# PART V -- FLEXIBLE SURFACE COURSES

### **ITEM P‑401 PLANT MIX BITUMINOUS PAVEMENTS**

DESCRIPTION

**401‑1.1** This item shall consist of pavement courses composed of
mineral aggregate and bituminous material mixed in a central mixing
plant and placed on a prepared course in accordance with these
specifications and shall conform to the lines, grades, thicknesses, and
typical cross sections shown on the plans. Each course shall be
constructed to the depth, typical section, and elevation required by the
plans and shall be rolled, finished, and approved before the placement
of the next course.

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> **This specification is intended to be used for the surface course for
> airfield flexible pavements subject to aircraft loadings of gross
> weights greater than 12,500 pounds (5670 kg) and is to apply within
> the limits of the pavement designed for full load bearing capacity.**
>
> **The dimensions and depth of the "surface course" for which this
> specification applies shall be that as is defined by the Engineer's
> pavement design as performed in accordance with FAA Advisory Circular
> 150/5320-6, current edition.**
>
> **For courses other than the surface course, such as stabilized base
> courses, binder courses and/or truing and leveling courses; for
> pavements designed to accommodate aircraft gross weights of 12,500
> pounds (5670 kg) or less; and for pavements intended to be used for
> roads, shoulder pavements, blast pads, and other pavements not subject
> to full aircraft loading, specification Item P-403 may be used.**
>
> **State highway department specifications may be used for shoulders,
> access roads, perimeter roads, stabilized base courses under Item
> P-501, and other pavements not subject to aircraft loading. When state
> highway specification are approved, include all applicable/approved
> state specifications in the contract documents.**

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MATERIALS

**401‑2.1 AGGREGATE.** Aggregates shall consist of crushed stone,
crushed gravel, or crushed slag with or without natural sand or other
inert finely divided mineral aggregate. The portion of combined
materials retained on the No. 4 (4.75 mm) sieve is coarse aggregate. The
portion of combined materials passing the No. 4 (4.75 mm) sieve and
retained on the No. 200 (0.075 mm) sieve is fine aggregate, and the
portion passing the No. 200 (0.075 mm) sieve is mineral filler.

**a. Coarse Aggregate.** Coarse aggregate shall consist of sound, tough,
durable particles, free from adherent films of matter that would prevent
thorough coating and bonding with the bituminous material and be free
from organic matter and other deleterious substances. The percentage of
wear shall not be greater than 40 percent when tested in accordance with
ASTM C 131. The sodium sulfate soundness loss shall not exceed 10
percent, or the magnesium sulfate soundness loss shall not exceed 13
percent, after five cycles, when tested in accordance with ASTM C 88.

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> **Aggregates with a higher percentage loss of wear or soundness may be
> specified in lieu of those above, provided a satisfactory service
> record under similar conditions of service and exposure has been
> demonstrated.**

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Aggregate shall contain at least **\[ \]** percent by weight of
individual pieces having two or more fractured faces and **\[   \]**
percent by weight having at least one fractured face. The area of each
face shall be equal to at least 75 percent of the smallest midsectional
area of the piece. When two fractured faces are contiguous, the angle
between the planes of fractures shall be at least 30 degrees to count as
two fractured faces. Fractured faces shall be obtained by crushing.

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> **For pavements designed for aircraft gross weights of 60,000 pounds
> (27 200 kg) or more, the Engineer shall specify 70 percent for two
> fractured faces and 85 percent for one fractured face. For pavements
> designed for aircraft gross weights less than 60,000 pounds (27 200
> kg), the Engineer shall specify 50 percent for two fractured faces and
> 65 percent for one fractured face.**
>
> **In areas where slag is not available or desired, the references to
> it should be deleted from all aggregate paragraphs.**

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The aggregate shall not contain more than a total of 8 percent, by
weight, of flat particles*,* elongated particles, and flat and elongated
particles*,* when tested in accordance with ASTM D 4791 with a value of
5:1.

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> **The Engineer may specify ASTM D 4791 with a ratio of 3:1. If so,
> replace the above paragraph as follows: "The aggregate shall not
> contain more than a total of 20 percent by weight of flat particles,
> elongated particles, and flat and elongated particles when tested in
> accordance with ASTM D4791 with a value of 3:1."**

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Slag shall be air‑cooled, blast furnace slag, and shall have a compacted
weight of not less than 70 pounds per cubic foot (1.12 mg/cubic meter)
when tested in accordance with ASTM C 29.

**b. Fine Aggregate.** Fine aggregate shall consist of clean, sound,
durable, angular shaped particles produced by crushing stone, slag, or
gravel that meets the requirements for wear and soundness specified for
coarse aggregate. The aggregate particles shall be free from coatings of
clay, silt, or other objectionable matter and shall contain no clay
balls. The fine aggregate, including any blended material for the fine
aggregate, shall have a plasticity index of not more than 6 and a liquid
limit of not more than 25 when tested in accordance with ASTM D 4318.

Natural (nonmanufactured) sand may be used to obtain the gradation of
the aggregate blend or to improve the workability of the mix. The amount
of sand to be added will be adjusted to produce mixtures conforming to
requirements of this specification. **\[The fine aggregate shall not
contain more than 15 percent natural sand by weight of total
aggregates.\]** If used, the natural sand shall meet the requirements of
ASTM D 1073 and shall have a plasticity index of not more than 6 and a
liquid limit of not more than 25 when tested in accordance with ASTM D
4318.

The aggregate shall have sand equivalent values of **\[ \]** or greater
when tested in accordance with ASTM D 2419.

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> **Typically the sand equivalent value should be 45, unless local
> conditions require lower value.**
>
> **The addition of natural sand to a mix containing all crushed coarse
> and fine aggregates will normally increase its workability and
> compactability. However, the addition of excessive amounts of natural
> sand tends to decrease the stability of the mixture. The requirement
> for a sand equivalent value of 45 usually limits the use of natural
> sand; however, the maximum of 15 percent natural sand may be included
> for locations where low stabilities are a chronic problem.**

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**c. Sampling.** ASTM D 75 shall be used in sampling coarse and fine
aggregate, and ASTM C 183 shall be used in sampling mineral filler.

**401‑2.2 MINERAL FILLER.** If filler, in addition to that naturally
present in the aggregate, is necessary, it shall meet the requirements
of ASTM D 242.

**401‑2.3 BITUMINOUS MATERIAL.** Bituminous material shall conform to
the following requirements: **\[ \]**.

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> **Asphalt cement binder shall conform to \[AASHTO M320 Performance
> Grade (PG) \[\_\_\_\_\_\]\] \[ASTM D 3381 Table 1, 2, or 3 Viscosity
> Grade\]\[ASTM D 946 Penetration Grade \[\_\_\_\_\_\]\]. Test data
> indicating grade certification shall be provided by the supplier at
> the time of delivery of each load to the mix plant. Copies of these
> certifications shall be submitted to the Engineer. The Engineer shall
> specify the grade of bituminous material, based on geographical
> location and climatic conditions. Asphalt Institute Superpave Series
> No. 1 (SP-1) provides guidance on the selection of performance graded
> binders. Table VI‑1, Selecting Asphalt Grade, contained in the Asphalt
> Institute\'s Manual Series‑1 (MS‑1) provides guidance on the selection
> of asphalt type. For cold climates, Table 2 of ASTM D 3381 may be
> specified to minimize the susceptibility for thermal cracking. The
> Engineer should be aware that PG asphalt binders may contain modifiers
> that require elevated mixing and compaction temperatures that exceed
> the temperatures specified in Item P-401.**
>
> **Grades of some materials are listed below:**
>
> **NOTE: Performance Graded (PG) asphalt binders should be specified
> wherever available. The same grade PG binder used by the state highway
> department in the area should be considered as the base grade for the
> project (e.g. the grade typically specified in that specific location
> for dense graded mixes on highways with design Equivalent Standard
> Axle Loads (ESALS) less than 10 million). The exception would be that
> grades with a low temperature higher than PG XX-22 should not be used
> (e.g. PG XX-16 or PG XX-10), unless the Engineer has had successful
> experience with them. Typically, rutting is not a problem on airport
> runways. However, at airports with a history of stacking on end of
> runways and taxiway areas, rutting has accrued due to the slow speed
> of loading on the pavement. If there has been rutting on the project
> or it is anticipated that stacking may accrue during the design life
> of the project, then the following grade \"bumping\" should be applied
> for the top 125 mm (5 inches) of paving in the end of runway and
> taxiway areas: for aircraft tire pressure between 100 and 200 psi,
> increase the high temperature one grade; for aircraft tire pressure
> greater than 200 psi, increase the high temperature two grades. Each
> grade adjustment is 6 degrees C. Polymer Modified Asphalt, PMA, has
> shown to perform very well in these areas. The low temperature grade
> should remain the same.**
>
> **Additional grade bumping and grade selection information is given in
> Table A.**

+-----------------------+----------------------+----------------------+
| > **Table A. Binder   |                      |                      |
| > Grade Selection and |                      |                      |
| > Grade Bumping**     |                      |                      |
| >                     |                      |                      |
| > **Based on Gross    |                      |                      |
| > Aircraft Weight.**  |                      |                      |
+=======================+======================+======================+
| **Aircraft Gross      | > **High Temperature |                      |
| Weight**              | > Adjustment to**    |                      |
|                       | >                    |                      |
| > **(pounds)**        | > **Base Binder      |                      |
|                       | > Grade**            |                      |
+-----------------------+----------------------+----------------------+
|                       | > **Pavement Type**  |                      |
+-----------------------+----------------------+----------------------+
|                       | > **Runway**         | > **Taxiway/Apron**  |
+-----------------------+----------------------+----------------------+
| > **Less than         | > **\--**            | > **\--**            |
| > 12,500**            |                      |                      |
+-----------------------+----------------------+----------------------+
| > **Less than         | > **\--**            | > **1**              |
| > 60,000**            |                      |                      |
+-----------------------+----------------------+----------------------+
| > **Less than         | > **\--**            | > **1**              |
| > 100,000**           |                      |                      |
+-----------------------+----------------------+----------------------+
| > **Greater than      | > **1**              | > **2**              |
| > 100,000**           |                      |                      |
+-----------------------+----------------------+----------------------+
| > **NOTES:**          |                      |                      |
| >                     |                      |                      |
| > **1. PG grades      |                      |                      |
| > above a --22 on the |                      |                      |
| > low end (e.g.       |                      |                      |
| > 64--16) are not     |                      |                      |
| > recommended.        |                      |                      |
| > Limited experience  |                      |                      |
| > has shown this to   |                      |                      |
| > be a poor           |                      |                      |
| > performer.**        |                      |                      |
| >                     |                      |                      |
| > **2. PG grades      |                      |                      |
| > below a 64 on the   |                      |                      |
| > high end (e.g.      |                      |                      |
| > 58-22) are not      |                      |                      |
| > recommended. These  |                      |                      |
| > binders often       |                      |                      |
| > provide tender      |                      |                      |
| > tendencies.**       |                      |                      |
| >                     |                      |                      |
| > **3. PG grades      |                      |                      |
| > above a 76 on the   |                      |                      |
| > high end (e.g.      |                      |                      |
| > 82-22) are very     |                      |                      |
| > stiff and may be    |                      |                      |
| > difficult to work   |                      |                      |
| > and compact.**      |                      |                      |
+-----------------------+----------------------+----------------------+

+------------+---------+-----------+----------------------------------+
| **Grade    |         |           |                                  |
| Speci      |         |           |                                  |
| fication** |         |           |                                  |
+------------+---------+-----------+----------------------------------+
| **P        | **Vi    |           | > **Performance Graded**         |
| enetration | scosity |           | >                                |
| Grade**    | Grade** |           | > **Asphalt Institute**          |
|            |         |           | >                                |
| **ASTM D   | >       |           | > **Superpave Series No.         |
| 946**      |  **ASTM |           | > 1(SP-1)**                      |
|            | > D     |           |                                  |
|            | >       |           |                                  |
|            |  3381** |           |                                  |
+------------+---------+-----------+----------------------------------+
| >          | > *     | > **      | > **In general, the Engineer     |
|  **40‑50** | *AC‑5** | AR‑1000** | > should choose a PG‑asphalt     |
| >          | >       | >         | > binder that has been approved  |
| >          | > **    | > **      | > for use in the vicinity by the |
|  **60‑70** | AC‑10** | AR‑2000** | > State DOT, and is locally      |
| >          | >       | >         | > available. In general, a high  |
| >          | > **    | > **      | > reliability (98 percent) on    |
| **85‑100** | AC‑15** | AR‑4000** | > both the high and low          |
| >          | >       | >         | > temperature categories is      |
| > *        | > **    | > **      | > sufficiently conservative.**   |
| *100‑120** | AC‑20** | AR‑8000** |                                  |
| >          | >       |           |                                  |
| > *        | > **    |           |                                  |
| *120‑150** | AC‑30** |           |                                  |
|            | >       |           |                                  |
|            | > **    |           |                                  |
|            | AC‑40** |           |                                  |
+------------+---------+-----------+----------------------------------+

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The Contractor shall furnish vendor\'s certified test reports for each
lot of bituminous material shipped to the project. The vendor\'s
certified test report for the bituminous material can be used for
acceptance or tested independently by the Engineer.

**401‑2.4 PRELIMINARY MATERIAL ACCEPTANCE.** Prior to delivery of
materials to the job site, the Contractor shall submit certified test
reports to the Engineer for the following materials:

**a. Coarse Aggregate.**

**(1)** Percent of wear.

**(2)** Soundness.

(3) Unit weight of slag.

(4) Percent fractured faces.

**b. Fine Aggregate.**

**(1)** Liquid limit.

**(2)** Plasticity index.

**(3)** Sand equivalent.

**c. Mineral Filler.**

**d. Bituminous Material.** Test results for bituminous material shall
include temperature/viscosity charts for mixing and compaction
temperatures.

The certification(s) shall show the appropriate ASTM test(s) for each
material, the test results, and a statement that the material meets the
specification requirement.

The Engineer may request samples for testing, prior to and during
production, to verify the quality of the materials and to ensure
conformance with the applicable specifications.

**401-2.5 ANTI-STRIPPING AGENT.** Any anti-stripping agent or additive
if required shall be heat stable, shall not change the asphalt cement
viscosity beyond specifications, shall contain no harmful ingredients,
shall be added in recommended proportion by approved method, and shall
be a material approved by the Department of Transportation of the State
in which the project is located.

COMPOSITION

**401‑3.1 COMPOSITION OF MIXTURE.** The bituminous plant mix shall be
composed of a mixture of well‑graded aggregate, filler and anti-strip
agent if required, and bituminous material. The several aggregate
fractions shall be sized, handled in separate size groups, and combined
in such proportions that the resulting mixture meets the grading
requirements of the job mix formula (JMF).

**401‑3.2 JOB MIX FORMULA.** No bituminous mixture for payment shall be
produced until a job mix formula has been approved in writing by the
Engineer. The bituminous mixture shall be designed using procedures
contained in Chapter 5*,* MARSHALL METHOD OF MIX DESIGN, of the Asphalt
Institute\'s Manual Series No. 2 (MS‑2), Mix Design Methods for Asphalt
Concrete, sixth edition.

The design criteria in Table 1 are target values necessary to meet the
acceptance requirements contained in paragraph 401‑5.2b. The criteria is
based on a production process which has a material variability with the
following standard deviations:

Stability (lbs.) = 270

Flow (0.01 inch) = 1.5

Air Voids (%) = 0.65

If material variability exceeds the standard deviations indicated, the
job mix formula and subsequent production targets shall be based on a
stability greater than shown in Table 1, and the flow and air voids
shall be targeted close to the mid‑range of the criteria in order to
meet the acceptance requirements.

Tensile Strength Ratio (TSR) of the composite mixture, as determined by
ASTM D 4867, shall not be less than 75. Anti‑stripping agent shall be
added to the asphalt, as necessary***,*** to produce a TSR of not less
than 75. If an antistrip agent is required, it will be provided by the
Contractor at no additional cost to the Owner.

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> **Engineer may specify a TSR of not less than 80 in areas that are
> prone to stripping at a TSR of 75. Engineer may specify one or more
> freeze-thaw conditioning cycles in areas that are prone to stripping
> at a TSR of 75.**

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The job mix formula shall be submitted in writing by the Contractor to
the Engineer at least **\[ \]** days prior to the start of paving
operations and shall include as a minimum:

**a.** Percent passing each sieve size for total combined gradation,
individual gradation of all aggregate stockpiles and percent by weight
of each stockpile used in the job mix formula.

**b.** Percent of asphalt cement.

**c.** Asphalt performance*,* viscosity or penetration grade, and type
of modifier if used.

**d.** Number of blows of hammer compaction per side of molded specimen.

**e.** Mixing temperature.

**f.** Compaction temperature.

**g.** Temperature of mix when discharged from the mixer.

**h.** Temperature‑viscosity relationship of the asphalt cement.

**i.** Plot of the combined gradation on the Federal Highway
Administration (FHWA) 45 power gradation curve.

**j.** Graphical plots of stability, flow, air voids, voids in the
mineral aggregate, and unit weight versus asphalt content.

**k.** Percent natural sand.

**l.** Percent fractured faces.

**m.** Percent by weight of flat particles**,** elongated particles, and
flat and elongated particles (and criteria).

**n.** Tensile Strength Ratio (TSR).

p.  Antistrip agent (if required).

q.  Date the job mix formula was developed.

The Contractor shall submit to the Engineer the results of verification
testing of three (3) asphalt samples prepared at the optimum asphalt
content. The average of the results of this testing shall indicate
conformance with the job mix formula requirements specified in Tables 1,
2 and 3.

When the project requires asphalt mixtures of differing aggregate
gradations, a separate job mix formula and the results of job mix
formula verification testing must be submitted for each mix.

The job mix formula for each mixture shall be in effect until a
modification is approved in writing by the Engineer. Should a change in
sources of materials be made, a new job mix formula must be submitted
within \[ \] days and approved by the Engineer in writing before the new
material is used. After the initial production job mix formula(s)
has/have been approved by the Engineer and a new or modified job mix
formula is required for whatever reason, the subsequent cost of the
Engineer's approval of the new or modified job mix formula will be borne
by the Contractor. There will be no time extension given or
considerations for extra costs associated with the stoppage of
production paving or restart of production paving due to the time needed
for the Engineer to approve the initial, new or modified job mix
formula.

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> **The Engineer shall specify the number of days. A minimum of 10 days
> is recommended.**
>
> **Job mix formula not developed within the previous 90 days are not
> recommended.**
>
> **The Marshall Design Criteria applicable to the project shall be
> specified by the Engineer from the information shown below and
> inserted into Table 1. Asterisks denote insert points.**

+---------------------+-----------------------+-----------------------+
| **Test Property**   | ### Pavements         | **Pavements Designed  |
|                     |  Designed for Aircraf | for Aircraft Gross    |
|                     | t Gross Weights of 60 | Weights Less Than     |
|                     | ,000 Lbs. or More or  | 60,000 Lbs. or Tire   |
|                     | Tire Pressures of 100 | Pressures Less Than   |
|                     |  Psi or More {#paveme | 100 Psi**             |
|                     | nts-designed-for-airc |                       |
|                     | raft-gross-weights-of |                       |
|                     | -60000-lbs.-or-more-o |                       |
|                     | r-tire-pressures-of-1 |                       |
|                     | 00-psi-or-more .Style |                       |
|                     | -Heading-3Heading-3-C |                       |
|                     | harHeading-3-Char1-Ch |                       |
|                     | arHeading-3-Char-...} |                       |
+---------------------+-----------------------+-----------------------+
| **Number of Blows** | **75**                | **50**                |
+---------------------+-----------------------+-----------------------+
| **Stability, pounds | **2150 (9564)**       | **1350 (6005)**       |
| (newtons)**         |                       |                       |
+---------------------+-----------------------+-----------------------+
| **Flow, 0.01 in.**  | **10‑14**             | **10‑18**             |
|                     |                       |                       |
| **(0.25 mm)**       |                       |                       |
+---------------------+-----------------------+-----------------------+
| **Air Voids**       | **2.8‑4.2**           | **2.8‑4.2**           |
|                     |                       |                       |
| **(percent)**       |                       |                       |
+---------------------+-----------------------+-----------------------+
| **Percent Voids     | **See Table 2**       | **See Table 2**       |
| in**                |                       |                       |
|                     |                       |                       |
| **Mineral           |                       |                       |
| Aggregate**         |                       |                       |
|                     |                       |                       |
| **(minimum)**       |                       |                       |
+---------------------+-----------------------+-----------------------+

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+-----------------------------------+-----------------------------------+
| ####                              |                                   |
| TABLE 1. MARSHALL DESIGN CRITERIA |                                   |
+-----------------------------------+-----------------------------------+
| TEST PROPERTY                     | \*                                |
+-----------------------------------+-----------------------------------+
| Number of blows                   | \*                                |
+-----------------------------------+-----------------------------------+
| Stability, pounds (newtons)       | \*                                |
| minimum                           |                                   |
+-----------------------------------+-----------------------------------+
| (newtons) minimum                 |                                   |
+-----------------------------------+-----------------------------------+
| Flow, 0.01 in. (0.25 mm)          | \*                                |
+-----------------------------------+-----------------------------------+
| Air voids (percent)               | \*                                |
+-----------------------------------+-----------------------------------+
| Percent voids in mineral          | See Table 2                       |
| aggregate, minimum                |                                   |
+-----------------------------------+-----------------------------------+

+---------------------+---------------------+-------------------------+
| **TABLE 2. MINIMUM  |                     |                         |
| PERCENT**           |                     |                         |
|                     |                     |                         |
| **VOIDS IN MINERAL  |                     |                         |
| AGGREGATE**         |                     |                         |
+---------------------+---------------------+-------------------------+
| **Maximum Particle  |                     | **Minimum Voids in      |
| Size**              |                     | Mineral Aggregate,      |
|                     |                     | percent**               |
+---------------------+---------------------+-------------------------+
| **in.**             | **mm**              | **Percent**             |
+---------------------+---------------------+-------------------------+
| ½                   | 12.5                | 16                      |
+---------------------+---------------------+-------------------------+
| ¾                   | 19.0                | 15                      |
+---------------------+---------------------+-------------------------+
| 1                   | 25.0                | 14                      |
+---------------------+---------------------+-------------------------+
| 1-½                 | 37.5                | 13                      |
+---------------------+---------------------+-------------------------+

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> **Modifications to the minimum Voids in Mineral Aggregate (VMA) as
> found in Table 2 may be made depending on the definition of maximum
> particle size and/or local conditions. Modifications to the flow
> criteria may be required for modified asphalt cement binders.**

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The mineral aggregate shall be of such size that the percentage
composition by weight, as determined by laboratory sieves, will conform
to the gradation or gradations specified in Table 3 when tested in
accordance with ASTM C 136 and C 117.

The gradations in Table 3 represent the limits that shall determine the
suitability of aggregate for use from the sources of supply. The
aggregate, as selected (and used in the JMF), shall have a gradation
within the limits designated in Table 3 and shall not vary from the low
limit on one sieve to the high limit on the adjacent sieve, or vice
versa, but shall be well graded from coarse to fine.

Deviations from the final approved mix design for bitumen content and
gradation of aggregates shall be within the action limits for individual
measurements as specified in paragraph 401‑6.5a. The limits still will
apply if they fall outside the master grading band in Table 3.

The maximum size aggregate used shall not be more than one‑half of the
thickness of the course being constructed except where otherwise shown
on the plans or ordered by the Engineer.

+---------------------------------+------------------------------------+
| **TABLE 3. AGGREGATE ‑          |                                    |
| BITUMINOUS PAVEMENTS**          |                                    |
+=================================+====================================+
| **Sieve Size**                  | **Percentage by Weight Passing     |
|                                 | Sieve**                            |
+---------------------------------+------------------------------------+
| 1‑½ in. (37.50 mm)              | \*                                 |
+---------------------------------+------------------------------------+
| 1 in. (25.0 mm)                 | \*                                 |
+---------------------------------+------------------------------------+
| ¾ in. (19.0 mm)                 | \*                                 |
+---------------------------------+------------------------------------+
| ½ in. (12.5 mm)                 | \*                                 |
+---------------------------------+------------------------------------+
| ⅜ in. (9.5 mm)                  | \*                                 |
+---------------------------------+------------------------------------+
| No. 4 (4.75 mm)                 | \*                                 |
+---------------------------------+------------------------------------+
| No. 8 (2.36 mm)                 | \*                                 |
+---------------------------------+------------------------------------+
| No. 16 (1.18 mm)                | \*                                 |
+---------------------------------+------------------------------------+
| No. 30 (0.60 mm)                | \*                                 |
+---------------------------------+------------------------------------+
| No. 50 (0.30 mm)                | \*                                 |
+---------------------------------+------------------------------------+
| No. 100 (0.15 mm)               | \*                                 |
+---------------------------------+------------------------------------+
| No. 200 (0.075 mm)              | \*                                 |
+---------------------------------+------------------------------------+
| Asphalt percent                 | \*                                 |
|                                 |                                    |
| Stone or gravel                 | \*                                 |
|                                 |                                    |
| Slag                            |                                    |
+---------------------------------+------------------------------------+

The aggregate gradations shown are based on aggregates of uniform
specific gravity. The percentages passing the various sieves shall be
corrected when aggregates of varying specific gravities are used, as
indicated in the Asphalt Institute Manual Series No. 2 (MS‑2), Chapter
3.

**\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

> **The aggregate gradation shall be specified by the Engineer from the
> gradations shown in this note. The gradation shall be inserted into
> Table 3. Asterisks denote insert points.**
>
> **Where locally‑available aggregates cannot be economically blended to
> meet the grading requirements of the gradations shown, the gradations
> may be modified to fit the characteristics of such local aggregates
> with approval of the FAA. The modified gradation must produce a paving
> mixture that satisfies the mix design requirements.**

+--------------------+-----------+-----------+-----------+-----------+
| **AGGREGATE ‑      |           |           |           |           |
| BITUMINOUS         |           |           |           |           |
| PAVEMENTS**        |           |           |           |           |
+====================+===========+===========+===========+===========+
| **Sieve Size**     | **P       |           |           |           |
|                    | ercentage |           |           |           |
|                    | by Weight |           |           |           |
|                    | Passing   |           |           |           |
|                    | Sieves**  |           |           |           |
+--------------------+-----------+-----------+-----------+-----------+
|                    | **1‑½"    | **1"      | **¾ "     | **½"      |
|                    | max**     | max**     | max**     | max**     |
+--------------------+-----------+-----------+-----------+-----------+
| 1‑½ in. (37.5 mm)  | 100       | ‑‑        | ‑‑        | ‑‑        |
+--------------------+-----------+-----------+-----------+-----------+
| 1 in. (24.0 mm)    | 86‑98     | 100       | ‑‑        | ‑‑        |
+--------------------+-----------+-----------+-----------+-----------+
| ¾ in. (19.0 mm)    | 68‑93     | 76‑98     | 100       | ‑‑        |
+--------------------+-----------+-----------+-----------+-----------+
| ½ in. (12.5 mm)    | 57‑81     | 66‑86     | 79‑99     | 100       |
+--------------------+-----------+-----------+-----------+-----------+
| ⅜ in. (9.5 mm)     | 49‑69     | 57‑77     | 68‑88     | 79‑99     |
+--------------------+-----------+-----------+-----------+-----------+
| No. 4 (4.75 mm)    | 34‑54     | 40‑60     | 48‑68     | 58‑78     |
+--------------------+-----------+-----------+-----------+-----------+
| No. 8 (2.36 mm)    | 22‑42     | 26‑46     | 33‑53     | 39‑59     |
+--------------------+-----------+-----------+-----------+-----------+
| No. 16 (1.18 mm)   | 13‑33     | 17‑37     | 20‑40     | 26‑46     |
+--------------------+-----------+-----------+-----------+-----------+
| No. 30 (0.600 mm)  | 8‑24      | 11‑27     | 14‑30     | 19‑35     |
+--------------------+-----------+-----------+-----------+-----------+
| No. 50 (0.300 mm)  | 6‑18      | 7‑19      | 9‑21      | 12‑24     |
+--------------------+-----------+-----------+-----------+-----------+
| No. 100 (0.150 mm) | 4‑12      | 6‑16      | 6‑16      | 7‑17      |
+--------------------+-----------+-----------+-----------+-----------+
| No. 200 (0.075 mm) | 3‑6       | 3‑6       | 3‑6       | 3‑6       |
+--------------------+-----------+-----------+-----------+-----------+
| Asphalt percent:   | 4.5‑7.0   | 4.5‑7.0   | 5.0‑7.5   | 5.5‑8.0   |
|                    |           |           |           |           |
| Stone or gravel    | 5.0‑7.5   | 5.0‑7.5   | 6.5‑9.5   | 7.0‑10.5  |
|                    |           |           |           |           |
| Slag               |           |           |           |           |
+--------------------+-----------+-----------+-----------+-----------+

**\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

**401‑3.3 RECYCLED ASPHALT CONCRETE.** Recycled HMA shall consist of
reclaimed asphalt pavement (RAP), coarse aggregate, fine aggregate,
mineral filler, and asphalt cement. The RAP shall be of a consistent
gradation and asphalt content and properties. When RAP is fed into the
plant, the maximum RAP chunk size shall not exceed 2 inches. The
recycled HMA mix shall be designed using procedures contained in AI
MS-02. The recycled asphalt concrete mix shall be designed using
procedures contained in the Asphalt Institute\'s Manual Series Number 2
(MS‑2). The percentage of asphalt in the RAP shall be established for
the mixture design according to ASTM D 2172 using the appropriate dust
correction procedure. The job mix shall meet the requirements of
paragraph 401‑3.2 RAP should only be used for shoulder surface course
mixes and for any intermediate courses. The amount of RAP shall be
limited to **\[ \]** percent.

\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \*

> **Reclaimed Asphalt Pavement (RAP) should not be used for surface
> mixes, except on shoulders. It can be used very effectively in lower
> layers or for shoulders. Engineer to specify the maximum percentage of
> reclaimed asphalt allowed in the mix. The amount of RAP shall be
> limited to 30 percent, as long as the resulting recycled mix meets all
> requirements that are specified for virgin mixtures. The Contractor
> may obtain the RAP from the job site or an existing source.**

**\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

In addition to the requirements of paragraph 401‑3.2, the job mix
formula shall indicate the percent of reclaimed asphalt pavement and the
percent and viscosity grade of new asphalt. The Contractor shall submit
documentation to the Engineer, indicating that the mixing equipment
proposed for use is adequate to mix the percent of RAP shown in the job
mix formula and meet all local and national environmental regulations.

**\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

> **The appropriate test should be selected to conform to the grade of
> new asphalt specified. If a penetration grade is specified, use
> penetration test. If a viscosity grade is specified, use a viscosity
> test. If a PG asphalt binder is specified, use the dynamic shear
> rheometer and bending beam tests.**

**\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

The blend of new asphalt cement and the RAP asphalt binder shall meet
the requirements in paragraph 401-2.3. The virgin asphalt cement shall
not be more than two standard asphalt material grades different than
that specified in paragraph 401-2.3

**\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

> **Delete paragraph 401-3.3 in its entirety if recycled asphalt
> pavement is not to be allowed and include a sentence that RAP will not
> be permitted to be used. RAP containing coal tars may require
> additional precautions during production and may be excluded.**

**\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

**401‑3.4 TEST SECTION.** Prior to full production, the Contractor shall
prepare and place a quantity of bituminous mixture according to the job
mix formula. The amount of mixture shall be sufficient to construct a
test section **\[ \]** long and **\[ \]** wide**,** placed in two lanes,
with a longitudinal cold joint, and shall be of the same depth specified
for the construction of the course which it represents. A cold joint is
an exposed construction joint at least 4 hours old or whose mat has
cooled to less than 160° F. The underlying grade or pavement structure
upon which the test section is to be constructed shall be the same as
the remainder of the course represented by the test section. The
equipment used in construction of the test section shall be the same
type and weight to be used on the remainder of the course represented by
the test section.

THE TEST SECTION SHALL BE EVALUATED FOR ACCEPTANCE AS A SINGLE LOT IN
ACCORDANCE WITH THE ACCEPTANCE CRITERIA IN PARAGRAPH 401-5.1 AND
401-6.3. THE TEST SECTION SHALL BE DIVIDED INTO EQUAL SUBLOTS. AS A
MINIMUM THE TEST SECTION SHALL CONSIST OF 3 SUBLOTS.

The test section shall be considered acceptable if; 1) stability, flow,
mat density, air voids, and joint density are 90 percent or more within
limits, 2) gradation and asphalt content are within the action limits
specified in paragraphs 401‑6.5a and 5b, and 3) the voids in the mineral
aggregate are within the limits of Table 2.

If the initial test section should prove to be unacceptable, the
necessary adjustments to the job mix formula, plant operation, placing
procedures, and/or rolling procedures shall be made. A second test
section shall then be placed. If the second test section also does not
meet specification requirements, both sections shall be removed at the
Contractor\'s expense. Additional test sections, as required, shall be
constructed and evaluated for conformance to the specifications. Any
additional sections that are not acceptable shall be removed at the
Contractor\'s expense. Full production shall not begin until an
acceptable section has been constructed and accepted in writing by the
Engineer. Once an acceptable test section has been placed, payment for
the initial test section and the section that meets specification
requirements shall be made in accordance with paragraph 401‑8.1.

Job mix control testing shall be performed by the Contractor at the
start of plant production and in conjunction with the calibration of the
plant for the job mix formula. If aggregates produced by the plant do
not satisfy the gradation requirements or produce a mix that meets the
JMF. It will be necessary to reevaluate and redesign the mix using
plant‑produced aggregates. Specimens shall be prepared and the optimum
bitumen content determined in the same manner as for the original design
tests.

**\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

> **The test section should be a minimum of 300 feet (90 m) long and 20
> to 30 feet (6 to 9 m) wide. The test section affords the Contractor
> and the Engineer an opportunity to determine the quality of the
> mixture in place, as well as performance of the plant and laydown
> equipment.**

**\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

Contractor will not be allowed to place the test section until the
Contractor Quality Control Program, showing conformance with the
requirements of Paragraph 401-6.1, has been approved, in writing, by the
Engineer.

**401‑3.5 TESTING LABORATORY.** The Contractor's laboratory used to
develop the job mix formula shall meet the requirements of ASTM D 3666
including the requirement to be accredited by a national authority such
as the National Voluntary Laboratory Accreditation Program (NVLAP), the
American Association for Laboratory Accreditation (AALA), or AASHTO
Accreditation Program (AAP). Laboratory personnel shall meet the
requirements of Section 100 of the General Provisions. A certification
signed by the manager of the laboratory stating that it meets these
requirements shall be submitted to the Engineer prior to the start of
construction. The certification shall contain as a minimum:

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

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

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

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

**e.** ASTM D 3666 certification of accreditation by a nationally
recognized accreditation program.

CONSTRUCTION METHODS

**401‑4.1 WEATHER LIMITATIONS.** The bituminous mixture shall not be
placed 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 Engineer, if requested; however, all
other requirements including compaction shall be met.

**TABLE 4. BASE TEMPERATURE LIMITATIONS**

+------------------------------+-------------------+-------------------+
| **Mat Thickness**            | **Base            |                   |
|                              | Temperature       |                   |
|                              | (Minimum)**       |                   |
+==============================+===================+===================+
|                              | **Deg. F**        | **Deg. C**        |
+------------------------------+-------------------+-------------------+
| 3 in. (7.5 cm) or greater    | 40                | 4                 |
+------------------------------+-------------------+-------------------+
| Greater than 1 in. (2.5 cm)  | 45                | 7                 |
|                              |                   |                   |
| but less than 3 in. (7.5 cm) |                   |                   |
+------------------------------+-------------------+-------------------+
| 1 in. (2.5 cm) or less       | 50                | 10                |
+------------------------------+-------------------+-------------------+

**401‑4.2 BITUMINOUS MIXING PLANT.** Plants used for the preparation of
bituminous mixtures shall conform to the requirements of ASTM D 995 with
the following changes:

**a. Requirements for All Plants.**

**(1) Truck Scales.** The bituminous mixture shall be weighed on
approved scales furnished by the Contractor, or on certified public
scales at the Contractor\'s expense. Scales shall be inspected and
sealed as often as the Engineer deems necessary to assure their
accuracy. Scales shall conform to the requirements of the General
Provisions, Section 90‑01.

In lieu of scales, and as approved by the Engineer, asphalt mixture
weights may be determined by the use of an electronic weighing system
equipped with an automatic printer that weighs the total paving mixture.
Contractor must furnish calibration certification of the weighing system
prior to mix production and as often thereafter as requested by the
Engineer.

**(2) Testing Facilities.** The Contractor shall provide laboratory
facilities at the plant for the use of the Engineer\'s acceptance
testing and the Contractor\'s quality control testing. The Engineer will
always have priority in the use of the laboratory. The lab shall have
sufficient space and equipment so that both testing representatives
(Engineer's and Contractor's) can operate efficiently. The lab shall
also meet the requirements of ASTM D 3666.

The plant testing laboratory shall have a floor space area of not less
than 150 square feet, with a ceiling height of not less than 7-½ feet.
The laboratory shall be weather tight, sufficiently heated in cold
weather, air-conditioned in hot weather to maintain temperatures for
testing purposes of 70 degrees F +/- 5 degrees F. The plant testing
laboratory shall be located on the plant site to provide an unobstructed
view, from one of its windows, of the trucks being loaded with the plant
mix materials.

Laboratory facilities shall be kept clean, and all equipment shall be
maintained in proper working condition. The Engineer shall be permitted
unrestricted access to inspect the Contractor's laboratory facility and
witness quality control activities. The Engineer will advise the
Contractor in writing of any noted deficiencies concerning the
laboratory facility, equipment, supplies, or testing personnel and
procedures. When the deficiencies are serious enough to be adversely
affecting the test results, the incorporation of the materials into the
work shall be suspended immediately and will not be permitted to resume
until the deficiencies are satisfactorily corrected.

As a minimum, the plant testing laboratory shall have:

> **(a)** Adequate artificial lighting
>
> **(b)** Electrical outlets sufficient in number and capacity for
> operating the required testing equipment and drying samples.
>
> **(c)** Fire extinguishers (2), Underwriter's Laboratories approved
>
> **(d)** Work benches for testing, minimum 2-½ feet by 10 feet.
>
> **(e)** Desk with 2 chairs
>
> **(f)** Sanitary facilities convenient to testing laboratory
>
> **(g)** Exhaust fan to outside air, minimum 12 inch blade diameter
>
> **(h)** A direct telephone line and telephone including a FAX machine
> operating 24 hours per day, seven days per week
>
> **(i)** File cabinet with lock for Engineer
>
> **(j)** Sink with running water, attached drain board and drain
> capable of handling separate material
>
> **(k)** Metal stand for holding washing sieves
>
> **(l)** Two element hot plate or other comparable heating device, with
> dial type thermostatic controls for drying aggregates
>
> **(m)** Mechanical shaker and appropriate sieves (listed in JMF, Table
> 3) meeting the requirements of ASTM E-11 for determining the gradation
> of coarse and fine aggregates in accordance with ASTM C 136
>
> **(n)** Marshall testing equipment meeting ASTM D 6926, ASTM D 6927,
> automatic compaction equipment capable of compacting three specimens
> at once and other apparatus as specified in ASTM C 127, D 2172, D
> 2726, and D 2041
>
> **(o)** Oven, thermostatically controlled, inside minimum 1 cubic foot
>
> **(p)** Two volumetric specific gravity flasks, 500 cc
>
> **(q)** Other necessary hand tools required for sampling and testing
>
> **(r)** Library containing contract specifications, latest ASTM
> volumes 4.01, 4.02, 4.03 and 4.09, AASHTO standard specification parts
> I and II, and Asphalt Institute Publication MS-2.
>
> **(s)** Equipment for Theoretical Specific Gravity testing including a
> 4,000 cc pycnometer, vacuum pump capable of maintaining 30 ml mercury
> pressure and a balance, 16-20 kilograms with accuracy of 0.5 grams
>
> **(t)** Extraction equipment, centrifuge and reflux types and ROTOflex
> equipment
>
> **(u)** A masonry saw with diamond blade for trimming pavement cores
> and samples
>
> **(v)** Telephone

Approval of the plant and testing laboratory by the Engineer requires
all facilities and equipment to be in good working order during
production, sampling and testing. Failure to provide the specified
facilities shall be sufficient cause for disapproving bituminous plant
operations.

The Owner shall have access to the lab and the plant whenever Contractor
is in production.

**(3) Inspection of Plant.** The Engineer, or Engineer\'s authorized
representative, shall have access, at all times, to all areas of the
plant for checking adequacy of equipment; inspecting operation of the
plant: verifying weights, proportions, and material properties; and
checking the temperatures maintained in the preparation of the mixtures.

**(4) Storage Bins and Surge Bins.** Use of surge and storage bins for
temporary storage of hot bituminous mixtures will be permitted as
follows:

> **(a)** The bituminous mixture may be stored in surge bins for ***a***
> period of time not to exceed 3 hours.
>
> **(b)** The bituminous mixture may be stored in insulated storage bins
> for a period of time not to exceed 24 hours***.***

The bins shall be such that mix drawn from them meets the same
requirements as mix loaded directly into trucks.

If the Engineer determines that there is an excessive amount of heat
loss, segregation***,*** or oxidation of the mixture due to temporary
storage, no temporary storage will be allowed.

**401‑4.3 HAULING EQUIPMENT.** Trucks used for hauling bituminous
mixtures shall have tight, clean, and smooth metal beds. To prevent the
mixture from adhering to them, the truck beds shall be lightly coated
with a minimum amount of paraffin oil, lime solution, or other approved
material. Petroleum products shall not be used for coating truck beds.
Each truck shall have a suitable cover to protect the mixture from
adverse weather. When necessary, to ensure that the mixture will be
delivered to the site at the specified temperature, truck beds shall be
insulated or heated and covers shall be securely fastened.

**401‑4.4 BITUMINOUS PAVERS.** Bituminous pavers shall be self‑propelled
with an activated heated screed, capable of spreading and finishing
courses of bituminous plant mix material that will meet the specified
thickness, smoothness, and grade. The paver shall have sufficient power
to propel itself and the hauling equipment without adversely affecting
the finished surface.

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

The paver shall be equipped with a control system capable of
automatically maintaining the specified screed elevation. The control
system shall be automatically actuated from either a reference line
and/or through a system of mechanical sensors or sensor‑directed
mechanisms or devices that will maintain the paver screed at a
predetermined transverse slope and at the proper elevation to obtain the
required surface. The transverse slope controller shall be capable of
maintaining the screed at the desired slope within plus or minus 0.1
percent.

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

**a.** Ski‑type device of not less than 30 feet (9.14 m) in length.

**b.** Taut stringline (wire) set to grade.

**c.** Short ski or shoe.

**d.** Laser control.

If, during construction, it is found that the spreading and finishing
equipment in use leaves tracks or indented areas, or produces other
blemishes in the pavement that are not satisfactorily corrected by the
scheduled operations, the use of such equipment shall be discontinued
and satisfactory equipment shall be provided by the Contractor.

**401‑4.5 ROLLERS.** Rollers of the vibratory, steel wheel, and
pneumatic‑tired type shall be used. They shall be in good condition,
capable of operating at slow speeds to avoid displacement of the
bituminous mixture. The number, type, and weight of rollers shall be
sufficient to compact the mixture to the required density while it is
still in a workable condition.

All rollers shall be specifically designed and suitable for compacting
hot mix bituminous concrete and shall be properly used. Rollers that
impair the stability of any layer of a pavement structure or underlying
soils shall not be used. Depressions in pavement surfaces caused by
rollers shall be repaired by the Contractor at its own expense.

The use of equipment that causes crushing of the aggregate will not be
permitted.

**a. Nuclear Densometer.** The Contractor shall have on site a nuclear
densometer during all paving operations in order to assist in the
determination of the optimum rolling pattern, type of roller and
frequencies, as well as to monitor the effect of the rolling operations
during production paving. The Contractor shall also supply a qualified
technician during all paving operations to calibrate the nuclear
densometer and obtain accurate density readings for all new bituminous
concrete. These densities shall be supplied to the Engineer upon request
at any time during construction. No separate payment will be made for
supplying the density gauge and technician.

**401‑4.6 PREPARATION OF BITUMINOUS MATERIAL.** The bituminous material
shall be heated in a manner that will avoid local overheating and
provide a continuous supply of the bituminous material to the mixer at a
uniform temperature. The temperature of the bituminous material
delivered to the mixer shall be sufficient to provide a suitable
viscosity for adequate coating of the aggregate particles, but shall not
exceed 325 degrees F (160 degrees C), unless otherwise required by the
manufacturer*.*

**401‑4.7 PREPARATION OF MINERAL AGGREGATE.** The aggregate for the
mixture shall be heated and dried prior to introduction into the mixer.
The maximum temperature and rate of heating shall be such that no damage
occurs to the aggregates. The temperature of the aggregate and mineral
filler shall not exceed 350 degrees F (175 degrees C) when the asphalt
is added. Particular care shall be taken that aggregates high in calcium
or magnesium content are not damaged by overheating. The temperature
shall not be lower than is required to obtain complete coating and
uniform distribution on the aggregate particles and to provide a mixture
of satisfactory workability.

**401‑4.8 PREPARATION OF BITUMINOUS MIXTURE.** The aggregates and the
bituminous material shall be weighed or metered and introduced into the
mixer in the amount specified by the job mix formula.

The combined materials shall be mixed until the aggregate obtains a
uniform coating of bitumen and is thoroughly distributed throughout the
mixture. Wet mixing time shall be the shortest time that will produce a
satisfactory mixture, but not less than 25 seconds for batch plants. The
wet mixing time for all plants shall be established by the Contractor,
based on the procedure for determining the percentage of coated
particles described in ASTM D 2489, for each individual plant and for
each type of aggregate used. The wet mixing time will be set to achieve
95 percent of coated particles. For continuous mix plants, the minimum
mixing time shall be determined by dividing the weight of its contents
at operating level by the weight of the mixture delivered per second by
the mixer. The moisture content of all bituminous mixtures upon
discharge shall not exceed 0.5 percent.

**\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

> **For batch plants, wet mixing time begins with the introduction of
> bituminous material into the mixer and ends with the opening of the
> mixer discharge gate. Distribution of aggregate and bituminous
> material as they enter the pugmill, speed of mixer shafts, and
> arrangement and pitch of paddles are factors governing efficiency of
> mixing. Prolonged exposure to air and heat in the pugmill harden the
> asphalt film on the aggregate. Mixing time, therefore, should be the
> shortest time required to obtain uniform distribution of aggregate
> sizes and thorough coating of aggregate particles with bituminous
> material.**

**\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

**401‑4.9 PREPARATION OF THE UNDERLYING SURFACE.** Immediately before
placing the bituminous mixture, the underlying course shall be cleaned
of all dust and debris. A prime coat or tack coat shall be applied in
accordance with Item P‑602 or P‑603, if shown on the plans.

**\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

> **Engineer should evaluate the presence of paint and/or rubber
> deposits on the existing pavement and, if needed, may specify milling,
> grinding or other suitable means to remove same prior to placement of
> new bituminous material.**

**\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

**401‑4.10 LAYDOWN PLAN, TRANSPORTING, PLACING, AND FINISHING.** Prior
to the placement of the bituminous mixture, the Contractor shall prepare
a laydown plan for approval by the Engineer. This is to minimize the
number of cold joints in the pavement. The laydown plan shall include
the sequence of paving laydown by stations, width of lanes, temporary
ramp location(s), and laydown temperature. The laydown plan shall also
include estimated time of completion for each portion of the work (i.e.
milling, paving, rolling, cooling, etc.). Modifications to the laydown
plan shall be approved by the Engineer.

The bituminous mixture shall be transported from the mixing plant to the
site in vehicles conforming to the requirements of paragraph 401-4.3.
Deliveries shall be scheduled so that placing and compacting of mixture
is uniform with minimum stopping and starting of the paver. Hauling over
freshly placed material shall not be permitted until the material has
been compacted, as specified, and allowed to cool to atmospheric
temperature.

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> **Engineer may, at his option, add the following language:**
>
> **"For all runway, taxiway and apron pavements, Contractor shall use a
> stringline to place each lane of each lift of bituminous surface
> course. However, at the Contractor's option, Contractor shall use
> stringline for first lift of bituminous surface course and then survey
> the grade of that lift. Provided grades of that lift of bituminous
> surface course meet the tolerances of paragraphs 401-5.2b(6), then
> Contractor may place successive lifts of bituminous surface course
> using a long ski, or laser control per paragraph 401-4.4. However,
> Contractor shall survey each lift of bituminous surface course and
> certify to Engineer that every lot of each lift meets the grade
> tolerances of paragraph 401-5.2b(6) before the next lift can be placed
> without a stringline. If the grades of a single lot do not meet the
> tolerances of 401-5.2b(6), then the Contractor shall use a stringline
> for each entire lift. Corrective action in paragraph 401-5.2b(6)
> applies to the final lift of surface course; however, for multiple
> lift construction, the Contractor shall correct to ensure the final
> lift of surface course is a minimum of \[ \] inches and a maximum of
> \[ \] inches." (Engineer to specify minimum and maximum tolerances for
> final lift of surface course)**

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**\[**The Contractor may elect to use a material transfer vehicle to
deliver mix to the paver.**\]**

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> **Use of a material transfer vehicle allows the paver to be operated
> almost continuously without stopping between truckloads of mix, if a
> continuous supply of mix is available from the asphalt plant. The use
> of a transfer vehicle is recommended on long paving lanes.**

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Paving during nighttime construction shall require the following:

**a.** All paving machines, rollers, distribution trucks and other
vehicles required by the Contractor for his operations shall be equipped
with artificial illumination sufficient to safely complete the work.

**b.** Minimum illumination level shall be twenty (20) horizontal foot
candles and maintained in the following areas:

**(1)** An area of 30 feet wide by 30 feet long immediately behind the
paving machines during the operations of the machines.

**(2)** An area 15 feet wide by 30 feet long immediately in front and
back of all rolling equipment, during operation of the equipment.

**(3)** An area 15 feet wide by 15 feet long at any point where an area
is being tack coated prior to the placement of pavement.

**c.** As partial fulfillment of the above requirements, the Contractor
shall furnish and use, complete artificial lighting units with a minimum
capacity of 3,000 watt electric beam lights, affixed to all equipment in
such a way to direct illumination on the area under construction.

**d.** In addition, the Contractor shall furnish \[ \] portable
floodlight units similar or equal to \[ \].

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> **Engineer to specify the minimum number of floodlighting units and
> may elect to specify a particular manufacturer's lighting unit "or
> equal".**
>
> **If nighttime paving requires the critical re-opening of airfield
> facilities, the following additional language should be added:**
>
> **"If the Contractor places any out of specification mix in the
> project work area, the Contractor is required to remove it at its own
> expense, to the satisfaction of the Engineer. If the Contractor has to
> continue placing non-payment bituminous concrete, as directed by the
> Engineer, to make the surfaces safe for aircraft operations, the
> Contractor shall do so to the satisfaction of the Engineer. It is the
> Contractor's responsibility to leave the facilities to be paved in a
> safe condition ready for aircraft operations. No consideration for
> extended closure time of the area being paved will be given. As a
> first order of work for the next paving shift, the Contractor shall
> remove all out of specification material and replace with approved
> material to the satisfaction of the Engineer. When the above
> situations occur, there will be no consideration given for additional
> construction time or payment for extra costs."**

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The initial placement and compaction of the mixture shall occur at a
temperature suitable for obtaining density, surface smoothness, and
other specified requirements but not less than 250 degrees F (121
degrees C).

Edges of existing bituminous pavement abutting the new work shall be saw
cut and carefully removed as shown on the drawings and painted with
bituminous tack coat before new material is placed against it.

Upon arrival, the mixture shall be placed to the full width by a
bituminous paver. It shall be struck off in a uniform layer of such
depth that, when the work is completed, it shall have the required
thickness and conform to the grade and contour indicated. The speed of
the paver shall be regulated to eliminate pulling and tearing of the
bituminous mat. Unless otherwise permitted, placement of the mixture
shall begin along the centerline of a crowned section or on the high
side of areas with a one‑way slope. The mixture shall be placed in
consecutive adjacent strips having a minimum width of **\[ \]** except
where edge lanes require less width to complete the area. Additional
screed sections shall not be attached to widen paver to meet the minimum
lane width requirements specified above unless additional auger sections
are added to match. The longitudinal joint in one course shall offset
the longitudinal joint in the course immediately below by at least 1
foot (30 cm); however, the joint in the surface top course shall be at
the centerline of crowned pavements. Transverse joints in one course
shall be offset by at least 10 feet (3 m) from transverse joints in the
previous course.

Transverse joints in adjacent lanes shall be offset a minimum of 10 feet
(3 m).

On areas where irregularities or unavoidable obstacles make the use of
mechanical spreading and finishing equipment impractical, the mixture
may be spread and luted by hand tools. Areas of segregation in the
surface course, as determined by the Engineer, shall be removed and
replaced at the Contractor's expense. The area shall be removed by saw
cutting and milling a minimum of 2 inches deep. The area to be removed
and replaced shall be a minimum width of the paver and a minimum of 10
feet long.

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> **The Engineer should add more detail as appropriate to areas that
> require removal and replacements. The Engineer should specify the
> widest paving lane practicable in an effort to hold the number of
> longitudinal joints to a minimum.**

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**401‑4.11 COMPACTION OF MIXTURE.** After placing, the mixture shall be
thoroughly and uniformly compacted by power rollers. The surface shall
be compacted as soon as possible when the mixture has attained
sufficient stability so that the rolling does not cause undue
displacement, cracking or shoving. The sequence of rolling operations
and the type of rollers used shall be at the discretion of the
Contractor. The speed of the roller shall, at all times, be sufficiently
slow to avoid displacement of the hot mixture and be effective in
compaction. Any displacement occurring as a result of reversing the
direction of the roller, or from any other cause, shall be corrected at
once.

Sufficient rollers shall be furnished to handle the output of the plant.
Rolling shall continue until the surface is of uniform texture, true to
grade and cross section, and the required field density is obtained.

To prevent adhesion of the mixture to the roller, the wheels shall be
equipped with a scraper and kept properly moistened but excessive water
will not be permitted.

In areas not accessible to the roller, the mixture shall be thoroughly
compacted with approved power driven tampers. Tampers shall weigh not
less than 275 pounds, have a tamping plate width not less than 15
inches, be rated at not less than 4,200 vibrations per minute, and be
suitably equipped with a standard tamping plate wetting device.

Any mixture that becomes loose and broken, mixed with dirt, contains
check‑cracking, or in any way defective shall be removed and replaced
with fresh hot mixture and immediately compacted to conform to the
surrounding area. This work shall be done at the Contractor\'s expense.
Skin patching shall not be allowed.

**401‑4.12 JOINTS.** The formation of all joints shall be made in such a
manner as to ensure a continuous bond between the courses and obtain the
required density. All joints shall have the same texture as other
sections of the course and meet the requirements for smoothness and
grade.

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

Longitudinal joints which are irregular, damaged, uncompacted, or
otherwise defective **\[**or which have been left exposed for more than
4 hours, or whose surface temperature has cooled to less than 160°
F**\]** shall be cut back \[specify cutback\] to expose a clean, sound
surface for the full depth of the course. All contact surfaces shall be
cleaned and dry prior and given a tack coat of bituminous material prior
to placing any fresh mixture against the joint. The cost of this work
and tack coat shall be considered incidental to the cost of the
bituminous course.

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> **Engineer may retain the bracketed language regarding the treatment
> of "cold joints" when considered necessary. The cutback should be no
> more than 6 inches.**

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**401-4.13 SKID RESISTANT SURFACES/SAW-CUT GROOVING.** If shown on the
plans, skid resistant surfaces for asphalt pavements shall be provided
by construction of saw-cut grooves. Pavement shall be sufficiently
cooled prior to grooving.

Transverse grooves shall be saw-cut in the pavement forming a ¼ inch
wide by ¼ inch deep by 1-½ inches center to center configuration. The
grooves shall be continuous for the entire length of the pavement. They
shall be saw-cut transversely in the pavement to within 10 feet of the
pavement edge to allow adequate space for equipment operation. The
tolerances for saw-cut grooves shall meet the following:

**a. Alignment tolerance** -- Plus or minus 1-½ inches in alignment for
75 feet.

**b. Groove tolerance** -- Minimum depth 3/16 inch, except that not more
than 60 percent of the grooves shall be less than ¼ inch. Maximum depth
5/16 inch. Minimum width ¼ inch. Maximum width 5/16 inch.

**c. Center-to-center spacing** -- Minimum spacing 1-⅜ inches. Maximum
spacing 1-½ inches.

Grooves shall not be less than 6 inches and not more than 18 inches from
in-pavement light fixtures. Cleanup of waste material shall be
continuous during the grooving operation. All waste material shall be
removed from the pavement surface and disposed of off-site in accordance
with governing laws and regulations. All arrangements for disposal of
waste material shall be made prior to the start of grooving. Waste
material shall not be allowed to enter the airport storm or sanitary
sewer system.

MATERIAL ACCEPTANCE

**401‑5.1 ACCEPTANCE SAMPLING AND TESTING.** Unless otherwise specified,
all acceptance sampling and testing necessary to determine conformance
with the requirements specified in this section will be performed by the
Engineer at no cost to the Contractor except that coring **\[**and
profilograph testing**\]** as required in this section shall be
completed and paid for by the Contractor. Testing organizations
performing these tests **\[**except profilograph**\]** shall meet the
requirements of ASTM D 3666. All equipment in Contractor furnished
laboratories shall be calibrated by an independent testing organization
prior to the start of operations at the Contractor\'s expense.

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> **See note to Engineer in section 401-5.2b(5) regarding the use of
> profilograph testing. If this testing is specified, it is performed
> and paid for by the Contractor.**

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**a. Plant‑Produced Material.** Plant‑produced material shall be tested
for stability, flow, and air voids on a lot basis. Sampling shall be
from material deposited into trucks at the plant or from trucks at the
job site. Samples shall be taken in accordance with ASTM D 979. A lot
will consist of:

-   one day or shift's production not to exceed 2,000 tons (1 814 000
    kg), or

-   a half day or shift's production where a day\'s production is
    expected to consist of between 2,000 and 4,000 tons (1 814 000 and 3
    628 000 kg), or

-   similar subdivisions for tonnages over 4,000 tons (3 628 000 kg).

Where more than one plant is simultaneously producing material for the
job, the lot sizes shall apply separately for each plant.

**(1) Sampling.** Each lot will consist of four equal sublots.
Sufficient material for preparation of test specimens for all testing
will be sampled by the Engineer on a random basis, in accordance with
the procedures contained in ASTM D 3665. One set of laboratory compacted
specimens will be prepared for each sublot in accordance with ASTM D
6926, at the number of blows required by paragraph 401‑3.2, Table 1.
Each set of laboratory compacted specimens will consist of three test
portions prepared from the same sample increment.

The sample of bituminous mixture may be put in a covered metal tin and
placed in an oven for not less than 30 minutes nor more than 60 minutes
to stabilize to compaction temperature. The compaction temperature of
the specimens shall be as specified in the job mix formula.

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> **Engineer should increase hold times to not less than 60 minutes and
> not more than 90 minutes when absorptive aggregates are used,**

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**(2) Testing.** Sample specimens shall be tested for stability and flow
in accordance with ASTM D 6927. Air voids will be determined by the
Engineer in accordance with ASTM D 3203.

Prior to testing, the bulk specific gravity of each test specimen shall
be measured by the Engineer in accordance with ASTM D 2726 using the
procedure for laboratory-prepared thoroughly dry specimens, or ASTM D
1188, whichever is applicable, for use in computing air voids and
pavement density.

For air voids determination, the theoretical maximum specific gravity of
the mixture shall be measured one time for each sublot in accordance
with ASTM D 2041, Type C, D or E container. The value used in the air
voids computation for each sublot shall be based on theoretical maximum
specific gravity measurement for the sublot.

The stability and flow for each sublot shall be computed by averaging
the results of all test specimens representing that sublot.

**(3) Acceptance.** Acceptance of plant produced material for stability,
flow, and air voids shall be determined by the Engineer in accordance
with the requirements of paragraph 401‑5.2b.

**b. Field Placed Material.** Material placed in the field shall be
tested for mat and joint density on a lot basis.

**(1) Mat Density.** The lot size shall be the same as that indicated in
paragraph 401‑5.1a and shall be divided into four equal sublots. One
core of finished, compacted materials shall be taken by the Contractor
from each sublot. Core locations will be determined by the Engineer on a
random basis in accordance with procedures contained in ASTM D 3665.
Cores shall not be taken closer than one foot from a transverse or
longitudinal joint.

**(2) Joint Density.** The lot size shall be the total length of
longitudinal joints constructed by a lot of material as defined in
paragraph 401‑5.1a. The lot shall be divided into four equal sublots.
One core of finished, compacted materials shall be taken by the
Contractor from each sublot. Core locations will be determined by the
Engineer on a random basis in accordance with procedures contained in
ASTM D 3665. ALL CORING SHALL BE CENTERED ON THE JOINT. THE MINIMUM CORE
DIAMETER FOR JOINT DENSITY DETERMINATION SHALL BE 5 INCHES.

**(3) Sampling.** Samples shall be neatly cut with a core drill. The
cutting edge of the core drill bit shall be of hardened steel or other
suitable material with diamond chips embedded in the metal cutting edge.
The minimum diameter of the sample shall be five inches. Samples that
are clearly defective, as a result of sampling, shall be discarded and
another sample taken. The Contractor shall furnish all tools, labor, and
materials for cutting samples, cleaning, and filling the cored pavement.
Cored pavement shall be cleaned and core holes shall be filled in a
manner acceptable to the Engineer and within one day after sampling.

**(4) Testing.** The bulk specific gravity of each cored sample will be
measured by the Engineer in accordance with ASTM D 2726 or ASTM D 1188,
whichever is applicable. The percent compaction (density) of each sample
will be determined by dividing the bulk specific gravity of each sublot
sample by the average bulk specific gravity of all laboratory prepared
specimens for the lot, as determined in paragraph 401‑5.1a(2). The bulk
specific gravity used to determine the joint density at joints formed
between different lots shall be the lowest of the bulk specific gravity
values from the two different lots.

**(5) Acceptance.** Acceptance of field placed material for mat density
will be determined by the Engineer in accordance with the requirements
of paragraph 401-5.2b(1). Acceptance for joint density will be
determined in accordance with the requirements of paragraph 401-5.2b(3).

**c. Partial Lots --- Plant‑Produced Material.** When operational
conditions cause a lot to be terminated before the specified number of
tests have been made for the lot, or when the Contractor and Engineer
agree in writing to allow overages or other minor tonnage placements to
be considered as partial lots, the following procedure will be used to
adjust the lot size and the number of tests for the lot.

The last batch produced where production is halted will be sampled, and
its properties shall be considered as representative of the particular
sublot from which it was taken. In addition, an agreed to minor
placement will be sampled, and its properties shall be considered as
representative of the particular sublot from which it was taken. Where
three sublots are produced, they shall constitute a lot. Where one or
two sublots are produced, they shall be incorporated into the next lot,
and the total number of sublots shall be used in the acceptance plan
calculation, i.e., n = 5 or n = 6, for example. Partial lots at the end
of asphalt production on the project shall be included with the previous
lot.

**d. Partial Lots --- Field Placed Material.** The lot size for field
placed material shall correspond to that of the plant material, except
that, in no cases, shall less than three (3) cored samples be obtained,
i.e., n = 3.

401‑5.2 ACCEPTANCE CRITERIA.

**a. General.** Acceptance will be based on the following
characteristics of the bituminous mixture and completed pavement as well
as the implementation of the Contractor Quality Control Program and test
results:

**(1)** Stability

**(2)** Flow

**(3)** Air voids

**(4)** Mat density

**(5)** Joint density

**(6)** Thickness

**(7)** Smoothness

**(8)** Grade

Mat density and air voids will be evaluated for acceptance in accordance
with paragraph 401-5.2b(1). Stability and flow will be evaluated for
acceptance in accordance with paragraph 401-5.2b(2). Joint density will
be evaluated for acceptance in accordance with paragraph 401-5.2b(3).

Thickness will be evaluated by the Engineer for compliance in accordance
with paragraph 401-5.2b(4). Acceptance for smoothness will be based on
the criteria contained in paragraph 401-5.2b(5). Acceptance for grade
will be based on the criteria contained in paragraph 401-5.2b(6).

The Engineer may at any time, notwithstanding previous plant acceptance,
reject and require the Contractor to dispose of any batch of bituminous
mixture which is rendered unfit for use due to contamination,
segregation, incomplete coating of aggregate, or improper mix
temperature. Such rejection may be based on only visual inspection or
temperature measurements. In the event of such rejection, the Contractor
may take a representative sample of the rejected material in the
presence of the Engineer, and if it can be demonstrated in the
laboratory, in the presence of the Engineer, that such material was
erroneously rejected, payment will be made for the material at the
contract unit price.

**b. Acceptance Criteria.**

**(1) Mat Density and Air Voids.** Acceptance of each lot of plant
produced material for mat density and air voids shall be based on the
percentage of material within specification limits (PWL). If the PWL of
the lot equals or exceeds 90 percent, the lot shall be acceptable.
Acceptance and payment shall be determined in accordance with paragraph
401‑8.1.

**(2) Stability and Flow.** Acceptance of each lot of plant produced
material for stability and flow shall be based on the percentage of
material within specification limits (PWL). If the PWL of the lot equals
or exceeds 90 percent, the lot shall be acceptable. If the PWL is less
than 90 percent, the Contractor shall determine the reason and take
corrective action. If the PWL is below 80 percent, the Contractor must
stop production until the reason for poor stability and/or flow has been
determined and adjustments to the mix are made

**(3) Joint Density.** Acceptance of each lot of plant produced material
for joint density shall be based on the percentage of material within
specification limits (PWL). If the PWL of the lot is equal to or exceeds
90 percent, the lot shall be considered acceptable. If the PWL is less
than 90 percent, the Contractor shall evaluate the reason and act
accordingly. If the PWL is less than 80 percent, the Contractor shall
cease operations and until the reason for poor compaction has been
determined. IF THE PWL IS LESS THAN 71 PERCENT, THE PAY FACTOR FOR THE
LOT USED TO COMPLETE THE JOINT SHALL BE REDUCED BY 5 PERCENTAGE POINTS.
This lot pay factor reduction shall be incorporated and evaluated in
accordance with paragraph 401‑8.1.

**(4) Thickness.** Thickness of each lift of surface course shall be
evaluated by the Engineer for compliance to the requirements shown on
the plans. Measurements of thickness shall be made by the Engineer using
the cores extracted for each sublot for density measurement. The maximum
allowable deficiency at any point shall not be more than ¼ inch less
than the thickness indicated for the lift. Average thickness of lift, or
combined lifts, shall not be less than the indicated thickness. Where
the thickness tolerances are not met, the lot or sublot shall be
corrected by the Contractor at his expense by removing the deficient
area and replacing with new pavement. The Contractor, at his expense,
may take additional cores as approved by the Engineer to circumscribe
the deficient area.

**(5) Smoothness.** The final surface shall be free from roller marks.
The finished surfaces of each course of the pavement, except the
finished surface of the final course, shall not vary more than ⅜ inch
when evaluated with a 16 foot straightedge. The finished surface of the
final course of pavement shall not vary more than ¼ inch when evaluated
with a 16 foot straightedge. The lot size shall be \[ \] square yards
(square meters). Smoothness measurements shall be made at 50 foot
intervals and as determined by the Engineer. In the longitudinal
direction, a smoothness reading shall be made at the center of each
paving lane. In the transverse direction, smoothness readings shall be
made continuously across the full width of the pavement. However,
transverse smoothness readings shall not be made across designed grade
changes. At warped transition areas, straightedge position shall be
adjusted to measure surface smoothness and not design grade transitions.
When more than 15 percent of all measurements within a lot exceed the
specified tolerance, the Contractor shall remove the deficient area to
the depth of the final course of pavement and replace with new material.
Skin patching shall not be permitted. Isolated high points may be ground
off providing the course thickness complies with the thickness specified
on the plans. High point grinding will be limited to 15 square yards.
Areas in excess of 15 square yards will require removal and replacement
of the pavement in accordance with the limitations noted above.

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> **The Engineer shall specify the lot size. A minimum of 2,000 square
> yards (1 650 square meters) is recommended.**
>
> **Use of a profilograph can be included in the specifications for
> surface smoothness for runways and taxiways on a case by case basis
> provided it is approved by the FAA. Use of a profilograph may not be
> practical for all asphalt construction. Thin lift overlays and other
> minimum resurfacing may not allow for removal of existing pavement
> roughness. However, the use of the profilograph is recommended for new
> construction or overlays designed to correct grade and smoothness
> deficiencies. If the profilograph is to be included, straightedge
> requirements need only apply to the perpendicular direction. To
> include profilograph requirements, add ASTM E 1274 to the referenced
> testing list and add the following:**
>
> **(a) Profilograph. The Contractor shall furnish a 25 foot wheel base
> California type profilograph and competent operator to measure
> pavement surface deviations. The profilograph shall be operated in
> accordance with the manufacturer's instructions and at a speed no
> greater than 3 mph. Original profilograms for the appropriate
> locations interpreted in accordance with ASTM E 1274 shall be
> furnished to the Engineer. The profilograms shall be recorded on a
> scale of one inch equal to 25 feet longitudinally and one inch equal
> to one inch (or full scale) vertically. Profilographs shall be
> calibrated prior to testing.**
>
> **The surface of the runway and/or taxiway pavements of continuous
> placement of 50 feet or more shall be tested and evaluated as
> described herein. One pass along the centerline shall be required for
> each paving lane. Runs shall be continuous through a day's production.
> Each trace shall be completely labeled to show paving lane and
> stationing.**
>
> **The Contractor shall furnish paving equipment and employ methods
> that produce a riding surface for each section of pavement having an
> average profile index meeting the requirements of Table 7. A typical
> section will be considered to be the width of the paving lane and 1/10
> of a mile long. The profile index will be determined in accordance
> with ASTM E 1274. A blanking band of 0.2 inches shall be used. Within
> each 1/10 mile section, all areas represented by high points having a
> deviation in excess of 0.4 inches in 25 feet or less shall be removed
> by the Contractor using an approved method. After removing all
> individual deviations in excess of 0.4 inches, additional corrective
> work shall be performed if necessary to achieve the required ride
> quality. All corrective work shall be completed prior to determination
> of pavement thickness.**
>
> **On pavement sections where corrections were necessary, second
> profilograph runs shall be performed to verify that the corrections
> have produced an average profile index of 15 inches per mile or less.
> If the initial average profile index was less than 15, only those
> areas representing greater than 0.4 inch deviation will be re-profiled
> for correction verification.**
>
> **Individual sections shorter than 50 feet and the last 15 feet of any
> section where the Contractor is not responsible for the adjoining
> section shall be straightedged in accordance with paragraph
> 401-5.2b(5).**
>
> **If there is a section of 250 feet or less, the profilogram for the
> section shall be included in the evaluation of the previous section.
> If there is an independently placed section of 50 to 250 feet in
> length, a profilogram shall be made for that section and the pay
> adjustment factors for short section of Table 7 shall apply.**
>
> **All costs necessary to provide the profilograph and related to
> furnishing the appropriate profilograms as required in this provision
> are incidental to pavement construction and no direct compensation
> will be made therefore.**

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**(6) Grade.** The finished surface of the pavement shall not vary from
the gradeline elevations and cross sections shown on the plans by more
than ½ inch (12.70 mm). The finished grade of each lot will be
determined by running levels at intervals of 50 feet (15.2 m) or less
longitudinally and all breaks in grade transversely (not to exceed 50
feet) to determine the elevation of the completed pavement. The
Contractor shall pay the cost of surveying of the level runs that shall
be performed by a licensed surveyor. The documentation, stamped and
signed by a licensed surveyor, shall be provided by the Contractor to
the Engineer. The lot size shall be **\[ \]** square yards (square
meters). When more than 15 percent of all the measurements within a lot
are outside the specified tolerance, or if any one shot within the lot
deviates ¾ inch or more from planned grade, the Contractor shall remove
the deficient area to the depth of the final course of pavement and
replace with new material. Skin patching shall not be permitted.
Isolated high points may be ground off providing the course thickness
complies with the thickness specified on the plans. The surface of the
ground pavement shall have a texture consisting of grooves between 0.090
and 0.130 inches wide. The peaks and ridges shall be approximately 1/32
inch higher than the bottom of the grooves. The pavement shall be left
in a clean condition. The removal of all of the slurry resulting form
the grinding operation shall be continuous The grinding operation should
be controlled so the residue from the operation does not flow across
other lanes of pavement. High point grinding will be limited to 15
square yards. Areas in excess of 15 square yards will require removal
and replacement of the pavement in accordance with the limitations noted
above.

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> **A minimum of 2,000 square yards (1 650 square meters) is
> recommended.**

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**c. Percentage of Material Within Specification Limits (PWL).** The
percentage of material within specification limits (PWL) shall be
determined in accordance with procedures specified in Section 110 of the
General Provisions. The specification tolerance limits (L) for lower and
(U) for upper are contained in Table 5.

**d. Outliers.** All individual tests for mat density and air voids
shall be checked for outliers (test criterion) in accordance with
ASTM E 178, at a significance level of 5 percent. Outliers shall be
discarded, and the PWL shall be determined using the remaining test
values.

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> **The specification tolerance limits applicable to the project, based
> on design criteria specified in Table 1, shall be specified by the
> Engineer from the information shown below and inserted into Table 5.
> Asterisks denote insert points.**

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**TABLE 5. MARSHALL ACCEPTANCE LIMITS FOR STABILITY, FLOW, AIR VOIDS,
DENSITY**

  -----------------------------------------------------------------------------------
  **TEST PROPERTY**      **Pavements                    **Pavements       
                         Designed for                   Designed for      
                         Aircraft Gross                 Aircraft Gross    
                         Weights of 60,000              Weights Less Than 
                         Lbs. or More or                60,000 Lbs. or    
                         Tire Pressures of              Tire Pressures    
                         100 Psi or More**              Less Than 100     
                                                        Psi**             
  ---------------------- ----------------- ------------ ----------------- -----------
  **Number of Blows**    **75**                         **50**            

                         **Specification                **Specification   
                         Tolerance                      Tolerance         
                         Limits**                       Limits**          

                         **L**             **U**        **L**             **U**

  **Stability, minimum,  1800              \--          1000              \--
  pounds**                                                                

  **Flow, 0.01‑inch**    8                 16           8                 20

  **Air Voids Total Mix, 2                 5            2                 5
  percent**                                                               

  **Surface Course Mat   96.3              \[101.3\]    96.3              \[101.3\]
  Density, percent**                                                      

  **Base Course Mat      95.5              101.3\]\--   95.5              \[101.3\]
  Density, percent**                                                      

  **Joint density,       93.3              \--          93.3              \--
  percent**                                                               
  -----------------------------------------------------------------------------------

**NOTE TO ENGINEER. The Engineer may specify both upper and lower PWL
acceptance criteria (two-sided) for density. Use 101.3 as the Upper
tolerance limits when two-sided density acceptance criteria is specified
AND insert edit paragraph 401-8.1. See Notes to Engineer following
paragraph 401-8.1.**

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**TABLE 5. MARSHALL ACCEPTANCE LIMITS FOR STABILITY, FLOW, AIR VOIDS,
DENSITY**

+---------------------------------+------------------+-----------------+
| ## TEST PROPERTY                | \*               |                 |
+---------------------------------+------------------+-----------------+
| Number of Blows                 | \*               |                 |
+---------------------------------+------------------+-----------------+
|                                 | Specification    |                 |
|                                 | Tolerance        |                 |
+---------------------------------+------------------+-----------------+
|                                 | L                | U               |
+---------------------------------+------------------+-----------------+
| Stability, minimum, pounds      | \*               | \*              |
+---------------------------------+------------------+-----------------+
| Flow, 0.01‑inch                 | \*               | \*              |
+---------------------------------+------------------+-----------------+
| Air Voids Total Mix, percent    | \*               | \*              |
+---------------------------------+------------------+-----------------+
| Mat Density, percent            | \*               | \*              |
+---------------------------------+------------------+-----------------+
| Joint density, percent          | \*               | \*              |
+---------------------------------+------------------+-----------------+

The criteria in Table 5 is based on production processes which have a
variability with the following standard deviations:

Surface Course Mat Density (%), 1.30

Base Course Mat Density (%), 1.55

Joint Density (%), 2.1

The Contractor should note that (1) 90 PWL is achieved when consistently
producing a surface course with an average mat density of at least 98
percent with 1.30% or less variability, (2) 90 PWL is achieved when
consistently producing a base course with an average mat density of at
least 97.5 percent with 1.55% or less variability, and (3) 90 PWL is
achieved when consistently producing joints with an average joint
density of at least 96 percent with 2.1% or less variability.

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> **A lot is the quantity of material to be controlled and may represent
> a specified tonnage or a specified number of truckloads. The lot size,
> to be determined by the Engineer, should, for the most part, depend on
> the operational capacity of the plant, but shall in no case exceed
> 2,000 tons (1 814 000 kg) in accordance with paragraph 401‑5.1a.**

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**401‑5.3 RESAMPLING PAVEMENT FOR MAT DENSITY.**

**a. General.** Resampling of a lot of pavement will only be allowed for
mat density***,*** and then, only if the Contractor requests same, in
writing, within 48 hours after receiving the written test results from
the Engineer. A retest will consist of all the sampling and testing
procedures contained in paragraphs 401‑5.1b and 401-5.2b(1). Only one
resampling per lot will be permitted.

**(1)** A redefined PWL shall be calculated for the resampled lot. The
number of tests used to calculate the redefined PWL shall include the
initial tests made for that lot plus the retests.

**(2)** The cost for resampling and retesting shall be borne by the
Contractor.

**b. Payment for Resampled Lots.** The redefined PWL for a resampled lot
shall be used to calculate the payment for that lot in accordance with
Table 6.

**c. Outliers.** Check for outliers in accordance with ASTM E 178, at a
significance level of 5 percent.

**\[401‑5.4 LEVELING COURSE.** Any course used for truing and leveling
shall meet the requirements of paragraph 401‑3.2, 401-5.2b(1) for air
voids and 401-5.2b(2)*,* but shall not be subject to the density
requirements of paragraph 401-5.2b(1) for mat density and 401-5.2b(3).
The leveling course shall be compacted with the same effort used to
achieve density of the test section. The truing and leveling course
shall not exceed a nominal thickness of 1‑½ inches (37.5 mm). The
leveling course is the first variable thickness lift of an overlay
placed prior to subsequent courses.**\]**

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> **Use this paragraph only when there is a need to restore proper
> cross‑section prior to overlaying. Areas of the pavement requiring a
> leveling course shall be shown on the plans.**

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CONTRACTOR QUALITY CONTROL

**401‑6.1 GENERAL.** The Contractor shall develop a Quality Control
Program in accordance with Section 100 of the General Provisions. The
program shall address all elements that affect the quality of the
pavement including, but not limited to:

**a.** Mix Design

**b.** Aggregate Grading

**c.** Quality of Materials

**d.** Stockpile Management

**e.** Proportioning

**f.** Mixing and Transportation

**g.** Placing and Finishing

**h.** Joints

**i.** Compaction

**j.** Surface Smoothness

**k.** Personnel

**l.** Laydown Plan

The Contractor shall perform quality control sampling, testing, and
inspection during all phases of the work and shall perform them at a
rate sufficient to ensure that the work conforms to the contract
requirements, and at minimum test frequencies required by paragraph
401-6.3 and Section 100 of the General Provisions. As a part of the
process for approving the Contractor's plan, the Engineer may require
the Contractor's technician to perform testing of samples to demonstrate
an acceptable level of performance.

No partial payment will be made for materials that are subject to
specific quality control requirements without an approved plan.

**401‑6.2 TESTING LABORATORY.** The Contractor shall provide a fully
equipped asphalt laboratory meeting the requirements of paragraph
401-3.5 and 401-4.2a(2) located at the plant or job site. The Contractor
shall provide the Engineer with certification stating that all of the
testing equipment to be used is properly calibrated and will meet the
specifications applicable for the specified test procedures.

**401‑6.3 QUALITY CONTROL TESTING.** The Contractor shall perform all
quality control tests necessary to control the production and
construction processes applicable to these specifications and as set
forth in the approved Quality Control Program. The testing program shall
include, but not necessarily be limited to, tests for the control of
asphalt content, aggregate gradation, temperatures, aggregate moisture,
field compaction, and surface smoothness. A Quality Control Testing Plan
shall be developed as part of the Quality Control Program.

**a. Asphalt Content.** A minimum of two tests shall be performed per
lot in accordance with ASTM D 6307 or ASTM D 2172 for determination of
asphalt content. The weight of ash portion of the test, as described in
ASTM D 2172, shall be determined as part of the first test performed at
the beginning of plant production; and as part of every tenth test
performed thereafter, for the duration of plan production. The last
weight of ash value obtained shall be used in the calculation of the
asphalt content for the mixture. The asphalt content for the lot will be
determined by averaging the test results.

The use of the nuclear method for determining asphalt content in
accordance with ASTM D 4125 is permitted, provided that it is calibrated
for the specific mix being used.

**b. Gradation.** Aggregate gradations shall be determined a minimum of
twice per lot from mechanical analysis of extracted aggregate in
accordance with ASTM D 5444 and ASTM C 136 (Dry Sieve). When asphalt
content is determined by the nuclear method, aggregate gradation shall
be determined from hot bin samples on batch plants, or from the cold
feed on drum mix or continuous mix plants, and tested in accordance with
ASTM C 136 (dry sieve) using actual batch weights to determine the
combined aggregate gradation of the mixture.

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

**d. Moisture Content of Mixture.** The moisture content of the mixture
shall be determined once per lot in accordance with ASTM D 1461 **\[**or
AASHTO T110**\]**.

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> **ASTM D 1461 may be replaced with AASHTO T110 moisture content
> testing procedure using a conventional oven or microwave.**

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**e. Temperatures.** Temperatures shall be checked, at least four times
per lot, at necessary locations to determine the temperatures of the
dryer, the bitumen in the storage tank, the mixture at the plant, and
the mixture at the job site.

**f. In‑Place Density Monitoring.** The Contractor shall conduct any
necessary testing to ensure that the specified density is being
achieved. A nuclear gauge may be used to monitor the pavement density in
accordance with ASTM D 2950.

**g. Additional Testing.** Any additional testing that the Contractor
deems necessary to control the process may be performed at the
Contractor\'s option.

**h. Monitoring.** The Engineer reserves the right to monitor any or all
of the above testing.

**401‑6.4 SAMPLING.** When directed by the Engineer, the Contractor
shall sample and test any material that appears inconsistent with
similar material being sampled, unless such material is voluntarily
removed and replaced or deficiencies corrected by the Contractor. All
sampling shall be in accordance with standard procedures specified.

**401‑6.5 CONTROL CHARTS.** The Contractor shall maintain linear control
charts both for individual measurements and range (i.e., difference
between highest and lowest measurements) for aggregate gradation and
asphalt content.

Control charts shall be posted in a location satisfactory to the
Engineer and shall be kept current. As a minimum, the control charts
shall identify the project number, the contract item number, the test
number, each test parameter, the Action and Suspension Limits applicable
to each test parameter, and the Contractor\'s test results. The
Contractor shall use the control charts as part of a process control
system for identifying potential problems and assignable causes before
they occur. If the Contractor\'s projected data during production
indicates a problem and the Contractor is not taking satisfactory
corrective action, the Engineer may suspend production or acceptance of
the material.

**a. Individual Measurements.** Control charts for individual
measurements shall be established to maintain process control within
tolerance for aggregate gradation and asphalt content. The control
charts shall use the job mix formula target values as indicators of
central tendency for the following test parameters with associated
Action and Suspension Limits:

  --------------------------- --------------------- ---------------------
  **CONTROL CHART LIMITS FOR                        
  INDIVIDUAL MEASUREMENTS**                         

  Sieve                       Action Limit          Suspension Limit

  ¾ inch (19.0 mm)            0%                    0%

  ½ inch (12.5 mm)            +/‑6%                 +/‑9%

  ⅜ inch (9.5 mm)             +/‑6%                 +/‑9%

  No. 4 (4.75 mm)             +/‑6%                 +/‑9%

  No. 16 (1.18 mm)            +/‑5%                 +/‑7.5%

  No. 50 (0.30 mm)            +/‑3%                 +/‑4.5%

  No. 200 (0.075 mm)          +/‑2%                 +/‑3%

  Asphalt Content             +/‑0.45%              +/‑0.70%
  --------------------------- --------------------- ---------------------

**b. Range.** Control charts for range shall be established to control
process variability for the test parameters and Suspension Limits listed
below. The range shall be computed for each lot as the difference
between the two test results for each control parameter. The Suspension
Limits specified below are based on a sample size of n = 2. Should the
Contractor elect to perform more than two tests per lot, the Suspension
Limits shall be adjusted by multiplying the Suspension Limit by 1.18 for
n = 3 and by 1.27 for n = 4.

+-------------------------------------+--------------------------------+
| **CONTROL CHART LIMITS BASED ON     |                                |
| RANGE**                             |                                |
|                                     |                                |
| **(Based on n = 2)**                |                                |
+-------------------------------------+--------------------------------+
| Sieve                               | Suspension Limit               |
+-------------------------------------+--------------------------------+
| ½ inch (12.5 mm)                    | 11 percent                     |
+-------------------------------------+--------------------------------+
| ⅜ inch (9.5 mm)                     | 11 percent                     |
+-------------------------------------+--------------------------------+
| No. 4 (4.75 mm)                     | 11 percent                     |
+-------------------------------------+--------------------------------+
| No. 16 (1.18 mm)                    | 9 percent                      |
+-------------------------------------+--------------------------------+
| No. 50 (0.30 mm)                    | 6 percent                      |
+-------------------------------------+--------------------------------+
| No. 200 (0.075 mm)                  | 3.5 percent                    |
+-------------------------------------+--------------------------------+
| Asphalt Content                     | 0.8 percent                    |
+-------------------------------------+--------------------------------+

**c. Corrective Action.** The Contractor Quality Control Program shall
indicate that appropriate action shall be taken when the process is
believed to be out of tolerance. The Plan shall contain sets of rules to
gauge when a process is out of control and detail what action will be
taken to bring the process into control. As a minimum, a process shall
be deemed out of control and production stopped and corrective action
taken, if:

**(1)** One point falls outside the Suspension Limit line for individual
measurements or range; or

**(2)** Two points in a row fall outside the Action Limit line for
individual measurements.

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> **The aggregate control chart parameters and Suspension and Action
> Limits contained in the above paragraphs are based on ¾ inch (19.0 mm)
> maximum size aggregate gradation. When 1‑inch (25.0 mm) or 1-½ inch
> (37.5 mm) maximum size aggregate is specified, the Individual
> Measurements Chart requirements should be amended as follows:**

  ----------------------- ----------------------- -----------------------
  **Sieve**               **Action Limit**        **Suspension Limit**

                                                  

  **1 inch or 1‑½ inch**  **0%**                  **0%**

  **¾ inch**              **6%**                  **11%**
  ----------------------- ----------------------- -----------------------

> **When ½‑inch (12.5 mm) maximum size aggregate is specified, the
> ¾‑inch (19.0 mm) and 1‑inch (25.0 mm) sieves should be deleted from
> the Individual Measurements Chart and the ½‑inch (12.5 mm) sieve
> Action and Suspension Limits should be changed to 0%. For the ½‑inch
> (12.5 mm) gradation, the ½‑inch sieve should be deleted from the Range
> Chart.**

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**401-6.6 QUALITY CONTROL REPORTS.** The Contractor shall maintain
records and shall submit reports of quality control activities daily, in
accordance with the Contractor Quality Control Program described in
General Provisions, Section 100.

METHOD OF MEASUREMENT

**401‑7.1 MEASUREMENT.** Plant mix bituminous concrete pavement shall be
measured by the number of tons (kg) of bituminous mixture used in the
accepted work. Recorded batch weights or truck scale weights will be
used to determine the basis for the tonnage.

Saw-cut grooving of bituminous pavement shall be measured by the number
of square yards of saw-cut grooving as specified in-place, completed and
accepted.

BASIS OF PAYMENT

**401‑8.1 PAYMENT.** Payment for an accepted lot of bituminous concrete
pavement shall be made at the contract unit price per ton (kg) for
bituminous mixture adjusted according to paragraph 401‑8.1a, subject to
the limitation that:

> The total project payment for plant mix bituminous concrete pavement
> shall not exceed **\[ \]** percent of the product of the contract unit
> price and the total number of tons (kg) of bituminous mixture used in
> the accepted work (See Note 2 under Table 6).

Payment for accepted saw-cut grooving shall be made at the contract unit
price per square yard.

The price shall be compensation for furnishing all materials, for all
preparation, mixing, and placing of these materials, and for all labor,
equipment, tools, and incidentals necessary to complete the item.

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> **The Engineer shall specify a value ranging from 100 to the maximum
> lot pay factor amount. (106 percent for single-sided density or 103
> percent when double-sided density is specified.) When the total
> project payment for Item P-401 pavement exceeds the contract unit
> price, any AIP or PFC funds used to pay the excess may require an
> amendment to the AIP grant or PFC application for the project.**

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**a. Basis of Adjusted Payment.** The pay factor for each individual lot
shall be calculated in accordance with Table 6. A pay factor shall be
calculated for both mat density and air voids. The lot pay factor shall
be the higher of the two values when calculations for both mat density
and air voids are 100 percent or higher. The lot pay factor shall be the
product of the two values when only one of the calculations for either
mat density or air voids is 100 percent or higher. The lot pay factor
shall be the lower of the two values when calculations for both mat
density and air voids are less than 100 percent.

**TABLE 6. PRICE ADJUSTMENT SCHEDULE ^1^**

+-----------------------------------------+----------------------------+
| **Percentage of Material Within**       | **Lot Pay Factor**         |
|                                         |                            |
| **Specification Limits (PWL)**          | **(Percent of Contract     |
|                                         | Unit Price)**              |
+=========================================+============================+
| 96 -- 100                               | 106                        |
+-----------------------------------------+----------------------------+
| 90 -- 95                                | PWL + 10                   |
+-----------------------------------------+----------------------------+
| 75 -- 89                                | 0.5 PWL + 55               |
+-----------------------------------------+----------------------------+
| 55 -- 74                                | 1.4PWL -- 12               |
+-----------------------------------------+----------------------------+
| Below 55                                | Reject ^2^                 |
+-----------------------------------------+----------------------------+

^1^ Although it is theoretically possible to achieve a pay factor of 106
percent for each lot, actual payment above 100 percent shall be subject
to the total project payment limitation specified in paragraph 401-8.1.

^2^ The lot shall be removed and replaced. However, the Engineer may
decide to allow the rejected lot to remain. In that case, if the
Engineer and Contractor agree in writing that the lot shall not be
removed, it shall be paid for at 50 percent of the contract unit price
and the total project payment shall be reduced by the amount withheld
for the rejected lot.

For each lot accepted, the adjusted contract unit price shall be the
product of the lot pay factor for the lot and the contract unit price.
Payment shall be subject to the total project payment limitation
specified in paragraph 401-8.1. Payment in excess of 100 percent for
accepted lots of bituminous concrete pavement shall be used to offset
payment for accepted lots of bituminous concrete pavement that achieve a
lot pay factor less than 100 percent.

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**NOTE TO ENGINEER. The Engineer may specify both upper and lower PWL
acceptance criteria (two-sided) for density. Use the following pay
adjustment schedule when two-sided acceptance criteria for density is
specified edit Table 5 to include the Upper tolerance limits and edit
paragraph 401-8.1.**

**TABLE 6. PRICE ADJUSTMENT SCHEDULE ^1^**

  ------------------------------------- ---------------------------------
  Percentage of Material Within         Lot Pay Factor (Percent of
  Specification Limits (PWL)            Contract Unit Price)

  93 -- 100                             103

  90 -- 93                              PWL + 10

  70 -- 89                              0.125PWL + 88.75

  40 -- 69                              0.75PWL +45

  Below 40                              Reject **^2^**
  ------------------------------------- ---------------------------------

> **^1^** ALTHOUGH IT IS THEORETICALLY POSSIBLE TO ACHIEVE A PAY FACTOR
> OF 103 PERCENT FOR EACH LOT, ACTUAL PAYMENT ABOVE 100 PERCENT SHALL BE
> SUBJECT TO THE TOTAL PROJECT PAYMENT LIMITATION SPECIFIED IN
> PARAGRAPH 401‑8.1.
>
> **^2^** The lot shall be removed and replaced. However, the Engineer
> may decide to allow the rejected lot to remain. In that case, if the
> Engineer and Contractor agree in writing that the lot shall not be
> removed, it shall be paid for at 50 percent of the contract unit price
> AND THE TOTAL PROJECT PAYMENT LIMITATION SHALL BE REDUCED BY THE
> AMOUNT WITHHELD FOR THE REJECTED LOT.

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> **If a profilograph is used, add the following paragraphs and change
> existing paragraph 401-8.1b to 401-8.1d (The pay adjustment in Table 7
> is optional to the Owner and Engineer when using the profilograph):**
>
> **b. Profilograph Smoothness. When the final average profile index
> (subsequent to any required corrective action) does not exceed 7
> inches per mile, payment will be made for that section at the contract
> unit price for the completed pavement. If the final average profile
> index (subsequent to any required corrective action) exceeds 7 inches
> per mile, but does not exceed 15 inches per mile, the Contractor may
> elect to accept a contract unit price adjustment in lieu of reducing
> the profile index.**
>
> **c. Basis of Adjusted Payment for Smoothness. Price adjustment for
> pavement smoothness will be made in accordance with Table 7. The
> adjustment will apply to the total tonnage of asphalt concrete within
> a lot of pavement and shall be applied with the following equation:**
>
> **(Tons of asphalt concrete in lot) x (lot pay factor) x (unit price
> per ton) x (smoothness pay factor) = payment for lot**

**TABLE 7. AVERAGE PROFILE INDEX SMOOTHNESS PAY FACTOR**

  ------------------------------------------------------------------------
  **(Inches per mile per 1/10    **Short         **Pay Factor**
  mile)**                        Sections**      
  ------------------------------ --------------- -------------------------
  **00.0 - 7**                   **00.0 - 15.0** **100%**

  **7.1 - 9**                    **15.1 - 16**   **98%**

  **9.1 - 11**                   **16.1 - 17**   **96%**

  **11.1 - 13**                  **17.1 - 18**   **94%**

  **13.1 - 14**                  **18.1 - 20**   **92%**

  **14.1 - 15**                  **20.1 - 22**   **90%**

  **15.1 & up**                  **22.1& up**    **corrective work
                                                 required^1^**
  ------------------------------------------------------------------------

> **1The Contractor shall correct pavement areas not meeting these
> tolerances by removing and replacing the defective work. If the
> Contractor elects to construct an overlay to correct deficiencies, the
> minimum thickness of the overlay shall not be less than twice the size
> of the maximum size aggregate. The corrective overlay shall not
> violate grade criteria and butt joints shall be constructed by sawing
> and removing the original pavement in compliance with the
> thickness/maximum aggregate size ratio. Skin patching shall not be
> permitted.**
>
> **Unit bid price adjustment will apply to total bituminous mixture and
> asphalt cement quantities within the 1/10 mile segment of pavement.
> Deductions will be applied to recorded project quantities. Any
> pavement section less than 1/10 mile will be accepted on a pro-rated
> basis.**
>
> **Material used in building the pavement above the specified grade
> shall not be included in the quantities for payment.**

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\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

**b. Payment.** Payment will be made under:

> Item P‑401‑8.1a Bituminous **\[Surface\] \[Base\] \[Binder\]
> \[Leveling\]** Course---per ton (kg)
>
> Item P-401-8.1b Saw-Cut Grooving---per square yard

TESTING REQUIREMENTS

> ASTM C 29 Bulk Density ("Unit Weight") and Voids in Aggregate
>
> ASTM C 88 Soundness of Aggregates by Use of Sodium Sulfate or
> Magnesium Sulfate
>
> ASTM C 117 Materials Finer than 75μm (No.200) Sieve in Mineral
> Aggregates by Washing
>
> ASTM C 127 Specific Gravity and Absorption of Coarse 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 C 566 Total Evaporable Moisture Content of Aggregate by Drying
>
> ASTM D 75 Sampling Aggregates
>
> ASTM D 979 Sampling Bituminous Paving Mixtures
>
> ASTM D 995 Mixing Plants for Hot‑Mixed Hot‑Laid Bituminous Paving
> Mixtures
>
> ASTM D 1073 Fine Aggregate for Bituminous Paving Mixtures
>
> ASTM D 1188 Bulk Specific Gravity and Density of Compacted Bituminous
> Mixtures Using Paraffin‑Coated Specimens
>
> ASTM D 1461 Moisture or Volatile Distillates in Bituminous Paving
> Mixtures
>
> ASTM D 2041 Theoretical Maximum Specific Gravity and Density of
> Bituminous Paving Mixtures
>
> ASTM D 2172 Quantitative Extraction of Bitumen from Bituminous Paving
> Mixtures
>
> ASTM D 2419 Sand Equivalent Value of Soils and Fine Aggregate
>
> ASTM D 2489 Estimating Degree of Particle Coating of
> Bituminous‑Aggregate Mixtures
>
> ASTM D 2726 Bulk Specific Gravity and Density of Non-Absorptive
> Compacted Bituminous Mixtures
>
> ASTM D 2950 Density of Bituminous Concrete in Place by Nuclear
> Method***s***
>
> ASTM D 3203 Percent Air Voids in Compacted Dense and Open Bituminous
> Paving Mixtures
>
> ASTM D 3665 Random Sampling of Construction Materials
>
> ASTM D 3666 Minimum Requirements for Agencies Testing and Inspecting
> Road and Paving Materials
>
> ASTM D 4125 Asphalt Content of Bituminous Mixtures by the Nuclear
> Method
>
> ASTM D 4318 Liquid Limit, Plastic Limit, and Plasticity Index of Soils
>
> ASTM D 4791 Flat Particles***,*** Elongated Particles***,*** or Flat
> and Elongated Particles in Coarse Aggregate
>
> ASTM D 4867 Effect of Moisture on Asphalt Concrete Paving Mixtures
>
> ASTM D 5444 Mechanical Size Analysis of Extracted Aggregate
>
> ASTM D 6926 Preparation of Bituminous Specimens Using MARSHALL
> Apparatus
>
> ASTM D 6927 MARSHALL Stability and Flow of Bituminous Mixtures
>
> ASTM E 11 Wire-Cloth Sieves for Testing Purposes
>
> ASTM E 178 Dealing with Outlying Observations
>
> ASTM E 1274 Measuring Pavement Roughness Using a Profilograph
>
> AASHTO T 30 Mechanical Analysis of Extracted Aggregate
>
> **\[**AASHTO T 110 Moisture or Volatile Distillates in Bituminous
> Paving Mixtures**\]**

The Asphalt Institute\'s Mix Design Methods for Asphalt Concrete

Manual No. 2 (MS‑2)

MATERIAL REQUIREMENTS

> ASTM D 242 Mineral Filler for Bituminous Paving Mixtures
>
> ASTM D 946 Penetration Graded Asphalt Cement for Use in Pavement
> Construction
>
> ASTM D 3381 Viscosity‑Graded Asphalt Cement for Use in Pavement
> Construction
>
> ASTM D 4552 Classifying Hot‑Mix Recycling Agents
>
> AASHTO M320 Performance Graded Asphalt Binder

**END OF ITEM P‑401**

#### 

**Intentionally Left Blank**

### **ITEM P‑402 POROUS FRICTION COURSE**

**(Central Plant Hot Mix)**

DESCRIPTION

**402‑1.1** This item shall consist of a plant mixed, open-graded porous
friction course, composed of mineral aggregate and bituminous material,
mixed in a central mixing plant, and placed on a prepared surface in
accordance with these specifications and shall conform to the dimensions
and typical cross section as shown on the plans.

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> **The porous friction course (PFC) shall be designed as a free
> draining wearing surface of uniform thickness. The PFC must be placed
> on a prepared surface, which drains freely and does not allow ponding.
> The PFC should not be applied over an existing PFC. Any existing PFC
> should be removed and the entire surface leveled prior to placement of
> a new PFC.**

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\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

MATERIALS

**402‑2.1 AGGREGATE**. The aggregate shall consist of crushed stone,
crushed gravel, or crushed slag with or without other inert finely
divided mineral aggregate. The aggregate shall be composed of clean,
sound, tough, durable particles, free from clay balls, organic matter,
and other deleterious substances. The portion of the material retained
on the No. 4 sieve shall be known as [coarse aggregate]{.underline}, the
portion passing the No. 4 sieve and retained on the No. 200 sieve as
[fine aggregate]{.underline}, and the portion passing the No. 200 sieve
as [mineral filler]{.underline}.

**a. Coarse Aggregate.** Coarse aggregate shall contain at least 75
percent by weight crushed pieces having two or more fractured faces and
100 percent by weight particles with one or more fractured faces. The
area of each face shall be equal to at least 75 percent of the smallest
mid-sectional area of the piece. When two fractures are contiguous, the
angle between the planes of fractures shall be at least 30 degrees to
count as two fractured faces. Fractured faces shall be obtained by
crushing. The coarse aggregate shall not contain more than 8 percent, by
weight of flat or elongated pieces as defined in ASTM D 693. The
percentage of wear shall not be greater than 30 percent when tested in
accordance with ASTM C 131. The sodium sulfate soundness loss shall not
exceed 12 percent after five cycles, when tested in accordance with ASTM
C 88.

**b. Fine Aggregate.** Fine aggregate shall have a plasticity index of
not more than 6.0 and a liquid limit of not more than 25 when tested in
accordance with ASTM D 4318. The percentage of wear shall not be greater
than 30 percent when tested in accordance with ASTM C 131. The sodium
sulfate soundness loss shall not exceed 12 percent after five cycles,
when tested in accordance with ASTM C 88.

If necessary, natural sand may be used to obtain the gradation of
aggregate blend or workability. The amount of sand to be added will be
adjusted to produce mixtures conforming to requirements of this
specification.

**402‑2.2 FILLER**. If filler, in addition to that naturally present in
the aggregate, is necessary, it shall meet the requirements of ASTM D
242. When mineral filler is required to be batched separately, hydrated
lime in the amount of 1.5 percent maximum by weight of the total
aggregate shall be batched as part of the added mineral filler. No
additional compensation will be allowed the Contractor for furnishing
and using hydrated lime or other approved mineral filler that may be
required by this specification.

**402‑2.3 BITUMINOUS MATERIAL**. The bituminous material shall be
viscosity graded asphalt cement meeting Table 1 of this section and ASTM
D-3381, Table 2. A synthetic rubber additive shall be added to the
bitumen in an amount not less than 2 percent by weight (% by weight of
synthetic rubber solids). The bitumen and additive shall be uniformly
mixed to provide a mixture meeting the following requirements:

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**[FOR FAA CENTRAL REGION PROJECTS:]{.underline}**

  ---------------------------- ------------------------ ------------------------ ------------------------
  **TABLE 1**                                                                    

  **[Property]{.underline}**   **[ASTM]{.underline}**   **[Min.]{.underline}**   **[Max.]{.underline}**

  **Viscosity @ 140°F.,        **D-2171**               **1600**                 **2400**
  Poises**                                                                       

  **Viscosity @ 275°F., cSt.** **D-2170**               **325**                  

  **Flash Point, °F.,**        **D-92**                 **450**                  

  **Ductility @ 77°F (5        **D-113**                **100**                  
  cm/min) cm.**                                                                  

  **Ductility @ 39.2°F (5      **D-113**                **50**                   
  cm/min) cm.**                                                                  

  **Toughness, inch-pounds**   **D-5801**               **110**                  

  **Tenacity, inch-pounds**    **D-5801**               **75**                   

  **Thin Film Oven Test:**                                                       

  **Tests on Residue**                                                           

  **Viscosity @ 140°F.,        **D-2170**               **\--**                  **8000**
  Poises**                                                                       

  **Ductility @ 77°F., (5      **D-113**                **100**                  
  cm/min) cm**                                                                   

  **Ductility @ 39.2°F., (5    **D-113**                **25**                   
  cm/min) cm**                                                                   
  ---------------------------- ------------------------ ------------------------ ------------------------

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\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

Certified test results plus a sample of the bitumen-synthetic rubber
mixture shall be provided for each tank load shipped to the project or
for each mixed batch, whichever is smaller. Samples being tested shall
contain the anti-stripping additive. No material shall be used before
the test results are delivered to the Engineer. The Engineer will
conduct independent acceptance tests on random samples. Material placed
which does not meet specification requirements shall be removed and
replaced at no additional cost to the owner. A temperature-viscosity
curve for the material shall be provided to the Engineer.

**\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

> **Samples shall be taken, however a minimum of one sample shall be
> tested by the Engineer to verify the submitted certification.
> Additional samples shall be tested if results are borderline or for
> any other reason. The initial test is recommended to be done early in
> the project.**

**\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
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\* \* \* \* \* \* \* \* \* \* \* \* \* \***

**402-2.4 ANTI-STRIPPING AGENT.** Any anti-stripping agent or additive
if required shall be heat stable, shall not change the asphalt cement
viscosity beyond specifications, shall contain no harmful ingredients,
shall be added in recommended proportion by approved method, and shall
be a material approved by the Department of Transportation of the State
in which the project is located.

COMPOSITION

**402‑3.1 COMPOSITION OF MIXTURE**. The porous friction course shall be
composed of aggregate, filler, bituminous material-synthetic rubber
mixture, and anti-stripping agent.

**402‑3.2 JOB MIX FORMULA**. No bituminous mixture shall be produced for
payment until the Engineer has given written approval of the job mix
formula. The job mix shall be prepared by a certified laboratory at the
Contractor's expense and shall remain in effect for the duration of the
project. The job mix formula shall establish a single percentage of
aggregate passing each required sieve size, a single percentage of
bituminous material to be added to the aggregate, the amount of anti
strip agent to be added (minimum of one half of one percent by weight),
and a single temperature for the mixture as it is discharged into the
hauling units. Silicone may be added to the mixture at a maximum rate of
1 ounce per 5,000 gallons of asphalt to facilitate laydown and rolling.
Proper asphalt content shall be determined by mixing trial batches in
the laboratory.

The job mix formula shall be submitted to the Engineer at least \[30\]
days prior to the start of paving and shall include:

**a.** Percent passing each sieve size and gradation requirements.

**b.** Percent of asphalt cement.

**c.** Asphalt viscosity.

**d.** Mixing temperature range.

**e.** Temperature of mix when discharged from the mixer.

**f.** Temperature viscosity relationship of the asphalt cement.

**g.** Percent of wear (LA abrasion).

**h.** Plasticity Index and Liquid Limit of fine aggregate.

**i.** Percent fractured faces.

**j.** Percent elongated particles.

**k.** Anti-strip agent.

The Contractor shall submit samples to the Engineer, upon request, for
job mix formula verification testing.

The combined aggregate shall be of such size that the percentage
composition by weight, as determined by laboratory sieves, will conform
to the gradation shown in Table 2 when tested in accordance with ASTM C
136.

The gradations in Table 2 represent the limits, which determine the
suitability of the aggregate for use from the source of supply. The
aggregate, as finally selected, shall have a gradation within the limits
designated in Table 2 and shall not vary from the low limit on one sieve
to the high limit on the adjacent sieve, or vice versa, but shall be
uniformly graded from coarse to fine.

#### TABLE 2. AGGREGATE-POROUS FRICTION COURSE

**PERCENTAGE BY WEIGHT PASSING SIEVES**

  ------------------- ----------------- ----------------- -----------------
  **Sieve**           **3/4\" maximum** **1/2\" maximum** **Job-Mix
                                                          (Production)**

                                                          Tolerances \*\*

  3/4\"               100               \-\--             \-\--

  1/2\"               70-90             100               +/- 5%

  3/8\"               40-65             85-95             +/- 5%

  #4                  15-25             30-45             +/- 5%

  #8                  8-15              20-30             +/- 2%

  #30                 5-9               9-17              +/- 2%

  #200                1-5               2-7               +/- 2%

  Bitumen                                                 +/- 0.2%

  [Temperature of                                         [+/- 20 degrees
  Mix]{.underline}                                        F.]{.underline}
  ------------------- ----------------- ----------------- -----------------

> \*\* The gradation job mix tolerance limits will apply if they fall
> outside the master grading band in Table 2 except for the top two
> sieve sizes starting at the 100% passing band. These two sieve size
> bands shall also be additional limits for production.

The gradations shown are based on aggregates of uniform specific
gravity. The percentages passing the various sieves will be subject to
appropriate adjustments by the Engineer when aggregates of varying
specific gravities are used. The adjustments to the job mix gradation
curve should result in a curve of the same general shape as the median
curve of the gradation band in Table 2 and fall within the gradation
band.

The Asphalt Institutes Manual Series No. 2 (MS-2) contains a convenient
procedure for \"adjusting\" the job mix gradation when aggregates of non
uniform specific gravity are proposed for use.

The bituminous content of porous friction courses shall be expressed as
a percentage of the total mix by weight and shall be approved by the
Engineer on the basis of laboratory tests. The materials used in the mix
design shall be the same as those used on the project.

The bituminous content shall be within plus or minus 1 percent of the
value obtained from the formula:

2K~c~ + 4.0

where K~c~ is the surface area constant for that part of the total dry
aggregate that will pass a 3/4\" (19.0 mm) sieve and be retained on the
No. 4 (4.75 mm) sieve. Procedures for determining K~c~ are contained in
the Asphalt Institute\'s Manual Series No. 2 (MS-2). The bituminous
content so estimated is the percentage by weight of the total dry
aggregates and must be converted to the percent by weight of the total
mix in the approved job-mix formula.

The laboratory used to develop the job mix formula shall meet the
requirements of ASTM D 3666. A certification signed by the lab manager
of the laboratory stating that it meets these requirements shall be
submitted to the Engineer prior to the start of construction. The
certification shall contain as a minimum:

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

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

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

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

**402‑3.3 TEST SECTION**. At least one full day prior to full
production, the Contractor shall prepare a quantity of bituminous
mixture according to the approved job mix formula. The amount of mixture
should be sufficient to construct a test section at least 50 feet long
and 20 feet wide, placed in two sections and of the same depth specified
on the plans. The test area will be designated by the Engineer. The
underlying pavement on which the test section is to be constructed shall
be the same as the remainder of the course represented by the test
section. The equipment to be used in construction of the test section
shall be the same type and weight to be used on the remainder of the
course represented by the test section. No bituminous mixture shall be
produced for payment prior to successful placement of and acceptance of
a test strip by the Engineer.

If the test section should prove to be unsatisfactory, the necessary
adjustments to plant operation, and/or placement procedures shall be
made. Additional test sections, as required, shall be constructed and
evaluated for conformance to the specifications. When the test section
does not conform to specification requirements the test section shall be
removed and replaced at the Contractors expense. Full production shall
not begin without approval of the Engineer. Test sections, which conform
to specification requirements, shall be measured and paid in accordance
with Paragraphs 402-5.1 and 402-6.1. The asphalt content may be adjusted
by the Engineer during the test section and will be used as the target
asphalt content.

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> **Note: The AC content should be adjusted during the placement of test
> section. One method to establish the optimum AC content is with the
> use of a glass dish. Various AC content mixes are made in increments
> of 0.5% (5.5%, 6.0%, 6.5%, etc.). The mix that will completely cover
> the bottom of the dish should be used to start the test strip. The AC
> content should then be increased in the test strip until it starts to
> bleed. The content then is decreased by 0.5%.**

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\* \* \* \* \* \* \* \* \* \* \* \* \* \***

CONSTRUCTION METHODS

**402‑4.1 WEATHER AND SEASONAL LIMITATIONS**. The porous friction course
shall be constructed only on a dry surface when the atmospheric
temperature is 50 F (10 C) and rising (at calm wind conditions) and when
the weather is not foggy or rainy.

**402‑4.2 BITUMINOUS MIXING PLANT**. Plants used for the preparation of
bituminous mixtures shall conform to the requirements of ASTM D 995 with
the following changes:

a\. Requirements for all Plants.

**(1)** **Truck Scales.** The bituminous mixture shall be weighed on
approved scales furnished by the Contractor, or on public scales at the
Contractor's expense. Such scales shall be inspected and sealed as often
as the Engineer deems necessary to assure their accuracy. Scales shall
conform to the requirements of Section 90.

**(2)** **Testing Laboratory.** The Contractor or producer shall provide
laboratory facilities for control and acceptance testing functions
during periods of mix production, sampling, and testing and whenever
materials subject to the provisions of these specifications are being
supplied or tested. The laboratory shall provide adequate equipment,
space, and utilities as required for the performance of the specified
tests.

**(3)** **Inspection of Plant.** The Engineer, or Engineer's authorized
representative, shall have access, at all times, to all parts of the
plant for checking adequacy of equipment; inspecting operation of the
plant; verifying weights, proportions, and materials properties; and
checking the temperatures maintained in the preparation of the mixtures.

**(4)** **Storage Bins and Surge Bins.** Paragraph 3.9 of ASTM D 995 is
deleted.

**402‑4.3 HAULING EQUIPMENT**. Trucks used for hauling bituminous
mixtures shall have tight, clean, smooth metal beds. Petroleum products
shall not be used for coating truck beds. To prevent the mixture from
adhering to them, the beds shall be lightly coated with an approved
asphalt release agent. The truck beds shall be raised to drain any
excess solution before loading the mixture in the trucks. Each truck
shall have a suitable cover to protect the mixture from adverse weather.
If conditions warrant, truck beds shall be insulated and covers shall be
securely fastened so that the mixture will be delivered to the site at
the specified temperature.

**402‑4.4 BITUMINOUS PAVERS**. Bituminous pavers shall be
self-contained, power-propelled units with an activated screed or
strike-off assembly, heated if necessary, and shall be capable of
spreading and finishing courses of bituminous plant-mix material which
will meet the specified thickness, smoothness, and grade.

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

The paver shall be capable of operating at forward speeds consistent
with satisfactory laying of the mixture.

Pavers shall be equipped with an automatic grade control system capable
of maintaining the screed elevation as specified herein. The control
system shall be automatically activated from either a reference line or
surface through a system of mechanical sensors or sensor-directed
mechanisms or devices that will maintain the paver screed at a
predetermined transverse slope and at the proper elevation to obtain the
required surface.

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

**a.** Ski-Type device of not less than 30 feet in length or as directed
by the Engineer.

**b.** Taut stringline (wire) set to grade.

**c.** Short ski or shoe.

**d.** Laser controls.

The controls shall be so arranged that independent longitudinal grade
controls can be operated simultaneously on both sides of the machine or
independently on either side. The electronic controls shall be arranged
so that the machine can be controlled automatically, semi-automatically,
or manually.

The automatic equipment shall be capable of controlling the grade to
within plus or minus one-eighth inch and the transverse slope to within
plus or minus one tenth of one percent from the controlling grade.

The machine shall be equipped with a spirit level or other type of slope
indicator that will continuously indicate the average transverse slope
of the screen. Curvature of spirit level tubes shall be as required to
produce a bubble movement of not less than one-eighth inch for each
one-tenth of one percent change in the transverse slope.

The paving machine shall be capable of being equipped with an infrared
joint heater if directed by the Engineer. The output of infrared energy
shall be in the one to six micron range. Converters shall be arranged
end to end directly over the joint to be heated in sufficient numbers to
continuously produce, when in operation, a minimum of 240,000 BTU per
hour. The joint heater shall be positioned not more than one inch above
the pavement to be heated and in front of the paver screed and shall be
fully adjustable. Heaters will be required to be in operation at all
times.

**402‑4.5 ROLLERS**. Rollers shall be steel wheel. Split drum rollers
are not acceptable. They shall be in good condition, capable of
reversing without backlash, and operating at slow speeds to avoid
displacement of the bituminous mixture. The wheels shall be equipped
with adjustable scrapers and sprinkling apparatuses using a water
soluble asphalt release agent, approved by the engineer, to prevent the
bituminous mixture from sticking to the wheels. The number, type, and
weight of rollers shall be sufficient to compact the mixture without
detrimentally affecting the material.

**402‑4.6 PREPARATION OF MINERAL AGGREGATE**. The aggregate for the
mixture shall be dried and heated at the central mixing plant before
entering the mixer. When introduced into the mixer, the combined
aggregate moisture content (weighted according to the composition of the
blend) shall be less than 0.25 percent for aggregate blends with water
absorption of 2.5 percent or less and less than 0.50 percent for
aggregate blends with water absorption greater than 2.5 percent. Water
absorption of aggregates shall be determined by ASTM C 127 and C 128.
The water absorption for the aggregate blend shall be the weighted
average of the absorption values for the coarse aggregate retained on
the No. 4 sieve (4.75 mm) and the fine aggregate passing the No. 4 sieve
(4.75 mm). The water content test will be conducted in accordance with
ASTM C 566. In no case shall the moisture content be such that foaming
of the mixture occurs prior to placement. At the time of mixing, the
temperature of the aggregate shall be within the range specified in the
job mix formula. The maximum temperature and rate of heating shall be
such that no damage occurs to the aggregates. Particular care shall be
taken so that aggregates high in calcium or magnesium content are not
damaged by overheating. The aggregate shall be screened to specified
sizes and conveyed in separate bins ready for mixing with bituminous
material.

**402‑4.7 PREPARATION OF BITUMINOUS MIXTURE**. The bituminous mixture
shall be prepared in a central mixing plant. The mixture shall be
prepared at the temperature designated by the mix design.

The dry aggregate shall be combined in the plant using the proportionate
amounts of each aggregate size required to meet the specified gradation.
The quantity of aggregate for each batch shall be determined, measured,
and conveyed into the mixer.

The quantity of bituminous material for each batch or the calibrated
amount for continuous mixers shall be determined by the certified
laboratory that prepared the mix design. It shall be measured by weight
and introduced into the mixer within the temperature range specified in
the job mix formula. For batch mixers, all aggregates shall be in the
mixer before the bitumen material is added. In no case shall the
temperature of the aggregate be more than 25°F above the temperature of
the bituminous material. Mixing shall continue until all particles are
coated uniformly. In no case shall the bituminous mixture be stored in
storage silos or surge bins.

**402‑4.8 TRANSPORTATION AND DELIVERY OF THE MIXTURE**. The mixture
shall be placed at a temperature between 250°F and 300°F. Loads shall be
sent from the plant so that all spreading and compacting of the mixture
may be accomplished during daylight hours. Excessive waiting or delay of
haul trucks at the job site shall not be allowed and mix supplied at
temperatures outside the specified range will not be accepted. Bleeding
and rich spots resulting from segregation during transportation shall
not be accepted.

**402‑4.9 SPREADING AND LAYING**. Immediately before placing the porous
friction course, the underlying course shall be cleared of all loose or
deleterious material with power blowers, power brooms, or hand brooms as
directed. A tack coat conforming to Item P-603 Bituminous Tack Coat
shall be placed on all existing surfaces for bonding the PFC to the
existing surface. Placement of the PFC must be delayed until the tack
coat has properly cured.

The mixture shall be deposited from haul units directly into the laydown
machine hopper and placed in a continuous operation.

Hauling over material already placed shall not be permitted until the
material has been thoroughly compacted and allowed to cure for a period
of at least 12 hours.

**402‑4.10 COMPACTION OF MIXTURE**. After spreading, rolling shall be
done immediately. Two or four passes, at the discretion of the Engineer,
with a steel wheel roller weighing no more than 10 tons, shall be made
for compaction. Care should be taken to avoid over rolling or rolling
when material is too cool. To prevent adhesion of the mixture to the
roller, the wheels shall be kept properly moistened using a water
soluble asphalt release agent approved by the engineer. Rolling
operations shall be conducted in such a manner that shoving or
distortion will not develop. The amount of rolling shall be limited to
only that necessary for compacting the porous friction course and
bonding it to the underlying surface course. Any mixture, which becomes
loose, broken, mixed with dirt, or in any way defective, shall be
removed and replaced with fresh mixture and immediately compacted to
conform to the surrounding area. Such rework shall be done at the
Contractor\'s expense. Spreading of the mixture shall be done carefully
with particular attention given to making the operation as continuous as
possible. Hand working shall be kept to an absolute minimum.

Contractor quality control shall utilize a nuclear gauge to monitor
compaction efforts.

**402‑4.11 JOINTS**. The formation of all joints shall be made in such a
manner as to ensure a continuous bond between old and new sections of
the course. All joints shall present the same texture, density, and
smoothness as other sections of the course.

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

Longitudinal joints which are irregular, damaged, or otherwise defective
shall be cut back to expose a clean, sound surface for the full depth of
the course. All contact surfaces shall be given a tack coat of
bituminous material prior to placing any fresh mixture against the
joint. The longitudinal joint shall offset that in the existing course
by at least 1 foot (30 cm).

**402‑4.12 SHAPING EDGES**. While the surface is being compacted and
finished, the Contractor shall carefully shape the longitudinal outside
edges of the PFC to a vertical face at the established edge. When
transitioning from PFC to existing pavement, transverse edges shall be
constructed with a finer graded bituminous mixture.

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> **Edge lips shall not exceed 3-inches; however, they are preferred to
> be less than 1.5-inches. This may be a problem on projects that have
> excessive surface irregularities.**

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**402‑4.13 SURFACE TESTS**. The Contractor is responsible for supplying
an acceptable metal 12-foot straight edge. After completion of final
rolling, the finished surface shall be tested with the 12-foot
straightedge and shall not vary more than 1/4 inch. The 12-foot straight
edge shall be applied parallel with and at right angles to the runway
centerline in a pattern that includes longitudinal and transverse
joints. The 12-foot straightedge shall be advanced approximately 1/2 its
length in the line of measurement. Areas of the porous friction course
exceeding the specified tolerances shall be removed, as directed by the
Engineer, and replaced with new material at the Contractor\'s expense.
The Engineer shall immediately notify the Contractor of such
unsatisfactory visual defects such as non-uniform texture, roller marks,
bleeding of bituminous material, cracking and shoving of the mixture
during rolling operations. Areas of the porous friction course, which
possess such defects, shall be removed, as directed by the Engineer, and
replaced with new material at the Contractors expense. Skin patching or
hand working shall not be permitted.

**402‑4.14 ACCEPTANCE SAMPLING AND TESTING OF BITUMINOUS MATERIAL AND
AGGREGATE.** The Engineer, at no cost to the Contractor, shall perform
all acceptance sampling and testing. The testing laboratory performing
the testing shall meet the requirements of ASTM D 3666.

Samples of the PFC mixture shall be taken at the point of discharge in
hauling units and tested to control uniformity in bituminous content and
gradation. Samples shall be taken in accordance with ASTM D 979 and
prepared in accordance with ASTM D 2172 or ASTM D 6307. One sample shall
be taken from each lot on a random basis in accordance with procedures
contained in ASTM D 3665. A lot shall consist of 1,000 tons or 1/2 day's
production, whichever is less. Should the average bituminous content for
any two consecutive lots not fall within job mix tolerances under
402‑3.1, the Contractor shall cease production until such
out‑of‑tolerance conditions have been remedied. Any material, placed
after the contractor has been informed of two consecutive failing tests,
shall be rejected and removed at the Contractor\'s expense.

Aggregate from each hot bin or aggregate feed shall be sampled on a
random basis and tested for gradation analysis in accordance with ASTM C
136. One sample shall be taken on a random basis in accordance with ASTM
D 3665 for each lot. A lot shall consist of 500 tons or 1/4 day's
production, whichever is less. If any two consecutive samples fail to
meet the tolerances of the job mix formula gradation, the Contractor
shall cease plant production until such out‑of tolerance conditions have
been remedied. Any material, placed after the contractor has been
informed of two consecutive failing tests, shall be rejected and removed
at the Contractor\'s expense.

The Engineer will notify the Contractor of unsatisfactory visual defects
in the completed bituminous friction course such as non-uniform texture,
roller marks, bleeding of bituminous material, cracking and shoving of
the mixture during the roller operations, or nonconformance to the
surface smoothness criteria specified. Unsatisfactory bituminous
friction course shall be removed and replaced at the Contractor\'s
expense as directed by the Engineer.

**402‑4.15 BITUMINOUS AND AGGREGATE MATERIAL (CONTRACTOR'S
RESPONSIBILITY)**. Samples of the bituminous and aggregate materials
that the Contractor proposes to use, together with a statement of their
source and character, shall be submitted for approval prior to use. The
Contractor shall require the manufacturer or producer of the bituminous
and aggregate materials to furnish material subject to this and all
other pertinent requirements of the contract. Only those materials that
have been tested and approved for the intended use shall be acceptable.

The Contractor shall furnish the vendor's certified test reports for
each carload or equivalent of bituminous material shipped to the
project. The report shall be delivered to the Engineer before permission
is granted to use the material. The vendor's certified test report for
the bituminous material shall not be interpreted as a basis for final
acceptance. All test reports shall be subject to verification by testing
sample materials received for use on the project.

**402‑4.16 PROTECTION OF PAVEMENT**. After final rolling, no vehicular
traffic of any kind shall be permitted on the pavement until it has
cured at least 12 hours or unless otherwise authorized by the Engineer.
Newly constructed pavement areas shall not be opened to aircraft traffic
until 24 hours after completion or unless otherwise authorized by the
Engineer.

METHOD OF MEASUREMENT

**402‑5.1** Porous friction course shall be measured by the number of
**\[square yards (square meters)\]\[tons (kg)\]** of mixture used in the
accepted work.

Only the areas of the porous friction course meeting the following
thickness requirements shall be measured for payment:

To determine the thickness of the finished PFC, the Engineer shall take
one core sample, not less than 2 inches (5 cm) in diameter, at random
from each unit of the completed PFC area. A unit of the completed area
shall be one paving lane wide by 1,000 feet (304 m) long. The last unit
in any one paving lane shall include any remaining length in addition to
the 1,000 feet (304 m).

When the measurement of any core is more than the maximum or less than
the minimum allowable thickness, as shown in Table 3, additional cores
shall be taken at 20‑foot intervals (6 m) (parallel to and at right
angles to the runway centerline) until the completed PFC is within such
maximum or minimum thickness for the subunit being tested.
Out‑of‑tolerance areas shall be deducted from the total **\[square yards
(square meters)\]\[tons (kg)\]** PFC for payment. If, in the Engineer's
judgment, such out of tolerance areas warrant removal, the PFC shall be
removed and the underlying course shall be cleaned (ready for
reconstruction), all at the Contractor's expense.

**TABLE 3. ALLOWABLE FINISHED PFC THICKNESS**

Nominal Maximum Minimum

in. mm in. mm in. mm

3/4 in. aggregate 1.0 25 1.50 37 0.75 19

1/2 in. aggregate 0.75 19 1.25 32 0.50 12

BASIS OF PAYMENT

**402‑6.1** Payment shall be made at the respective contract prices per
**\[square yard (square meter)\]\[ton (kg)\]** for porous friction
course and per **\[gallon (liter)\]\[ton (kg)\]** for bituminous
material. The prices shall be full compensation for furnishing all
materials; for all preparation and storage of materials; for cleaning
the existing surface; for mixing, hauling, placing, and compacting the
mixture (including initial test section); and for all tools, equipment,
and incidentals necessary to complete each item. No separate payment is
included in the contract for furnishing and batching mineral filler, or
anti-stripping agents, should such items be required.

Rehabilitation of the existing pavement surface and the tack coat shall
be measured and paid for at their respective contract prices.

Payment will be made under:

Item P‑402‑6.1 Porous Friction Course---**\[per square yard (square
meter)\]\[ton (kg)\]**

Item P‑402‑6.2 Bituminous material---**\[per gallon (liter)\]\[ton
(kg)\]**

TESTING REQUIREMENTS

ASTM C 88 Soundness of Aggregates by Use of Sodium Sulfate or Magnesium
Sulfate

ASTM C 127 Density, Specific Gravity, and Absorption of Coarse
Aggregates

ASTM C 128 Density, Specific Gravity, and Absorption of Fine Aggregate

ASTM C 131 Resistance to Abrasion of Small Size Coarse Aggregate by Use
of the Los

Angeles Machine

ASTM C 136 Sieve Analysis of Fine and Coarse Aggregates

ASTM C 566 Total Evaporable Moisture Content of Aggregate by Drying

ASTM D 693 Crushed Aggregate for Macadam Pavements

ASTM D 979 Sampling Bituminous Paving Mixtures

ASTM D 995 Mixing Plants for Hot-Mixed Hot-Laid Bituminous Paving
Mixtures

ASTM D 2172 Quantitative Extraction of Bitumen from Bituminous Paving
Mixtures

ASTM D 2741 Susceptibility of Polyethylene Bottles to Soot Accumulation

ASTM D 3665 Random Sampling of Paving Materials

ASTM D 3666 Minimum Requirements for Agencies Testing and Inspecting
Bituminous Paving Materials

ASTM D 4318 Liquid Limit, Plastic Limit, and Plasticity Index of Soils

ASTM D 6307 Standard Test Method for Asphalt Content of Hot Mix Asphalt
by Ignition Method

MATERIAL REQUIREMENTS

ASTM D 242 Mineral Filler for Bituminous Paving Mixtures

ASTM D 3381 Viscosity‑Graded Asphalt Cement for Use in Pavement
Construction

**END OF ITEM P‑402**

###  {#section-1 .unnumbered}

### **ITEM P‑403 PLANT MIX BITUMINOUS PAVEMENTS (Base, Leveling or Surface Course)**

DESCRIPTION

**403‑1.1** This item shall consist of a **\[ \]** course composed of
mineral aggregate and bituminous material mixed in a central mixing
plant and placed on a prepared course in accordance with these
specifications and shall conform to the lines, grades, thicknesses, and
typical cross sections shown on the plans. Each course shall be
constructed to the depth, typical section, and elevation required by the
plans and shall be rolled, finished, and approved before the placement
of the next course.

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> **Specify base and/or leveling course(s). Surface course may also be
> specified but only for those pavements designed to accommodate
> aircraft of gross weights less than or equal to 12,500 pounds (5,670
> kg) or for surface course of shoulders, blast pads, service roads,
> etc. Item P-401 is to be specified for surface courses for pavements
> designed to accommodate aircraft gross weights greater than 12,500
> pounds (5,670 kg).**
>
> **This specification is to be used as a base or leveling course for
> pavements designed to accommodate aircraft of gross weights greater
> than 12,500 pounds (5,670 kg). State highway department specifications
> may be used in lieu of this specification for access roads, perimeter
> roads, stabilized base courses under Item P-501, and other pavements
> not subject to aircraft loading, or for pavements designed for
> aircraft gross weights of 12,500 pounds (5,670 kg) or less.**
>
> **Where a state highway department specification is to be used in lieu
> of this specification, the state specification must have a
> demonstrated satisfactory performance record under equivalent loadings
> and exposure. When a density requirement is not specified by a state
> specification, it is to be modified to incorporate the language found
> in paragraphs 403-5.1, 403-5.2 and 403-5.3. When state highway
> specification are approved, include all applicable/approved state
> specifications in the contract documents.**

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MATERIALS

**403‑2.1 AGGREGATE.** Aggregates shall consist of crushed stone,
crushed gravel, or crushed slag with or without natural sand or other
inert finely divided mineral aggregate. The portion of combined
materials retained on the No. 4 (4.75 mm) sieve is coarse aggregate. The
portion of combined materials passing the No. 4 (4.75 mm) sieve and
retained on the No. 200 (0.075 mm) sieve is fine aggregate, and the
portion passing the No. 200 (0.075 mm) sieve is mineral filler.

**a. Coarse Aggregate.** Coarse aggregate shall consist of sound, tough,
durable particles, free from adherent films of matter that would prevent
thorough coating and bonding with the bituminous material and be free
from organic matter and other deleterious substances. The percentage of
wear shall not be greater than **\[ \]** percent when tested in
accordance with ASTM C 131. The sodium sulfate soundness loss shall not
exceed 10 percent, or the magnesium sulfate soundness loss shall not
exceed 13 percent, after five cycles, when tested in accordance with
ASTM C 88.

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> **Percentage of wear shall not exceed 40 for surface, binder, and
> leveling courses and 50 for base course. Aggregates with a higher
> percentage loss of wear or soundness may be specified in lieu of those
> indicated, provided a satisfactory service record under similar
> conditions of service and exposure has been demonstrated.**

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Aggregate shall contain at least **\[ \]** percent by weight of
individual pieces having two or more fractured faces and **\[ \]**
percent by weight having at least one fractured face. The area of each
face shall be equal to at least 75 percent of the smallest midsectional
area of the piece. When two fractured faces are contiguous, the angle
between the planes of fractures shall be at least 30 degrees to count as
two fractured faces. Fractured faces shall be obtained by crushing.

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> **For pavement courses designed for aircraft gross weights of 60,000
> pounds (27 200 kg) or more, the Engineer shall specify 70 percent for
> two fractured faces and 85 percent for one fractured face. For
> pavement courses designed for aircraft gross weights less than 60,000
> pounds (27 200 kg), the Engineer shall specify 50 percent for two
> fractured faces and 65 percent for one fractured face.**
>
> **In areas where slag is not available or desired, the references to
> it should be deleted from all aggregate paragraphs.**

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The aggregate shall not contain more than a total of 8 percent, by
weight, of flat particles*,* elongated particles, and flat and elongated
particles*,* when tested in accordance with ASTM D 4791 with a value of
5:1.

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> **The Engineer may specify ASTM D 4791 with a ratio of 3:1. If so,
> replace the above paragraph as follows: "The aggregate shall not
> contain more than a total of 20 percent by weight of flat particles,
> elongated particles, and flat and elongated particles when tested in
> accordance with ASTM D4791 with a value of 3:1."**

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Slag shall be air‑cooled, blast furnace slag, and shall have a compacted
weight of not less than 70 pounds per cubic foot (1.12 mg/cubic meter)
when tested in accordance with ASTM C 29.

**b. Fine Aggregate.** Fine aggregate shall consist of clean, sound,
durable, angular shaped particles produced by crushing stone, slag, or
gravel that meets the requirements for wear and soundness specified for
coarse aggregate. The aggregate particles shall be free from coatings of
clay, silt, or other objectionable matter and shall contain no clay
balls. The fine aggregate, including any blended material for the fine
aggregate, shall have a plasticity index of not more than 6 and a liquid
limit of not more than 25 when tested in accordance with ASTM D 4318.

Natural (nonmanufactured) sand may be used to obtain the gradation of
the aggregate blend or to improve the workability of the mix. The amount
of sand to be added will be adjusted to produce mixtures conforming to
requirements of this specification. **\[**The fine aggregate shall not
contain more than 15 percent natural sand by weight of total
aggregates.**\]** If used, the natural sand shall meet the requirements
of ASTM D 1073 and shall have a plasticity index of not more than 6 and
a liquid limit of not more than 25 when tested in accordance with ASTM D
4318.

The aggregate shall have sand equivalent values of **\[ \]** or greater
when tested in accordance with ASTM D 2419.

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> **Typically the sand equivalent value should be 45, unless local
> conditions require lower value.**
>
> **The addition of natural sand to a mix containing all crushed coarse
> and fine aggregates will normally increase its workability and
> compactability. However, the addition of excessive amounts of natural
> sand tends to decrease the stability of the mixture. The requirement
> for a sand equivalent value of 45 usually limits the use of natural
> sand; however, the maximum of 15 percent natural sand may be included
> for locations where low stabilities are a chronic problem.**

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\* \* \* \* \* \* \* \* \* \* \* \* \* \***

**c. Sampling.** ASTM D 75 shall be used in sampling coarse and fine
aggregate, and ASTM C 183 shall be used in sampling mineral filler.

**403‑2.2 MINERAL FILLER.** If filler, in addition to that naturally
present in the aggregate, is necessary, it shall meet the requirements
of ASTM D 242.

**403‑2.3 BITUMINOUS MATERIAL.** Bituminous material shall conform to
the following requirements: **\[ \]**.

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> **Asphalt cement binder shall conform to \[AASHTO MP1 Performance
> Grade (PG) \[\_\_\_\_\_\]\] \[ASTM D 3381 Table 1, 2, or 3 Viscosity
> Grade\]\[ASTM D 946 Penetration Grade \[\_\_\_\_\_\]\]. Test data
> indicating grade certification shall be provided by the supplier at
> the time of delivery of each load to the mix plant. Copies of these
> certifications shall be submitted to the Engineer. The Engineer shall
> specify the grade of bituminous material, based on geographical
> location and climatic conditions. Asphalt Institute Superpave Series
> No. 1 (SP-1) provides guidance on the selection of performance graded
> binders. Table VI‑1, Selecting Asphalt Grade, contained in the Asphalt
> Institute\'s Manual Series‑1 (MS‑1) provides guidance on the selection
> of asphalt type. For cold climates, Table 2 of ASTM D 3381 may be
> specified to minimize the susceptibility for thermal cracking. The
> Engineer should be aware that PG asphalt binders may contain modifiers
> that require elevated mixing and compaction temperatures that exceed
> the temperatures specified in Item P-403.**
>
> **Grades of some materials are listed below:**
>
> **NOTE: Performance Graded (PG) asphalt binders should be specified
> wherever available. The same grade PG binder used by the state highway
> department in the area should be considered as the base grade for the
> project (e.g. the grade typically specified in that specific location
> for dense graded mixes on highways with design ESALS less than 10
> million). The exception would be that grades with a low temperature
> higher than PG XX-22 should not be used (e.g. PG XX-16 or PG XX-10),
> unless the Engineer has had successful experience with them.
> Typically, rutting is not a problem on airport runways. However, at
> airports with a history of stacking on end of runways and taxiway
> areas, rutting has accrued due to the slow speed of loading on the
> pavement. If there has been rutting on the project or it is
> anticipated that stacking may accrue during the design life of the
> project, then the following grade \"bumping\" should be applied for
> the top 125 mm (5 inches) of paving in the end of runway and taxiway
> areas: for aircraft tire pressure between 100 and 200 psi, increase
> the high temperature one grade; for aircraft tire pressure greater
> than 200 psi, increase the high temperature two grades. Each grade
> adjustment is 6 degrees C. Polymer Modified Asphalt, PMA, has shown to
> perform very well in these areas. The low temperature grade should
> remain the same.**
>
> **Additional grade bumping and grade selection information is given in
> Table A.**

+-----------------------+----------------------+----------------------+
| > **TABLE A. BINDER   |                      |                      |
| > GRADE SELECTION AND |                      |                      |
| > GRADE BUMPING**     |                      |                      |
| >                     |                      |                      |
| > **BASED ON GROSS    |                      |                      |
| > AIRCRAFT WEIGHT.**  |                      |                      |
+-----------------------+----------------------+----------------------+
| **Aircraft Gross      | > **High Temperature |                      |
| Weight**              | > Adjustment to**    |                      |
|                       | >                    |                      |
| > **(pounds)**        | > **Base Binder      |                      |
|                       | > Grade**            |                      |
+-----------------------+----------------------+----------------------+
|                       | > **Pavement Type**  |                      |
+-----------------------+----------------------+----------------------+
|                       | > **Runway**         | > **Taxiway/Apron**  |
+-----------------------+----------------------+----------------------+
| > **Less than         | > **\--**            | > **\--**            |
| > 12,500**            |                      |                      |
+-----------------------+----------------------+----------------------+
| > **Less than         | > **\--**            | > **1**              |
| > 60,000**            |                      |                      |
+-----------------------+----------------------+----------------------+
| > **Less than         | > **\--**            | > **1**              |
| > 100,000**           |                      |                      |
+-----------------------+----------------------+----------------------+
| > **Greater than      | > **1**              | > **2**              |
| > 100,000**           |                      |                      |
+-----------------------+----------------------+----------------------+
| > **NOTES:**          |                      |                      |
| >                     |                      |                      |
| > **1. PG grades      |                      |                      |
| > above a --22 on the |                      |                      |
| > low end (e.g.       |                      |                      |
| > 64--16) are not     |                      |                      |
| > recommended.        |                      |                      |
| > Limited experience  |                      |                      |
| > has shown this to   |                      |                      |
| > be a poor           |                      |                      |
| > performer.**        |                      |                      |
| >                     |                      |                      |
| > **2. PG grades      |                      |                      |
| > below a 64 on the   |                      |                      |
| > high end (e.g.      |                      |                      |
| > 58-22) are not      |                      |                      |
| > recommended. These  |                      |                      |
| > binders often       |                      |                      |
| > provide tender      |                      |                      |
| > tendencies.**       |                      |                      |
| >                     |                      |                      |
| > **3. PG grades      |                      |                      |
| > above a 76 on the   |                      |                      |
| > high end (e.g.      |                      |                      |
| > 82-22) are very     |                      |                      |
| > stiff and may be    |                      |                      |
| > difficult to work   |                      |                      |
| > and compact.**      |                      |                      |
+-----------------------+----------------------+----------------------+

+------------+---------+-----------+----------------------------------+
| **Grade    |         |           |                                  |
| Speci      |         |           |                                  |
| fication** |         |           |                                  |
+------------+---------+-----------+----------------------------------+
| **P        | **Vi    |           | > **Performance Graded**         |
| enetration | scosity |           | >                                |
| Grade**    | Grade** |           | > **Asphalt Institute**          |
|            |         |           | >                                |
| **ASTM D   | >       |           | > **Superpave Series No.         |
| 946**      |  **ASTM |           | > 1(SP-1)**                      |
|            | > D     |           |                                  |
|            | >       |           |                                  |
|            |  3381** |           |                                  |
+------------+---------+-----------+----------------------------------+
| >          | > *     | > **      | > **In general, the Engineer     |
|  **40‑50** | *AC‑5** | AR‑1000** | > should choose a PG‑asphalt     |
| >          | >       | >         | > binder that has been approved  |
| >          | > **    | > **      | > for use in the vicinity by the |
|  **60‑70** | AC‑10** | AR‑2000** | > State DOT, and is locally      |
| >          | >       | >         | > available. In general, a high  |
| >          | > **    | > **      | > reliability (98 percent) on    |
| **85‑100** | AC‑15** | AR‑4000** | > both the high and low          |
| >          | >       | >         | > temperature categories is      |
| > *        | > **    | > **      | > sufficiently conservative.**   |
| *100‑120** | AC‑20** | AR‑8000** |                                  |
| >          | >       |           |                                  |
| > *        | > **    |           |                                  |
| *120‑150** | AC‑30** |           |                                  |
|            | >       |           |                                  |
|            | > **    |           |                                  |
|            | AC‑40** |           |                                  |
+------------+---------+-----------+----------------------------------+

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The Contractor shall furnish vendor\'s certified test reports for each
lot of bituminous material shipped to the project. The vendor\'s
certified test report for the bituminous material can be used for
acceptance or tested independently by the Engineer.

**403‑2.4 PRELIMINARY MATERIAL ACCEPTANCE.** Prior to delivery of
materials to the job site, the Contractor shall submit certified test
reports to the Engineer for the following materials:

**a. Coarse Aggregate.**

**(1)** Percent of wear.

**(2)** Soundness.

(3) Unit weight of slag.

(4) Percent fractured faces

**b. Fine Aggregate.**

**(1)** Liquid limit.

**(2)** Plasticity index.

**(3)** Sand equivalent.

**c. Mineral Filler.**

**d. Bituminous Material.** Test results for bituminous material shall
include temperature/viscosity charts for mixing and compaction
temperatures.

The certification(s) shall show the appropriate ASTM test(s) for each
material, the test results, and a statement that the material meets the
specification requirement.

The Engineer may request samples for testing, prior to and during
production, to verify the quality of the materials and to ensure
conformance with the applicable specifications.

**403-2.5 ANTI-STRIPPING AGENT.** Any anti-stripping agent or additive
if required shall be heat stable, shall not change the asphalt cement
viscosity beyond specifications, shall contain no harmful ingredients,
shall be added in recommended proportion by approved method, and shall
be a material approved by the Department of Transportation of the State
in which the project is located.

COMPOSITION

**403‑3.1 COMPOSITION OF MIXTURE.** The bituminous plant mix shall be
composed of a mixture of well‑graded aggregate, filler and anti-strip
agent if required, and bituminous material. The several aggregate
fractions shall be sized, handled in separate size groups, and combined
in such proportions that the resulting mixture meets the grading
requirements of the job mix formula (JMF).

**403‑3.2 JOB MIX FORMULA.** No bituminous mixture for payment shall be
produced until a job mix formula has been approved in writing by the
Engineer. The bituminous mixture shall be designed using procedures
contained in Chapter 5, MARSHALL METHOD OF MIX DESIGN, of the Asphalt
Institute\'s Manual Series No. 2 (MS‑2), Mix Design Methods for Asphalt
Concrete, sixth edition, and shall meet the requirements of Tables 1, 2
and 3.

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\* \* \* \* \* \* \* \* \* \* \* \* \* \***

> **Engineer may specify the Eastern Region Laboratory Procedures Manual
> (ERLPM), Section 2 in lieu of MS-2.**

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\* \* \* \* \* \* \* \* \* \* \* \* \* \***

Tensile Strength Ratio (TSR) of the composite mixture, as determined by
ASTM D 4867, shall not be less than 75. Anti‑stripping agent shall be
added to the asphalt, as necessary, to produce a TSR of not less than
75. If an antistrip agent is required, it will be provided by the
Contractor at no additional cost to the Owner.

**\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

> **Engineer may specify a TSR of not less than 80 in areas that are
> prone to stripping at a TSR of 75.**

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\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
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The job mix formula shall be submitted in writing by the Contractor to
the Engineer at least **\[ \]** days prior to the start of paving
operations and shall include as a minimum:

**a.** Percent passing each sieve size for total combined gradation,
individual gradation of all aggregate stockpiles and percent by weight
of each stockpile used in the job mix formula.

**b.** Percent of asphalt cement.

**c.** Asphalt performance, viscosity or penetration grade, and type of
modifier if used.

**d.** Number of blows of hammer compaction per side of molded specimen.

**e.** Mixing temperature.

**f.** Compaction temperature.

**g.** Temperature of mix when discharged from the mixer.

**h.** Temperature‑viscosity relationship of the asphalt cement.

**i.** Plot of the combined gradation on the Federal Highway
Administration (FHWA) 45 power gradation curve.

**j.** Graphical plots of stability, flow, air voids, voids in the
mineral aggregate, and unit weight versus asphalt content.

**k.** Percent natural sand.

**l.** Percent fractured faces.

**m.** Percent by weight of flat particles, elongated particles, and
flat and elongated particles (and criteria).

**n.** Tensile Strength Ratio (TSR).

**o.** Antistrip agent (if required).

The Contractor shall submit to the Engineer the results of verification
testing of three (3) asphalt samples prepared at the optimum asphalt
content. The average of the results of this testing shall indicate
conformance with the job mix formula requirements specified in Tables 1,
2 and 3.

When the project requires asphalt mixtures of differing aggregate
gradations, a separate job mix formula and the results of job mix
formula verification testing must be submitted for each mix.

The job mix formula for each mixture shall be in effect until a
modification is approved in writing by the Engineer. Should a change in
sources of materials be made, a new job mix formula must be submitted
within \[ \] days and approved by the Engineer in writing before the new
material is used. After the initial production job mix formula(s)
has/have been approved by the Engineer and a new or modified job mix
formula is required for whatever reason, the subsequent cost of the
Engineer's approval of the new or modified job mix formula will be borne
by the Contractor. There will be no time extension given or
considerations for extra costs associated with the stoppage of
production paving or restart of production paving due to the time needed
for the Engineer to approve the initial, new or modified job mix
formula.

**\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

> **The Engineer shall specify the number of days. A minimum of 10 days
> is recommended.**
>
> **For mixes with maximum size aggregate of 1\" or less, the Marshall
> Design Criteria applicable to the project shall be specified by the
> Engineer from the information shown below and inserted into Table 1.
> Asterisks denote insert points.**

+---------------------+-------------------------+---------------------+
| **Test Property**   | **Pavements Designed    | **Pavements         |
|                     | for Aircraft Gross      | Designed for        |
|                     | Weights of 60,000 Lbs.  | Aircraft Gross      |
|                     | or More or Tire         | Weights Less Than   |
|                     | Pressures of 100 Psi or | 60,000 Lbs. or Tire |
|                     | More**                  | Pressures Less Than |
|                     |                         | 100 Psi**           |
+=====================+=========================+=====================+
| **Number of Blows** | **75**                  | **50**              |
+---------------------+-------------------------+---------------------+
| **Stability, pounds | **1800 (8006)**         | **1000 (4448)**     |
| (newtons)**         |                         |                     |
+---------------------+-------------------------+---------------------+
| **Flow, 0.01 in.**  | **8-16**                | **8-20**            |
|                     |                         |                     |
| **(0.25 mm)**       |                         |                     |
+---------------------+-------------------------+---------------------+
| **Air Voids**       | **2-5**                 | **2-5**             |
|                     |                         |                     |
| **(percent)**       |                         |                     |
+---------------------+-------------------------+---------------------+
| **Percent Voids     | **See Table 2**         | **See Table 2**     |
| in**                |                         |                     |
|                     |                         |                     |
| **Mineral           |                         |                     |
| Aggregate**         |                         |                     |
|                     |                         |                     |
| **(minimum)**       |                         |                     |
+---------------------+-------------------------+---------------------+

**For mixes with maximum size aggregate greater than 1 inch up to a
maximum of 1-½ inches, the Marshall Design Criteria shall be modified by
the Engineer per the guidance found in Asphalt Institute Manual Series
No. 2 (MS-2), Chapter 5 and the test method specified shall be ASTM D
5581 in lieu of ASTM D 6926. Modifications to the flow criteria may be
required for modified asphalt cement binders.**

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\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

  ----------------------------------- -----------------------------------
  **TABLE 1. MARSHALL DESIGN          
  CRITERIA**                          

  TEST PROPERTY                       \*

  Number of blows                     \*

  Stability, pounds (newtons) minimum \*

  (newtons) minimum                   

  Flow, 0.01 in. (0.25 mm)            \*

  Air voids (percent)                 \*

  Percent voids in mineral aggregate, See Table 2
  minimum                             
  ----------------------------------- -----------------------------------

+---------------------+---------------------+-------------------------+
| **TABLE 2. MINIMUM  |                     |                         |
| PERCENT**           |                     |                         |
|                     |                     |                         |
| **VOIDS IN MINERAL  |                     |                         |
| AGGREGATE**         |                     |                         |
+---------------------+---------------------+-------------------------+
| Maximum Particle    |                     | Minimum Voids in        |
| Size                |                     | Mineral Aggregate,      |
|                     |                     | percent                 |
+---------------------+---------------------+-------------------------+
| in.                 | mm                  | Percent                 |
+---------------------+---------------------+-------------------------+
| ½                   | 12.5                | 16                      |
+---------------------+---------------------+-------------------------+
| ¾                   | 19.0                | 15                      |
+---------------------+---------------------+-------------------------+
| 1                   | 25.0                | 14                      |
+---------------------+---------------------+-------------------------+
| 1-½                 | 37.5                | 13                      |
+---------------------+---------------------+-------------------------+

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\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

> **Modifications to the minimum VMA as found in Table 2 may be made
> depending on the definition of maximum particle size and/or local
> conditions.**

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\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

The mineral aggregate shall be of such size that the percentage
composition by weight, as determined by laboratory sieves, will conform
to the gradation or gradations specified in Table 3 when tested in
accordance with ASTM C 136 and C 117.

The gradations in Table 3 represent the limits that shall determine the
suitability of aggregate for use from the sources of supply. The
aggregate, as selected (and used in the JMF), shall have a gradation
within the limits designated in Table 3 and shall not vary from the low
limit on one sieve to the high limit on the adjacent sieve, or vice
versa, but shall be well graded from coarse to fine.

Deviations from the final approved mix design for bitumen content and
gradation of aggregates shall be within the action limits for individual
measurements as specified in paragraph 403‑6.5a. The limits still will
apply if they fall outside the master grading band in Table 3.

The maximum size aggregate used shall not be more than one‑half of the
thickness of the course being constructed except where otherwise shown
on the plans or ordered by the Engineer.

+-----------------------------------+-----------------------------------+
| **TABLE 3. AGGREGATE ‑ BITUMINOUS |                                   |
| PAVEMENTS**                       |                                   |
+-----------------------------------+-----------------------------------+
| Sieve Size                        | Percentage by Weight Passing      |
|                                   | Sieve                             |
+-----------------------------------+-----------------------------------+
| 1‑½ in. (37.50 mm)                | \*                                |
+-----------------------------------+-----------------------------------+
| 1 in. (25.0 mm)                   | \*                                |
+-----------------------------------+-----------------------------------+
| ¾ in. (19.0 mm)                   | \*                                |
+-----------------------------------+-----------------------------------+
| ½ in. (12.5 mm)                   | \*                                |
+-----------------------------------+-----------------------------------+
| ⅜ in. (9.5 mm)                    | \*                                |
+-----------------------------------+-----------------------------------+
| No. 4 (4.75 mm)                   | \*                                |
+-----------------------------------+-----------------------------------+
| No. 8 (2.36 mm)                   | \*                                |
+-----------------------------------+-----------------------------------+
| No. 16 (1.18 mm)                  | \*                                |
+-----------------------------------+-----------------------------------+
| No. 30 (0.60 mm)                  | \*                                |
+-----------------------------------+-----------------------------------+
| No. 50 (0.30 mm)                  | \*                                |
+-----------------------------------+-----------------------------------+
| No. 100 (0.15 mm)                 | \*                                |
+-----------------------------------+-----------------------------------+
| No. 200 (0.075 mm)                | \*                                |
+-----------------------------------+-----------------------------------+
| Asphalt percent                   | \*                                |
|                                   |                                   |
| Stone or gravel                   | \*                                |
|                                   |                                   |
| Slag                              |                                   |
+-----------------------------------+-----------------------------------+

The aggregate gradations shown are based on aggregates of uniform
specific gravity. The percentages passing the various sieves shall be
corrected when aggregates of varying specific gravities are used, as
indicated in the Asphalt Institute Manual Series No. 2 (MS‑2), Chapter
3.

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> **The aggregate gradation shall be specified by the Engineer from the
> gradations shown in this note. The gradation shall be inserted into
> Table 3. Asterisks denote insert points.**
>
> **Where locally‑available aggregates cannot be economically blended to
> meet the grading requirements of the gradations shown, the gradations
> may be modified to fit the characteristics of such local aggregates
> with approval of the FAA. The modified gradation must produce a paving
> mixture that satisfies the mix design requirements.**

+--------------------+-----------+-----------+-----------+-----------+
| #                  |           |           |           |           |
| ### AGGREGATE ‑ BI |           |           |           |           |
| TUMINOUS PAVEMENTS |           |           |           |           |
+--------------------+-----------+-----------+-----------+-----------+
| **Sieve Size**     | **P       |           |           |           |
|                    | ercentage |           |           |           |
|                    | by Weight |           |           |           |
|                    | Passing   |           |           |           |
|                    | Sieves**  |           |           |           |
+--------------------+-----------+-----------+-----------+-----------+
|                    | **1‑½"    | **1"      | **¾ "     | **½"      |
|                    | max**     | max**     | max**     | max**     |
+--------------------+-----------+-----------+-----------+-----------+
| **1‑½ in. (37.5    | **100**   | **‑‑**    | **‑‑**    | **‑‑**    |
| mm)**              |           |           |           |           |
+--------------------+-----------+-----------+-----------+-----------+
| **1 in. (24.0      | **86‑98** | **100**   | **‑‑**    | **‑‑**    |
| mm)**              |           |           |           |           |
+--------------------+-----------+-----------+-----------+-----------+
| **¾ in. (19.0      | **68‑93** | **76‑98** | **100**   | **‑‑**    |
| mm)**              |           |           |           |           |
+--------------------+-----------+-----------+-----------+-----------+
| **½ in. (12.5      | **57‑81** | **66‑86** | **79‑99** | **100**   |
| mm)**              |           |           |           |           |
+--------------------+-----------+-----------+-----------+-----------+
| **⅜ in. (9.5 mm)** | **49‑69** | **57‑77** | **68‑88** | **79‑99** |
+--------------------+-----------+-----------+-----------+-----------+
| **No. 4 (4.75      | **34‑54** | **40‑60** | **48‑68** | **58‑78** |
| mm)**              |           |           |           |           |
+--------------------+-----------+-----------+-----------+-----------+
| **No. 8 (2.36      | **22‑42** | **26‑46** | **33‑53** | **39‑59** |
| mm)**              |           |           |           |           |
+--------------------+-----------+-----------+-----------+-----------+
| **No. 16 (1.18     | **13‑33** | **17‑37** | **20‑40** | **26‑46** |
| mm)**              |           |           |           |           |
+--------------------+-----------+-----------+-----------+-----------+
| **No. 30 (0.600    | **8‑24**  | **11‑27** | **14‑30** | **19‑35** |
| mm)**              |           |           |           |           |
+--------------------+-----------+-----------+-----------+-----------+
| **No. 50 (0.300    | **6‑18**  | **7‑19**  | **9‑21**  | **12‑24** |
| mm)**              |           |           |           |           |
+--------------------+-----------+-----------+-----------+-----------+
| **No. 100 (0.150   | **4‑12**  | **6‑16**  | **6‑16**  | **7‑17**  |
| mm)**              |           |           |           |           |
+--------------------+-----------+-----------+-----------+-----------+
| **No. 200 (0.075   | **3‑6**   | **3‑6**   | **3‑6**   | **3‑6**   |
| mm)**              |           |           |           |           |
+--------------------+-----------+-----------+-----------+-----------+
| **Asphalt          | **        | **        | **        | **        |
| percent:**         | 4.5‑7.0** | 4.5‑7.0** | 5.0‑7.5** | 5.5‑8.0** |
|                    |           |           |           |           |
| **Stone or         | **        | **        | **        | **7       |
| gravel**           | 5.0‑7.5** | 5.0‑7.5** | 6.5‑9.5** | .0‑10.5** |
|                    |           |           |           |           |
| **Slag**           |           |           |           |           |
+--------------------+-----------+-----------+-----------+-----------+

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\* \* \* \* \* \* \* \* \* \* \* \* \* \***

**403‑3.3 RECYCLED ASPHALT CONCRETE.** Recycled HMA shall consist of
reclaimed asphalt pavement (RAP), coarse aggregate, fine aggregate,
mineral filler, and asphalt cement. The RAP shall be of a consistent
gradation and asphalt content and properties. When RAP is fed into the
plant, the maximum RAP chunk size shall not exceed 2 inches. The
recycled HMA mix shall be designed using procedures contained in AI
MS-02. The recycled asphalt concrete mix shall be designed using
procedures contained in the Asphalt Institute\'s Manual Series Number 2
(MS‑2). The percentage of asphalt in the RAP shall be established for
the mixture design according to ASTM D 2172 using the appropriate dust
correction procedure. The job mix shall meet the requirements of
paragraph 403‑3.2 RAP should only be used for shoulder surface course
mixes and for any intermediate courses. The amount of RAP shall be
limited to **\[ \]** percent.

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\* \* \* \* \* \* \* \* \* \* \* \* \* \***

> **Reclaimed Asphalt Pavement (RAP) should not be used for surface
> mixes, except on shoulders. It can be used very effectively in lower
> layers or for shoulders. Engineer to specify the maximum percentage of
> reclaimed asphalt allowed in the mix. The amount of RAP shall be
> limited to 30 percent, as long as the resulting recycled mix meets all
> requirements that are specified for virgin mixtures. The Contractor
> may obtain the RAP from the job site or an existing source.**

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\* \* \* \* \* \* \* \* \* \* \* \* \* \***

In addition to the requirements of paragraph 403‑3.2, the job mix
formula shall indicate the percent of reclaimed asphalt pavement and the
percent and viscosity grade of new asphalt. The Contractor shall submit
documentation to the Engineer, indicating that the mixing equipment
proposed for use is adequate to mix the percent of RAP shown in the job
mix formula and meet all local and national environmental regulations.

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\* \* \* \* \* \* \* \* \* \* \* \* \* \***

> **The appropriate test should be selected to conform to the grade of
> new asphalt specified. If a penetration grade is specified, use
> penetration test. If a viscosity grade is specified, use a viscosity
> test. If a PG asphalt binder is specified, use the dynamic shear
> rheometer and bending beam tests. RAP containing coal tars may be
> require additional precautions during production and may be
> excluded.**

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\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

The blend of new asphalt cement and the RAP asphalt binder shall meet
the requirements in paragraph 403-2.3. The virgin asphalt cement shall
not be more than two standard asphalt material grades different than
that specified in paragraph 403-2.3

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\* \* \* \* \* \* \* \* \* \* \* \* \* \***

> **Delete paragraph 403-3.3 in its entirety if recycled asphalt
> pavement is not to be allowed and include a sentence that RAP will not
> be permitted to be used.**

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\* \* \* \* \* \* \* \* \* \* \* \* \* \***

**403‑3.4 TEST SECTION.** Prior to full production, the Contractor shall
prepare and place a quantity of bituminous mixture according to the job
mix formula. The amount of mixture shall be sufficient to construct a
test section **\[ \]** long and **\[ \]** wide**,** placed in two lanes,
with a longitudinal cold joint, and shall be of the same depth specified
for the construction of the course which it represents. A cold joint is
an exposed construction joint at least 4 hours old or whose mat has
cooled to less than 160°F. The underlying grade or pavement structure
upon which the test section is to be constructed shall be the same as
the remainder of the course represented by the test section. The
equipment used in construction of the test section shall be the same
type and weight to be used on the remainder of the course represented by
the test section.

THE TEST SECTION SHALL BE EVALUATED FOR ACCEPTANCE AS A SINGLE LOT IN
ACCORDANCE WITH THE ACCEPTANCE CRITERIA IN PARAGRAPH 403-5.1 AND
403-6.3. THE TEST SECTION SHALL BE DIVIDED INTO EQUAL SUBLOTS. AS A
MINIMUM THE TEST SECTION SHALL CONSIST OF 3 SUBLOTS.

The test section shall be considered acceptable if the average mat
density of the test section cores is greater than or equal to 98 percent
and the average joint density of the test section cores is greater than
or equal to 95 percent. If the initial test section should prove to be
unacceptable, the necessary adjustments to the job mix formula, plant
operation, placing procedures, and/or rolling procedures shall be made.
A second test section shall then be placed. If the second test section
also does not meet specification requirements, both sections shall be
removed at the Contractor\'s expense. Additional test sections, as
required, shall be constructed and evaluated for conformance to the
specifications. Any additional sections that are not acceptable shall be
removed at the Contractor\'s expense. Full production shall not begin
until an acceptable section has been constructed and accepted in writing
by the Engineer. Once an acceptable test section has been placed,
payment for the initial test section and the section that meets
specification requirements shall be made in accordance with paragraph
403‑8.1.

Job mix control testing shall be performed by the Contractor at the
start of plant production and in conjunction with the calibration of the
plant for the job mix formula. If the aggregates produced by the plant
do not satisfy the gradation requirements or produce a mix that meets
the JMF, it will be necessary to reevaluate and redesign the mix using
plant‑produced aggregates. Specimens shall be prepared and the optimum
bitumen content determined in the same manner as for the original design
tests.

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\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

> **The test section should be a minimum of 300 feet (90 m) long and 20
> to 30 feet (6 to 9 m) wide. The test section affords the Contractor
> and the Engineer an opportunity to determine the quality of the
> mixture in place, as well as performance of the plant and laydown
> equipment.**

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\* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \* \*
\* \* \* \* \* \* \* \* \* \* \* \* \* \***

**403‑3.5 TESTING LABORATORY.** The Contractor's laboratory used to
develop the job mix formula shall meet the requirements of ASTM D 3666
including the requirement to be accredited by a national authority such
as the National Voluntary Laboratory Accreditation Program (NVLAP), the
American Association for Laboratory Accreditation (AALA), or AASHTO
Accreditation Program (AAP). A certification signed by the manager of
the laboratory stating that it meets these requirements shall be
submitted to the Engineer prior to the start of construction. The
certification shall contain as a minimum:

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

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

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

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

**e.** ASTM D 3666 certification of accreditation by a nationally
recognized accreditation program.

CONSTRUCTION METHODS

**403‑4.1 WEATHER LIMITATIONS.** The bituminous mixture shall not be
placed 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 Engineer, if requested; however, all
other requirements including compaction shall be met.

**TABLE 4. BASE TEMPERATURE LIMITATIONS**

+------------------------------+-------------------+-------------------+
| Mat Thickness                | Base Temperature  |                   |
|                              | (Minimum)         |                   |
+------------------------------+-------------------+-------------------+
|                              | Deg. F            | Deg. C            |
+------------------------------+-------------------+-------------------+
| 3 in. (7.5 cm) or greater    | 40                | 4                 |
+------------------------------+-------------------+-------------------+
| Greater than 1 in. (2.5 cm)  | 45                | 7                 |
|                              |                   |                   |
| but less than 3 in. (7.5 cm) |                   |                   |
+------------------------------+-------------------+-------------------+
| 1 in. (2.5 cm) or less       | 50                | 10                |
+------------------------------+-------------------+-------------------+

**403‑4.2 BITUMINOUS MIXING PLANT.** Plants used for the preparation of
bituminous mixtures shall conform to the requirements of ASTM D 995 with
the following changes:

**a. Requirements for All Plants.**

**(1) Truck Scales.** The bituminous mixture shall be weighed on
approved scales furnished by the Contractor, or on certified public
scales at the Contractor\'s expense. Scales shall be inspected and
sealed as often as the Engineer deems necessary to assure their
accuracy. Scales shall conform to the requirements of the General
Provisions, Section 90‑01.

In lieu of scales, and as approved by the Engineer, asphalt mixture
weights may be determined by the use of an electronic weighing system
equipped with an automatic printer that weighs the total paving mixture.
Contractor must furnish calibration certification of the weighing system
prior to mix production and as often thereafter as requested by the
Engineer.

**(2) Testing Facilities.** The Contractor shall provide laboratory
facilities at the plant for the use of the Engineer\'s acceptance
testing and the Contractor\'s quality control testing. The Engineer will
always have priority in the use of the laboratory. The lab shall have
sufficient space and equipment so that both testing representatives
(Engineer's and Contractor's) can operate efficiently. The lab shall
also meet the requirements of ASTM D 3666.

The plant testing laboratory shall have a floor space area of not less
than 150 square feet, with a ceiling height of not less than 7-½ feet.
The laboratory shall be weather tight, sufficiently heated in cold
weather, air-conditioned in hot weather to maintain temperatures for
testing purposes of 70 degrees F +/- 5 degrees F. The plant testing
laboratory shall be located on the plant site to provide an unobstructed
view, from one of its windows, of the trucks being loaded with the plant
mix materials.

Laboratory facilities shall be kept clean, and all equipment shall be
maintained in proper working condition. The Engineer shall be permitted
unrestricted access to inspect the Contractor's laboratory facility and
witness quality control activities. The Engineer will advise the
Contractor in writing of any noted deficiencies concerning the
laboratory facility, equipment, supplies, or testing personnel and
procedures. When the deficiencies are serious enough to be adversely
affecting the test results, the incorporation of the materials into the
work shall be suspended immediately and will not be permitted to resume
until the deficiencies are satisfactorily corrected.

As a minimum, the plant testing laboratory shall have:

**(a)** Adequate artificial lighting

**(b)** Electrical outlets sufficient in number and capacity for
operating the required testing equipment and drying samples.

**(c)** Fire extinguishers (2), Underwriter's Laboratories approved

**(d)** Work benches for testing, minimum 2-½ feet by 10 feet.

**(e)** Desk with 2 chairs

**(f)** Sanitary facilities convenient to testing laboratory

**(g)** Exhaust fan to outside air, minimum 12 inch blade diameter

**(h)** A direct telephone line and telephone including a FAX machine
operating 24 hours per day, seven days per week

**(i)** File cabinet with lock for Engineer

**(j)** Sink with running water, attached drain board and drain capable
of handling separate material

**(k)** Metal stand for holding washing sieves

**(l)** Two element hot plate or other comparable heating device, with
dial type thermostatic controls for drying aggregates

**(m)** Mechanical shaker and appropriate sieves (listed in JMF, Table
3) meeting the requirements of ASTM E-11 for determining the gradation
of coarse and fine aggregates in accordance with ASTM C 136

**(n)** Marshall testing equipment meeting ASTM D 6926, ASTM D 6927, or
ASTM D 5581 as necessary, automatic compaction equipment capable of
compacting three specimens at once and other apparatus as specified in
ASTM C 127, D 2172, D 2726, and D 2041

**(o)** Oven, thermostatically controlled, inside minimum 1 cubic foot

**(p)** Two volumetric specific gravity flasks, 500 CC

**(q)** Other necessary hand tools required for sampling and testing

**(r)** Library containing contract specifications, latest ASTM volumes
4.01, 4.02,4.03 and 4.09, AASHTO standard specification parts I and II,
and Asphalt Institute Publication MS-2.

**(s)** Equipment for Theoretical Specific Gravity testing including a
4,000 cc pycnometer, vacuum pump capable of maintaining 30 ml mercury
pressure and a balance, 16-20 kilograms with accuracy of 0.5 grams

**(t)** Extraction equipment, centrifuge and reflux types and ROTOflex
equipment

**(u)** A masonry saw with diamond blade for trimming pavement cores and
samples

**(v)** Telephone

Approval of the plant and testing laboratory by the Engineer requires
all facilities and equipment to be in good working order during
production, sampling and testing. Failure to provide the specified
facilities shall be sufficient cause for disapproving bituminous plant
operations.

The Owner shall have access to the lab and at the plant whenever
Contractor is producing asphalt for the project.

**(3) Inspection of Plant.** The Engineer, or Engineer\'s authorized
representative, shall have access, at all times, to all areas of the
plant for checking adequacy of equipment; inspecting operation of the
plant: verifying weights, proportions, and material properties; and
checking the temperatures maintained in the preparation of the mixtures.

**(4) Storage Bins and Surge Bins.** Use of surge bins or storage bins
for temporary storage of hot bituminous mixtures will be permitted as
follows:

**(a)** The bituminous mixture may be stored in surge bins for a period
of time not to exceed 3 hours.

**(b)** The bituminous mixture may be stored in insulated storage bins
for a period of time not to exceed 24 hours**.**

The bins shall be such that mix drawn from them meets the same
requirements as mix loaded directly into trucks.

If the Engineer determines that there is an excessive amount of heat
loss, segregation or oxidation of the mixture due to temporary storage,
no temporary storage will be allowed.

**403‑4.3 HAULING EQUIPMENT.** Trucks used for hauling bituminous
mixtures shall have tight, clean, and smooth metal beds. To prevent the
mixture from adhering to them, the truck beds shall be lightly coated
with a minimum amount of an approved asphalt release agent. Petroleum
products shall not be used for coating truck beds. Each truck shall have
a suitable cover to protect the mixture from adverse weather. When
necessary, to ensure that the mixture will be delivered to the site at
the specified temperature, truck beds shall be insulated or heated and
covers shall be securely fastened.

**403‑4.4 BITUMINOUS PAVERS.** Bituminous pavers shall be self‑propelled
with an activated heated screed, capable of spreading and finishing
courses of bituminous plant mix material that will meet the specified
thickness, smoothness, and grade. The paver shall have sufficient power
to propel itself and the hauling equipment without adversely affecting
the finished surface.

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

The paver shall be equipped with a control system capable of
automatically maintaining the specified screed elevation. The control
system shall be automatically actuated from either a reference line
and/or through a system of mechanical sensors or sensor‑directed
mechanisms or devices that will maintain the paver screed at a
predetermined transverse slope and at the proper elevation to obtain the
required surface. The transverse slope controller shall be capable of
maintaining the screed at the desired slope within plus or minus 0.1
percent.

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

**a.** Ski‑type device of not less than 30 feet (9.14 m) in length.

**b.** Taut stringline (wire) set to grade.

**c.** Short ski or shoe.

**d.** Laser control.

If, during construction, it is found that the spreading and finishing
equipment in use leaves tracks or indented areas, or produces other
blemishes in the pavement and/or base course that are not satisfactorily
corrected by the scheduled operations, the use of such equipment shall
be discontinued and satisfactory equipment shall be provided by the
Contractor.

**403‑4.5 ROLLERS.** Rollers of the vibratory, steel wheel, and
pneumatic‑tired type shall be used. They shall be in good condition,
capable of operating at slow speeds to avoid displacement of the
bituminous mixture. The number, type, and weight of rollers shall be
sufficient to compact the mixture to the required density while it is
still in a workable condition.

All rollers shall be specifically designed and suitable for compacting
hot mix bituminous concrete and shall be properly used. Rollers that
impair the stability of any layer of a pavement structure or underlying
soils shall not be used. Depressions in pavement surfaces caused by
rollers shall be repaired by the Contractor at its own expense.

The use of equipment that causes crushing of the aggregate will not be
permitted.

**a. Nuclear Densometer.** The Contractor shall have on site a nuclear
densometer during all paving operations in order to assist in the
determination of the optimum rolling pattern, type of roller and
frequencies, as well as to monitor the effect of the rolling operations
during production paving. The Contractor shall also supply a qualified
technician during all paving operations to calibrate the nuclear
densometer and obtain accurate density readings for all new bituminous
concrete. These densities shall be supplied to the Engineer upon request
at any time during construction. No separate payment will be made for
supplying the density gauge and technician.

**403‑4.6 PREPARATION OF BITUMINOUS MATERIAL.** The bituminous material
shall be heated in a manner that will avoid local overheating and
provide a continuous supply of the bituminous material to the mixer at a
uniform temperature. The temperature of the bituminous material
delivered to the mixer shall be sufficient to provide a suitable
viscosity for adequate coating of the aggregate particles, but shall not
exceed 325 degrees F (160 degrees C), unless otherwise required by the
manufacturer*.*

**403‑4.7 PREPARATION OF MINERAL AGGREGATE.** The aggregate for the
mixture shall be heated and dried prior to introduction into the mixer.
The maximum temperature and rate of heating shall be such that no damage
occurs to the aggregates. The temperature of the aggregate and mineral
filler shall not exceed 350 degrees F (175 degrees C) when the asphalt
is added. Particular care shall be taken that aggregates high in calcium
or magnesium content are not damaged by overheating. The temperature
shall not be lower than is required to obtain complete coating and
uniform distribution on the aggregate particles and to provide a mixture
of satisfactory workability.

**403‑4.8 PREPARATION OF BITUMINOUS MIXTURE.** The aggregates and the
bituminous material shall be weighed or metered and introduced into the
mixer in the amount specified by the job mix formula.

The combined materials shall be mixed until the aggregate obtains a
uniform coating of bitumen and is thoroughly distributed throughout the
mixture. Wet mixing time shall be the shortest time that will produce a
satisfactory mixture, but not less than 25 seconds for batch plants. The
wet mixing time for all plants shall be established by the Contractor,
based on the procedure for determining the percentage of coated
particles described in ASTM D 2489, for each individual plant and for
each type of aggregate used. The wet mixing time will be set to achieve
95 percent of coated particles. For continuous mix plants, the minimum
mixing time shall be determined by dividing the weight of its contents
at operating level by the weight of the mixture delivered per second by
the mixer. The moisture content of all bituminous mixtures upon
discharge shall not exceed 0.5 percent.

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> **For batch plants, wet mixing time begins with the introduction of
> bituminous material into the mixer and ends with the opening of the
> mixer discharge gate. Distribution of aggregate and bituminous
> material as they enter the pugmill, speed of mixer shafts, and
> arrangement and pitch of paddles are factors governing efficiency of
> mixing. Prolonged exposure to air and heat in the pugmill hardens the
> asphalt film on the aggregate. Mixing time, therefore, should be the
> shortest time required to obtain uniform distribution of aggregate
> sizes and thorough coating of aggregate particles with bituminous
> material.**

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**403‑4.9 PREPARATION OF THE UNDERLYING SURFACE.** Immediately before
placing the bituminous mixture, the underlying course shall be cleaned
of all dust and debris. A prime coat or tack coat shall be applied in
accordance with Item P‑602 or P‑603, if shown on the plans.

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> **Engineer should evaluate the presence of paint and rubber deposits
> on the existing pavement and, if needed, may specify milling, grinding
> or other suitable means to remove same prior to placement of new
> bituminous material.**

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**403‑4.10 LAYDOWN PLAN, TRANSPORTING, PLACING, AND FINISHING.** Prior
to the placement of the bituminous mixture, the Contractor shall prepare
a laydown plan for approval by the Engineer. This is to minimize the
number of cold joints in the pavement. The laydown plan shall include
the sequence of paving laydown by stations, width of lanes, temporary
ramp location(s), and laydown temperature. The laydown plan shall also
include estimated time of completion for each portion of the work (i.e.
milling, paving, rolling, cooling, etc.). Modifications to the laydown
plan shall be approved by the Engineer.

The bituminous mixture shall be transported from the mixing plant to the
site in vehicles conforming to the requirements of paragraph 403-4.3.
Deliveries shall be scheduled so that placing and compacting of mixture
is uniform with minimum stopping and starting of the paver. Hauling over
freshly placed material shall not be permitted until the material has
been compacted, as specified, and allowed to cool to atmospheric
temperature.

**\[**The Contractor may elect to use a material transfer vehicle to
deliver mix to the paver.**\]**

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> **Use of a material transfer vehicle allows the paver to be operated
> almost continuously without stopping between truckloads of mix, if a
> continuous supply of mix is available from the asphalt plant. The use
> of a transfer vehicle is recommended on long paving lanes.**

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Paving during nighttime construction shall require the following:

**a.** All paving machines, rollers, distribution trucks and other
vehicles required by the Contractor for his operations shall be equipped
with artificial illumination sufficient to safely complete the work.

**b.** Minimum illumination level shall be twenty (20) horizontal foot
candles and maintained in the following areas:

**(1)** An area of 30 feet wide by 30 feet long immediately behind the
paving machines during the operations of the machines.

**(2)** An area 15 feet wide by 30 feet long immediately in front and
back of all rolling equipment, during operation of the equipment.

**(3)** An area 15 feet wide by 15 feet long at any point where an area
is being tack coated prior to the placement of pavement.

**c.** As partial fulfillment of the above requirements, the Contractor
shall furnish and use, complete artificial lighting units with a minimum
capacity of 3,000 watt electric beam lights, affixed to all equipment in
such a way to direct illumination on the area under construction.

> **d.** In addition, the Contractor shall furnish \[ \] portable
> floodlight units similar or equal to \[ \].

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> **Engineer to specify the minimum number of floodlighting units and
> may elect to specify a particular manufacturer's lighting unit "or
> equal".**
>
> **If nighttime paving requires the critical re-opening of airfield
> facilities, the following additional language should be added:**
>
> **"If the Contractor places any out of specification mix in the
> project work area, the Contractor is required to remove it at its own
> expense, to the satisfaction of the Engineer. If the Contractor has to
> continue placing non-payment bituminous concrete, as directed by the
> Engineer, to make the surfaces safe for aircraft operations, the
> Contractor shall do so to the satisfaction of the Engineer. It is the
> Contractor's responsibility to leave the facilities to be paved in a
> safe condition ready for aircraft operations. No consideration for
> extended closure time of the area being paved will be given. As a
> first order of work for the next paving shift, the Contractor shall
> remove all out of specification material and replace with approved
> material to the satisfaction of the Engineer. When the above
> situations occur, there will be no consideration given for additional
> construction time or payment for extra costs."**

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The initial placement and compaction of the mixture shall occur at a
temperature suitable for obtaining density, surface smoothness, and
other specified requirements but not less than 250ºF (121ºC).

Edges of existing bituminous pavement abutting the new work shall be saw
cut and carefully removed as shown on the drawings and painted with
bituminous tack coat before new material is placed against it.

Upon arrival, the mixture shall be placed to the full width by a
bituminous paver. It shall be struck off in a uniform layer of such
depth that, when the work is completed, it shall have the required
thickness and conform to the grade and contour indicated. The speed of
the paver shall be regulated to eliminate pulling and tearing of the
bituminous mat. Unless otherwise permitted, placement of the mixture
shall begin along the centerline of a crowned section or on the high
side of areas with a one‑way slope. The mixture shall be placed in
consecutive adjacent strips having a minimum width of **\[ \]** except
where edge lanes require less width to complete the area. Additional
screed sections shall not be attached to widen paver to meet the minimum
lane width requirements specified above unless additional auger sections
are added to match. The longitudinal joint in one course shall offset
the longitudinal joint in the course immediately below by at least 1
foot (30 cm); however, the joint in the surface top course shall be at
the centerline of crowned pavements. Transverse joints in one course
shall be offset by at least 10 feet (3 m) from transverse joints in the
previous course.

Transverse joints in adjacent lanes shall be offset a minimum of 10 feet
(3 m).

On areas where irregularities or unavoidable obstacles make the use of
mechanical spreading and finishing equipment impractical, the mixture
may be spread and luted by hand tools. Areas of segregation in the
course, as determined by the Engineer, shall be removed and replaced at
the Contractor's expense. The area shall be removed by saw cutting and
milling a minimum of 2 inches deep. The area to be removed and replaced
shall be a minimum width of the paver and a minimum of 10 feet long.

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> **The Engineer should specify the widest paving lane practicable in an
> effort to hold the number of longitudinal joints to a minimum.**

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**403‑4.11 COMPACTION OF MIXTURE.** After placing, the mixture shall be
thoroughly and uniformly compacted by power rollers. The surface shall
be compacted as soon as possible when the mixture has attained
sufficient stability so that the rolling does not cause undue
displacement, cracking or shoving. The sequence of rolling operations
and the type of rollers used shall be at the discretion of the
Contractor. The speed of the roller shall, at all times, be sufficiently
slow to avoid displacement of the hot mixture and be effective in
compaction. Any displacement occurring as a result of reversing the
direction of the roller, or from any other cause, shall be corrected at
once.

Sufficient rollers shall be furnished to handle the output of the plant.
Rolling shall continue until the surface is of uniform texture, true to
grade and cross section, and the required field density is obtained.

To prevent adhesion of the mixture to the roller, the wheels shall be
equipped with a scraper and kept properly moistened using a water
soluble asphalt release agent approved by the engineer.

In areas not accessible to the roller, the mixture shall be thoroughly
compacted with approved power driven tampers. Tampers shall weigh not
less than 275 pounds, have a tamping plate width not less than 15
inches, be rated at not less than 4,200 vibrations per minute, and be
suitably equipped with a standard tamping plate wetting device.

Any mixture that becomes loose and broken, mixed with dirt, contains
check‑cracking, or in any way defective shall be removed and replaced
with fresh hot mixture and immediately compacted to conform to the
surrounding area. This work shall be done at the Contractor\'s expense.
Skin patching shall not be allowed.

**403‑4.12 JOINTS.** The formation of all joints shall be made in such a
manner as to ensure a continuous bond between the courses and obtain the
required density. All joints shall have the same texture as other
sections of the course and meet the requirements for smoothness and
grade.

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

Longitudinal joints which are irregular, damaged, uncompacted, or
otherwise defective **\[**or which have been left exposed for more than
4 hours, or whose surface temperature has cooled to less than 160^0^
F**\]** shall be cut back \[specify cutback\] to expose a clean, sound
surface for the full depth of the course. All contact surfaces shall be
cleaned and dry and given a tack coat of bituminous material prior to
placing any fresh mixture against the joint. The cost of this work and
tack coat shall be considered incidental to the cost of the bituminous
course.

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> **Engineer may retain the bracketed language regarding the treatment
> of "cold joints" when considered necessary. The cutback should be no
> more than 6 inches.**

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MATERIAL ACCEPTANCE

**403‑5.1 ACCEPTANCE SAMPLING AND TESTING.** Unless otherwise specified,
all acceptance sampling and testing necessary to determine conformance
with the requirements specified in this section will be performed by the
Engineer at no cost to the Contractor. Testing organizations performing
these tests shall meet the requirements of ASTM D 3666. All equipment in
Contractor furnished laboratories shall be calibrated by the testing
organization prior to the start of operations.

**a. Field Placed Material.** Material placed in the field shall be
tested for mat and joint density on a lot basis. A lot will consist of:

-   one day or shift's production not to exceed 2,000 tons (1 814 000
    kg), or

-   a half day or shift's production where a day\'s production is
    expected to consist of between 2,000 and 4,000 tons (1 814 000 and 3
    628 000 kg), or

-   similar subdivisions for tonnages over 4,000 tons (3 628 000 kg).

Where more than one plant is simultaneously producing material for the
job, the lot sizes shall apply separately for each plant.

**(1) Mat Density.** The lot shall be divided into four equal sublots.
One core of finished, compacted materials shall be taken by the
Contractor from each sublot. Core locations will be determined by the
Engineer on a random basis in accordance with procedures contained in
ASTM D 3665. Cores shall not be taken closer than one foot from a
transverse or longitudinal joint.

**(2) Joint Density.** The lot shall be divided into four equal sublots.
One core of finished, compacted materials shall be taken by the
Contractor from each sublot. Core locations will be determined by the
Engineer on a random basis in accordance with procedures contained in
ASTM D 3665. Edge of cores will be taken within 6 inches of the joint of
the same lot material but not directly on the joint.

**(3) Sampling.** Samples shall be neatly cut with a core drill. The
cutting edge of the core drill bit shall be of hardened steel or other
suitable material with diamond chips embedded in the metal cutting edge.
The minimum diameter of the sample shall be five inches. Samples that
are clearly defective, as a result of sampling, shall be discarded and
another sample taken. The Contractor shall furnish all tools, labor, and
materials for cutting samples, cleaning, and filling the cored pavement.
Cored pavement shall be cleaned and core holes shall be filled in a
manner acceptable to the Engineer and within one day after sampling.

**(4) Testing.** The bulk specific gravity of each cored sample will be
measured by the Engineer in accordance with ASTM D 2726 or ASTM D 1188,
whichever is applicable. The percent compaction (density) of each sample
will be determined by dividing the bulk specific gravity of each sublot
sample by the average bulk specific gravity of all laboratory prepared
specimens for the lot, as determined as follows:

**(a)** Sufficient material for preparation of test specimens for all
testing will be sampled by the Engineer on a random basis, in accordance
with the procedures contained in ASTM D 3665. One set of laboratory
compacted specimens will be prepared for each sublot in accordance with
ASTM D 6926, at the number of blows required by paragraph 403‑3.2,
Table 1. Each set of laboratory compacted specimens will consist of
three test portions prepared from the same sample increment. The sample
of bituminous mixture may be put in a covered metal tin and placed in an
oven for not less than 30 minutes or more than 60 minutes to stabilize
to compaction temperature. The compaction temperature of the specimens
shall be as specified in the job mix formula.

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> **Engineer should increase hold times to not less than 60 minutes and
> not more than 90 minutes when absorptive aggregates are used,**

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**(b)** The bulk specific gravity of each test specimen shall be
measured by the Engineer in accordance with ASTM D 2726 using the
procedure for laboratory-prepared thoroughly dry specimens, or ASTM D
1188, whichever is applicable, for use in computing pavement density.

**(c)** The bulk specific gravity used to determine the joint density at
joints formed between different lots shall be the lowest of the bulk
specific gravity values from the two different lots.

**(5) Acceptance.** Acceptance of field placed material for mat and
joint density will be determined by the Engineer in accordance with the
requirements of paragraph 403-5.2b.

**d. Partial Lots --- Field Placed Material.** When operational
conditions cause a lot to be terminated before the specified number of
tests have been made for the lot, or when the Contractor and Engineer
agree in writing to allow overages or other minor tonnage placements to
be considered as partial lots, the following procedure will be used to
adjust the lot size and the number of tests for the lot.

The last batch produced where production is halted will be sampled, and
its properties shall be considered as representative of the particular
sublot from which it was taken. In addition, an agreed to minor
placement will be sampled, and its properties shall be considered as
representative of the particular sublot from which it was taken. Where
three sublots are produced, they shall constitute a lot. Where one or
two sublots are produced, they shall be incorporated into the next lot,
and the total number of sublots shall be used in the acceptance plan
calculation, i.e., n = 5 or n = 6, for example. Partial lots at the end
of asphalt production on the project shall be included with the previous
lot.

**403‑5.2 ACCEPTANCE CRITERIA.**

**a. General.** Acceptance will be based on the following
characteristics of the bituminous mixture and completed pavement and
test results:

**(1)** Mat density

**(2)** Joint density

**(3)** Thickness

**(4)** Smoothness

**(5)** Grade

Mat density will be evaluated for acceptance in accordance with
paragraph 403-5.2b(1). Joint density will be evaluated for acceptance in
accordance with paragraph 403-5.2b(2).

Thickness will be evaluated by the Engineer for compliance in accordance
with paragraph 403-5.2b(3). Acceptance for smoothness will be based on
the criteria contained in paragraph 403-5.2b(4). Acceptance for grade
will be based on the criteria contained in paragraph 403-5.2b(5).

The Engineer may at any time, notwithstanding previous plant acceptance,
reject and require the Contractor to dispose of any batch of bituminous
mixture which is rendered unfit for use due to contamination,
segregation, incomplete coating of aggregate, or improper mix
temperature. Such rejection may be based on only visual inspection or
temperature measurements. In the event of such rejection, the Contractor
may take a representative sample of the rejected material in the
presence of the Engineer, and if it can be demonstrated in the
laboratory, in the presence of the Engineer, that such material was
erroneously rejected, payment will be made for the material at the
contract unit price.

**b. Acceptance Criteria.**

**(1) Mat Density.** Acceptance of each lot of plant produced material
for mat density shall be based on the average of all of the densities
taken from the sublots. If the average mat density of the lot so
established equals or exceeds 96 percent, the lot shall be acceptable.
If the average mat density of the lot is below 96 percent, the lot shall
be removed and replaced at the Contractor's expense.

**(2) Joint Density.** Acceptance of each lot of plant produced material
for joint density shall be based on the average of all of the joint
densities taken from the sublots. If the average joint density of the
lot so established equals or exceeds 94 percent, the lot shall be
acceptable. If the average joint density of the lot is less than 94
percent, the Contractor shall stop production and evaluate the method of
compacting joints. Production may resume once the reason for poor
compaction has been determined and appropriate measures have been taken
to ensure proper compaction.

**(3) Thickness.** Thickness of each course shall be evaluated by the
Engineer for compliance to the requirements shown on the plans.
Measurements of thickness shall be made by the Engineer using the cores
extracted for each sublot for density measurement. The maximum allowable
deficiency at any point shall not be more than ¼ inch less than the
thickness indicated for the lift. Average thickness of lift, or combined
lifts, shall not be less than the indicated thickness. Where thickness
deficiency exceeds the specified tolerances, the lot or sublot shall be
corrected by the Contractor at his expense by removing the deficient
area and replacing with new pavement. The Contractor, at his expense,
may take additional cores as approved by the Engineer to circumscribe
the deficient area.

**(4) Smoothness.** The final surface shall be free from roller marks.
The finished surfaces of each course of the pavement, except the
finished surface of the final surface course, shall not vary more than ⅜
inch when evaluated with a 16 foot straightedge. The finished surface of
the final surface course shall not vary more than ¼ inch when evaluated
with a 16 foot straightedge. The lot size shall be \[ \] square yards
(square meters). Smoothness measurements shall be made at 50 foot
intervals and as determined by the Engineer. In the longitudinal
direction, a smoothness reading shall be made at the center of each
paving lane. In the transverse direction, smoothness readings shall be
made continuously across the full width of the pavement. However,
transverse smoothness readings shall not be made across designed grade
changes. At warped transition areas, straightedge position shall be
adjusted to measure surface smoothness and not design grade transitions.
When more than 15 percent of all measurements within a lot exceed the
specified tolerance, the Contractor shall remove the deficient area to
the depth of the course of pavement and replace with new material. Skin
patching shall not be permitted. Isolated high points may be ground off
providing the course thickness complies with the thickness specified on
the plans. High point grinding will be limited to 15 square yards. Areas
in excess of 15 square yards will require removal and replacement of the
course in accordance with the limitations noted above.

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> **The Engineer shall specify the lot size. A minimum of 2,000 square
> yards (1 650 square meters) is recommended.**

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**(5) Grade.** The finished surface of the pavement shall not vary from
the gradeline elevations and cross sections shown on the plans by more
than ½ inch (12.70 mm). The finished grade of each lot will be
determined by running levels at intervals of 50 feet (15.2 m) or less
longitudinally and all breaks in grade transversely (not to exceed 50
feet) to determine the elevation of the completed pavement. The
Contractor shall pay the cost of surveying of the level runs that shall
be performed by a licensed surveyor. The documentation, stamped and
signed by a licensed surveyor, shall be provided by the Contractor to
the Engineer. The lot size shall be \[ \] square yards (square meters).
When more than 15 percent of all the measurements within a lot are
outside the specified tolerance, or if any one shot within the lot
deviates ¾ inch or more from planned grade, the Contractor shall remove
the deficient area to the depth of the final course of pavement and
replace with new material. Skin patching shall not be permitted.
Isolated high points may be ground off providing the course thickness
complies with the thickness specified on the plans. High point grinding
will be limited to 15 square yards. The surface of the ground pavement
shall have a texture consisting of grooves between 0.090 and 0.130
inches wide. The peaks and ridges shall be approximately 1/32 inch
higher than the bottom of the grooves. The pavement shall be left in a
clean condition. The removal of all of the slurry resulting form the
grinding operation shall be continuous. The grinding operation should be
controlled so the residue from the operation does not flow across other
lanes of pavement. Areas in excess of 15 square yards will require
removal and replacement of the pavement in accordance with the
limitations noted above.

**c. Density Outliers.** If the tests within a lot include a very large
or a very small value that appears to be outside the normal limits of
variation, check for an outlier in accordance with ASTM E 178, at a
significance level of 5 percent, to determine if this value should be
discarded.

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> **A minimum of 2,000 square yards (1,650 square meters) is
> recommended.**

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**403‑5.3 RESAMPLING PAVEMENT FOR MAT DENSITY.**

**a. General.** Resampling of a lot of pavement will only be allowed for
mat density and then, only if the Contractor requests same in writing,
within 48 hours after receiving the written test results from the
Engineer. A retest will consist of all the sampling and testing
procedures contained in paragraphs 403‑5.1b(1). Only one resampling per
lot will be permitted.

**(1)** A redefined mat density shall be calculated for the resampled
lot. The number of tests used to calculate the redefined mat density
shall include the initial tests made for that lot plus the retests.

**(2)** The cost for resampling and retesting shall be borne by the
Contractor.

**b. Payment for Resampled Lots.** The redefined mat density for a
resampled lot shall be used to evaluate the acceptance of that lot in
accordance with Paragraph 403-5.2.

**\[403‑5.4 LEVELING COURSE.** Any course used for truing and leveling
shall meet the requirements of paragraph 403‑3.2, but shall not be
subject to the density requirements of paragraph 403-5.1. The leveling
course shall be compacted with the same effort used to achieve density
of the test section. The truing and leveling course shall not exceed a
nominal thickness of 1‑½ inches (37.5 mm). The leveling course is the
first variable thickness lift of an overlay placed prior to subsequent
courses.**\]**

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> **Use this paragraph only when there is a need to restore proper
> cross‑section prior to overlaying. Areas of the pavement requiring a
> leveling course shall be shown on the plans.**

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Contractor QUALITY CONTROL

**403‑6.1 GENERAL.** The Contractor shall perform quality control
sampling, testing, and inspection during all phases of the work and
shall perform them at a rate sufficient to ensure that the work conforms
to the contract requirements, and at minimum test frequencies required
by paragraph 403-6.3, including but not limited to:

**a.** Mix Design

**b.** Aggregate Grading

**c.** Quality of Materials

**d.** Stockpile Management

**e.** Proportioning

**f.** Mixing and Transportation

**g.** Placing and Finishing

**h.** Joints

**i.** Compaction

**j.** Surface smoothness

**403‑6.2 TESTING LABORATORY.** The Contractor shall provide a fully
equipped asphalt laboratory meeting the requirements of paragraph
403-3.5 and 403-4.2a(2) located at the plant or job site. The Contractor
shall provide the Engineer with certification stating that all of the
testing equipment to be used is properly calibrated and will meet the
specifications applicable for the specified test procedures.

**403‑6.3 QUALITY CONTROL TESTING.** The Contractor shall perform all
quality control tests necessary to control the production and
construction processes applicable to these specifications and as set
forth in the approved Quality Control Program. The testing program shall
include, but not necessarily be limited to, tests for the control of
asphalt content, aggregate gradation, temperatures, aggregate moisture,
field compaction, and surface smoothness.

**a. Asphalt Content.** A minimum of two tests shall be performed per
lot in accordance with ASTM D 2172 for determination of asphalt content.
The weight of ash portion of the test, as described in ASTM D 2172,
shall be determined as part of the first test performed at the beginning
of plant production; and as part of every tenth test performed
thereafter, for the duration of plant production. The last weight of ash
value obtained shall be used in the calculation of the asphalt content
for the mixture. The asphalt content for the lot will be determined by
averaging the test results.

The use of the nuclear method for determining asphalt content in
accordance with ASTM D 4125 is permitted, provided that it is calibrated
for the specific mix being used.

**b. Gradation.** Aggregate gradations shall be determined a minimum of
twice per lot from mechanical analysis of extracted aggregate in
accordance with ASTM D 5444 and ASTM C 136 (Dry Sieve). When asphalt
content is determined by the nuclear method, aggregate gradation shall
be determined from hot bin samples on batch plants, or from the cold
feed on drum mix or continuous mix plants, and tested in accordance with
ASTM C 136 (dry sieve) using actual batch weights to determine the
combined aggregate gradation of the mixture.

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

**d. Moisture Content of Mixture.** The moisture content of the mixture
shall be determined once per lot in accordance with ASTM D 1461 **\[**or
AASHTO T110**\]**.

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\* \* \* \* \* \* \* \* \* \* \* \* \* \***

> **ASTM D 1461 may be replaced with an AASHTO moisture content testing
> procedure using a conventional oven or microwave. The frequency can
> also change in the specification depending on the probability of
> incurring a moisture problem.**

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**e. Temperatures.** Temperatures shall be checked, at least four times
per lot, at necessary locations to determine the temperatures of the
dryer, the bitumen in the storage tank, the mixture at the plant, and
the mixture at the job site.

**f. In‑Place Density Monitoring.** The Contractor shall conduct any
necessary testing to ensure that the specified density is being
achieved. A nuclear gauge may be used to monitor the pavement density in
accordance with ASTM D 2950.

**g. Additional Testing.** Any additional testing that the Contractor
deems necessary to control the process may be performed at the
Contractor\'s option.

**h. Monitoring.** The Engineer reserves the right to monitor any or all
of the above testing.

**403‑6.4 SAMPLING.** When directed by the Engineer, the Contractor
shall sample and test any material that appears inconsistent with
similar material being sampled, unless such material is voluntarily
removed and replaced or deficiencies corrected by the Contractor. All
sampling shall be in accordance with standard procedures specified.

**403‑6.5 CONTROL CHARTS.** The Contractor shall maintain linear control
charts both for individual measurements and range (i.e., difference
between highest and lowest measurements) for aggregate gradation and
asphalt content.

Control charts shall be posted in a location satisfactory to the
Engineer and shall be kept current. As a minimum, the control charts
shall identify the project number, the contract item number, the test
number, each test parameter, the Action and Suspension Limits applicable
to each test parameter, and the Contractor\'s test results. The
Contractor shall use the control charts as part of a process control
system for identifying potential problems and assignable causes before
they occur. If the Contractor\'s projected data during production
indicates a problem and the Contractor is not taking satisfactory
corrective action, the Engineer may suspend production or acceptance of
the material.

**a. Individual Measurements.** Control charts for individual
measurements shall be established to maintain process control within
tolerance for aggregate gradation and asphalt content. The control
charts shall use the job mix formula target values as indicators of
central tendency for the following test parameters with associated
Action and Suspension Limits:

  --------------------------- --------------------- ---------------------
  **CONTROL CHART LIMITS FOR                        
  INDIVIDUAL MEASUREMENTS**                         

  Sieve                       Action Limit          Suspension Limit

  ¾ inch (19.0 mm)            0%                    0%

  ½ inch (12.5 mm)            +/‑6%                 +/‑9%

  ⅜ inch (9.5 mm)             +/‑6%                 +/‑9%

  No. 4 (4.75 mm)             +/‑6%                 +/‑9%

  No. 16 (1.18 mm)            +/‑5%                 +/‑7.5%

  No. 50 (0.30 mm)            +/‑3%                 +/‑4.5%

  No. 200 (0.075 mm)          +/‑2%                 +/‑3%

  Asphalt Content             +/‑0.45%              +/‑0.70%
  --------------------------- --------------------- ---------------------

**b. Range.** Control charts for range shall be established to control
process variability for the test parameters and Suspension Limits listed
below. The range shall be computed for each lot as the difference
between the two test results for each control parameter. The Suspension
Limits specified below are based on a sample size of n = 2. Should the
Contractor elect to perform more than two tests per lot, the Suspension
Limits shall be adjusted by multiplying the Suspension Limit by 1.18 for
n = 3 and by 1.27 for n = 4.

+-------------------------------------+--------------------------------+
| **CONTROL CHART LIMITS BASED ON     |                                |
| RANGE**                             |                                |
|                                     |                                |
| **(Based on n = 2)**                |                                |
+-------------------------------------+--------------------------------+
| Sieve                               | Suspension Limit               |
+-------------------------------------+--------------------------------+
| ½ inch (12.5 mm)                    | 11 percent                     |
+-------------------------------------+--------------------------------+
| ⅜ inch (9.5 mm)                     | 11 percent                     |
+-------------------------------------+--------------------------------+
| No. 4 (4.75 mm)                     | 11 percent                     |
+-------------------------------------+--------------------------------+
| No. 16 (1.18 mm)                    | 9 percent                      |
+-------------------------------------+--------------------------------+
| No. 50 (0.30 mm)                    | 6 percent                      |
+-------------------------------------+--------------------------------+
| No. 200 (0.075 mm)                  | 3.5 percent                    |
+-------------------------------------+--------------------------------+
| Asphalt Content                     | 0.8 percent                    |
+-------------------------------------+--------------------------------+

**c. Corrective Action.** The Contractor Quality Control Program shall
indicate that appropriate action shall be taken when the process is
believed to be out of tolerance. The Plan shall contain sets of rules to
gauge when a process is out of control and detail what action will be
taken to bring the process into control. As a minimum, a process shall
be deemed out of control and production stopped and corrective action
taken, if:

**(1)** One point falls outside the Suspension Limit line for individual
measurements or range; or

**(2)** Two points in a row fall outside the Action Limit line for
individual measurements.

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> **The aggregate control chart parameters and Suspension and Action
> Limits contained in the above** **paragraphs are based on ¾ inch (19.0
> mm) maximum size aggregate gradation. When 1‑inch (25.0 mm) or 1‑¼
> inch (31.2 mm) maximum size aggregate greater than ¾\" is specified,
> the Individual Measurements Chart requirements should be amended as
> follows:**

  ----------------------------- ----------------- -----------------------
  **Sieve**                     **Action Limit**  **Suspension Limit**

  **1 inch or greater or 1‑½    **0%**            **0%**
  inch**                                          

  **¾ inch**                    **26%**           **11%**
  ----------------------------- ----------------- -----------------------

> **When ½‑inch (12.5 mm) maximum size aggregate is specified, the
> ¾-inch (19.0 mm) and 1‑inch (25.0 mm) sieves should be deleted from
> the Individual Measurements Chart and the ½‑inch (12.5 mm) sieve
> Action and Suspension Limits should be changed to 0%. For the ½‑inch
> (12.5 mm) gradation, the ½‑inch sieve should be deleted from the Range
> Chart.**

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**403-6.6 QUALITY CONTROL REPORTS.** The Contractor shall maintain
records and shall submit reports of quality control activities daily.

METHOD OF MEASUREMENT

**403‑7.1 MEASUREMENT.** Plant mix bituminous concrete pavement shall be
measured by the number of tons (kg) of bituminous mixture used in the
accepted work. Recorded batch weights or truck scale weights will be
used to determine the basis for the tonnage.

BASIS OF PAYMENT

**403‑8.1 PAYMENT.** Payment for an accepted lot of bituminous concrete
pavement shall be made at the contract unit price per ton (kg) for
bituminous mixture**.** The price shall be compensation for furnishing
all materials, for all preparation, mixing, and placing of these
materials, and for all labor, equipment, tools, and incidentals
necessary to complete the item.

Payment will be made under:

> Item P‑403‑8.1a Bituminous **\[ \] \[**Surface**\] \[**Base**\]
> \[**Binder**\] \[**Leveling**\]** Course

---per ton (kg)

TESTING REQUIREMENTS

> ASTM C 29 Bulk Density ("Unit Weight") and Voids in Aggregate
>
> ASTM C 88 Soundness of Aggregates by Use of Sodium Sulfate or
> Magnesium Sulfate
>
> ASTM C 117 Materials Finer than 75μm (No.200) Sieve in Mineral
> Aggregates by Washing
>
> ASTM C 127 Specific Gravity and Absorption of Coarse 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 C 566 Total Evaporable Moisture Content of Aggregate by Drying
>
> ASTM D 75 Sampling Aggregates
>
> ASTM D 979 Sampling Bituminous Paving Mixtures
>
> ASTM D 995 Mixing Plants for Hot‑Mixed Hot‑Laid Bituminous Paving
> Mixtures
>
> ASTM D 1073 Fine Aggregate for Bituminous Paving Mixtures
>
> ASTM D 1074 Compressive Strength of Bituminous Mixtures
>
> ASTM D 1188 Bulk Specific Gravity and Density of Compacted Bituminous
> Mixtures Using Paraffin‑Coated Specimens
>
> ASTM D 1461 Moisture or Volatile Distillates in Bituminous Paving
> Mixtures
>
> ASTM D 2041 Theoretical Maximum Specific Gravity and Density of
> Bituminous Paving Mixtures
>
> ASTM D 2172 Quantitative Extraction of Bitumen from Bituminous Paving
> Mixtures
>
> ASTM D 2419 Sand Equivalent Value of Soils and Fine Aggregate
>
> ASTM D 2489 Estimating Degree of Particle Coating of
> Bituminous‑Aggregate Mixtures
>
> ASTM D 2726 Bulk Specific Gravity and Density of Non-Absorptive
> Compacted Bituminous Mixtures
>
> ASTM D 2950 Density of Bituminous Concrete in Place by Nuclear Methods
>
> ASTM D 3203 Percent Air Voids in Compacted Dense and Open Bituminous
> Paving Mixtures
>
> ASTM D 3665 Random Sampling of Construction Materials
>
> ASTM D 3666 Minimum Requirements for Agencies Testing and Inspecting
> Road and Paving Materials
>
> ASTM D 4125 Asphalt Content of Bituminous Mixtures by the Nuclear
> Method
>
> ASTM D 4318 Liquid Limit, Plastic Limit, and Plasticity Index of Soils
>
> ASTM D 4791 Flat Particles***,*** Elongated Particles***,*** or Flat
> and Elongated Particles in Coarse Aggregate
>
> ASTM D 4867 Effect of Moisture on Asphalt Concrete Paving Mixtures
>
> ASTM D 5444 Mechanical Size Analysis of Extracted Aggregate
>
> ASTM D 5581 Resistance to Plastic Flow of Bituminous Mixtures Using
> Marshall Apparatus (6\" Diameter Specimen)
>
> ASTM D 6926 Preparation of Bituminous Specimens Using MARSHALL
> Apparatus
>
> ASTM D 6927 MARSHALL Stability and Flow of Bituminous Mixtures
>
> ASTM E 11 Wire-Cloth Sieves for Testing Purposes
>
> ASTM E 178 Dealing with Outlying Observations
>
> AASHTO T 30 Mechanical Analysis of Extracted Aggregate
>
> **\[**AASHTO T 110 Moisture or Volatile Distillates in Bituminous
> Paving Mixtures**\]**

The Asphalt Institute\'s Mix Design Methods for Asphalt Concrete

Manual No. 2 (MS‑2)

MATERIAL REQUIREMENTS

> ASTM D 242 Mineral Filler for Bituminous Paving Mixtures
>
> ASTM D 946 Penetration Graded Asphalt Cement for Use in Pavement
> Construction
>
> ASTM D 3381 Viscosity‑Graded Asphalt Cement for Use in Pavement
> Construction
>
> ASTM D 4552 Classifying Hot‑Mix Recycling Agents
>
> AASHTO MP1 Performance Graded Binder Designation

**END OF ITEM P‑403**