409TRIPLE LAYER BITUMINOUS SURFACE TREATMENT

204

these limits can properly seat the aggregate without fracturing the aggregate. Only one coverage shall be made with the steel wheel roller. A self-propelled, two axles, pneumatic-tired rollers with smooth-tread rubber tires aligned such that gaps between the tires on one axle are covered by the tires of the other axle shall be required. The Contractor shall ensure that all tires are of the same size and ply rating and inflated to a minimum of 60 psi {415 kPa}. The Contractor shall maintain tire pressure such that the difference in pressure between any two tires does not exceed 5 psi {35 kPa}.

All bituminous treatments shall be applied in strict conformity with the following:

Bituminous surface treatments shall not be placed on a wet surface or when the Engineer will not allow the placement due to existing unfavorable weather conditions. They shall not be placed when the temperature is expected to fall below freezing during the night regardless of daytime temperature, when the ground is frozen, or when the surface temperature is less than 32°F {0°C}. Triple Layer Bituminous Surface Treatment shall not be placed when the air temperature is below 60 °F {15°C}. All three layers of the bituminous surface treatment shall be placed prior to allowing traffic on the new surface when the air temperature is equal to or greater than 95°F {35°C} and the relative humidity is 85% or greater

Aggregates spread when the temperature is 70 °F {20°C} and above may be surface damp but not wet. Aggregates spread when the temperature is below 70 °F {20°C} shall be surface dry. Aggregates found by the Engineer to contain excessive moisture or free water at the time of use shall be rejected. The above limitations shall not be waived unless approved in writing by the Engineer.

Loose material, dust, dirt, caked clay, or any foreign material shall be removed. Cleaning shall be continued until the surface is clean or, in case of application on a soil or aggregate surface, all the loose dirt is removed and the surfaces of the larger size aggregate in the road surface are exposed but not dislodged. All cleaning of the area to be treated shall be completed before any bituminous material is applied.

No bituminous material or treatment shall be applied until the base or underlying surface has been approved.

Bituminous materials used for each treatment shall be heated as previously noted. The material shall be maintained within the specific temperature range during application. Any material which has not been maintained within the specified range shall be rejected. The application temperature (°F {°C}) range for the Emulsified Asphalt with polymer additive shall be 140 °F – 180 °F {60°C - 80°C}. The bitumen shall be applied uniformly over the area to be treated. Where the treatment width is 26 feet {8 m} or less, the entire width shall be treated in one application, unless otherwise directed. Where only a partial width is treated in one application, extreme care shall be used to ensure a slight overlap of adjacent treatments, but not in excess of 4 inches {100 mm}. The spray bar shall be adjusted to the proper height for exact single or double overlap of spray area without partial overlap. Uniformity of discharge shall be checked before beginning application and at other times as directed by the Engineer. Streaked areas and any other areas lacking uniform distribution shall immediately be made uniform. In all cases the distributor shall be stopped before the application begins to run light (just before the distributor tank is completely empty). A method of making joints shall be used that will ensure that in beginning and ending the distribution of each load, a proper junction is made with the preceding and succeeding work without excessive bituminous material at the joints. In applying bituminous materials, the Contractor shall use effective means to protect structures, walls, curbs, etc. from discoloration or spattering. TRIPLE LAYER BITUMINOUS SURFACE TREATMENT 205

Rates of application for each layer shall be as follows: Layer Gallons {Liters} of Bituminous Material per square yard {m2} of Treatment CRS-2p CRS-2hp CRS-2l 1 0.23 – 0.32 {1.04 – 1.45} 2 0.20 – 0.26 {0.91 – 1.18} 3 0.20 -0.26 {0.91 – 1.18}

The aggregate stone size and application rate of aggregates used shall be as follows: Layer ALDOT Stone Size Application Rate cu.ft./sq.yd. {m3/m2} 1 7 0.18 - 0.26 {0.006 – 0.009} 2 89 0.16 – 0.22 {0.005 - 0.007} 3 W 10 0.10 – 0.14 {0.003 – 0.005} Spreading of aggregate shall follow application of bituminous material as closely as practicable using mechanical aggregate spreaders; inaccessible areas shall be covered as directed. Sufficient aggregate to cover each distributor load, in loaded trucks along with an adequate crew of workmen equipped with brooms standing by, shall be at the site before bituminous application begins. Spreading of the aggregate shall begin and continue immediately behind the application of the bituminous material. Rolling shall begin immediately behind the spreading operation. Sufficient rollers shall be furnished to ensure that the initial pass of the roller is made immediately behind the spreading of the aggregate. Rolling shall be continuous, providing coverage of the entire area of treatment a minimum of three (3) passes for each layer of aggregate to ensure thorough embedment of the aggregate. Unless a sufficient number of rollers are in operation to complete the above requirement, the next load of bituminous material shall not be applied until the rolling of the previous application is completed. When the Engineer determines the aggregate has been thoroughly embedded, rolling shall cease and the Contractor shall, without delay, remove all excess aggregate from the treatment area. The Contractor shall stage his day’s work such that all three layers are placed at the end of each day’s work.

409.04Maintenance and Protection of Surface and Traffic

Maintenance shall include immediate repair of any failures or defects that occur, repeated as often as is necessary to keep the surface continuously intact and acceptable. Maintenance shall be performed without direct compensation. Unless otherwise specified on the plans or in the proposal, the Contractor shall handle traffic through the work and over the surface except while bituminous material is actually being applied and covered with aggregate. It shall be his responsibility to take whatever steps are necessary or directed to protect both the work and the traveling public. Both the first application layer and the second application layer shall be completed before opening the road to traffic. Traffic control shall be established such that traffic is not allowed to sit on the newly applied bituminous surface treatment.

409.05Method of Measurement

Measurement will be made of the number of square yards {square meters} of accepted triple layer bituminous treatment, complete in place. ASPHALT PAVEMENTS 206

The length shall be the actual length measured along the surface of the treatment. The width shall be the designated width of completed surface. Where the pay item specifies a prime coat plus an overlying treatment, the measurement will not include the additional width of the prime coat.

409.06Basis of Payment

Payment for accepted triple layer bituminous surface treatment, Pay Item No. 409-A Triple Layer Bituminous Treatment, measured as provided above, will be paid for at the contract unit price per square yard {square meter} complete in place; except that adjustments in the contract unit price shall be made as follows: When changes in amounts of treatment materials are ordered as provided in Article

409.01, the contract unit price will be adjusted upward or downward accordingly. Adjustment will be

based on the increase or decrease in amounts per square yard {square meter}, at the verified cost, f.o.b. delivery point plus 2 cents per gallon {0.5 cent per liter} for the bitumen, and the verified cost per square yard {cubic meter} for the aggregate delivered to the spreader. The contract unit price or adjusted contract unit price for the accepted area complete in place shall be payment in full for furnishing all material, placement of materials, maintenance thereof and for all equipment, tools, labor, and incidentals necessary to complete the work.

409-A Triple Layer Bituminous Treatment, - per square yard {square meter} ASPHALT PAVEMENTS

410.01Description

The work under this Section covers the general requirements that are applicable to all types of hot and warm mix asphalt pavements of the plant mix type. Deviations from these general requirements will be indicated in the specific requirements for various types of mixes noted in the following sections of these Specifications. This work shall consist of one or more courses of hot and warm mix asphalt plant mix constructed in accordance with these specifications and the specific requirements of the type of mixture required and in reasonably close conformity with the lines, grades, thicknesses, and typical cross sections shown on the plans or established by the Engineer. The Contractor may use either hot mix or warm mix for all mixes in Sections 420, 423, and 424. Warm mix asphalt shall be defined as the use of an approved warm mix technology in the plant mix at the time of production. This work shall also include the preparation of the underlying surface on which the plant mix is to be placed, including patching and/or leveling as shown on the plans or directed by the Engineer. In addition, this work shall also include the placing of widening at locations shown on the plans and/or directed by the Engineer. In general, widening shall consist of (1) narrow width build-ups, three feet or less, required for widening existing pavement, (2) paving for turn-outs beyond three feet from the edge of pavement, (3) pavement crossovers, and (4) turning lanes of less than 200 feet for crossovers. Paving used on turn-outs for intersecting paved roads and shoulder paving will not be considered as widening unless shown on the plans. Surface layers and wearing layers are defined as those layers where the pay item contains the wording “Wearing Surface”. All ALDOT procedures referenced are applicable to both hot and warm mix asphalt.

410.02Materials

Materials shall conform to requirements given in Sections 327, 420, 423 and 424.

Warm Mix Asphalt products and processes shall be selected from List II-27, “Warm Mix Asphalt Products and Processes” of the MSDSAR manual. Information concerning this list is given in Subarticle

106.01(f) and ALDOT-355

All mixes shall include an anti-stripping agent. If using a warm mix additive, the warm mix additive supplier shall certify that an anti-stripping agent is an integral part of the warm mix additive. ASPHALT PAVEMENTS 207

All hot mix asphalt mixtures shall be tested during design to determine the dosage rate of the anti-stripping agent. During design, all mixes except 327E and 420, shall have a tensile strength ratio

visual stripping occurs during field production, a TSR test will be required to determine a new dosage rate of the anti-stripping agent. If subsequent visual stripping occurs, such work will be paid for as Extra Work as defined by Article 104.03. Payment for the additional anti-strip agent will not be made in cases where the same mix has been previously used in field production and visual stripping occurred.

For amine based materials, the amount of anti-stripping agent, when required, shall be 0.25 to 1.0 % by weight of the liquid asphalt binder content for liquid agents and 0.5 to 2.0 % by weight of the total aggregate for powdered agents. Liquid anti-stripping agent shall be added to the liquid asphalt binder within 10% of the specified rate, either at the refinery or the Contractor's mixing plant, using approved on-line blending equipment.

For hydrated lime materials the amount of anti-stripping agent, when required, shall be 0.5 to 2.0 % by weight of the total aggregate for powdered agents. Hydrated lime materials shall meet the requirements as given in Section 805.

For organo silane based materials the amount of anti-stripping agent, when required, shall be 0.05 to 0.1 % by weight {mass} of the liquid asphalt binder content for liquid agents. Liquid anti-stripping agent shall be added to the liquid asphalt binder by approved on-line blending equipment either at the refinery or the Contractor's mixing plant within 10% of the specified rate.

Silicone may be used in liquid asphalt binder, not to exceed 2 ounces per 5000 gallons. Except when producing Warm Mix Asphalt, other additives shall not be added to the liquid asphalt binder unless expressly authorized in writing by the Materials and Tests Engineer. The use of any unauthorized additive will be cause for rejection of the mixture.

Approved Warm Mix Asphalt Additives from ALDOT List II-27 may be used in liquid Asphalt Binder as an anti-striping agent when used as directed by the Manufacturer. The use of any unauthorized additive will be cause for rejection of the mixture.

The project designated rate per square yard of the plant mix layers are designed assuming a compacted mix unit weight of not greater than 158 pounds per cubic foot for dense graded mixes (light weight aggregates excepted.) Hence, a correction to the plan designated rate per square yard will be made in accordance with the following:  If the compacted mix density as determined in the job mix formula design exceeds 158, or is below 130, pounds per cubic foot, the correction will be based on the formula: x = ab/158 {x = ab/2530}, where x = corrected rate per square yard, a = laboratory compacted mix unit weight in pounds per cubic foot as shown in the job mix formula, and b = project designated rate per square yard of plant mix as shown on the job plans.  If the laboratory compacted density is between 130 pounds per cubic foot and 158 pounds per cubic foot, no correction will be made to the pounds per square yard designated by the plans or proposal.  If the plans provide for the use of lightweight aggregate (expanded clay or shale), the pounds per square yard of the layer shown by the plans or proposal will not be adjusted.  If the plans provide for the use of an "Open Graded" plant mix layer, the pounds per square yard of the layer shown by the plans or proposal will not be adjusted.

Work shall not be started under this Section on a specific project until the Contractor has submitted and received approval of a job mix formula from the Materials and Tests Engineer and the job mix formula has been checked by the Area Materials Engineer for use on the project. ASPHALT PAVEMENTS 208

A change in aggregate sources will require a new job mix formula before the new material is used. A change in liquid asphalt binder source and anti-stripping agent will be allowed without a new job mix formula provided the design criteria is met by a one-point check of the mixture. The one-point check shall include the Air Void content, VMA, Stability, Flow, and TSR (Tensile Strength Ratio) and may be determined during the production of the mix. However, no change in the grade of liquid asphalt binder will be allowed without the written approval of the Materials and Tests Engineer.

Designs for all mixes shall be the responsibility of the Contractor and shall be submitted by the Contractor for approval. Refer to applicable Sections (420, 424, etc.) for design criteria. The submitted formula shall have been designed by a certified technician (Level III - Designer) in a laboratory that has been certified by the Department.

The Contractor shall submit to the Materials and Tests Engineer, for approval, a Job Mix Formula

four weeks for the evaluation and approval of the job mix formula. The submitted formula shall include any additive by type and trade name and be accompanied by samples from the material sources the Contractor proposes to use in producing the mix. The job mix formula for each mixture shall establish a single percentage of aggregate passing each required sieve size, a single percentage of liquid asphalt binder to be added to the aggregate, a single percentage of any additive, and a mixing temperature range suitable for the type, grade, etc. of liquid asphalt binder to be used in the mix. Each job mix formula shall be accompanied by a test report from an approved laboratory certifying that all current Departmental design test parameters have been met (copies of the Departmental current design test parameters may be obtained from the office of the Materials and Tests Engineer). There will be no charge for the Department's checking of the Contractor's job mix formula. The approved job mix formula for each mixture shall be in effect for a maximum of two years from the approval date on the job mix formula or until the Materials and Tests Engineer withdraws approval by written order.

At least two full working days prior to beginning the production of asphalt mix for a specific project, the Contractor shall submit a mix design (approved by the Materials and Tests Engineer) to the Area Materials Engineer. The project number shall be inserted on the approved job mix formula. The Area Materials Engineer will review the mix design to determine if the job mix formula is appropriate for the specific project. If the job mix formula is appropriate for the project, the Area Materials Engineer will sign the mix design as being approved, will note the date of approval, and will distribute copies for inspection of the asphalt production. A copy of this approved job mix formula with the Materials and Tests Engineer's approval and the Area Materials Engineer's approval (with the date of approval) shall be available at the plant any time material is being delivered to the State.

Before placement operations begin, the Contractor shall notify the Engineer, in writing, of the intended mix delivery temperature. The Engineer will check and record the temperature of the mixture upon delivery to the project site. The minimum delivery temperature for warm mix asphalt shall be 220 °F. The minimum delivery temperature for hot mix asphalt shall be 250 °F. The Engineer should monitor the work to ensure that there is not high variability in the delivery temperatures or isolated loads of temperature differentials that appear extreme. For pay items that do not require density as a pay factor (patching, widening, etc.) and for mixes that do not require density as a pay factor (OGFC, PATB, etc) the Contractor shall provide a +/- 25 oF delivery temperature range. No loads will be accepted at a temperature greater than 350 °F for hot mix or warm mix asphalt.

All mixtures furnished for use on the project shall conform to the approved job mix formulas within the following ranges of tolerances:  All liquid asphalt binders used shall meet the requirements given in Section 804. See appropriate pay factor table for liquid asphalt binder content requirements.  The mixing temperature shall not exceed 350 °F {177 °C}. ASPHALT PAVEMENTS 209

 Tolerances for 327, 420 and 424 mixes: - +/- 7 % for the #4 {4.75 mm} and larger sieve requirements. - +/- 4 % for the #8 through #100 {2.36 mm through 150 mm} sieve requirements. - +/- 2.0 % for the #200 {75 mm} sieve requirement. See Section 423 for gradation requirements for 423 mixes. The initial setting of the controls for all materials shall be those amounts shown on the job mix formula. The above tolerances are provided for slight variations inherent in job control applications. The Contractor shall make changes as necessary to ensure that the mixture produced is as close as practical to the job mix formula.

More than one job mix formula may be submitted and approved for a layer of pavement. The placement of the entire wearing layer shall be from the same job mix unless otherwise approved in writing by the Engineer. For layers other than the wearing layer, the Contractor shall notify the Engineer in writing of the mix design change prior to changing production.

On all projects utilizing recycled/reclaimed material in the mixture, the Contractor's paving operation and RAP and RAS processing shall conform to the requirements given in ALDOT-372. The recycled hot and warm mix asphalt shall be a homogeneous mixture of reclaimed material, new aggregate (fine or coarse aggregate, or a mixture of fine and coarse aggregate) and new liquid asphalt binder material.

The Contractor shall have the option to use RAP and RAS in accordance with the requirements given in the following table unless shown otherwise on the plans:

RAP used in 3/8 inch {9.5 mm} Section 424 "Superpave" maximum aggregate size mix shall be processed so that 100 % of the RAP passes the 1/2 inch {12.5 mm} sieve. For all other mixes, the maximum size of the aggregate in the RAP shall meet the maximum size for the mix specified. The aggregate in the RAP shall meet the aggregate requirements of the mix it is used in and the requirements given in Sections 801 and 802 (no gravel in Section 327 PATB, Section 420 and Section 423 mixes). ALLOWABLE USE OF RAP AND RAS Maximum Allowable Percent of RAP and RAS by mass of Total Aggregate Content Type of Mix Maximum RAP Content # Maximum RAP and RAS Content ** 327, Plant Mix Bituminous Base 35% RAS Not Allowed 327-E, Permeable Asphalt Treated Base RAP Not Allowed RAS Not Allowed 420, Open Graded Friction Course RAP Not Allowed RAS Not Allowed 423, Stone Matrix Asphalt 424, Superpave (Maximum Aggregate Size ½”, ¾”, 1”, 1 ½”) Surface Layers: 20 % with no more than 15 % containing chert *; All Other Layers: 35 % Surface Layers: 20 % *; All Other Layers: 35 % 424, Superpave (Maximum Aggregate Size 3/8”) Surface Layers: 20% All Other Layers: 35% RAS Not Allowed*** * This limitation applies even if the surface layer is to be covered by an Open Graded Friction Course (Section 420). If the aggregate is chert gravel with a bulk specific gravity that is less than 2.550, a maximum of 15 % of the RAP will be allowed. RAP containing chert gravel shall be crushed so that 100 % of the RAP passes the 1/2 inch {12.5 mm} sieve. Additional RAP that does not contain chert gravel may be added to the mixture through a separate feeder. ** RAS shall be limited to 3% by mass of the total aggregate content for surface layers and 5 % by mass of the total aggregate content for all other layers. *** For projects where the ADT is less than 100 or the surface to be paved is non-trafficked, RAS may be allowed at the contents given for the other 424 Superpave maximum aggregate sizes. ASPHALT PAVEMENTS 210

Reclaimed Asphalt Shingles (RAS) shall be handled, stored, and used in accordance with the requirements given in ALDOT 372 and the following requirements. The RAS shall be materials produced as a by-product of the manufacturing process for roofing shingles and/or scrap shingle (from roofing materials). The RAS shall be free from foreign materials such as paper, nails, wood, and metal flashing. The RAS shall be shredded or ground prior to being incorporated into the mixture. The shredded RAS shall have 100% passing the 1/2 inch {12.5 mm} sieve in any dimension and a minimum of 95% passing the 3/8 inch sieve. In addition to the requirements set forth in ALDOT-372, RAP stockpiles utilized for job mix formula’s with RAP content greater than 25 % shall also meet the following requirements.

ADDITIONAL RAP STOCKPILE REQUIREMENTS FOR RAP USED IN A JOB MIX FORMULA WITH INCREASED RAP CONTENT Control Parameter Standard Deviation* Asphalt Content 0.5 % % Passing #200 Sieve 1.5 % Sieve with 50 % RAP Passing 5.0 % *Based on a minimum of 10 tests

Testing for RAP stockpile shall be included as part of the design JMF submittal.

A fiber stabilizer is required for some mix types (Section 420, 423, etc). For section 420 mixes the warm mix additive Evotherm 3G may be used in lieu of fibers. A fiber stabilizer may be used on other mix types where asphalt binder cement draindown is a problem. Where RAS is included in the job mix formula, fiber stabilizer shall not be required provided the draindown requirements of 0.30% or less are met when tested at 325°F and 350°F in accordance with AASHTO T305. When fiber or Evotherm 3G is used, the dosage rate shall produce a maximum liquid asphalt binder cement draindown of 0.30 % or less when tested at 325°F and 350°F in accordance with AASHTO T305. When fiber is used, the sampling and testing frequency for all mixes for both Contractor and Department testing during production shall be one test for each 5000 tons {metric tons} or portion thereof. The fiber shall be listed on List II-23, Fibers for use in Hot Mix Asphalt (from the MSDSAR manual). If pelletized fibers are used, the fiber within the pellet shall be listed on List II-23. All fibers listed on List II-23 shall meet the requirements of either Item 2, 3, or 4 of this Subarticle.

The maximum length of the fiber shall be 0.25 inches. A representative 3 gram sample, when heated in a crucible between 1100 and 1200 F for at least 2 hours, shall show between 13 % and 23 % non-volatiles. A representative 5 gram sample, when stirred into 100 ml of distilled water, shall have a pH between 6.5 and 8.5 after sitting for 30 minutes. A representative 5 gram sample, when saturated with mineral spirits for 5 minutes and then sieved for 10 minutes on a No. 40 {425 m} sieve, shall absorb between 4 % and 6 % its own weight of mineral spirits. A representative 10 gram sample, when weighed and placed into a 250 F oven for two hours, shall lose less than 5 % by weight when weighed immediately upon removal from the oven. Sieve analysis of the cellulose fiber shall be either of the following methods:  Using an Alpine Air Jet Sieve (Type LS), a representative 5 gram sample of the fiber is sieved for 14 minutes at a controlled vacuum of 11 psi {75.8 kPa}. The fibers remaining on the screen are weighed. The results of this analysis shall indicate that 60 % to 80 % of the fiber passes the No. 100 {150 m} sieve. Or:  Using a Mesh Screen Analysis, a representative 10 gram sample of the fiber is sieved using a shaker with two nylon brushes on each screen. The results of this analysis shall indicate that the fiber has the following amounts passing the specified screens: 75 % to 95 % on the No. 20 {850 m} sieve, 55 % to 75 % on the No. 40 {425 m} sieve, and 20 % to 40 % on the No. 140 {100 m} sieve. ASPHALT PAVEMENTS 211

When tested in accordance with the Bauer-McNett Classifier (BCM) fractionation method process procedure, the fiber length shall have a maximum mean test value of 0.25 inches {6.35 mm}. By using a phase contrast microscope, and a representative test sample of at least 200 fibers, the fiber diameter shall have a maximum mean test value of 0.0002 inches {5.1 m}. The shot content passing the No. 60 {285 m} sieve shall be 85% to 95%. The shot content passing the No. 230 {65 m} sieve shall be 60 % to 80 %. This is a measure of non-fibrous material determined on vibrating sieves (for further information see ASTM C 612).

Synthetic fibers shall include but are not limited to one or a combination of the following: polyolefins (such as polyethylene and polypropylene) and aramids (such as Kevlar, Twaron and Nomex). Fibers shall be twisted fibrillated, flat fibrillated or monofilament with a maximum fiber length of 0.75 inches {19 mm}

Provided it can be demonstrated to the satisfaction of the Engineer that the proper dosage of the fibers is uniformly distributed into the mix, manual introduction of fibers is acceptable when a batch plant is used to make the mix. When the fibers are available in prepackaged

interrupt mixture production and warn the plant operator if the operator manually feeding the fiber fails to introduce it properly. Dry mixing time shall be increased at least five seconds to ensure adequate blending. Wet mixing time shall be increased at least five seconds for cellulose fibers and up to five seconds for mineral fibers. Manual introduction of fibers shall not be used in drum plants.

Methodology and equipment for metering bulk loose and pelletized fiber into asphalt plants has been developed by the fiber suppliers. Whenever the fiber supplier’s recommendations are more stringent than this specification, the fiber supplier’s recommendations are controlling. This specification requires specialized equipment that can accurately proportion and meter, by weight {mass}, the proper amount per batch (for batch plants) or continuously, in a steady uniform manner (for drum plants). Fiber, pelletized or loose, shall not be fed through the cold feed bins or through the rap bin. These proportioning devices shall be interlocked with the plant system and controlled to +/- 10% of the weight of the fibers required so as to maintain the correct proportions for all production rates and batch sizes. During the test strip, an equipment calibration check which shows the fiber is being accurately metered and uniformly distributed into the mix shall be performed to the satisfaction of the Engineer. These metering devices shall provide in process high flow (+ 10% or more) and low flow (-10% or less) plant operator notification and interrupt the mix production where the fiber rate is not properly controlled. The fiber metering system shall also provide a record of feed rate (weight or mass per time) and include a section of translucent pipe for visual confirmation of consistent flow rates. Care shall be taken to ensure that the fibers are not entrained in the plant’s exhaust system. If there is any evidence of fiber in the bag-house or wet-washer fines, the liquid asphalt binder line and/or the fiber line shall be relocated so that the fiber is captured by liquid asphalt binder spray and incorporated into the mix. If there is any evidence of clumps of fibers or pellets at the discharge chute, the contractor shall increase the mixing time and/or intensity. This may entail extending the liquid asphalt binder and fiber feeding lines further into the drum.

Aggregates will be accepted in stockpiles in accordance with the Department's Testing Manual provided there is no segregation or contamination, but production of required gradation in the mix shall be the Contractor's responsibility. Liquid asphalt binder will be accepted in accordance with the requirements given in ALDOT-243. The right is reserved to take samples, including aggregates from stockpiles, plant mix from the hot elevator, plant mix from the spreader, liquid asphalt binder from storage tanks at the plant, etc., and to make further tests as needed as a basis for continued acceptance of the materials. Samples of the mixture in use will be taken and tested in accordance with Subarticle 106.09(b). ASPHALT PAVEMENTS 212

When directed, the Contractor shall use mechanical equipment to cut samples for testing from the compacted pavement. Samples not smaller than 4 inches square or 4 inches in diameter for the full depth of the course to be tested shall be taken at the locations directed by the Engineer. Furnishing of suitable approved cutting equipment, the cutting of the samples, and the immediate repair of the sample holes with similar type of material shall be performed by the Contractor without extra compensation. A laboratory shall be furnished for the control of each hot and warm mix asphalt plant in accordance with the provisions of Section 601.

410.03Construction Requirements

In general, the choice of equipment will be left to the Contractor. It is the Contractor’s responsibility to provide proper sized and amounts of equipment that will produce, deliver to the roadbed, spread, and compact the plant mixed material in sufficient quantities for the continuous movement of the spreaders under normal operating conditions. The mixing plant, hauling, spreading, and compaction equipment shall meet the requirements listed below; however, other equipment that will produce equally satisfactory results, such as electronically or automatically controlled devices of proven performance, will be considered for use in lieu thereof. The Contractor shall secure the Engineer’s approval of all equipment prior to beginning work and any equipment determined by the Engineer to be unsatisfactory shall be promptly replaced or supplemented.

Mixing plants shall comply with the requirements of AASHTO M 156 as modified by ALDOT-324, Mixing Plant Requirements for Hot-Mixed, Hot-Laid Asphalt Paving Mixtures. In addition to the above, if a recycled/reclaimed mix is used, the mixing plant shall be modified as necessary to accommodate the use of the reclaimed material and necessary additives. Mixing plants shall be inspected at least annually to ensure compliance with the requirements of AASHTO M 156 and ALDOT-324. The Contractor/Vendor will be charged a fee as specified by ALDOT-355, General Information Concerning Materials, Sources, and Devices with Special Acceptance Requirements. If the plant is relocated or substantially modified in any way within a year of the last inspection, an additional inspection and related fee will be required. The plant shall be equipped with a dust collector constructed to waste or store and later return uniformly to the aggregate mixture all or any part of the material collected.

A digital recorder shall be installed as part of the platform truck scales. The recorder shall produce a printed digital record on a ticket of the gross and tare weights of the delivery trucks along with a time and date print for each ticket. Provisions shall be made so that scales may not be manually manipulated during the printing process and so interlocked as to allow printing only when the scale has come to rest. The scales and recorders shall be of sufficient capacity and size to accurately determine the weight of the heaviest loaded truck or tractor trailers that are used for the delivery of the hot and warm mix asphalt from that plant. In lieu of plant and truck scales, the Contractor may provide either (1) an approved automatic printer system which will print the weights of the material delivered (evidenced by a weight ticket for each load), provided the system is used in conjunction with an approved automatic batching and control system, or (2) an electronic load cell weight determination system with associated computer hardware and automated printing system. The Contractor may provide a "weigh batcher" system utilizing a weigh hopper equipped with load cells that determine the net amount of mix delivered from the weight hopper. An automated weigh printing system shall be provided to accurately print the weight of material delivered, the time, and the date for each ticket. All scales which determine the weight of the mix for pay purposes shall meet the requirements of Subarticle 109.01(h).

Reference is made to Article 105.12 concerning load limitations on hauling equipment. Wherever a Material Remixing Device is used, the following restrictions shall apply: ASPHALT PAVEMENTS 213

o The device shall be empty while on a bridge. o The device shall be moved across a bridge without any other vehicles or equipment being on the bridge. o The device shall be moved on a bridge only within the limits of a lane and shall not be moved on the shoulder of a bridge. o The device shall move at a speed no greater than 5 miles per hour without acceleration or deceleration.

Each truck shall have a hole approximately 5/16 of an inch in diameter suitably placed in the side of the body, to allow for temperature measurement of the asphalt mix. Trucks used for hauling hot and warm mix asphalt mixtures shall have tight, clean, smooth metal beds that have been thinly coated with a minimum amount of approved asphalt release agent (List II-6, Hot Mix Asphalt Release Coating for Truck Beds, in the MSDSAR manual) to prevent the mixture from adhering to the beds. The use of gasoline, kerosene, diesel or other volatile material is prohibited. Each truck shall be equipped with a tarpaulin that shall be used as needed to protect the mixture from adverse conditions. The tarpaulin shall be made of water repellent material, be of sufficient weight and strength to resist tearing and be in good condition with no holes or tears. The tarpaulin shall be large enough to cover the load. Mixture shall not leave the plant unless the load is covered when the following conditions exist: o When the air temperature is below 60 F; o When hauling time exceeds 30 minutes; or o When threatening weather is present.

When Pay Item 410-H is included in the contract, a material remixing device shall be used for the placement of all asphalt layers except the following: o 327-E, Permeable Asphalt Treated Base (PATB); o A layer placed directly on top of PATB if the placement must be accomplished by operating the remixing device on the PATB. If a pay item is not shown on the Plans, the Contractor may use a material remixing device without compensation. A material remixing device shall not be placed on a Permeable Asphalt Treated Base. The material remixing device shall be capable of remixing plant mix between the trucks and the finished mat. Plant mix shall be remixed in the device prior to being laid by the paver or spreader. The plant mix delivered by the material remixing device shall be a homogeneous, non-segregated mixture. All Material Remixing Devices furnished for use shall be from an approved source listed on List I-18, MATERIAL REMIXING DEVICES, of the MSDSAR Manual. A material remixing device will not be required for the following situations:  Temporary work of short duration,  Bridge replacements having less than 1000 feet of pavement at each end of a bridge,  Acceleration and deceleration lanes less than 1000 feet in length,  Tapered sections, widening, patching, spot leveling, shoulders, crossovers, side street returns and other areas designated by the Engineer.  When placing a continuous leveling layer where the thickness of the layer is required to be transversely tapered (i.e. to correct cross slope) to a thickness less than twice the maximum aggregate size of the layer being placed. The Contractor shall use a hopper insert with a material remixing device if Pay Item 410-H is included in the contract. On projects where Pay Item 410-H is not included in the contract, use of a hopper insert is preferred, but not required.

Asphalt pavers or spreaders shall be self-contained and of sufficient size, power, and stability to receive, distribute, and strike off the asphalt material at rates and widths consistent with the specified typical section requirements and details shown on the plans and noted in Item 410.03(f)2. ASPHALT PAVEMENTS 214

All asphalt pavers or spreaders used for mainline paving, including shoulders and interchange ramps, shall be equipped with a full width vibratory, or other compactive type, screed. The augers used to move the material across the width of the screed shall extend within 1.5 feet of the edge of the screed. It will be permissible to use a hydraulically extendable strike off for paving turnouts and short sections of pavement including variable width sections and crossovers. When laying mixtures, the paver shall be capable of being operated at forward speeds consistent with satisfactory laying of the mixture, providing a finished surface of the required evenness and texture without tearing, gouging, or shoving of the mixture. All asphalt paving machines shall be operated with automatic grade and slope controls unless otherwise directed by the Engineer. The automatic grade controls shall be a contact ski, a mobile stringline, or non-contact sonic averaging sensors. The effective length of these controls shall be a minimum of 24 feet. In the event of a malfunction of the automatic control system, the spreading operation shall be discontinued after one hour until the equipment is repaired. If shown to be required on the plans, special attachments to the pavers and spreaders will be required to shape and finish the pavement.

Compaction equipment shall be capable of compacting the mixture to the required density throughout the depth of the layer while it is still in a workable condition without damage to the material. The Contractor shall be responsible for the selection of the types and number of rollers to be used.

Placement and compaction operations shall be performed during daylight hours unless noted otherwise on the plans or directed otherwise by the Engineer. (The requirements for lighting for nighttime work are given in Subarticle 104.04(a)).

The mixture shall be laid only upon an approved underlying course, which is dry, and only when weather conditions are suitable. The Engineer may, however, permit work of this character to continue when overtaken by sudden rains, up to the amount which may be in transit from the plant at the time, provided the surface just ahead of the placement is swept clear of water and the mixture is within the allowable temperature tolerances. The layer placed under such conditions shall be at the Contractor's risk and shall be removed and replaced by the Contractor without extra compensation should it prove unsatisfactory.

Hot mix asphalt (HMA) layers of 200 pounds per square yard or less shall not be placed when the surface or air temperature is below 40 ºF; air temperature shall be 40 ºF before the spreading operation is started. Spreading operations shall be stopped when the air temperature is below 45 ºF and falling. For HMA layers over 200 pounds per square yard, the above temperature may be lowered 5 F. Unless otherwise stated in the plans and specifications, polymer modified HMA layers of 200 pounds per square yard or less shall not be placed when the surface or air temperature is below 60 oF; for layers over 200 pounds per square yard, the above temperature may be lowered 10 F. Warm mix asphalt (WMA) layers of 200 pounds per square yard or less shall not be placed when the surface or air temperature is below 32 ºF; air temperature shall be 32 ºF before the spreading operation is started. Spreading operations shall be stopped when the air temperature is below 35 ºF and falling. For WMA layers over 200 pounds per square yard, the above temperature may be lowered 5 F. Unless otherwise stated in the plans and specifications, polymer modified WMA layers of 200 pounds per square yard {110 kg/m 2} or less shall not be placed when the surface or air temperature is below 50 oF; for layers over 200 pounds per square yard, the above temperature may be lowered 10 F. With the exception of Section 420 "Polymer Modified Open Graded Friction Course" layers and any asphalt mixes containing RAS, the Contractor may place HMA and WMA layers at temperatures lower than the cold weather limits. The Contractor is warned that other factors such as wind speed and percent humidity may increase the heat loss from the HMA and WMA layers. All other requirements for the installation and quality of the HMA and WMA layers shall be applicable to the work even when the restrictions against placement of the HMA and WMA during cold weather are ASPHALT PAVEMENTS 215

not followed. The layers placed under such conditions shall be at the Contractor's risk and shall be removed and replaced without extra compensation if they are unacceptable. There will be no direct payment for additional costs associated with the placement of HMA and WMA during cold weather.

The underlying surface must be approved by the Engineer before the placement of a plant mix application will be allowed. The underlying surface, whether an old surface or a new surface, shall be thoroughly cleaned of all foreign or loose material and maintained in such condition in advance of the placement operations. Failures in existing pavement or base shall be corrected, as noted in Item 410.03(c)2, in advance of the placement of an overlying layer. A prime coat, when required, shall be placed in accordance with Section 401. Tack coat shall be placed in accordance with Section 405.

When patching of an existing surface is provided by the plans, the Engineer will examine the pavement surface and designate the area to be patched. The designated areas shall be trimmed to the depth of the unstable material as directed. The loose faulty material shall be picked up and removed from the area. The newly exposed patch area shall be cleaned and treated with prime or tack material as directed before placement of patching material. The hot and/or warm mix asphalt patching material shall be placed and compacted by methods approved by the Engineer until the patch area is filled to the elevation of the surrounding surface. Compaction of the patching material shall be to the degree that further consolidation of the patching material is not anticipated and is acceptable to the Engineer.

When leveling of an existing pavement or base is provided by the plans, the surface shall be brought to required grade and cross section with plant mix material. The surface to be treated shall be prepared as noted herein and approved before placing the new material. The plant mix material shall be spread in accordance with the provisions of Item 410.03(f)2 and shall be compacted in accordance with section 410.03(g). Leveling shall include the placement of asphalt plant mix layers to correct superelevation when directed.

When widening is provided by the plans, the widening shall be placed at the locations designated by the plans and/or as directed by the Engineer. The requirements for placing the widening shall be the same, as far as practical, as for the placing of the normal roadway. Compaction of the widening material shall be to the degree that further consolidation of the widening material is not anticipated and is acceptable to the Engineer.

The liquid asphalt binder material shall be heated in a manner that ensures the even heating of the entire mass under efficient and positive control at all times. Any liquid asphalt binder material which, in the opinion of the Engineer, has been damaged shall be rejected.

All aggregates shall be dried so that the moisture content of the hot and warm mix asphalt at the point of sampling is less than 0.20 % by weight {mass} in accordance with ALDOT-130. The temperature of the aggregate at the dryer shall not exceed 600 ºF {315 ºC}. When more than two ingredients enter into the composition of the mineral aggregate, they shall be combined as directed. The aggregate, immediately after being heated, shall be screened into three or more sizes and conveyed into separate bins, ready for batching and mixing with liquid asphalt binder material. However, for mixes using aggregate of 1/2 inch {12.5 mm} maximum size, the number of bins may be reduced to two. ASPHALT PAVEMENTS 216

Maintenance of a uniform aggregate gradation is essential for a dryer drum operation; hence, caution and care shall be exercised in stockpiling of materials to avoid segregation.

The mixing temperature of HMA and WMA shall be in accordance with the refineries’ recommendations, based upon the temperature-viscosity curve, and shall be adequate to produce a mixture in accordance with the specification requirements. The mixing temperature shall not exceed 350 F. The mixing temperature for HMA and WMA shall be continuously recorded and delivered to the Engineer on the next working day.

The dried mineral aggregate, and measured mineral filler when used, prepared as prescribed above, shall be combined in uniform batches by determining the weight of and conveying into the mixer the proportionate amounts of each aggregate required to meet the job mix formula. The largest size aggregate shall be introduced first, then smaller sizes progressively, with mineral filler last, or all mineral components may be added simultaneously. The mineral components shall be thoroughly mixed. The required quantity of liquid asphalt binder material for each batch shall be measured by weight using scales or a liquid asphalt binder material metering device attached to the liquid asphalt binder material bucket. After the mineral components have been mixed, the liquid asphalt binder material shall be added and the mixing continued for a period of at least 45 seconds, or longer if necessary to produce a homogeneous mixture. However, if a check by ASTM D 2489 (Ross Method) shows that 95% plus coating is obtained, a shorter mixing time will suffice. The Engineer may then give written permission for a change. Each batch must be kept separate throughout the weight determining and mixing operations. The mixture shall be uniform in composition, free from lumps or balls of material containing an excess quantity of asphalt, or from pockets deficient in asphalt.

Components shall be introduced and proportioned volumetrically by continuous methods utilizing equipment specified herein for continuous plants. Amounts of aggregate and liquid asphalt binder material entering the mixer, and the rate of travel through the mixer, shall be so coordinated that a uniform mixture of specified gradation and liquid asphalt binder content will be produced.

Components shall be proportioned by weight as noted herein in Item 410.03(a)1 for this method of mixing. Amounts of aggregate and liquid asphalt binder material entering the mixer, and the rate of travel through the mixer, shall be so coordinated that a uniform mixture of specified gradation and liquid asphalt binder content will be produced. An anti-stripping agent may be required to ensure adequate coating of the aggregates, if so directed by the Engineer.

The new aggregate shall be super-heated to a temperature such that, when combined with the reclaimed material, the specified discharge temperature is produced; however, in no case shall the temperature of the new aggregate exceed 600 F.

The plant shall be designed and operated so that heat transfer will take place in the mixing unit without damage to, or vaporization of, the liquid asphalt binder material. For batch type plants, a minimum dry mixing cycle of 15 seconds shall be required for the new aggregate and reclaimed material before introduction of the new liquid asphalt binder material. All environmental regulations shall be met as required by Article 107.22.

The mixture shall be transported in haul trucks meeting the requirements of Item 410.03(a)3. The equipment shall be in sufficient numbers to deliver the material to the roadbed without delay in the quantity required. Loads shall not be delivered too late in the day to be spread, compacted, and ASPHALT PAVEMENTS 217

finished during daylight hours, unless nighttime work is allowed as shown on the plans or directed by the Engineer.

The placement rate of plant mix will be specified by the plans; however, this rate may require correction to adjust for the compacted mix unit weight {density} as determined in the job mix formula design as outlined in Subarticle 410.02(b). The Engineer may direct in writing that the designated weight be increased or decreased in certain areas. It shall be the Contractor's responsibility to place and spread the material uniformly and compact it to such a thickness that will produce the specified rate, separately for each layer of base, binder, and surface, and to maintain a continuing check on tonnage and yardage {area} throughout the day's operation to ensure uniform specified rate. The unit for checking the average rate shall be approximately 5000 square yards to the nearest even truck load. If the last check performed in any day or any section of roadway is between 2000 and 5000 square yards, this section shall be classified as a unit; if less than 2000 square yards, this section shall be added to the previous unit and the revised unit rechecked. When the initial day's operation is less than 2000 square yards, this initial section will be carried over to subsequent days' operations to make a unit of approximately 5000 square yards. In any unit checked, the average rate shall not vary from the specified rate by more than 10 pounds per square yard for layers of 225 pounds per square yard or less, and 15 pounds per square yard for layers greater than 225 pounds per square yard. On the first applied layer of resurfacing where there is no required milling or leveling, this tolerance is increased to 15 pounds per square yard for layers of 225 pounds per square yard or less, and 25 pounds per square yard for layers greater than 225 pounds per square yard. This tolerance is for providing leeway in equipment adjustment only. A consistent and uncorrected variation from the specified rate, even within this tolerance, will not be allowed without the Engineer's written approval. This tolerance does not apply to patching, leveling, and widening. If the average rate of any unit is found deficient by more than the above referenced tolerance, the Engineer will determine (1) whether the Contractor shall remove and replace the deficient unit without payment for the removal or the material removed, or (2) whether the Contractor may leave the deficient unit in place and cover it with a layer of the same mix of adjusted maximum size aggregate of not less than 80 pounds per square yard average. In case (2), the surface layer shall not be feather-edged at the end of the overlay layer, but a sufficient amount of the surface beyond the ends of the deficient unit shall be removed, to a neat line across the pavement, to allow placing the full 80 pounds per square yard and to make a joint that will meet the surface requirements. There will be no payment for any portion of the overlay needed to bring the total up to the designated average rate for that unit. If the average rate of any unit is found to exceed the above referenced tolerance, the tonnage {metric tonnage} in the unit that is in excess of the specified rate will be paid for as specified in Subarticle 410.09(a). Unless otherwise provided in the following sections of these specifications, or shown on the plans, the average rate placed and compacted in one layer shall not exceed 350 pounds per square yard for base or binder layers, and 225 pounds per square yard for surface layers. Where the amount to be placed exceeds these limits, it shall be placed and compacted in two or more approximately equal layers or as shown on the plans.

Spreading of the hot and warm mix asphalt mixture shall be performed by equipment meeting the requirements of Item 410.03(a)4, except as noted in this Item. Approved specialized equipment may be employed to spread the hot and warm mix asphalt material where standard full scale equipment is impractical due to size and irregularity of the area to be paved. Spreading operations shall be correlated with plant operations and hauling equipment such that the spreading operation, once begun, shall proceed at a speed as uniform and continuous as practical. The continual forward movement of the spreader requires the use of hauling vehicles capable of supplying the spreader with hot and warm mix asphalt material while the spreader is in motion. Repetitive interruptions or stopping of the spreader shall be cause for ASPHALT PAVEMENTS 218

the Engineer to suspend the work until the Contractor evaluates the cause of the stoppage and has provided a definite action plan for correction of the interruptions. Any interruption will require the thorough check of the area immediately under the spreader and any variances shall be corrected immediately or the material removed and replaced, as directed, without additional compensation. Material placed in the spreader shall be immediately spread and screeded to a uniform depth so that the specified rate of the mixture required is achieved. Alignment of the outside edges of the pavement shall be controlled by preset control lines, and shall be finished in conformity with these controls. Any spreading operation, which cannot produce acceptable joints within the surface tolerances and density requirements, shall be cause for requiring the Contractor to modify his operations to include additional spreading equipment.

For areas of a hot and warm mix asphalt plant mix surface inaccessible to the mechanical spreader, patching of pot holes and correcting failures in existing pavement, the plant mix may be dumped in low areas in the amounts directed, windrowed, spread, and compacted to bring the elevation and section to the desired level. If shown on the plans, the Contractor shall use a motor grader or a motor grader equipped with a dragbox to perform the spreading for the leveling operation. The motor grader shall be equipped with smooth faced tires. The dragbox, when required, shall be of sufficient size and weight {mass} to effectively shape and level the plant mix and shall be approved by the Engineer prior to use.

For areas inaccessible to mechanical spreading equipment, and when patching potholes and minor pavement failures, hand spreading of the hot and warm mix asphalt mixture may be permitted. The mixture shall be distributed immediately into place by means of suitable tools and spread in a uniformly loose layer.

As soon as the mixture has been spread and has set sufficiently to prevent undue cracking or shoving, rolling shall begin. A delay in the initial rolling will not be tolerated and the initial or breakdown rolling should in general be performed by rolling longitudinally, beginning at the sides and proceeding toward the center of the surface. When initially constructing any leveling layers, the Contractor, as part of his QC plan, shall establish a rolling pattern using the nondestructive testing devices approved in Section 306 of the Specifications. The device shall either be calibrated to roadway cores or gage counts and shall be used to determine the rolling pattern producing maximum density. Contractor QC personnel shall be on site throughout each day to perform periodic checks and verify that the rolling pattern continually produces the maximum density that is achievable. When paving abuts a previously placed lane, the longitudinal joint shall be rolled in the first pass. On superelevated curves rolling shall begin at the low side and progress toward the high side. If any displacement occurs during rolling, it shall be corrected at once. To prevent adhesion of surface mixture to the rollers, the wheels shall be kept adequately moistened with water and a non-foaming detergent, but an excess of water will not be permitted. Adequate precaution shall be taken to prevent dropping of gasoline or oil on the pavement. In places inaccessible to a roller, compaction shall be obtained with hand or mechanical tampers that produce adequate pressure to obtain the required density. When the roller is in contact with a bridge deck, vibratory mode shall be turned off and the roller shall operate in static mode only. Throughout the process of compacting, tests for surface smoothness as required by Article 410.05 and density as required by Section 306 shall be made continuously.

Placing of hot and warm mix asphalt paving layers shall be as continuous as possible. All joints shall be constructed in such a way as to provide a smooth, well–bonded and sealed joint meeting the density and surface requirements of Articles 410.04 and 410.05. Failure to meet requirements noted above shall be cause for ordering the removal and reconstruction of the joint without additional compensation. ASPHALT PAVEMENTS 219

The contact surface of concrete structures shall be treated with a thin coat of liquid asphalt binder material, tack material, or the liquid asphalt binder material used in the mix, prior to construction of the joint. When directed by the Engineer, the same treatment noted above shall be used on cold asphalt joints.

Longitudinal joints in the wearing surface shall conform with the edges of proposed traffic lanes, insofar as practical. Any necessary longitudinal joints in underlying layers shall be offset so as to be at least 6 inches from the joint in the next overlying layer.

Transverse joints shall be carefully constructed. Rollers shall not pass over the unprotected edge of the freshly laid mixture unless laying operations are to be discontinued. To facilitate the expeditious removal of the plant mix joint when laying operations are resumed, the Contractor shall place a heavy wrapping paper on the underlying surface across the joint and place plant mix on top of the paper. Upon resumption of the work, a neat vertical joint shall be formed into the previously laid material to expose the full depth of the layer. The fresh mixture shall be raked and tamped to provide a well-bonded and sealed joint meeting surface and density requirements.

410.04Density Requirements

Density requirements shall be as specified in Table IV, Subarticle 410.08(e).

410.05Surface and Edge Requirements

Surface smoothness and roadway section will be checked by the use of string, Engineer's level, and straight edge. The Contractor shall furnish string, straightedges, and the necessary personnel to handle them under the supervision of the Engineer. Surface smoothness tests shall be made continuously during and immediately after rolling so that irregularities may be eliminated to the extent possible by rolling while the material is still workable; otherwise, deficiencies shall be corrected as provided in Article 410.06.

The finished surface of all base, binder, and wearing surface layers shall not vary more than 1/4 of an inch from a 10-foot straightedge placed perpendicular (at a right angle) to the centerline of the roadway anywhere on the surface. Unless shown otherwise on the plans, the slope shall not vary by more than 0.20 % from the required slope in any 10-foot distance over which the slope is measured without the Engineer's written approval. (If, for example, a 2.0 % slope is required, the measured slope shall not be greater than 2.2 % or less than 1.8 %.)

The surface shall not vary more than 1/4 of an inch {6 mm} from a 16-foot straightedge placed parallel to the centerline anywhere on the surface. A 16-foot rolling straightedge, equipped with marking capability, may be used in lieu of the fixed straightedge if approved by the Engineer. The finished surface shall not vary more than 3/8 of an inch in any 25-foot section from a taut string applied parallel to the surface at the following locations: 1 foot {300 mm} inside of the edges of pavement, at the centerline, and at other points designated by the Engineer. The variance from the designated grade shall not increase or decrease by more than 1/2 of an inch in 100 feet.

Unless shown otherwise on the plans, surface, binder, and leveling pavement edges not confined by curbing or other structures may be lightly tamped behind the placement operation as a preventative measure against cracking and bulging during the rolling process. This procedure shall also be required on the initial edge of a longitudinal cold joint. These edges shall be neatly shaped to line behind the breakdown roller and shall be trimmed as necessary after final rolling, to an accurately lined string or wire providing a maximum tolerance of 2 inches outside the theoretical edge of pavement, with a maximum variation from a true line of 1/2 of an inch in 10 feet and a slope not flatter than 1:1. Edges that are distorted by rolling shall be corrected promptly. ASPHALT PAVEMENTS 220

The smoothness requirements and testing covered in this Subarticle shall apply for pay factor adjustments on the final wearing layer only if Item 410-I Smoothness Testing – Certified Inertial Profiler is included on the plans or in the proposal.

The testing device shall be an inertial profiler that satisfies the requirements of ALDOT-448, “Evaluating Pavement Profiles,” including the portable storage device(s) referenced herein. Portable storage devices containing profile measurements shall become the property of the Department at the time the measurements are taken.

The inertial profiler shall be a certified, non-contact, laser-based device capable of simultaneously measuring both wheel paths meeting all the requirements of ALDOT-448. Portable storage device(s) for the inertial profiler shall be furnished in sufficient quantities for all calibration, test runs, and actual tests deemed necessary by the Engineer. Unless approved in advance by the Engineer, all portable storage devices provided by the Contractor will take the form of commonly available 2G USB flash drives.

The testing device shall be an inertial profiler that satisfies the requirements of ALDOT-448, “Evaluating Pavement Profiles”, including the portable storage device(s) referenced herein. Portable storage devices containing profile measurements shall become the property of the Department at the time the measurements are taken. Smoothness testing shall be performed and reported daily until the contractor demonstrates the ability to achieve a Mean Roughness Index (MRI) value of less than 65 in/mile. If the Contractor demonstrates the ability to achieve a MRI value of less than 65 in/mile then the Contractor may elect to perform and report the smoothness testing at a frequency he determines but not to exceed 5 working days production.

The results of the inertial profiler tests shall be evaluated by Department personnel as outlined in ALDOT-448. If a Mean Roughness Index (MRI) value of 90 inches per mile {1.4 m/km} is exceeded in any test section of any daily paving operation, the paving operation will be suspended as soon as possible after results of the unacceptable test section are obtained. The paving will not be allowed to resume until corrective action is taken by the Contractor. When the MRI is more than 65 inches per mile {1.0 m/km}, per section, a unit price reduction will be assessed. When the MRI is less than 45 inches per mile {0.7 m/km} per section, a unit price increase will be added. The price adjustments are given in Table 1. TABLE I Mean Roughness Index Inches/Mile/Section {meters/Kilometer/Section} Contract Price Adjustment Percent of Pavement Unit Bid Price Under 35 {Under 0.6} 105 35 to less than 45 {0.6 to less than 0.7} 105 – (MRI – 35)/2 {105 – (MRI – 0.6)/0.02 45 to less than 65 {0.7 to less than 1.0} 100 65 thru 90 {1.0 thru 1.4} 100 – (MRI – 65)/1.25 {100 – (MRI – 1.0)/0.02} Over 90 {Over 1.4} Unacceptable For Pay Item 410-I, any price adjustment for smoothness considerations will be applied to the theoretical tonnage {metric tonnage}, calculated using the plan specified rate of ASPHALT PAVEMENTS 221

placement, placed in those sections testing under 40 in/mile, or more than 65 inches/mile {0.6 m/km, or more than 1.0 m/km} per section. There will be no payment greater than 100% for any section in which there were transverse joints that have been corrected by grinding per Article 410.06.

410.06Correction of Deficiencies and Defects

Deficiencies in surface smoothness as determined in Subarticle 410.05(a) shall be remedied to the extent practicable by rolling while the material is still workable. Otherwise, the layer shall be removed and replaced as necessary to obtain required smoothness. "Skin patching" of a surface layer to correct low areas or heating and scraping to correct high areas will not be permitted. Overlays of not less than 80 pounds per square yard may be authorized by the Engineer for surface smoothness deficiencies provided all material in the overlay is without additional cost to the Department. Diamond grinding to correct transverse joints may be allowed at the sole discretion of the Engineer. Micro-milling or fine milling may be used to correct joints in underlying layers. Grinding shall not be used on an Open-Graded Friction Course. Slurry and residue from the grinding shall not be allowed to flow across travel lanes or into drainage facilities or adjacent bodies of water. A fog seal shall be applied over any grinding areas in a wearing surface. Placement of the fog seal shall be as directed by the Engineer. Deficiencies in thickness shall be remedied as specified in Item 410.03(f)1. All areas containing excessive or deficient amounts of liquid asphalt binder, all areas showing unacceptable segregation of materials, and all areas unbonded after rolling shall be removed and replaced at no cost to the Department. Unacceptable segregation of a hot and warm mix asphalt mat is defined as any area in which two six inch cores are taken and the average percent liquid asphalt binder content of the cores have an absolute difference greater than 0.50 percentage points of the design liquid asphalt binder content, or the combined gradation analysis of the two cores on selected sieves has an absolute difference greater than 10 percentage points from the job mix formula. All testing shall be in accordance with ALDOT-389, "Evaluation of Segregated Areas in Hot Mix Asphalt Pavement." The location of all cores taken for segregation evaluation will be determined by the Department. All coring and traffic control required by ALDOT-389 shall be conducted /supplied by the Contractor at no cost to the Department; however, the Contractor will be reimbursed $500.00 per core when core results are within tolerances and the coring operations require additional traffic control. At any time that segregation is determined to be unacceptable, work shall be automatically suspended if positive corrective action is not taken by the Contractor to prevent further segregation in the mat. Upon suspension, the Contractor shall place a test section not to exceed 500 tons of the affected mixture for evaluation by the Engineer. However, if after a few loads it is apparent that the corrective actions were not adequate, work shall again be suspended and the segregated areas evaluated in accordance with ALDOT-389. Likewise, if after 500 tons it is apparent that the problem has been solved, work will be allowed to continue. When correcting subsurface mixtures (base and binder layers), the removal and replacement may be limited to the actual defective areas or the full mat width within the limits of individual defective areas as directed by the Engineer. Removal and replacement of hot and warm mix asphalt wearing surface layers shall be a minimum of the full mat width and 10 feet in length. All surface tolerance requirements shall apply to the corrected areas for both subsurface and surface mixes. Areas found deficient in density shall be removed and replaced or immediately re-rolled until density is acceptable. All work specified in this Article shall be performed without additional compensation.

410.07Maintenance and Protection

Sections of newly finished work shall be protected from all traffic until properly hardened. Maintenance shall include immediate repairs of any defects that may occur on the work; such repairs shall be repeated as often as necessary to maintain the work in a continuously satisfactory condition. The Contractor shall be responsible for the protection of the work and protection of any traffic using the work. No additional compensation will be paid for maintenance and protection.

410.08Method of Measurement

The accepted quantity of hot and warm mix asphalt plant mix used as directed will be measured in tons of 2000 pounds in accordance with the following: ASPHALT PAVEMENTS 222

When the laboratory compacted density as determined in the job mix formula design exceeds 158 pounds per cubic foot, the actual total tonnage of mix placed will be adjusted for pay purposes in accordance with the following formula (this shall not apply to Section 327 PATB and Section 420 OGFC):  y = 158 c / a { y = 2530 c / a}, where  y = total tonnage of plant mix for pay purposes;  c = actual tonnage of plant mix measured and placed, except items subject to pay factor adjustment under the QC/QA provisions. On items subject to pay factor adjustment, the adjusted tonnage (after pay factor adjustment) will be used;  a = laboratory compacted mix unit weight in pounds per cubic foot as shown in the job mix formula. No adjustments to the actual total tonnage placed will be made where the laboratory compacted mix density is below 158 pounds per cubic foot. No adjustments to the actual tonnage placed will be made when the use of lightweight aggregate (expanded clay or shale) is designated. For determining weight, each load of hot and warm mix asphalt mixture shall have its weight { determined on approved certified scales, as specified in Article 109.01, furnished by the Contractor without direct compensation. The weight measurement shall include all components of the mixture. No deductions will be made for any of the components, including the liquid asphalt binder material, contained in the mixture. The laboratory compacted density requirements for OGFC are given in Section 420. Section 327 PATB does not have a laboratory compacted density requirement because a layer thickness (typically 4 inches) is required instead of a rate of placement.

The hot and warm mix asphalt mixture will be evaluated at the plant on a LOT to LOT basis. The material will be tested for acceptance in accordance with the provisions of Section 106 and the following requirements. However, any load or loads of mixture, which, in the opinion of the Engineer, are obviously unacceptable, will be rejected for use in the work. The Contractor shall control all operations in the handling, preparation, and mixing of the hot and warm mix asphalt plant mix so that the percent liquid asphalt binder and voids in laboratory compacted samples or gradation will meet the approved job mix formula within the tolerances shown in Tables II, III, and VI for the 1.00 pay factor. In recognition of the fact that the drying and screening operations may generate additional dust over that shown in the approved mix design, the Contractor's attention is directed to the fact that the dust must be controlled in order to control VMA and voids in the total mix. Acceptance of the mixture will be in accordance with Subarticle 106.09(c). LOT pay factors for asphalt content and air voids will be determined from Table II for Section 423 mixes and from Table III for a Section 424 mix after the requirements of Item 106.09(c)3 are satisfied. LOT pay factors for asphalt content will be determined from the top half of Table II for Section 327E and 420 mixes after the requirements of Item 106.09(c)3 are satisfied. Air voids are not a pay factor for Section 327E and 420 mixes. Gradation is shown as a pay factor for Section 420 mixes in Table VI. The pay factor values determined for each sieve noted in Table VI will be averaged. This average will then be compared to the asphalt content pay factor. The lowest of these two pay factors will be applied to the mix. Calculations for the acceptance test results for asphalt content and voids in total mix shall be carried to the thousandths (0.001) and rounded to the nearest hundredth (0.01). Calculations for averages shall be carried to the thousandths (0.001) and rounded to the nearest hundredth (0.01) in accordance with ASTM E 29 rules of rounding. LOT pay factors will be calculated to the nearest hundredth (0.01). Payment for Section 327 and423 mixes will be on the basis of Table II Acceptance Schedule for Payment. Payment for a Section 424 mix will be on the basis of Table III Acceptance Schedule for Payment. Payment for Section 420 mixes will be on the basis of Table II and Table VI.

The production process will be considered out of control when any individual test result (asphalt content, gradation, or air voids) from a LOT has a pay factor equal to 0.80 computed from the "1 Test" row in Table II, the “1 Test” row in Table III, or the “1 Test” column in Table VI, whichever is appropriate. When gradation is a pay factor, a 0.80 result for an individual screen (before averaging) is considered out of control. If any single gradation for the 327 mixes falls outside of the gradation band shown in Section 327 the process is considered out of control. When this happens, production shall be ASPHALT PAVEMENTS 223

suspended. If mix from the suspended LOT is contained in storage/surge bins, that mix will be considered part of the suspended LOT, and shall not be placed on any State project. When production is suspended as described above, or when the contractor voluntarily terminates a lot, production shall not be re-started until after all of the following has been accomplished:

control, or that the LOT has been terminated voluntarily, and that production has been suspended;

process under control and inform the Project Manager in writing of these adjustments;

tons and test for control characteristics (asphalt content, gradation, and air voids);

factors for asphalt content, gradation, and air voids equal 1.00, minimum, at which time production may be re-started. Mix utilized as a trial batch shall not be used on the project.

TABLE II SECTION 420 MIXES (OPEN GRADED FRICTION COURSE)** SECTION 423 MIXES (STONE MATRIX ASPHALT) ACCEPTANCE SCHEDULE OF PAYMENT FOR ASPHALT PLANT MIX CHARACTERISTICS Arithmetic Average of the Absolute Values of Deviations of the LOT Acceptance Tests From Job Mix Formula Values Asphalt Content LOT Pay Factor -> 1.02 1.00 0.98 0.95 0.90 0.80* 1 Test - 0.00-0.48 0.49-0.51 0.52-0.57 0.58-0.66 Over 0.66 2 Tests - 0.00-0.34 0.35-0.36 0.37-0.40 0.41-0.47 Over 0.47 3 Tests - 0.00-0.28 0.29-0.29 0.30-0.33 0.34-0.38 Over 0.38 4 Tests 0.00-0.14 0.15-0.24 0.25-0.26 0.27-0.28 0.29-0.33 Over 0.33 Voids in Total Mix (Lab. Compacted Samples) LOT Pay Factor -> 1.02 1.00 0.98 0.95 0.90 0.80* 1 Test - 0.00-1.50 1.51-1.62 1.63-1.80 1.81-2.10 Over 2.10 2 Tests - 0.00-1.06 1.07-1.15 1.16-1.27 1.28-1.48 Over 1.48 3 Tests - 0.00-0.87 0.88-0.94 0.95-1.04 1.05-1.21 Over 1.21 4 Tests 0.00-0.45 0.46-0.75 0.76-0.81 0.82-0.90 0.91-1.05 Over 1.05 * If approved by the Department, the Contractor may accept the indicated LOT partial pay. The Department may require removal and replacement. If the LOT pay factor is greater than 0.80, the Contractor has the option to remove at no cost to the Department and to replace at contract unit bid price rather than accepting the reduced LOT payment. ** The Acceptance Schedule of Payment for “Voids in Total Mix” will not apply to the 327E and 420 mixes

ASPHALT PAVEMENTS 224

TABLE VI SECTION 420 MIXES (OPEN GRADED FRICTION COURSE) ACCEPTANCE SCHEDULE OF PAYMENT FOR ASPHALT PLANT MIX CHARACTERISTICS Arithmetic Average of the Absolute Values of Deviations of the LOT Acceptance Tests From Job Mix Formula Values Gradation 3/8" {9.5 mm} Sieve LOT Pay Factor 1 Test 2 Tests 3 Tests 4 Tests 1.02 - - - 0.00 – 3.60 1.00 0.00 – 12.00 0.00 – 8.48 0.00 – 6.93 3.61 – 6.00 0.98 12.01 – 12.96 8.49 – 9.16 6.94 – 7.48 6.01 – 6.48 0.95 12.97 – 14.40 9.17 – 10.18 7.49 – 8.31 6.49 – 7.20 0.90 14.41 – 16.80 10.19 – 11.88 8.32 – 9.70 7.21 – 8.40 0.80* Over 16.80 Over 11.88 Over 9.70 Over 8.40 Gradation No. 8 {2.36 mm} Sieve LOT Pay Factor 1 Test 2 Tests 3 Tests 4 Tests 1.02 - - - 0.00 – 2.40 1.00 0.00 – 8.00 0.00 – 5.66 0.00 – 4.62 2.41 – 4.00 0.98 8.01 – 8.64 5.67 – 6.11 4.63 – 4.99 4.01 – 4.32 0.95 8.65 – 9.60 6.12 – 6.79 5.00 – 5.54 4.33 – 4.80 0.90 9.61 – 11.20 6.80 – 7.92 5.55 – 6.47 4.81 – 5.60 0.80* Over 11.20 Over 7.92 Over 6.47 Over 5.60 The comparison value for ALDOT and Contractor testing for the 3/8" {9.5 mm} and No. 8 {2.36 mm} sieves is +/- 2.0%. * If approved by the Department, the Contractor may accept the indicated LOT partial pay. The Department may require removal and replacement. If the LOT pay factor is greater than 0.80, the Contractor has the option to remove at no cost to the Department and to replace at contract unit bid price rather than accepting the reduced LOT payment.

TABLE III SECTION 424 MIXES (SUPERPAVE) ACCEPTANCE SCHEDULE OF PAYMENT FOR ASPHALT PLANT MIX CHARACTERISTICS Arithmetic Average of the Absolute Values of Deviations of the LOT Acceptance Tests From Job Mix Formula Values Asphalt Content LOT Pay Factor -> 1.02 1.00 0.98 0.95 0.90 0.80* 1 Test - 0.00-0.62 0.63-0.68 0.69-0.75 0.76-0.88 Over 0.88 2 Tests - 0.00-0.44 0.45-0.48 0.49-0.53 0.54-0.62 Over 0.62 3 Tests - 0.00-0.36 0.37-0.39 0.40-0.43 0.44-0.51 Over 0.51 4 Tests 0.00-0.19 0.20-0.31 0.32-0.34 0.35-0.38 0.39-0.44 Over 0.44 Voids in Total Mix (Lab. Compacted Samples) LOT Pay Factor -> 1.02 1.00 0.98 0.95 0.90 0.80* 1 Test - 0.00-2.50 2.51-2.70 2.71-3.00 3.01-3.50 Over 3.50 2 Tests - 0.00-1.77 1.78-1.91 1.92-2.12 2.13-2.47 Over 2.47 3 Tests - 0.00-1.44 1.45-1.56 1.57-1.73 1.74-2.02 Over 2.02 4 Tests 0.00-0.75 0.76-1.25 1.26-1.35 1.36-1.50 1.51-1.75 Over 1.75 * If approved by the Department, the Contractor may accept the indicated LOT partial pay. The Department may require removal and replacement. If the LOT pay factor is greater than 0.80, the Contractor has the option to remove at no cost to the Department and to replace at contract unit bid price rather than accepting the reduced LOT payment. ASPHALT PAVEMENTS 225

For paving that is not mainline paving (paving for patching, widening, and crossovers and leveling), in-place density pay factors will not be applied. For mainline paving (including shoulders, ramps, and acceleration/deceleration lanes), in-place density pay factors will be applied as specified herein unless otherwise noted on the plans or in the specifications. After the hot and/or warm mix asphalt mixture has been placed and compacted, it shall be evaluated for density. A core for mat density determination shall be taken by the Contractor on each 3000 foot segment of roadway lane of asphalt mixture placed. The location of each test will be designated by the Department. The core shall meet a minimum thickness for use in determining the roadway density. If the core’s average thickness in inches {millimeters} is not at least 0.008 times the rate in pounds per square yard, another core shall be taken (as close a practical to the original location) where the Engineer believes the pavement is thick enough for roadway density determination. The core’s average thickness shall be determined by measuring the core’s thickness at six equidistant locations around the circumference of the core. The Department will take immediate possession of the core and will make a density determination of the core in accordance with AASHTO T 166, Method A. The density values of the cores will be used to compute the pay factor for that sublot. Testing locations will be selected with the random number method outlined in ALDOT-210. Contractors are allowed, but not required, to take cores anywhere, anytime for quality control. This includes taking cores from the wearing layer. The contractor must have the permission of the Engineer to take cores from a PATB

purposes of evaluation, a LOT will be as defined in Item 106.09(c)1. A SUBLOT for evaluation of density will be equal to 12,000 feet (4 test results) or fraction of a 12,000 foot length as applicable. For instance, a 27,000 foot LOT would be divided into two 12,000 foot SUBLOTS and one 3000 foot SUBLOT. The in-place density will be expressed as a percentage of the theoretical maximum density (TMD) of the mix with the following relationship: % TMD = In Place Density X 100 Maximum Mix Density Maximum mix density is equated to maximum mix specific gravity as measured with AASHTO T 209, Flask determination with dry back. The maximum mix specific gravity used will be the average of the values from the four most recent determinations using Contractor data. The appropriate pay factor for each SUBLOT will be determined from Table IV for the appropriate number of test results. The pay factor for the LOT will be determined by computing the weighted average of the SUBLOTS:

LOT Pay Factor (PF) = PF SUBLOT 1 (Length SUBLOT 1) + PF SUBLOT 2 (Length SUBLOT 2) + … Length SUBLOT 1 + Length SUBLOT 2 + …

Calculations for the acceptance test results for in-place density will be carried to the hundredths (0.01) and rounded to the nearest tenth (0.1). LOT and SUBLOT pay factor calculations will be carried to the thousandths (0.001) and rounded to the nearest hundredth (0.01) in accordance with ASTM E 29 rules of rounding. The low rates of placement at which minimum density does not apply are given in Section 306. Density pay factors will not be applied to pavement layers placed at these rates. ASPHALT PAVEMENTS 226

TABLE IV ACCEPTANCE SCHEDULE OF PAYMENT FOR IN-PLACE DENSITY SECTION 423 MIXES (STONE MATRIX ASPHALT) Characteristic SUBLOT PAY FACTOR Arithmetic Average of the Absolute Values of Deviations of SUBLOT Acceptance Tests From Target** 1 Test 2 Tests 3 Tests 4 Tests In-Place Density 1.02 0.00 - 2.00 0.00 - 1.41 0.00 - 1.15 0.00 - 1.00 1.00 2.01 - 3.33 1.42 - 2.36 1.16 - 1.92 1.01 - 1.67 0.98 3.34 - 3.60 2.37 - 2.55 1.93 - 2.08 1.68 - 1.80 0.95 3.61 - 4.00 2.56 - 2.83 2.09 - 2.31 1.81 - 2.00 0.90 4.01 - 4.67 2.84 - 3.30 2.32 - 2.69 2.01 - 2.33 0.80* Over 4.67 Over 3.30 Over 2.69 Over 2.33 SECTION 327 BITUMINOUS BLACK BASE MIXES and 424 MIXES (SUPERPAVE) Characteristic SUBLOT PAY FACTOR Arithmetic Average of the Absolute Values of Deviations of SUBLOT Acceptance Tests From Target** 1 Test 2 Tests 3 Tests 4 Tests In-Place Density 1.02 0.0-2.25 0.0-1.59 0.0-1.30 0.0-1.12 1.00 2.26-3.75 1.60-2.65 1.31-2.17 1.13-1.88 0.98 3.76-4.05 2.66-2.86 2.18-2.34 1.89-2.02 0.95 4.06-4.50 2.87-3.18 2.35-2.60 2.03-2.25 0.90 4.51-5.25 3.19-3.71 2.61-3.03 2.26-2.62 0.80* Over 5.25 over 3.71 over 3.03 Over 2.62 * If approved by the Department, the Contractor may accept the indicated partial SUBLOT pay. The Department may require removal and replacement. The Contractor has the option to remove at no cost to the Department and replace at contract unit bid price rathe r than accepting the reduced SUBLOT payment. ** Target density shall be 94.0 % of the theoretical maximum density for all mixes except for: - the range of placement rates given in Item 306.03(g)3 (140 pounds per square yard or greater and less than 200 pounds per square yard over surface treatments) the target density shall be 92.0 %. The Contractor may request in writing that the target density remain 94% of the theoretical maximum density in these instances. Regardless of the target density, pay factors will be applied. - ESAL Range A and B mixes where the Contractor demonstrates and explains in writing why 94 % of the theoretical maximum density cannot be achieved and the Engineer informs the Contractor by written notification that the target density can be reduced to 93 % or 92 %. Regardless of the target density, pay factors will be applied.

TABLE V COMPARISON OF ALDOT AND CONTRACTOR TESTING TEST ACCEPTABLE ASPHALT CONTENT ± 0.30 % AIR VOIDS ± 0.50 % GRADATION * See Table VI * Gradations given in Articles 327.02 and 420.02.

Tack coat liquid asphalt material will be measured and paid for as specified in Section 405.

Deductions in measurement will be made for all material wasted or lost due to negligence of the Contractor or applied beyond the limits of the work.

The number of material remixing devices measured for payment will be the number of units approved by the Engineer for use. These devices will be measured per each device.