Section 402 — Asphalt Concrete Pavement By Hveem or Marshall Mix Design Method

MARSHALL MIX DESIGN METHOD

Description

402.01This work consists of constructing asphalt concrete pavement using HMA or WMA.

Material

402.02Conform to the following Subsections: Antistrip additive 702.05 Asphalt binder 702.01 Asphalt concrete aggregate 703.07 Mineral filler 725.05

Construction Requirements

402.03Composition of Mix (Job -Mix Formula). Provide asphalt concrete mixes of aggregate, asphalt binder, RAP, and additives that meet the applicable aggregate gradation in Table 703-3 and design parameters (a), (c), and (d) or (b), (c), and (d) in Table 402-1 for the class of mix listed in the bid schedule. Apply asphalt concrete mix design requirements for HMA to the development of the WMA mix design. Provide modifications to the process required for WMA technology. S ubmit modifications to the asphalt concrete mix design process according to Appendix X.2 of AASHTO R 35 for approval. Table 402-1

Asphalt Concrete Mix Requirements

Design Parameters Class of Mix

A B C

(a)Hveem (AASHTO T 246 and AASHTO T 247) Percent air voids(1) 3.0 to 5.0 3.0 to 5.0 3.0 to 5.0 Stabilometer, minimum 37 35 30 VMA, minimum, % See Table 402 -2

(b)Marshall (AASHTO T 245) Percent air voids(1) 3.0 to 5.0 3.0 to 5.0 3.0 to 5.0

Compaction, number of blows each end

of test specimen 75 50 50 Stability, pounds minimum 2000 1500 1000 Flow, 0.01 inch 8 to 14 8 to 16 8 to 20 VMA, minimum, % See Table 402 -2

(c)Moisture Susceptibility (AASHTO T 283)(2) Tensile strength ratio, minimum 0.80 0.80 0.80

(d)Dust- to-binder ratio(3) 0.8 to 1.6 0.8 to 1.6 0.8 to 1.6

(1)The percent of air voids is based on AASHTO T 166, AASHTO T 209, and AASHTO T 269. Maximum specific gravity (density) is based on AASHTO T 209.

(2)Use 4 -inch diameter specimens. AASHTO T 283 requires a freeze- thaw cycle.

(3)Dust -to-binder ratio is the percent of material including lime, bag -house fines, and other mineral matter added to the mi xture. Calculate the ratio using the effective asphalt content calculated by mass of mix. Table 402-2 Voids in Mineral Aggregate Hveem or Marshall Mix Design Sieve Size(1) VMA, Minimum, Percent(2),(3)

Hveem Marshall

No. 4 16.0 to 19.0 18.0 to 21.0 ⅜ in 14.0 to 17.0 16.0 to 19.0 ½ in 13.0 to 16.0 15.0 to 18.0 ¾ in 12.0 to 15.0 14.0 to 17.0 1 in 11.0 to 14.0 13.0 to 16.0

(1)The largest sieve size listed in the applicable specification upon which material is allowed to be retained.

(2)Determine VMA according to AASHTO R 35 .

(3)If mineral filler or hydrated lime is used, include in the calculation for compliance with the VMA.

(a)RAP. Conform to Subsection 401.03(a) .

(b)Baghouse fines. Conform to Subsection 401.03(b) . 336 (c) Antistrip additive. Conform to Subsection 401.03(c) .

(d)Submittals. Submit written JMFs and associated material with Form FHWA 1607, Worksheet For A Hveem Mix Design AASHTO T 246 or Form FHWA 1622, Worksheet For A Marshall Mix Design AASHTO T 245 for verification at least 30 days before the control strip. Include a signed statement prepared by the testing laboratory that certifies the proposed JMF meets the requirements and can be compacted in the field during production. For each proposed JMF, submit the following:

(1)Aggregate and mineral filler. Conform to Subsection 401.03(d)(1) .

(2)Asphalt binder. Conform to Subsection 401.03(d)(2) .

(3)Antistrip additives. Conform to Subsection 401.03(d)(3) .

(4)RAP. Conform to Subsection 401.03(d)(4) .

(5)WMA technology and additive information. Conform to Subsection 401.03(d)(5).

(e)Verification. The verification process starts when required documentation and material have been received. After the JMF is verified, start asphalt concrete mix production for the control strip.

(1)Aggregate gradations. Conform to Subsection 401.03(e)(1) .

(2)RAP asphalt binder content and gradation. Conform to Subsection 401.03(e)(2) .

(3)Bulk specific gravity of aggregate (G sb). Conform to Subsection 401.03(e)(3) .

(4)Hveem stabilometer value. The Hveem stabilometer value is verified if the CO’s result is above the minimum specification limit in Table 402-1.

(5)Marshall stability and flow value. The Marshall stability and flow values are verified if the CO’s results meet the requirements in Table 402-1.

(6)Air voids (V a). Conform to Subsection 401.03(e)(6) .

(7)TSR. Conform to Subsection 401.03(e)(7) .

(8)VMA. The VMA result is verified if the CO’s result is within the specification limit in Table 402-2.

(f)Changes and resubmissions. Conform to Subsection 401.03(f) .

402.04Mixing Plant. Conform to Subsection 401.04.

402.05Equipment. Conform to Subsection 401.05.

402.06Surface Preparation. Conform to Subsection 401.06.

402.07Weather Limitations. Con form to Subsection 401.07 .

402.08Asphalt Preparation. Conform to Subsection 401.08.

402.09Aggregate Preparation. Conform to Subsection 401.09.

402.10Mixing. Conform to Subsection 401.10.

402.11Hauling. Conform to Subsection 401.11.

402.12Production Start- Up Procedures.

(a)Preparatory phase meeting. Conduct a pre -paving preparatory phase meeting according to Subsection 153.06(a) at least 3 days before the start of paving operations . Be prepared to discuss and provide the following:

(1)Calibration certification for the Hveem or Marshall compactor. If the Hveem or Marshall compactor is moved, recalibrate; and

(2)Asphalt and aggregate correction factors according to AASHTO T 308 and AASHTO T 30 on Form FHWA 1640, Worksheet for Ignition Furnace Binder Correction Factor AASHTO T 308. If RAP is included as part of the JMF, provide the asphalt and aggregate correction factors according to AASHTO T 30 and the FLH Addendum to AASHTO T 308 on Form FHWA 1648, Worksheet For Ignition Furnace Binder Correction Factor And Aggregate Gradation Correction Factor For Mixes Including RAP .

(b)Control strip. Provide at least 7 days’ notice before starting production of an asphalt concrete mix. On the first day of production, produce sufficient asphalt concrete mix to construct a 1000-foot-long control strip, one -lane wide, and at the designated lift thickness. Construct the control strip on the project at an approved location. Construct the control strip using asphalt concrete mix production, lay- down, and compaction procedures intended for the entire mix. Construct a control strip for each equipment combination and each plant from which production is intended. Stop production after construction of the control strip until asphalt concrete mix and the control strip are accepted. Acceptance will be based on the following:

(1)Mixture. Take and test at least three control strip asphalt concrete mix samples and evaluate according to Subsection 402.17. The asphalt concrete mix is acceptable if all test results are within specification limits for gradation and asphalt content and the calculated pay factor for gradation and asphalt content is 0.90 or greater.

(2)Compaction. Compact according to Subsection 401.14. Take nuclear density gauge readings behind each roller pass to determine the roller pattern necessary to achieve required density. Use Form FHWA 1646, Asphalt Control St rip Worksheet . Document if roller was operated in vibratory or static mode. Provide frequency and amplitude settings if operated in vibratory mode. Submit documentation after completion of the control strip. Take nuclear gauge density readings and cut core samples according to Table 402-3. Density is acceptable if the calculated pay factor is 0.90 or greater. Provide the CO with documented nuclear gauge readings correlated to core specific gravities. 338 (3) Control strip mat defects. Cont rol strips that exhibit physical or visual defects may be rejected. Defects include tearing, cracking, rutting, shoving, segregation, bleeding, excessive pavement roughness, and poor joints. Repeat the control strip process until an acceptable control strip is produced. Conform to Subsection 106.01 for the disposition of material in rejected control strips. Accepted control strips may remain in place and will be accepted and measured as a part of the completed pavement. Test s used for the control strip will not be included in the evaluation for payment according to Subsection 106.05. After a control strip is verified and accepted, full production may start. Use start -up procedures if resuming production after a termination of production due to unsatisfactory quality according to Subsection 106.05.

402.13Placing and Finishing. Conform to Subsection 401.13.

402.14Compacting. C onform to Subsection 401.14.

402.15Joints, Trimming Edges, and Cleanup. Conform to Subsection 401.15.

402.16Pavement Roughness. Conform to Subsection 401.16.

402.17Acceptance. See Table 402-3 for sampling, testing, and acceptance requirements. Aggregate quality properties will be evaluated under Subsec tions 106.02 and 106.04. Mineral filler, antistrip additives, and WMA additives will be evaluated under Subsections 106.02 and 106.03. Asphalt content, core density, and aggregate gradation will be evaluated under Subsection 106.05. Pavement roughness will be evaluated under Subsection 106.04. Asphalt binder will be evaluat ed under Subsections 106.03 and 106.04. Evaluations will consider the following:

(a)Asphalt content. The upper and lower specification limits are the approved JMF target value ±0.4 percent;

(b)Density (core). The lower specification limit is 91.0 percent of the maximum specific gravity (density) determined according to AASHTO T 166 and AASHTO T 209. The percent compaction will be determined using the average maximum specific gravity (AASHTO T 209) from all samples tested the day the core was obtained;

(c)Aggregate gradation. The upper and lower specification limits are the approved JMF target values plus or minus the allowable deviations shown in Table 703-2 ;

(d)Pavement roughnes s. The evaluation for payment will be made after defective areas are addressed. Conform to Subsection 401.18(d) ; and

(e)Asphalt binder. The pay factor is determined from Table 401-5. Construction of HMA and WMA pavement courses will be evaluated under Subsections 106.02 and 106.04.

Measurement

402.18Measure the Section 402 pay items lis ted in the bid schedule according to Subsection 109.02 .

Payment

402.19The accepted quantities will be paid at the contract price per unit of measurement for the Section 402 pay items liste d in the bid schedule, except the asphalt concrete pavement contract price will be adjusted according to Subsections 106.05, 402.17(d) and (e). Payment will be full compensation for the work prescribed in this Section. See Subsection 109.05. Payment will be adjusted according to the following:

(a)Asphalt concrete pavement. Payment for asphalt concrete pavement will b e made at a price determined by multiplying the contract price by the material pay factor for each lot. The material pay factor is calculated as follows: PFmaterial = 1 + [(PF Volumetric – 1) + (PF PG – 1)] where: PFmaterial = Material pay factor. PFVolumetric = Pay factor for asphalt concrete pavement. PF Volumetric is the lowest single pay factor determined for asphalt binder content, VMA, and core density. PFPG = Pay factor for asphalt binder. The PF PG formula is as follows: 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 =(𝑃𝑃𝑃𝑃1 + 𝑃𝑃𝑃𝑃2 + 𝑃𝑃𝑃𝑃3 + … .𝑃𝑃𝑃𝑃𝑛𝑛) 𝑛𝑛 where: PF# = For each sample, the lowest pay factor determined from any test in Table 401-5. If the lowest pay factor for a sample is in reject, the sample’s pay factor is zero. n = Number of samples tested. If either the pay factor for the asphalt binder (PF PG) or the pay factor for asphalt concrete pavement (PF Volumetric ) is below 0.75, the lot for asphalt concrete pavement is in reject.

(b)Pavement roughness. If the contract specifies a pavement roughness Type I, Type II, or Type III, a separate pay adjustment will be made for pavement roughness calculated as follows: Type I, Type II, or Type III Pay Adjustment = (RF)(PF rough - 1.00)(L) – (LRPR) where: PFrough = Pay factor from Tables 401-6, 401-7, or 401-8. L = Total project length in lane miles. 340 LRPR = Localized roughness pay reduction. Each area of localized roughness more than the localized roughness threshold MRI specified for the designated pavement roughness type will receive a reduction in payment according to Table 401-9. RF = Roughness factor: 100,000. For Type I and Type II pavement roughness, the localized roughness threshold computed to the nearest whole number is equal to the following: Type I Localized Roughness Threshold = Initial Overall MRI + 1.881(S 25) Type II Localized Roughness Threshold = Initial Overall MRI + 1.282(S 25) where: Initial Overall MRI = MRI obtained before construction activities start. S25 = sample standard deviation of the 25- foot fixed interval MRI values. The overall percent improvement in MR I will be determined to one decimal place for the traveled way according to the following formula: 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑛𝑛𝑓𝑓 𝐼𝐼𝐼𝐼𝐼𝐼𝑃𝑃𝑇𝑇𝐼𝐼𝑃𝑃𝐼𝐼𝑃𝑃𝑛𝑛𝑓𝑓 = �(𝐼𝐼𝑛𝑛𝐼𝐼𝑓𝑓𝐼𝐼𝐼𝐼𝐼𝐼 𝑂𝑂𝐼𝐼𝑃𝑃𝑃𝑃𝐼𝐼𝐼𝐼𝐼𝐼 𝑀𝑀𝑅𝑅𝐼𝐼 – 𝑃𝑃𝐼𝐼𝑛𝑛𝐼𝐼𝐼𝐼 𝑂𝑂𝐼𝐼𝑃𝑃𝑃𝑃𝐼𝐼𝐼𝐼𝐼𝐼 𝑀𝑀𝑅𝑅𝐼𝐼 ) 𝐼𝐼𝑛𝑛𝐼𝐼𝑓𝑓𝐼𝐼𝐼𝐼𝐼𝐼 𝑂𝑂𝐼𝐼𝑃𝑃𝑃𝑃𝐼𝐼𝐼𝐼𝐼𝐼 𝑀𝑀𝑅𝑅𝐼𝐼�× 100 For Type I pavement roughness, Table 401-6 will be used to determine the final pay factor (PF rough) for the traveled way to two decimal places. If the percent improvement is less than 25.0 percent and the final overall MRI value is le ss than or equal to 70.0 inches per mile, Type III -A from Table 401 -8 will be used to determine the final PF rough. For Type II pavement roughness, Table 401 -7 will be used to determine the final PF rough for the traveled way to two decimal places. If the percent improvement is less than 49.0 percent and the final overall MRI value is less than or equal to 70.0 inches per mile, Type III -A from Table 401-8 will be used to determine the final PF rough. For Type III pavement roughness, pay factors from Table 401-8 will be used in conjunction with the long continuous histogram printout from ProVAL’s Smoothness Assuran ce Analysis function and by utilizing a long continuous 528- foot segment length for analysis. The localized roughness threshold for Type III pavement roughness is 140 inches per mile. The final PF rough is equal to the sum of the products of the individual pay factors shown in Table 401 -8 multiplied by the ratio of individual lane miles to the overall project lane miles and by ProVAL’s corresponding histogram percentages, divided by 100. The final PF rough will be determined to three decimal places. For Type IV pavement roughness, each defective area as determined by a 10- foot metal straightedge will receive a reduction in payment according to Table 401-9. Table 402-3 Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection) Type of

Acceptance

(Subsection) Characteristic Category Test Method s

Specifications Sampling

Frequency Point of

Sampling Split

Sample Reporting

Time Remarks

Source

Asphalt

concrete aggregate (703.07 ) Measured & tested for conformance (106.04 & 105) Aggregate quality − Subsection

703.071 per type & source of material Source of material Yes Before producing Not required if using

Government-

furnished source

Asphalt

binder (702.01 ) Measured & tested for conformance (106.04 ) Quality − AASHTO M 320 1 per type & source of material Asphalt supplier or mixing plant Yes Before producing −

Asphalt

concrete aggregate (703.07 ) Process control (153.03 ) Gradation − AASHTO T 27& T 11 2 per day per stockpile Crusher belt (during production) No 24 hours Not required if using a pre -crushed commercial source Table 402- 3 (continued) Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection) Type of

Acceptance

(Subsection) Characteristic Category Test Methods

Specifications Sampling

Frequency Point of

Sampling Split

Sample Reporting

Time Remarks

Mix Design

Asphalt

concrete mixture Measured & tested for conformance (106.04 ) Gradation − AASHTO T 27 & T 11 1 per submitted mix design Stockpiles Yes 30 days before paving −

RAP asphalt

binder content − AASHTO T 308 " " " " −

RAP asphalt

gradation − AASHTO T 30 " " " " Dry gradation, no binder removed

Bulk specific

gravity of aggregate (coarse & fine) − AASHTO T 84 & T 85 " " " " − VMA − AASHTO R 35 " − " " − VFA − " " − " " − Air voids − AASHTO T 269 " − " " −

Hveem

S-value − AASHTO T 246 & T 247 " − " " Required only for

Hveem

mix

Marshall

stability & flow − AASHTO T 245 " − " " Required only for

Marshall

mix

Tensile

strength ratio − AASHTO T 283 " − " " − Table 402- 3 (continued) Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection) Type of

Acceptance

(Subsection) Characteristic Category Test Methods

Specifications Sampling

Frequency Point of

Sampling Split

Sample Reporting

Time Remarks

Production Start -up (control strip)

Asphalt

concrete pavement Statistical (106.05 ) Gradation:

AASHTO

T 30 3 minimum Behind the paver before compaction Yes 6 hours − ½ in I No. 4 I No. 30 I No. 200 I

Other

specified sieves II

Asphalt

content(1) I AASHTO T 308 " " " " − Density(2) I AASHTO T 166 5 minimum In-place after compacting " 24 hours Deliver core to the CO Table 402- 3 (continued) Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection) Type of

Acceptance

(Subsection) Characteristic Category Test Methods

Specifications Sampling

Frequency Point of

Sampling Split

Sample Reporting

Time Remarks

Production Start -up (control strip)

Asphalt

concrete pavement Measured & tested for conformance (106.04 ) Maximum specific gravity(4) − AASHTO T 209 3 minimum Behind the paver before compaction Yes 24 hours −

Mix

temperature − − First load & as directed thereafter Hauling vehicle before dumping or windrow before pickup No Upon completion of test −

Process

control (153.03 ) Density − ASTM D2950 5 minimum At core location before coring No 24 hours See

Subsection

402.12 Table 402- 3 (continued) Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection) Type of

Acceptance

(Subsection) Characteristic Category Test Methods

Specifications Sampling

Frequency Point of

Sampling Split

Sample Reporting

Time Remarks

Production

Asphalt

concrete pavement Statistical (106.05 ) Gradation:

AASHTO

T 30 1 per 700 tons Behind the paver before compaction Yes 6 hours − ½ in I No. 4 I No. 30 I No. 200 I

Other

specified sieves II

Asphalt

content(1) I AASHTO T 308 " " " " − Density(2) I AASHTO T 166 " In-place after compacting " 24 hours − Table 402- 3 (continued) Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection) Type of

Acceptance

(Subsection) Characteristic Category Test Methods

Specifications Sampling

Frequency Point of

Sampling Split

Sample Reporting

Time Remarks

Production (continued)

Asphalt

concrete pavement Measured & tested for conformance (106.04 ) Maximum specific gravity(3),(4) − AASHTO T 209 1 per day minimum Behind the paver before compaction Yes 24 hours −

Placement

temperature − − First load & as directed thereafter Hauling vehicle before dumping, or windrow before pickup No Upon completion of measurement −

Surface

tolerance − Straightedge measurements

Subsection

401.16(d) As directed See

Subsection

401.16(d) No 24 hours −

Asphalt

binder (702.01 ) Measured & tested for conformance (106.04 ) Quality See Table 401-5 AASHTO M 320 1 per 2000 tons of mix In line between tank & mixing plan Yes, 1-quart samples − Tested by

Government

Asphalt

concrete pavement Process control (153.03 ) Gradation at plant − AASHTO T 27 & T 11 Contractor determined Cold feed or hot bins as applicable No 24 hours −

Moisture

content of aggregates − AASHTO T 255 Contractor determined Stockpile " " − Density − ASTM D2950 1 per 500 ft In-place after compacting " " − Table 402- 3 (continued) Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection) Type of

Acceptance

(Subsection) Characteristic Category Test Methods

Specifications Sampling

Frequency Point of

Sampling Split

Sample Reporting

Time Remarks

Finished Product

Asphalt

concrete pavement Measured & tested for conformance (106.04 ) Type I pavement roughness, before construction (Initial MRI) − AASHTO R 56 & R 57 See

Subsection

402.16Left and right wheel paths No Within 21 days before ground disturbing work Original surface before construction

Type I

pavement roughness, after construction (Final MRI) − " " " " Within 21 days after completing paving −

Type II

pavement roughness, before construction (Initial MRI) − " " " " Within 21 days before ground disturbing work Original surface before construction

Type II

pavement roughness, after construction (Final MRI) − " " " " Within 21 days after completing paving − Table 402- 3 (continued) Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection) Type of

Acceptance

(Subsection) Characteristic Category Test Methods

Specifications Sampling

Frequency Point of

Sampling Split

Sample Reporting

Time Remarks

Finished Product (continued)

Asphalt

concrete pavement Measured & tested for conformance (106.04) Type III pavement roughness (Final MRI) − AASHTO R 56 & R 57 See

Subsection

402.16Left and right wheel paths No Within 21 days after completing paving −

Measured &

tested for conformance (106.04) Surface tolerance − Straightedge measurements

Subsection

401.16(d) As directed See

Subsection

401.16(d) No 24 hours −

(1)Use AASHTO T 308, Method A. Calculate the asphalt binder content by weighing the sample before and after the burn using a calibrated external balance.

(2)Cut two 6- inch diameter side by side cores. Obtain cores as soon as the pavement has cooled sufficiently to allow coring, but not later than 12 hours after final rolling. Remove them with a core retriever and fill and compact the core holes with asphalt concrete mixture. Lab el the cores and protect them from damage due to handling and temperature. Submit one core for verif ication testing. Dry the other core to constant mass at 125±5 °F or vacuum dry it according to ASTM D7227 before p erforming the core density and measuring the thickness. Use 62.245 pounds per cubic foot to convert specific gravity to density.

(3)After pro duction paving has begun, use the average maximum specific gravity value (AASHTO T 209) for each day to adjust the percent compaction for the cores that represent that day’s paving.

(4)Do not use the supplemental procedure for mixtures containing porous a ggregate (dry back method of AASHTO T 209).