GENERAL SECTION 1000 629 DIVISION 1000 — MATERIALS 1000.1 General . Perform sampling, testing, and inspection of all materials included in this division in accordance with the guidelines set forth in the Department’s Materials Manual, latest edition, unless otherwise specified in the contract. Submit and track the proposed sources of all materials incorporated in the project. Material must conform as included and approved on the “source of supply.” All source approvals are conditional based on the continued production of the respective materials meeting the requirements of the contract. Refer to Sections 106.1 and 106.2 for more detailed information. BORROW SECTION 1001 630 SECTION 1001 — BORROW 1001.1 Material Requirements. A. Use classification, characteristics, and definitions of terms for borrow according to requirements of:
Article 1 — Aashto M57
Article 2 — Aashto M145
Article 3 — Aashto M146
Article 4 — Aashto M147
B. Material must have: 1. Maximum dry density ≥ 90 pounds per cubic foot 2. Liquid limit ≤ 40 3. No frozen material, rubbish, boulders more than 6 inches, or organics C. Types and requirements in addition to above : Table 1001.1 -1. Dry Weight Percent Passing Square Mesh Sieves for Borrow Types Type A Type B (Special Fill) Type C (Backfill) Type D (Cement Stabilization) Type F (Common Borrow) 3” 100% 100% Must meet general requirements listed in the paragraph above . 2-1/2” 95 – 100% 1” 85 – 100% No. 200 Max 35% –Max 10% Max 25% 8 – 30% CLAY BORROW SECTION 1002 631 SECTION 1002 — CLAY BORROW 1002.1 Material Requirements. Clay material must not contain rubbish, organic matter, or stones larger than 6 -inches. Material Unified Soil Classification System Designation Clay Borrow Type 1 GC, SC, CL, CH Clay Borrow Type 2 GC, SC, CL, FINE AGGREGATE SECTION 1003 632 SECTION 1003 — FINE AGGREGATE 1003.1 Material Requirements. Fine Aggregate must not contain frozen material, rubbish, or organics. Table 1003.1 -1. Fine Aggregate Gradation Requirements Sieve Size % Passing Concrete Sand Mortar Sand 3/8” (9.5 mm) 100 No. 4 (4.75 mm) 95 – 100 100 No. 8 (2.36 mm) 95 – 100 No. 50 (300 µm) 5 - 30 No. 100 (150 µm) 1-10 0 – 25 No. 200 (75 µm) 0 – 4 0 – 5 COARSE AGGREGATE SECTION 1004 633 SECTION 1004 — COARSE AGGREGATE 1004.1 Description. A. Use crushed particles of the same origin consisting of either minimum single faced crushed gravel, coarse crushed stone, crushed slag aggregate, or recycled concrete aggregate. 1004.2 Material Requirements. A. Submissions. The engineer will sample and test. Once a stockpile of material has been tested and approved, do not add additional material. B. Material Properties. Uniform in quality and free of silt, clay, decomposed fragments, overburden material, soil, reinforcement, and other deleterious debris. C. Gradation. Graded aggregate material conforming to the gradation requirements in Table 1004. 2- 1 or Table 1004.2 -2 for the appropriate type: Table 1004.2 -1. Coarse Aggregate Gradation Requirements Aggregate Size Sieve Size (square openings), millimeters except where noted 4" (100) 3 ½"
2.5 (bulk saturated, surface dry).
Table 1006.1 -1. Riprap Gradation (Percent Passing (Square Openings) by Weight) National Stone, Sand, and Gravel Association (NSSGA) Rock Size R-7 R-6 R-5 R-4 30” 100 ---- ---- ---- 24” --- 100 ---- ---- 18” 15-50 ---- 100 ---- 12” ---- 15-50 ---- 100 9” 0-15 ---- 15-50 ---- 6” ----- 0-15 ----- 15-50 4” ----- ----- 0-15 ---- 3” ----- ----- ----- 0-15 1006.2 Stone for Channel Bed Fill Material Requirements. A. Use aggregate for channel bed fill that is natural, rounded, unwashed, and uncrushed meeting the gradation of Table 1006.2 -1 when tested in accordance with AASHTO T -11 and T -27: Table 1006.2 -1. Channel Bed Fill Gradation (Percent Passing (Square Openings) by Weight) Gradation Identification Light Medium Heavy 5-inch 100 90-100 1 Gradation to be noted on Plan sheets 1-inch 70-100 1 0-20 2 3/4-inch 30-95 - 3/8-inch 0-10 2 - 1 Salvaged materials may contain material exceeding this size and be acceptable. 2 Salvaged materials may contain up to 20% passing the 3/8 -inch sieve but not to exceed 10% passing the #200 sieve when tested in accordance with AASHTO T -11. B. Aggregate material may be located within the excavation area of the project. This material may be salvaged by separating and stockpiling the material. C. Angular quarried aggregate is unacceptable. D. Gradation applications: 1. Use l ight gradation in Sussex County . 2. Use m edium gradation in Kent and New Castle Counties. RELEASE AGENTS SECTION 1010 637 SECTION 1010 — RELEASE AGENTS 1010.1 Material Requirements. Use asphalt release agents on truck beds, tools, and equipment to prevent asphalt and asphalt mix from adhering to surfaces. Material is to be formulated to not damage the asphalt mix by stripping asphalt from the aggregate. Material must be non -petroleum and non -hazardous and meet the requirements of Table 1010.1 -1. Table 1010.1 -1. Asphalt Release Agent Requirements Property Test Method Requirement Flash point ASTM D92 or D93 > 450 F Stripping Test (Diluted) AASHTO T383 ≤ 0.08 % Asphalt Pull -Off Test AASHTO T383 ≤ 65.0 % TACK COAT SECTION 1011 638 SECTION 1011 — TACK COAT 1011.1 Description. Provide material in accordance with 1011.2 for thin lift maintenance applications, typically less than 1 1/4-inches thick. Provide material selected from the approved product list and in accordance with manufacturer recommendations for all other applicatio ns. 1011.2 Asphalt Cement (PG Graded). Provide PG -64-22 (PG 64S -22) as tack coat in lieu of emulsified asphalts. 1011.3 Emulsified Asphalts. A. Anionic emulsified asphalt in accordance with M140 except the sieve test requirement for field samples collected at the point of use shall be a maximum of 0.4 percent. B. Cationic emulsified asphalt in accordance with M208 except the sieve test requirement for field samples collected at the point of use shall be a maximum of 0.4 percent. C. Polymer -modified cationic emulsified asphalts in accordance with M316 except the sieve test requirement for field samples collected at the point of use shall be a maximum of 0.4 percent. D. Non -Tracking emulsified asphalt in conformance with Table 1011.3 -1. Table 1011.3 -1. Non -Tracking Emulsified Asphalt Requirements. Property Test Method Requirement Saybolt Viscosity at 77 F, (SFS) AASHTO T59 15-100 Storage Stability Test, 24 hours, (%) AASHTO T59 1 maximum Residue by Distillation or Residue by Evaportation , (%) AASHTO T59 50 minimum Sieve Test, No. 20, (%) AASHTO T59 0.4 maximum for field samples Penetration at 77 F, 100 g, 5 s, (dmm) AASHTO T49 10-40 Solubility in Trichloroethylene, (%) AASHTO T44 97.5 minimum ASPHALT CEMENT SECTION 1012 639 SECTION 1012 — ASPHALT CEMENT 1012.1 Material Requirements. A. Asphalt Cement (PG Graded). Per AASHTO M320, Table 1 and tested per AASHTO R29 with the following exceptions: 1. Original DSR will be 1.00 to 2.20 kPa as tested by AASHTO T315 2. Use of recycled materials cannot raise the low temperature properties of the combined binder above 23 degrees C as tested by AASHTO T313. B. Asphalt Cement (MSCR Graded). Per AASHTO M332 and tested per AASHTO R29 with the following supplemental information: 1. The standard test temperature is 64 degrees C for all grades except PG 58S -28 which is 58 degrees C. 2. Polymer modified asphalts for extreme grade, PG 64E -22, must meet the following equation when subject to a 3.2kPa shear stress in accordance to AASHTO R92: R - (29.371 * J nr-0.2633) ≥ 0.0 Where: R = Average Percent Recovery Jnr =Non -recoverable creep compliance 3. Use of recycled materials cannot raise the low temperature properties of the combined binder above -23 degrees C as tested by AASHTO T313. ANTI -STRIPPING ADDITIVES SECTION 1013 640 SECTION 1013 — ANTI -STRIPPING ADDITIVES 1013.1 Material Requirements. Use antistripping additives that are oil soluble, compatible with the asphalt cement, and promote strong adhesion characteristics with aggregates when added to asphalt cement. The additives will not change the binder grade of the asphalt cement. Additives must be heat stable for a minimum of 96 hours at the bituminous material’s normal storage temperature. ASPHALT MATERIALS PRODUCTION SECTION 1014 641 SECTION 1014 — ASPHALT MATERIALS PRODUCTION 1014.1 Material Requirements. Produce asphaltic base and surface material in accordance with: Fine aggregate See below Coarse aggregate See below Antistripping additive Section 1013 Asphalt cement Section 1012 Tack coat Section 1011 Recycled asphalt pavement (RAP) See below Recycled asphalt shingles (RAS) See below Mineral filler AASHTO M17 Warm mix additives See below 1014.2 Fine Aggregate. Table 1014. 2-1. Fine Aggregate Requirements Fine Aggregate Angularity (AASHTO T304) % M inimum Sand Equivalency (AASHTO T176) % Minimum Sodium Sulfate (AASHTO T104) Deleterious Materials (AASHTO T112) ≤ 100 mm > 100 mm Maximum % Loss 40 40 40 20 10 1014.3 Coarse Aggregate. Table 1014. 3-1. Coarse Aggregate Requirements Coarse Aggregate Angularity (AASHTO T326) % Minimum1 Flat and Elongated (ASTM 4791 with a 5:1 Aspect Ratio) % Maximum LA Abrasion (AASHTO T96) Sodium Sulfate (AASHTO T104) Deleterious Materials (AASHTO T112) ≤ 100 mm > 100 mm Maximum % Loss 75/- 50/- 10 40 20 10 1XX/YY denotes that XX% of the coarse aggregate has 1 fractured face and YY% has 2 or more fractured faces. 1014.4 RAP / RAS. The percent of recycled materials (RAP / RAS) allowed in the pavement mixture is calculated using the Materials and Research Recycled Mixture Program (RAP Calculator) available through the Materials and Research Section. RAP used from stockpiles which have material continuously added must be blended from multiple sources. The Department will not permit incorporation of RAP materials from single source stockpiles. ASPHALT MATERIALS PRODUCTION SECTION 1014 642 Process the RAS materials so that 100 percent passes the 3/8” (9.5 mm) sieve. Use post -consumer or pre-consumer shingles free of foreign material, moisture, and asbestos fibers. Keep pre -consumer fiberglass -backed and organic felt -backed shingles separate and do not incorporate the 2 types of shingle s into a single mix. The deleterious materials for RAS cannot exceed 1.5 percent of the total mass retained on the #4 (4.75mm) sieve. 1014.5 Warm Mix Additives. Submit the following information at least 30 calendar days before production: A. WMA technology and additive information , if applicable . B. WMA technology manufacturer’s recommendation for usage. C. WMA technology target dosage rate and tolerance envelope . Support tolerance envelope with test data demonstrating acceptable mix production properties conforming to all sections of this specification. D. WMA technology manufacturer’s MSDS. E. Documentation of past WMA technology field application including points of contact. F. Temperature ranges for mixing and compacting. G. Laboratory test data, samples, and sources of all mix components, and asphalt binder viscosity - temperature relationships. Follow the manufacturer’s recommendation for incorporating additives and WMA technologies into the mix. Comply with the manufacturer’s recommendation regarding receiving, storage, and delivery of additives. If the producer performs blending of the WMA technology in its tank, submit a separate quality control plan developed by the producer to the Department for review and approval at least 30 calendar days before production. 1014.6 Production Quality Control Plan Requirements. Submit a quality control (QC) plan to the Materials and Research Section on an annual basis for each proposed production facility for review and approval before material production. The QC plan will include actions to assure all materials and products will conform to the specifications, whether manufactured or processed by the contractor, or procured from suppliers, subcontractors, or vendors. The contractor will perform inspection and testing required to ensure product conformance to contract requirements. Document QC inspections and tests and provide copies to the Materials and Research section when requested. Maintain records of all inspections and tests for at least 1 year. Records must include the date, time, and nature of deficiency or deficiencies fou nd; the quantities of material involved until correction of the deficiency; and the date, time, and nature of corrective actions taken. The QC plan will detail the type and frequency of inspection, sampling, and testing deemed necessary to measure and control the various properties of material and construction governed by the specifications. The QC plan will include the following: A. Production plant - make, type, capacity, and location. B. Production plant calibration - components and calibration schedule. C. Personnel - include name and telephone number for the following individuals: 1. The person responsible for quality control including inspection, sampling, and testing personnel. 2. The person who has the authority to take corrective actions on behalf of the contractor. ASPHALT MATERIALS PRODUCTION SECTION 1014 643 D. Testing laboratory – frequency of equipment calibrations used for testing. E. Load number of QC samples. F. Sampling technique. G. Performance and frequency of tests: 1. Mixture temperature: first five trucks and each sampled load. 2. Aggregate, RAP, and RAS stockpile gradation analysis.
25.0 mm 19.0 mm 12.5 mm 9.5 mm 4.75 mm
Sieve Size Min Max Min Max Min Max Min Max Min Max
37.5 mm 100
25.0 mm 90 100 100 - - - - - - -
19.0 mm - 90 90 100 100 - - - - -
12.5 mm - - - 90 90 100 100 - 100 -
9.5 mm - - - - - 90 90 100 95 100
4.75 mm - - - - - - - 90 90 100
2.36 mm 19 45 23 49 28 58 32 67 - -
1.18 mm - - - - - - - - 30 60
0.075 mm 1 7 2 8 2 10 2 10 6 12 Note: the aggregate’s gradation for each sieve must fall within the minimum and maximum limits. The mixture must have a minimum percent moisture sensitivity per AASHTO T283 of 80. ASPHALT MATERIALS PRODUCTION SECTION 1014 646 Satisfy the volumetric criteria of the target asphalt cement content in Table 1014. 8-2 for the design aggregate structure: Table 1014. 8-2. Volumetric Property Requirements Volumetric Property Target Value Plant Production Tolerance Air Voids (V a) at N design (%) 4 ±2 Voids in Mineral Aggregate (VMA) at N design
25.0 mm Bituminous Concrete Base Course 12.5
-1.5 to +2.0 from target 19.0 mm Type B Bituminous Concrete 13.5
12.5 mm Type C Bituminous Concrete 14.5
9.5 mm Type C Bituminous Concrete 15.5
4.75 mm Type C Bituminous Concrete 16.5
The primary control sieve (PCS) defines the break point of fine and coarse mixtures. Classify the combined aggregates as coarse graded when it passes below the primary control sieve (PCS) control point as defined below. Classify all other gradations as fine graded. Table 1014.8 -3. PCS Control Point for Mixture Nominal Maximum Aggregate Sizes (NMAS) (% Passing) NMAS 25.0 mm 19.0 mm 12.5 mm 9.5 mm 4.5 mm Primary Control Sieve 4.75 mm 4.75 mm 2.36 mm 2.36 mm 1.18 mm PCS Control Point 40 47 39 47 30-60 For any roadway with a minimum average daily traffic volume (ADT) of 8,000 vehicles and a posted speed of 35 mph or greater, the aggregate blend is required to be non -carbonate. The coarse aggregate (aggregate larger than or equal to #8 stone) must be a non -carbonate source. If RAP is used in the mixture, coarse aggregate (larger than or equal to # 8 stone) must be equal to a minimum of half the RAP percentage in the mix. 1014.9 Approval of JMF. Upon submittal of the JMF, the engineer will have up to 30 calendar days to review the submitted information. 1014.10 Production Facility Laboratory Requirements. Establish, maintain, and operate a qualified testing laboratory at the production plant site of sufficient size and layout that will accommodate the testing operations of both the contractor and the engineer. Laboratory facilities must meet requirements li sted within the Asphalt Plant Lab Inspection Chelist in DelDOT’s Materials Manual. 1014.11 Material Production Requirements. ASPHALT MATERIALS PRODUCTION SECTION 1014 647 Notify the Department’s Materials and Research Section of the quantity and time of scheduled release by 3:00 P.M. the non -holiday weekday before the release. 1014.12 Material Production Testing Equipment. Maintain all the equipment used for handling, preparing, and testing materials in proper operating condition. Correct laboratory equipment malfunctions within 1 working day or production will be suspended. In the case of an equipment malfunction, the contr actor must develop a solution, approved by the engineer, to fulfil testing requirements. Document and maintain calibration records for the following referenced equipment in accordance with the manufacturer’s guidelines: A. Superpave gyratory compactor: once every year. B. Ovens: once every 3 months. C. Vacuum container and gauge (rice bowls): once every 3 months, verified once every month. D. Balances and scales: once every year. E. Thermometers: once every year; verified once every month. F. Gyratory compactor molds and base plates: once every year. G. Mechanical shakers: once every year. H. Verify sieve conditions daily by visual inspection. Document and file all calibrations. Provide records for review by the engineer at any time. 1014.13 Material Production Test Methods. Perform material production tests in accordance with the following: A. AASHTO T312 - Standard Method of Test for Preparing and Determining the Density of Asphalt Mixture Specimens by Means of the Superpave Gyratory Compactor. B. AASHTO T166, Method A (rapid method) - Standard Method of Test for Bulk Specific gravity (GMB) of Compacted Asphalt Mixtures Using Saturated Surface -Dry Specimens. C. AASHTO T308 - Standard Method of Test for Determining the Asphalt Binder Content of Asphalt Mixtures by the Ignition Method. D. AASHTO T30 - Standard Method of Test for Mechanical Analysis of Extracted Aggregate. E. AASHTO T209 - Standard Method of Test for Theoretical Maximum Specific gravity (G MM) and Density of Aspha lt Mixtures. 1014.14 Plant Production. Operate plants per the manufacturer’s recommendations. Allow the engineer access to all parts of the mixing plant at all times for checking the adequacy of the equipment in use, inspecting the conditions and operation of the plant, verifying the weights or proportions and character of materials, and determinin g and checking the temperatures maintained in the preparation of the mixtures. 1014.15 Anti -stripping Additive Blending. If required, blend anti -strip additive per the manufacturer’s recommendations.