B.08_AMENDMENT 0003 SPECIFICATIONS - 22R0004 (480570).pdf

Super Hornet F-18, Parking Aprons and Shelters (Pkg 4), Kuwait 480570

SECTION TABLE OF CONTENTS

DIVISION 32 - EXTERIOR IMPROVEMENTS

SECTION 32 12 15.13

ASPHALT PAVING FOR AIRFIELDS -- REVISED BY AMENDMENT NO. 0003

PART 1 GENERAL

1.1 ACCEPTANCE

1.1.1 Mat and Joint Densities

1.1.2 Smoothness (Final Wearing Surface Only)

1.1.3 Laboratory Air Voids and Theoretical Maximum Density

1.1.4 Mean Absolute Deviation

1.1.5 Acceptance Based on Grade

1.2 REFERENCES

1.3 REQUIREMENT PRECEDENCE

1.4 SUBMITTALS

1.5 QUALITY ASSURANCE AND QUALITY CONTROL

1.5.1 Sublot Sampling

1.5.2 Additional Sampling and Testing

1.5.3 In-place Density

1.5.4 Surface Smoothness

1.5.4.1 Smoothness Requirements

1.5.4.1.1 Straightedge Testing

1.5.4.2 Testing Method

1.5.4.2.1 Straightedge Testing

1.5.4.2.2 Bumps ("Must Grind" Areas)

1.6 ENVIRONMENTAL REQUIREMENTS

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

2.1.1 Asphalt Mixing Plant

2.1.1.1 Truck Scales

2.1.1.2 Inspection of Plant

2.1.1.3 Storage Bins

2.1.2 Hauling Equipment

2.1.3 Material Transfer Vehicle (MTV)

2.1.4 Asphalt Pavers

2.1.4.1 Receiving Hopper

2.1.4.2 Automatic Grade Controls

2.1.5 Rollers

2.1.6 Diamond Grinding

2.2 AGGREGATES

2.2.1 Coarse Aggregate

2.2.2 Fine Aggregate

2.2.3 Mineral Filler

2.2.4 Aggregate Gradation

2.3 ASPHALT CEMENT BINDER

2.4 MIX DESIGN

2.4.1 JMF Requirements

2.4.2 Adjustments to JMF

SECTION 32 12 15.13 Page 1

W912ER22R0004 AMENDMENT 0003

2.5 RECYCLED ASPHALT PAVEMENT

PART 3 EXECUTION

3.1 CONTRACTOR QUALITY CONTROL

3.1.1 General Quality Control Requirements

3.1.2 Testing Laboratory

3.1.3 Quality Control Testing

3.1.3.1 Asphalt Content

3.1.3.2 Aggregate Properties

3.1.3.3 Temperatures

3.1.3.4 Aggregate Moisture

3.1.3.5 Moisture Content of Mixture

3.1.3.6 Laboratory Air Voids, VMA, Marshall Stability and Flow

3.1.3.7 In-Place Density

3.1.3.8 Grade and Smoothness

3.1.3.9 Additional Testing

3.1.3.10 QC Monitoring

3.1.4 Sampling

3.1.5 Control Charts

3.2 PREPARATION OF ASPHALT BINDER MATERIAL

3.3 PREPARATION OF MINERAL AGGREGATE

3.4 PREPARATION OF HOT-MIX ASPHALT MIXTURE

3.5 PREPARATION OF THE UNDERLYING SURFACE

3.6 TEST SECTION

3.6.1 Sampling and Testing for Test Section

3.6.2 Additional Test Sections

3.7 TESTING LABORATORY

3.8 TRANSPORTING AND PLACING

3.8.1 Transporting

3.8.2 Placing

3.9 COMPACTION OF MIXTURE

3.9.1 General

3.9.2 Segregation

3.10 JOINTS

3.10.1 Transverse Joints

3.10.2 Longitudinal Joints

3.10.3 Asphalt Pavement-Portland Cement Concrete Joints

-- End of Section Table of Contents --

SECTION 32 12 15.13 Page 2

SECTION 32 12 15.13

ASPHALT PAVING FOR AIRFIELDS --

REVISED BY AMENDMENT NO. 0003

PART 1 GENERAL

1.1 FULL PAYMENT

1.1.1 Method of Measurement

Measurement of the quantity of hot-mix asphalt pavement, per ton placed and accepted, shall be made for the purposes of assessing the pay factors stipulated below.

1.1.2 Basis of Payment

The measured quantity of hot-mixed asphalt pavement will be paid for and included in the lump sum contract price. If less than 100 percent payment is due based on the pay factors stipulated in paragraph QUALITY ASSURANCE, a unit price of US$100 per ton will be used for purposes of calculating the payment reduction.

1.1 PERCENT PAYMENTACCEPTANCE

When a lot of material fails to meet the specification requirements for 100 percent pay as outlined in the following paragraphs, that lot shall be removed and replaced, or accepted at a reduced price which will be computed by multiplying the unit price by the lot's pay factor. The lot pay factor is determined by taking the lowest computed pay factor based on either laboratory air voids, in-place density, grade or smoothness (each discussed below). At the end of the project, an average of all lot pay factors will be calculated. If this average lot pay factor exceeds 95.0 percent and no individual lot has a pay factor less than 75.0 percent, then the percent payment for the entire project will be 100 percent of the unit bid price. If the average lot pay factor is less than 95.0 percent, then each lot will be paid for at the unit price multiplied by the lot's pay factor. For any lots which are less than 2000 metric tons, a weighted lot pay factor will be used to calculate the average lot pay factor. When work on a lot is required to be terminated before all sublots are completed, the results from the completed sublots will be analyzed to determine the percent payment for the lot following the same procedures and requirements for full lots but with fewer test results.

1.1.1 Mat and Joint Densities

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

First, a pay factor for both mat density and joint density are determined from Table 1. The area associated with the joint is then determined and will be considered to be 3 m wide times the length of completed

SECTION 32 12 15.13 Page 3 longitudinal construction joint in the lot. This area will not exceed the total lot size. The length of joint to be considered will be that length where a new lane has been placed against an adjacent lane of asphalt pavement, either an adjacent freshly paved lane or one paved at any time previously. The area associated with the joint is expressed as a percentage of the total lot area. A weighted pay factor for the joint is determined based on this percentage (see example below). The pay factor for mat density and the weighted pay factor for joint density is compared and the lowest selected. This selected pay factor is the pay factor based on density for the lot. When the TMD on both sides of a longitudinal joint is different, the average of these two TMD will be used as the TMD needed to calculate the percent joint density. Rejected lots shall be removed and replaced. Rejected areas adjacent to longitudinal joints shall be removed 100 mm into the cold (existing) lane. All density results for a lot will be completed and reported within 24 hours after the construction of that lot.

Table 1. Pay Factor Based on In-place Density

Average Mat Density (4 cores)

Pay Factor, percent Accept/Reject

Average Joint Density (4 cores)

94.0 - 96.0 93.9 - 96.0 100.0 Accept Above 92.5 92.4 and above

93.9 93.8 and below or above 96.1

100.0 Reject 92.4 below 92.3

1.1.2 Pay Factor Based on In-place Density

An example of the computation of a pay factor (in I-P units only) based on in-place density, is as follows: Assume the following test results for field density made on the lot: (1) Average mat density = 93.2 percent (of lab TMD). (2) Average joint density = 91.5 percent (of lab TMD). (3) Total area of lot = 30,000 square feet. (4) Length of completed longitudinal construction joint = 2,000 feet.

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

Mat density of 93.2 percent = 98.3 pay factor.

Joint density of 91.5 percent = 97.3 pay factor.

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

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

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

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

97.3 + (100-97.3) (1-0.6667) = 98.2 percent

d. Step 4: Compare weighted pay factor for joint density to pay factor

SECTION 32 12 15.13 Page 4 for mat density and select the smaller:

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

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

98.2 percent

1.1.2 Payment Adjustment for Smoothness (Final Wearing Surface Only)

Profilograph Testing. Record the location and data from all profilograph measurements. When the Profile Index of a lot exceeds the tolerance specified in paragraph SMOOTHNESS REQUIREMENTS by 16 mm per km, but less than 32 mm per km, after any reduction of high spots or removal and replacement , the computed pay factor for that lot based on surface smoothness will be 95 percent. When the Profile Index exceeds the tolerance by 32 mm per km, but less than 47 mm per km, the computed pay factor will be 90 percent. When the Profile Index exceeds the tolerance by 47 mm per km, but less than 63 mm per km, the computed pay factor will be 75 percent. Remove and replace the lot when the Profile Index exceeds the tolerance by 63 mm per km or more, at no additional cost to the Government .

Remove and replace lot at no additional cost to the Government.

Regardless of the above, correct any small individual area with surface deviation which exceeds the tolerance given above by more than 79 mm per km or more, by grinding to meet the specification requirements above or remove and replace at no additional cost to the Government .

1.1.3 Laboratory Air Voids and Theoretical Maximum Density

Laboratory air voids will be calculated in accordance with ASTM D3203/D3203M by determining the density of each lab compacted specimen using the laboratory-prepared, thoroughly dry method in ASTM D2726/D2726M and determining the theoretical maximum density (TMD) of four of the sublots using ASTM D2041/D2041M . Laboratory air void calculations for each lot will use the average theoretical maximum density values obtained for the lot. The mean absolute deviation of the four laboratory air void contents (one from each sublot) from the JMF air void content will be evaluated and a pay factor determined from Table 2. All laboratory air void tests will be completed and reported within 24 hours after completion of construction of each lot. The TMD is also used for computation of compaction, as required in paragraph MAT AND JOINT DENSITIES above.

1.1.4 Mean Absolute Deviation

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

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

- 4.0|)/4

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

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

SECTION 32 12 15.13 Page 5

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

Table 2. Pay Factor Based on Laboratory Air Voids Acceptance

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

O.60 or less 0.80 or less 100 Accept

0.61 - 0.80 0.81 or above 98Reject

1.1.5 Pay Adjustment Acceptance Based on Grade

Within 5 working days after completion of a particular lot incorporating the final wearing course, test the final wearing surface of the pavement for conformance with specified plan grade requirements. Perform all testing in the presence of the Government . Provide a final wearing surface of pavement conforming to the elevations and cross sections shown and not vary more than 9 mm for runways or 15 mm for taxiways and aprons from the plan grade established and approved at site of work. Match finished surfaces at juncture with other pavements with finished surfaces of abutting pavements. Deviation from the plan elevation will not be permitted in areas of pavements where closer conformance with planned elevation is required for the proper functioning of drainage and other appurtenant structures involved. The grade will be determined by running lines of levels at intervals of 7.6 m, or less, longitudinally and transversely, to determine the elevation of the completed pavement surface. Maintain detailed notes of the results of the testing and provide a copy to the Government immediately after each day's testing.

When more than 5 percent of all measurements made within a lot are outside the 9 or 15 mm tolerance, the pay factor based on grade for that lot will be 95 percent. In areas where the grade exceeds the tolerance by more than 50 percent, remove the surface lift full depth; and replace the lift with asphalt pavement to meet specification requirements, at no additional cost to the Government remove the surface lift full depth; and replace the lift with hot-mix asphalt to meet specification requirements, at no additional cost to the Government . Diamond grinding may be used to remove high spots to meet grade requirements. Skin patching for correcting low areas or planing or milling for correcting high areas will not be permitted.

1.2 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 (2013; R 2017) Standard Specification for Requirements for Mixing Plants for Hot-Mixed, Hot-Laid Bituminous Paving Mixtures

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

SECTION 32 12 15.13 Page 6

AASHTO T 308 (2016) Standard Method of Test for Determining the Asphalt Binder Content of Hot Mix Asphalt (HMA) by the Ignition Method

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

ASPHALT INSTITUTE (AI)

AI MS-2 (2015) Asphalt Mix Design Methods

ASTM INTERNATIONAL (ASTM)

ASTM C88 (2018) Standard Test Method for Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate

ASTM C117 (2017) Standard Test Method for Materials Finer than 75-um (No. 200) Sieve in Mineral Aggregates by Washing

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

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

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

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

ASTM C142/C142M (2017) Standard Test Method for Clay Lumps and Friable Particles in Aggregates

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

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

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

ASTM D946/D946M (2015) Penetration-Graded Asphalt Cement for Use in Pavement Construction

ASTM D979/D979M (2015) Sampling Bituminous Paving Mixtures

ASTM D1461 (2017) Standard Test Method for Moisture or Volatile Distillates in Asphalt Mixtures

SECTION 32 12 15.13 Page 7

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

ASTM D2172/D2172M (2017; E 2018) Standard Test Methods for Quantitative Extraction of Asphalt Binder from Asphalt Mixtures

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

ASTM D2489/D2489M (2016) Standard Test Method for Estimating Degree of Particle Coating of Asphalt Mixtures

ASTM D2726/D2726M (2019) Standard Test Method for Bulk Specific Gravity and Density of Non-Absorptive Compacted Bituminous Mixtures

ASTM D3203/D3203M (2017) Standard Test Method for Percent Air Voids in Compacted Asphalt Mixtures

ASTM D3665 (2012; R 2017) Standard Practice for Random Sampling of Construction Materials

ASTM D3666 (2016) Standard Specification for Minimum Requirements for Agencies Testing and Inspecting Road and Paving Materials

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

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

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

ASTM D5444 (2015) Mechanical Size Analysis of Extracted Aggregate

ASTM D5821 (2013; R 2017) Standard Test Method for Determining the Percentage of Fractured Particles in Coarse Aggregate

ASTM D6307 (2019) Standard Test Method for Asphalt Content of Asphalt Mixture by Ignition Method

ASTM D6926 (2016) Standard Practice for Preparation of Asphalt Mixture Specimens Using Marshall Apparatus

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

SECTION 32 12 15.13 Page 8

STATE OF KUWAIT, MINISTRY OF DEFENSE, MILITARY ENGINEERING

PROJECTS (DOCUMENT)

DOCUMENT III-1 (2007) Military Engineering Projects, General Specifications

1.3 REQUIREMENT PRECEDENCE

These specifications have been prepared using information from the following Host Nation criteria: DOCUMENT III-1 .

In the case of conflicts between these Volume 1 Specifications and the Volume 2 Host Nation requirements DOCUMENT III-1 , the Volume 1 Specifications shall take precedence over Volume 2 Host Nation requirements DOCUMENT III-1 .

See attachments for DOCUMENT III-1 , Military Engineering Projects, General Specifications, April 2007 for reference and supplemental information.

1.4 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 M

SD-03 Product Data

Diamond Grinding Plan; G M Mix Design; G M Contractor Quality Control; G M

SD-04 Samples

Aggregates; G M Asphalt Cement Binder; G M

SD-06 Test Reports

Aggregates; G M QC Monitoring; G M

SD-07 Certificates

Asphalt Cement Binder; G M Testing Laboratory; G M

1.5 QUALITY ASSURANCE AND QUALITY CONTROL

The Government 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 an independent laboratory hired by the Contractor . Submit qualifications of the independent commercial laboratory, indicating conformance with

SECTION 32 12 15.13 Page 9

Specification Section 01 45 00.00 10 Paragraph 3.7.2, to the Contracting Officer for review and approval prior to start of construction. Acceptance of the plant produced mix and in-place requirements will be on a lot to lot basis. A standard lot for all requirements will be equal to 2000 metric tons. Where appropriate, adjustment in payment for individual lots of asphalt pavement will be made based on in-place density, laboratory air voids, grade and smoothness in accordance with the following paragraphs.

Grade and surface smoothness determinations will be made on the lot as a whole. Exceptions or adjustments to this will be made in situations where the mix within one lot is placed as part of both the intermediate and surface courses, thus grade and smoothness measurements for the entire lot cannot be made. In order to evaluate laboratory air voids and in-place (field) density, each lot will be divided into four equal sublots.

1.5.1 Sublot Sampling

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

1.5.2 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 treated as a separate lot.

Payment Acceptance will be made for the quantity of asphalt pavement represented by these tests in accordance with the provisions of this section.

1.5.3 In-place Density

For determining in-place density, obtain one random core (100 mm or 150 mm in diameter) at locations identified by the Government from the mat (interior of the lane and at least 300 mm from longitudinal joint or pavement edge) of each sublot, and one random core taken from the joint (immediately over joint) of each sublot, in accordance with ASTM D979/D979M.

Fill all core holes with asphalt pavement and compact using a standard Marshall hammer to a mat density as specified. Tack coat dry core holes before filling. Each random core will be full thickness of the layer being placed. When the random core is less than 25 mm thick, it will not be included in the analysis. In this case, another random core will be taken. After air drying to meet the requirements for laboratory-prepared, thoroughly dry specimens, cores obtained from the mat and from the joints will be used for in-place density determination in accordance with

ASTM D2726/D2726M .

1.5.4 Surface Smoothness

Use a straightedge for measuring surface smoothness of pavements for this

SECTION 32 12 15.13 Page 10 project. Perform all testing in the presence of the Government . Maintain detailed notes of the testing results and provide a copy to the Government immediately after each day's testing. Where drawings show required deviations from a plane surface (for instance crowns, drainage inlets), finish the surface to meet the approval of the Government .

1.5.4.1 Smoothness Requirements

1.5.4.1.1 Straightedge Testing

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

Table 3. Straightedge Surface Smoothness--Pavements

Pavement Category Direction of Testing Tolerance, mm

Taxiways Longitudinal 3

Transverse 6

Shoulders (outside edge stripe)

Longitudinal 6

Transverse 6

1.5.4.2 Testing Method

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

1.5.4.2.1 Straightedge Testing

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

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

1.5.4.2.2 Bumps ("Must Grind" Areas)

Reduce any bumps ("must grind" areas) exceeding the tolerance by diamond grinding. Taper diamond grinding in all directions to provide smooth transitions to areas not requiring diamond grinding. The following will not be permitted: (1) skin patching for correcting low areas, (2) planing or milling for correcting high areas.

SECTION 32 12 15.13 Page 11

1.6 ENVIRONMENTAL REQUIREMENTS

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

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

Table 4. Surface Temperature Limitations of Underlying Course

Mat Thickness, mm Degrees C

75 or greater 4

Less than 75 7

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

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

2.1.1 Asphalt Mixing Plant

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

2.1.1.1 Truck Scales

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

2.1.1.2 Inspection of Plant

Provide access to the Contracting Officer 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.

2.1.1.3 Storage Bins

The asphalt mixture may be stored in non-insulated storage bins for a period of time not exceeding 3 hours. The asphalt mixture may be stored in insulated storage bins for a period of time not exceeding 8 hours.

Provide the mix drawn from bins that meets the same requirements as mix loaded directly into trucks.

SECTION 32 12 15.13 Page 12

2.1.2 Hauling Equipment

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

2.1.3 Material Transfer Vehicle (MTV)

Provide Material Transfer Vehicles for placement of the asphalt mixture.

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

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

2.1.4 Asphalt Pavers

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

2.1.4.1 Receiving Hopper

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

2.1.4.2 Automatic Grade Controls

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

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

b. Taut stringline set to grade.

SECTION 32 12 15.13 Page 13

c. Short ski or shoe for joint matching.

d. Laser control.

2.1.5 Rollers

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

2.1.6 Diamond Grinding

Those performing diamond grinding are required to have a minimum of three years experience in diamond grinding of airfield pavements. In areas not meeting the specified limits for surface smoothness and plan grade, reduce high areas to attain the required smoothness and grade, except as depth is limited below. Reduce high areas by diamond grinding the asphalt pavement with approved equipment after the asphalt pavement is at a minimum age of 14 days. Perform diamond grinding by sawing with saw blades impregnated with an industrial diamond abrasive. Assemble the saw blades in a cutting head mounted on a machine designed specifically for diamond grinding that produces the required texture and smoothness level without damage to the asphalt pavement or joint faces. Provide diamond grinding equipment with saw blades that are 3 mm wide, a minimum of 60 blades per 300 mm of cutting head width, and capable of cutting a path a minimum of 0.9 m wide. Diamond grinding equipment that causes raveling, fracturing of aggregate, or disturbance to the underlying material will not be allowed.

The maximum area corrected by diamond grinding the surface of the asphalt pavement is 10 percent of the total area of any sublot. The maximum depth of diamond grinding is 12 mm. Provide diamond grinding machine equipped to flush and vacuum the pavement surface. Dispose of all debris from diamond grinding operations off Government property. Prior to diamond grinding, submit a Diamond Grinding Plan for review and approval. At a minimum, include the daily reports for the deficient areas, the location and extent of deficiencies, corrective actions, and equipment. Remove and replace all pavement areas requiring plan grade or surface smoothness corrections in excess of the limits specified.

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

2.2 AGGREGATES

Sample aggregates in the presence of a Government Representative. Obtain samples in accordance with ASTM D75/D75M and be representative of the materials to be used for the project. Provide aggregates consisting of crushed stone, crushed gravel, crushed slag, screenings, natural sand and mineral filler, as required. The portion of material retained on the 4.75 mm sieve is coarse aggregate. The portion of material passing the 4.75 mm sieve and retained on the 0.075 mm sieve is fine aggregate. The portion passing the 0.075 mm sieve is defined as mineral filler. Submit sufficient materials to produce 90 kg of blended mixture for mix design verification. Submit all aggregate test results and samples to the Government at least 14 days prior to start of construction. Perform job

SECTION 32 12 15.13 Page 14 aggregate testing no earlier than 6 months before contract award.

2.2.1 Coarse Aggregate

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

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

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

c. At least 75 percent by weight of coarse aggregate contain at least two or more fractured faces when tested in accordance with ASTM D5821 with fractured faces produced by crushing.

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

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

2.2.2 Fine Aggregate

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

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

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

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

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

2.2.3 Mineral Filler

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

2.2.4 Aggregate Gradation

Provide a combined aggregate gradation that conforms to gradations specified in Table 5, when tested in accordance with ASTM C136/C136M and ASTM C117, and does not vary from the low limit on one sieve to the high

SECTION 32 12 15.13 Page 15 limit on the adjacent sieve or vice versa, but grades uniformly from coarse to fine. Provide a JMF within the specification limits; however, the gradation can exceed the limits when the allowable deviation from the JMF shown in Tables 8 and 9 are applied.

Table 5. Aggregate Gradations

Gradation 1

BASE COURSE ASPHALT

Gradation 2

SHOULDER AND TIE-IN AREAS

ASPHALT SURFACE COURSE

Sieve Size, mm Percent Passing by Mass Percent Passing by Mass

25.0 100 ---

19.0 90-100 100

12.5 68-88 90-100

9.5 60-82 69-89

4.75 45-67 53-73

2.36 32-54 38-60

1.18 22-44 26-48

0.60 15-35 18-38

0.30 9-25 11-27

0.15 6-18 6-18

0.075 3-6 3-6

2.3 ASPHALT CEMENT BINDER

Provide ASTM D946/D946M Penetration Grade 60/70 for shoulder pavements;

and 40/50 for taxiway and base asphalt pavements. Provide test data indicating grade certification by the supplier at the time of delivery of each load to the mix plant. Submit copies of these certifications 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.

2.4 MIX DESIGN

Develop the mix design. Perform Job Mix formula (JMF) and aggregates testing no earlier than 6 months before contract award. Provide asphalt mixture composed of well-graded aggregate, mineral filler if required, and asphalt material. Provide aggregate fractions sized, handled in separate size groups, and combined in such proportions that the resulting mixture meets the grading requirements of Table 5. Do not produce asphalt pavement for payment acceptance until a JMF has been approved. Design the asphalt mixture using hand-held hammer procedures contained in AI MS-2 and

SECTION 32 12 15.13 Page 16 the criteria shown in Table 6. Use laboratory compaction temperatures for Polymer Modified Asphalts as recommended by the asphalt cement manufacturer. If the Tensile Strength Ratio (TSR) of the composite mixture, as determined by ASTM D4867/D4867M is less than 75, reject the aggregates or the asphalt mixture treated with an anti-stripping agent.

Add a sufficient amount of anti-stripping agent to produce a TSR of not less than 75. If an antistrip agent is required, provide it at no additional cost to the Government. Provide sufficient materials to produce 90 kg of blended mixture to the Government for verification of mix design at least 14 days prior to construction of test section.

The following JMF needs to be prepared:

a. Taxiway Asphalt: PEN 40/50, Gradation 2, 75-blow count.

b. Base Asphalt: PEN 60/70, Gradation 2, 50-blow count.

2.4.1 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 stability, flow, air voids, voids in the mineral aggregate, and unit weight versus asphalt content as shown in AI MS-2 . Include summary tabulation that includes 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.

SECTION 32 12 15.13 Page 17

q. Antistrip agent (if required).

r. List of all modifiers.

s. If automatic hammer is used, provide correlation to manual hammer.

Table 6. Marshall Design Criteria

Test Property 75 Blow Mix Taxiway and Base Asphalt

Pavement

50 Blow Mix Shoulder Pavement

Stability, N minimum 9560 (1) 6000 (1)

Flow, 0.25 mm 8-16 (2) 8-18 (2)

Air voids, percent 4(4) 4(4)

Percent Voids in mineral aggregate (minimum)

See Table 7 See Table 7

Dust Proportion (3) 0.8-1.2 0.8-1.2

TSR, minimum percent 75 75

TSR Conditioned Strength (minimum kPa)

415 415

(1) This is a minimum requirement. Provide significantly higher average during construction to ensure compliance with the specifications.

(2) The flow requirement is not applicable for Polymer Modified Asphalts

(3) Dust Proportion is calculated as the aggregate content, expressed as a percent of mass, passing the 0.075 mm sieve, divided by the effective asphalt content, in percent of total mass of the mixture.

(4) Select the JMF asphalt content corresponding to an air void content of 4 percent. Verify the other properties of Table 6 meet the specification requirements at this asphalt content.

Table 7. Minimum Percent Voids in Mineral Aggregate (VMA) (1)

Aggregate (See Table 5) Minimum VMA, percent

Gradation 1 13

Gradation 2 14

(1) Calculate VMA in accordance with AI MS-2, based on ASTM D2726/D2726M bulk specific gravity for the aggregate.

SECTION 32 12 15.13 Page 18

2.4.2 Adjustments to JMF

The JMF for each mixture is in effect until a new formula is approved in writing by the Government . Should a change in sources of any materials be made, perform a new mix design and a new JMF approved before the new material is used. Make minor adjustments within the specification limits to the JMF to optimize mix volumetric properties. Adjustments to the original JMF are limited to plus or minus 4 percent on the 4.75 mm and coarser sieves; plus or minus 3 percent on the 2.36 mm to 0.30 mm sieves;

and plus or minus 1 percent on the 0.15 mm sieve. Adjustments to the JMF are limited to plus or minus 1.0 percent on the 0.075 mm sieve. Asphalt content adjustments are limited to plus or minus 0.40 from the original JMF. If adjustments are needed that exceed these limits, develop a new mix design.

2.5 RECYCLED ASPHALT PAVEMENT

Recycled asphalt is not allowed for the project.

PART 3 EXECUTION

3.1 CONTRACTOR QUALITY CONTROL

3.1.1 General Quality Control Requirements

Submit the Quality Control Plan. Do not produce hot-mix asphalt pavement for payment acceptance until the quality control plan has been approved.

In the quality control plan, 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 Asphalt Pavement-Portland Cement Concrete joints

m. Surface Smoothness

SECTION 32 12 15.13 Page 19

n. Truck bed release agent

3.1.2 Testing Laboratory

Provide a fully equipped asphalt laboratory located at the plant or job site that is equipped with heating and air conditioning units to maintain a temperature of 24 plus or minus 2.3 degrees C. Provide laboratory facilities that are kept clean and all equipment maintained in proper working condition. Provide the Government with unrestricted access to inspect the laboratory facility, to witness quality control activities, and to perform any check testing desired. The Government will advise 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, immediately suspend the incorporation of the materials into the work.

Incorporation of the materials into the work 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. Required elements of the testing program include, but are not 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. Develop a Quality Control Testing Plan 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 D2172/D2172M , Method A or B, the ignition method in accordance with the AASHTO T 308 , ASTM D6307, or the nuclear method in accordance with ASTM D4125/D4125M , provided each method is calibrated for the specific mix being used. For the extraction method, determine the weight of ash, as described in ASTM D2172/D2172M , 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. Use the last weight of ash value in the calculation of the asphalt content for the mixture.

3.1.3.2 Aggregate Properties

Determine aggregate gradations a minimum of twice per lot from mechanical analysis of recovered aggregate in accordance with ASTM D5444 or ASTM D6307.

For batch plants, test aggregates in accordance with ASTM C136/C136M using actual batch weights to determine the combined aggregate gradation of the mixture. Determine the specific gravity of each aggregate size grouping for each 18,000 metric tons in accordance with ASTM C127 or ASTM C128.

Determine fractured faces for gravel sources for each 18,000 metric tons in accordance with ASTM D5821. Determine the uncompacted void content of manufactured sand for each 18,000 metric tons in accordance with AASHTO T 304 Method A.

3.1.3.3 Temperatures

Check temperatures at least four times per lot, at necessary locations, to

SECTION 32 12 15.13 Page 20 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

Determine the moisture content of aggregate used for production a minimum of once per lot in accordance with ASTM C566.

3.1.3.5 Moisture Content of Mixture

Determine the moisture content of the mixture at least once per lot in accordance with AASHTO T 329 .

3.1.3.6 Laboratory Air Voids, VMA , Marshall Stability and Flow

Obtain mixture samples at least four times per lot and compacted into specimens, using 50 or 75 blows per side with the Marshall hand-held hammer as described in ASTM D6926. After compaction, determine the laboratory air voids and VMA of each specimen , as well as the Marshall stability and flow, as described in ASTM D6927. Provide VMA within the limits of Table 7.

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

Perform any additional testing, deemed necessary to control the process.

3.1.3.10 QC Monitoring

Submit all QC test results to the Government on a daily basis as the tests are performed. The Government 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.

Perform all sampling 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 8, as a minimum. Post the control charts as directed by the Government and maintain current at all times. Identify the following on the control charts, the project number, the test

SECTION 32 12 15.13 Page 21 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 test results. Also show target values (JMF) 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 Government has the option to require removal and replacement of 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. Make decisions concerning mix modifications based on analysis of the results provided in the control charts. In the Quality Control Plan, indicate the appropriate action to be taken to bring the process into control when certain parameters exceed their Action Limits.

Table 8. 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

Parameter to be Plotted Action Limit

Suspension Limit

Action Limit Suspension Limit

4.75 mm sieve, Cumulative Percent Passing, deviation from JMF target; plus or minus values

6 8 4 5

0.6 mm sieve, Cumulative Percent Passing, deviation from JMF target; plus or minus values

4 6 3 4

0.075 mm sieve, Cumulative Percent Passing, deviation from JMF target; plus or minus values

1.4 2.0 1.1 1.5

SECTION 32 12 15.13 Page 22

Table 8. 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

Parameter to be Plotted Action Limit

Suspension Limit

Action Limit Suspension Limit

Asphalt content, percent deviation from JMF target;

plus or minus value

0.4 0.5 0.2 0.3

Laboratory Air Voids, percent deviation from JMF target value

No specific action and suspension limits set since this parameter is used to determine percent payment acceptance

In-place Mat Density,…