioning of drainage and other appurtenant structures involved.

3.5.2. Surface Smoothness

Finished surfaces shall not deviate from the testing edge of a 12 foot straightedge more than 1/4 inch in any direction.

3.5.3. Equipment

The Contractor shall furnish and maintain at the site, in good condition, one straightedge for each bituminous paver for use in testing the finished surface. Straightedges shall be aluminum and have blades of box or box-girder cross section with flat bottom reinforced to insure rigidity and accuracy. Straightedges shall have handles to facilitate movement on pavement.

3.6. COMPACTION OF MIXTURE

Rolling shall begin as soon after placing as the mixture will bear roller without undue displacement. Delays in rolling freshly spread mixture will not be permitted. After the initial rolling, preliminary tests of the crown, grade, and smoothness shall be made by the Contractor. Deficiencies shall be corrected so that the finished course will conform to requirements for the grade and smoothness specified herein. After the Contractor assures himself of meeting crown, grade, and smoothness requirements, rolling shall be continued until a density of at least 96 percent of laboratory compacted specimens of the same mixture is obtained. Places inaccessible to rollers shall be thoroughly compacted with hot hand tampers.

3.6.1. Testing of Mixture

At the start of plant operation, a quantity of the mixture sufficient to construct a test section at least 50 feet long and two spreader widths wide shall be prepared. The mixture shall be placed, spread, and rolled with equipment to be used in the project and in accordance with requirements specified above. This test section shall be tested and evaluated and shall conform to all specified requirements. If tests indicate that the pavement does not conform to specification requirements, necessary adjustments to plant operations and rolling procedures shall be made immediately. Additional test sections shall be constructed and sampled for conformance to specification requirements. In no case shall the Contractor start production of the bituminous base course mixture without approval.

3.6.2. Correcting Deficient Areas

Mixtures that become contaminated or are defective shall be removed. Skin patching of an area that has been rolled will not be permitted. Holes shall be cut the full thickness of the base course so that the sides are perpendicular and parallel to the direction of traffic and the edges are vertical. Bulges shall be sprayed with bituminous materials conforming to requirements of Section 02560 BITUMINOUS SEAL COATS. Fresh paving mixture shall be placed in holes in sufficient quantity so that the finished surface will conform to grade, smoothness, and density requirements.

3.7. JOINTS

3.7.1. General

Joints between old and new pavements or between successive day's work, or joints that have become cold because of delay, shall be made carefully to insure continuous bond between old and new sections of course. All joints shall have the same texture, density, and smoothness as other sections of the course. Contact surfaces of previously constructed pavements that have become coated with dust, sand, or other objectionable material shall be cleaned by brushing or cut back with approved power saw, as directed. The surface against which new material is placed shall be sprayed with a thin, uniform coat of bituminous material conforming to requirements of Section 02559 BITUMINOUS TACK COATS. The material shall be applied far enough in advance of placement of the fresh mixture to insure adequate curing. Care shall be taken to prevent damage or contamination of sprayed surface.

3.7.2. Transverse Joints

The roller shall pass over the unprotected end of freshly placed mixture only when placing of the course is discontinued or when delivery of the mixture is interrupted to the extent that the unrolled material may become cold. In all cases, the edge of the previously placed course shall be cut back to expose an even, vertical surface for the full thickness of the course. In continuing placement of the strip, the mechanical spreader shall be positioned on the transverse joint so that sufficient hot mixture will be spread to obtain a joint after rolling that conforms to the required density and smoothness specified herein.

3.7.3. Longitudinal Joints

Edges of a previously placed strip that have cooled or are irregular, honeycombed, poorly compacted, damaged, or otherwise defective, and unsatisfactory sections of the joint shall be cut back to expose a clean, sound surface for the full thickness of the course as directed.

3.8. EDGES OF PAVEMENT

Bulges adjacent to shoulders shall be trimmed neatly to the line.

3.9. PROTECTION OF PAVEMENT

After final rolling of the pavement, no vehicular traffic of any kind shall be permitted until the pavement has cooled to ambient temperature.

3.10 METHOD OF MEASUREMENT AND PAYMENT: All measurements shall be units as identified in the appropriate SLINS in the Unit Price Schedule. Measurements for preparing payments shall be taken jointly with the Government Representative.

Payment for these items shall constitute full compensation for completed work including all labor and incidentals necessary to accomplish the work required by this section of the specifications.

END OF SECTION

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