03E06/13/07

S403-03E.doc

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  Use on projects **without** statistical acceptance (typically between 0
  and 4000 tons).

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**Section 403. - HOT ASPHALT CONCRETE PAVEMENT**

[Delete the Section and substitute the following:]{.underline}

**Section 403. - HOT ASPHALT CONCRETE PAVEMENT**

Description

**403.01** This work consists of constructing one or more courses of hot
asphalt concrete pavement.

Asphalt binder is designated according to AASHTO M 20, M 226, or M 320.

Construction Requirements

**403.02 Composition of Mix (Job-Mix Formula).**

Furnish hot asphalt concrete mix composed of crushed stone or gravel and
asphalt binder mixed in an approved plant. Use an aggregate quality,
gradation and an asphalt binder grade conforming to those used locally
in the construction of highways by the State Department of
Transportation. A job-mix formula developed solely for this project will
not be allowed.

Submit a currently approved State Department of Transportation job-mix
formula for approval at least 28 days before production. Include the
location of all commercial mixing plants to be used and a separate
job-mix formula for each plant.

For each proposed job-mix formula, submit a production certification
meeting state agency specifications and conforms to design parameters
(a), (b), or (c) from Table 403-1 for the type of mix submitted. The
job-mix formula must meet design parameter (d) in Table 403-1. Submit a
sample of loose mix to the CO 21 days prior to placement. Include a
signed statement prepared by the testing laboratory that certifies the
proposed job-mix formula meets the requirements of the contract and can
be compacted in the field during production to meet the contract
requirements. For each job-mix formula include copies of laboratory test
results with the following information:

> • Stockpile blend ratios
>
> • Individual stockpile and combined aggregate gradations
>
> • Target value for percent passing each sieve size for the aggregate
> blend
>
> • Aggregate properties
>
> • Target asphalt binder content
>
> • Maximum density value according to AASHTO T 209
>
> • Test values for (a), (b), or (c) and (d) from the Table 403-1
>
> • Submit loose mix sample three weeks prior to paving
>
> • History demonstrating the job-mix formula has been used in the area

**Table 403-1**

Hot Asphalt Concrete Mix Requirements

+--------------------------------------------------------+-------------+
| **Design Parameters**                                  | **Spec      |
|                                                        | ification** |
+--------------------------------------------------------+-------------+
| \(a\) Superpave (AASHTO M 323, R 35, and T 312)        | 7, 75, 115  |
|                                                        |             |
| > \(1\) Gyratory compactive effort                     | see Table   |
| >                                                      | 401-1       |
| > \(2\) Volumetric properties at 0.3 to 3 million      |             |
| > ESAL's (AASHTO M 323)                                |             |
+--------------------------------------------------------+-------------+
| \(b\) Hveem (AASHTO T 246 and AASHTO T 247)            | 35          |
|                                                        |             |
| > \(1\) Stabilometer, minimum                          | 3 - 5       |
| >                                                      |             |
| > \(2\) Percent Air Voids ^(1)^                        |             |
+--------------------------------------------------------+-------------+
| \(c\) Marshall (AASHTO T 245)                          | 2800        |
|                                                        |             |
| > \(1\) Stability, pounds minimum                      | 8 - 16      |
| >                                                      |             |
| > \(2\) Flow, 0.01 inch                                | 3 - 5       |
| >                                                      |             |
| > \(3\) Percent Air Voids ^(1)^                        | 75          |
| >                                                      |             |
| > \(4\) Compaction, number of blows per side           |             |
+--------------------------------------------------------+-------------+
| \(d\) Moisture Susceptibility                          | 70          |
|                                                        |             |
| > \(1\) Retained strength, % minimum (AASHTO T 165 and | 80          |
| > T 167) **or**                                        |             |
| >                                                      |             |
| > \(2\) Retained strength, % minimum (AASHTO T 283)    |             |
+--------------------------------------------------------+-------------+

> ^(1)^ The percent of air voids are based on AASHTO T 166, AASHTO T 209
> and AASHTO T 269.

Up to 25 percent recycled asphalt pavement material by mass may be used
in the mix.

**403.03 Surface Preparation.** Prepare the surface according to
Subsection 401.06.

**403.04 Weather Limitations.** Place hot asphalt concrete according to
Subsection 401.07.

**403.05 Hauling.** Haul the asphalt mix using vehicles conforming to
Subsection 401.11.

**403.06 Placing and Finishing.** Do not use mixes produced from
different plants unless the mixes are produced according to the same
job-mix formula, use material from the same sources, and are approved.

Place Hot asphalt concrete mix at a temperature conforming to Table
401-2. Measure temperature of the mix in the hauling vehicle just before
dumping into spreader or measure it in the windrow immediately before
pickup.

Place the mix with a paver conforming to Subsection 401.05. Control
horizontal alignment using a reference line. Automatically control the
grade and slope from reference lines, a ski and slope control device, or
dual skis. Use skis having a minimum length of 30 feet.

In areas where mechanical spreading and finishing is impractical, place
and finish the mix with alternate equipment to produce a uniform surface
closely matching the surface obtained when using a mechanical paver.

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  For **all 4R projects** add the following to Subsection 403.06 (also
  include detail C634-50):

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[Add the following 2 paragraphs at the end of the
Subsection]{.underline}:

Offset the longitudinal joint of one layer at least 6 inches from the
joint in the layer immediately below. Make the longitudinal joint in the
top layer along the centerline of two-lane roadways or at the lane lines
of roadways with more than two lanes. For simple curve widening
locations (widening only on one side) shift the centerline joint
location such that the final layer is midway between the normal edge of
shoulders. The shift from the staked centerline will be towards the
widened lane one-half the total curve widening specified for the given
station as shown in the plans.

The CO will designate the job-mix formula to be used for wedge and
leveling courses at each location. Place wedge and leveling courses in
maximum 3 inch lifts. Complete the wedge and leveling before starting
normal paving operations.

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  **OR** For **all 3R projects** add the following to Subsection 403.06:

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[Add the following 2 paragraphs at the end of the
Subsection]{.underline}:

Offset the longitudinal joint of one layer at least 6 inches from the
joint in the layer immediately below. Make the longitudinal joint in the
top layer along the centerline of two-lane roadways or at the lane lines
of roadways with more than two lanes. Make the longitudinal joint in the
top layer along the existing striped centerline, as recorded under
Subsection 152.03(n), or at the lane lines of roadways with more than
two lanes.

The CO will designate the job-mix formula to be used for wedge and
leveling courses at each location. Place wedge and leveling courses in
maximum 3 inch lifts. Complete the wedge and leveling before starting
normal paving operations.

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  Add the following to Subsection 403.06 when the hot mix haul is
  anticipated to be long. Also be sure to include the pay item 62202-1000
  for "Material Transfer Vehicle".

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**403.06 Placing and Finishing**. [Add the following]{.underline}:

Use a Materials Transfer Vehicle (MTV) with storage and remixing
capabilities on all mainline construction when placing asphalt concrete
mixtures. The MTV will independently remix and deliver mixture from the
hauling equipment to the paving equipment.

Furnish an MTV with the following capabilities:

> • An unloading system to receive mixtures from the hauling equipment.
>
> • A minimum storage capacity of 13 tons with a remixing system in the
> MTV storage bin.
>
> • A discharge conveyor to deliver the mixture to the paver hopper.
>
> • The MTV system cannot exceed maximum legal loadings on structures.

Acceptable Material Transfer Vehicles are:

> • Barber Greene MTV-3500
>
> • Roadtec SB-1500
>
> • Roadtec SB-2500

In the event the MTV malfunctions during paving operations, the
Contractor must suspend paving, however hot mix in transit and stored in
the silo at the time of breakdown may be placed without the use of an
MTV. Do not resume hot mix placement until the MTV is operational.

**403.07 Compacting.** Thoroughly and uniformly compact the asphalt
surface by rolling. Do not cause cracking, shoving, or undue
displacement. Continue rolling until all roller marks are eliminated,
all cracks are sealed, and the required density is obtained. Do not roll
the mix after the surface cools below 175 ºF.

Monitor the compaction process with a nuclear density gauge. Compact to
a pavement specific gravity (density) that is no less than 92.0 percent
of the maximum specific gravity (density) determined according to AASHTO
T 209.

Cut 4 or 6-inch diameter core samples from the compacted pavement. Fill
and compact the core holes with asphalt concrete mixture. Label the
cores and protect them from damage due to handling or temperature during
storage. Perform specific gravity and thickness tests on the cores and
deliver them to CO.

Along forms, curbs, headers, walls, and other places not accessible to
the rollers, compact the mix with alternate equipment to obtain the
required compaction.

**403.08 Pavement Smoothness.** Use a 10-foot metal straightedge to
measure at right angles and parallel to the centerline. Defective areas
are surface deviations in excess of ¼ inch in 10 feet between any two
contacts of the straightedge with the surface. Correct defective areas
using approved methods.

**403.09 Acceptance.** See Table 403-2 for sampling and testing
requirements.

Hot asphalt concrete pavement will be evaluated under Subsections 106.02
and 106.03.

Hot asphalt concrete construction work will be evaluated under
Subsections 106.02 and 106.04.

During placement of the mix the contractor will sample the loose mix
according to Table 403-2. A split sample will be submitted to the CO for
verification. Materials that do not meet the approved job-mix formula
are considered unacceptable.

Measurement

**403.10** Measure the Section 403 items listed in the bid schedule
according to Subsection 109.02.

Payment

**403.11** The accepted quantities will be paid at the contract price
per unit of measurement for the Section 403 pay items listed in the bid
schedule. Payment will be full compensation for the work prescribed in
this Section. See Subsection 109.05.

**TABLE 403-2**

Sampling, Testing and Acceptance Requirements

+--------+--------+-------+----------+-------+---------+-----+-------+
| **Ma   | **Type | **C   | **Test   | **    | **Point | **S | **R   |
| terial | of     | harac | Methods  | Sampl | of**    | pli | eport |
| or     | Accept | teris | or       | ing** |         | t** | ing** |
| Prop   | ance** | tic** | Specific |       | **Sam   |     |       |
| erty** |        |       | ations** | **F   | pling** | *   | **T   |
|        | **(S   |       |          | reque |         | *Sa | ime** |
|        | ubsect |       |          | ncy** |         | mpl |       |
|        | ion)** |       |          |       |         | e** |       |
+--------+--------+-------+----------+-------+---------+-----+-------+
| Hot    | Me     | Jo    | Su       | 1 per | Flowing | \-  | 21    |
| A      | asured | b-mix | bsection | jo    | mix     | \-- | days  |
| sphalt | and    | fo    | 403.02   | b-mix | stream  |     | b     |
| Co     | Tested | rmula | ^(1)^    | fo    | (bin or |     | efore |
| ncrete | for    | ve    |          | rmula | belt    |     | app   |
| Pa     | Confo  | rific |          |       | dis     |     | roval |
| vement | rmance | ation |          |       | charge) |     | of    |
|        |        |       |          |       | or      |     | jo    |
| (d     | (      |       |          |       | behind  |     | b-mix |
| esign) | 106.03 |       |          |       | the     |     | fo    |
|        | &      |       |          |       | laydown |     | rmula |
|        | 1      |       |          |       | machine |     |       |
|        | 06.04) |       |          |       | before  |     |       |
|        |        |       |          |       | r       |     |       |
|        |        |       |          |       | olling. |     |       |
+--------+--------+-------+----------+-------+---------+-----+-------+
| Hot    | Me     | Jo    | Su       | 1 per | Behind  | Yes | 24    |
| A      | asured | b-mix | bsection | 700   | the     |     | hours |
| sphalt | and    | fo    | 403.02   | ton   | laydown |     |       |
| Co     | Tested | rmula | ^(1)^    |       | machine |     |       |
| ncrete | for    | ve    |          |       | before  |     |       |
| Pa     | Confo  | rific |          |       | rolling |     |       |
| vement | rmance | ation |          |       |         |     |       |
|        |        |       |          |       |         |     |       |
| (produ | (1     |       |          |       |         |     |       |
| ction) | 06.04) |       |          |       |         |     |       |
+--------+--------+-------+----------+-------+---------+-----+-------+
|        |        | Compa | AASHTO T | 1 per | I       | "   | "     |
|        |        | ction | 166 and  | 700   | n-place |     |       |
|        |        | ^(2)^ | AASHTO T | ton   | after   |     |       |
|        |        |       | 209      |       | comp    |     |       |
|        |        |       |          |       | action. |     |       |
+--------+--------+-------+----------+-------+---------+-----+-------+
|        |        | Smoot | Su       | \-\-- | \-\--   | \-  | \-\-- |
|        |        | hness | bsection |       |         | \-- |       |
|        |        |       | 403.08   |       |         |     |       |
+--------+--------+-------+----------+-------+---------+-----+-------+

> ^(1)^ Use only sieves indicated on the job-mix formula for the
> specified gradation.
>
> ^(2)^ Cut core samples from the compacted pavement and carefully
> remove using a core retriever. Fill and compact the sample holes with
> asphalt concrete mixture.