Hot -Mix Asphalt Art. 1030.02 Warm mix asphalt (WMA) is an asphalt mixture which can be produced at temperatures lower than allowed for HMA by utilizing qualified WMA technologies. WMA is produced with the use of additives, a water foaming process, or a combination of both. WMA shall conform to all HMA specifications unless specificly noted. F or simplicity of text, the following HMA nomenclature applies to this Section. Mixture Type Application Mixture-Nominal Maximum Aggregate Size High ESAL Binder Course IL-19.0, IL-9.5, IL-9.5FG, IL-4.75, SMA-12.5, SMA-9.5 Surface Course IL-9.5, IL-9.5FG, SMA-12.5, SMA-9.5 Low ESAL 1/ Binder Course IL-19.0L, IL-9.5L Surface Course IL-9.5L 1/ High ESAL mixtures may be used in similar Low ESAL mixture applications.
1030.02 Materials. Materials shall be according to the following.
Item Article/Section
a.Coarse Aggregate .............................................................................. 1004.03
b.Fine Aggregate .................................................................................. 1003.03
c.Reclaimed Asphalt Pavement ................................................................. 1031
d.Mineral Filler ........................................................................................... 1011
e.Hydrated Lime ................................................................................... 1012.01
f.Slaked Quicklime (Note 1)
g.Performance Graded Asphalt Binder ...................................................... 1032
h.Fibers (Note 2)
i.WMA Technologies (Note 3)
j.Reclaimed Asphalt Shingles ................................................................... 1031
k.Collected Dust .......................................................................... 1102.01(a)(4)
l.Truck Bed Release Agents for HMA (Note 4) .................................... 1030.12
m.Liquid Anti-Strip (Note 5)
n.Packaged, Dry, Rapid Hardening Mortar or Concrete ............................ 1018 Not e 1. Slaked quicklime shall be according to ASTM C 5. Note 2. A stabilizing additive such as cellulose or mineral fiber shall be added to stone matrix asphalt (SMA) mixtures and shall meet the requirements listed in Illinois Modified AASHTO M 325. Prior to approval and use of fibers, the Contractor shall submit a notarized certification by the producer of these materials stating they meet these requirements. Note 3. WMA additives or foaming processes shall be selected from the Department’s qualified producer list “Technologies for the Production of Warm Mix Asphalt (WMA)”. Art. 1030.03 Hot-Mix Asphalt Note 4. Truck Bed Release Agents for HMA shall be selected from the Department’s Qualified Product List “Asphalt Release Agents for Vehicles Transporting Hot-Mix Asphalt”. Note 5. Liquid additives to control stripping shall be shown effective by the Contractor by completing tensile strength and tensile strength ratio (TSR) testing according to AASHTO T 283 for the mix design and submitting the results to the Engineer.
1030.03 Equipment. Equipment shall be according to the following.
Item ............................................................................ Article/Section
a.Hot-Mix Asphalt Plant ........................................................................ 1102.01
b.Storage Tanks for Asphalt Binders (Note 1) ............................. 1102.01(a)(6)
c.Heating Equipment (Note 2) .............................................................. 1102.07 Note 1. Tanks for the storage of asphalt binder shall be clearly and uniquely identified. Different grades of asphalt binder shall not be blended. Note 2. The asphalt binder shall be transferred to the asphalt tanks and brought to a temperature of 250 to 350 °F (120 to 180 °C). If, at anytime, the asphalt binder temperature exceeds 350 °F (180 °C), the asphalt binder shall not be used. Polymer modified asphalt binder, when specified, shall be shipped, maintained, and stored at the mix plant according to the manufacturer's requirements.
1030.04 Reference Documents. The HMA mixtures shall be designed,
sampled, tested, and accepted according to the following.
a.Appendices listed in the Manual of Test Procedures for Materials.
1.Development of Gradation Bands on Incoming Aggregate at Hot-Mix Asphalt and Portland Cement Concrete Plants
2.Model Annual Quality Control Plan for Hot-Mix Asphalt Production
3.Model Quality Control Addendum for Hot-Mix Asphalt Production
4.Procedure for Correlating Nuclear Gauge Densities with Core Densities for Hot-Mix Asphalt
5.Hot-Mix Asphalt Test Strip Procedures
6.Hot-Mix Asphalt QC/QA QC Personnel Responsibilities and Duties Checklist
7.Hot-Mix Asphalt QC/QA Initial Daily Plant and Random Samples
8.Hot-Mix Asphalt QC/QA Procedure for Determining Random Density Locations
9.Hot-Mix Asphalt QC/QA Control Charts
10.Hot-Mix Asphalt Mix Design Verification Procedure
11.Calibration of Equipment for Asphalt Binder Content Determination (Nuclear Asphalt Binder Content Gauge and Ignition Oven)
12.Hot-Mix Asphalt Mix Design Procedure for Dust Correction Factor Determination
13.Calibration of the Ignition Oven for the Purpose of Characterizing Reclaimed Asphalt Pavements (RAP)
14.Hot-Mix Asphalt Composite Sample Blending and Splitting Diagram Hot -Mix Asphalt Art. 1030.04
15.Hot-Mix Asphalt (HMA) Production Gradation Windage Procedure for Minus #200 (minus 75 µm) Material
16.Stripping of Hot-Mix Asphalt Mixtures Visual Identification and Classification
17.Procedure for Introducing Additives to Hot-Mix Asphalt Mixtures and Testing in the Lab
18.Ignition Oven Aggregate Mass Loss Procedure
19.Procedure for Internal Angle Calibration of Superpave Gyratory Compactors (SGCs) Using the Dynamic Angle Validator (DAV-2)
20.Segregation Control of Hot-Mix Asphalt
21.Determination of Aggregate Bulk (Dry) Specific Gravity (Gsb) of Reclaimed Asphalt Pavement (RAP) and Reclaimed Asphalt Shingles (RAS)
22.Use of Corrections Factors for Adjusting the Gradation of Cores to Estimate the Gradation of the In-Place Pavement
23.Off-Site Preliminary Test Strip Procedures for Hot-Mix Asphalt
24.Hot-Mix Asphalt Production Inspection Checklist
25.Hot-Mix Asphalt Rounding Test Values
26.Hot-Mix Asphalt Laboratory Equipment
27.Illinois Specification 101 Minimum Requirements for Electronic Balances
28.Hot-Mix Asphalt PFP Pay Adjustments
29.Hot-Mix Asphalt PFP and QCP Procedure for Determining Random Density Locations
30.Hot-Mix Asphalt PFP and QCP Random Jobsite Sampling
31.Hot-Mix Asphalt PFP Dispute Resolution
32.Hot-Mix Asphalt QCP Pay Adjustments
33.Best Practices for Hot-Mix Asphalt PFP and QCP
34.Hot-Mix Asphalt PFP and QCP Calculations of Monetary Deductions
b.Illinois Modified AASHTO procedures listed in the Manual of Test Procedures for Materials. AASHTO M 323 Standard Specification for Superpave Volumetric Mix Design AASHTO M 325 Standard Specification for Stone Matrix Asphalt (SMA) AASHTO R 30 Standard Practice for Mixture Conditioning of Hot Mix Asphalt (HMA) AASHTO R 35 Standard Practice for Superpave Volumetric Design for Asphalt Mixtures AASHTO R 46 Standard Practice for Designing Stone Matrix Asphalt (SMA) AASHTO T 30 Standard Method of Test for Mechanical Analysis of Extracted Aggregate AASHTO T 164 Standard Method of Test for Quantitative Extraction of Asphalt Binder from Hot Mix Asphalt (HMA) AASHTO T 166 Standard Method of Test for Bulk Specific Gravity (G mb) of Compacted Asphalt Mixtures Using Saturated Surface-Dry Specimens AASHTO T 209 Standard Method of Test for Theoretical Maximum Specific Gravity (Gmm) and Density of Asphalt Mixtures A rt. 1030.05 Hot-Mix Asphalt AASHTO T 283 Standard Method of Test for Resistance of Compacted Asphalt Mixtures to Moisture-Induced Damage AASHTO T 287 Standard Method of Test for Asphalt Binder Content of Asphalt Mixtures by the Nuclear Method AASHTO T 305 Standard Method of Test for Determination of Draindown Characteristics in Uncompacted Asphalt Mixtures AASHTO T 308 Standard Method of Test for Determining the Asphalt Binder Content of Asphalt Mixtures by the Ignition Method AASHTO T 312 Standard Method of Test for Preparing and Determining the Density of Asphalt Mixture Specimens by Means of the Superpave Gyratory Compactor AASHTO T 324 Standard Method of Test for Hamburg Wheel-Track Testing of Compacted Asphalt Mixtures AASHTO T 393 Standard Test Method for Determining the Fracture Potential of Asphalt Mixtures Using the Illinois Flexibility Index Test (I-FIT)
c.Illinois Modified ASTM procedures listed in the Manual of Test Procedures for Materials. ASTM D 2950 Standard Test Method for Density of Bituminous Concrete in Place by Nuclear Methods ASTM D 8159 Standard Test Method for Automated Extraction of Asphalt Binder from Asphalt Mixtures
d.Bureau of Materials Policy Memorandums.
1.1-08 Performance Graded Asphalt Binder Qualification Procedure
2.4-08 Approval of Hot-Mix Asphalt Plants and Equipment
3.6-08 Minimum Private Laboratory Requirements for Construction Materials Testing or Mix Design
4.21-08 Minimum Department and Local Agency Laboratory Requirements for Construction Materials Testing or Mix Design 0.05 Mixture Design. The Contractor shall submit designs for each required mixture. The mixture design shall be performed at a HMA mix design laboratory according to the Bureau of Materials Policy Memorandum, “Minimum Private Laboratory Requirements for Construction Materials Testing or Mix Design”. Each design shall be verified and approved by the Department as detailed in the document "Hot-Mix Asphalt Mixture Design Verification Procedure”. (a) Mixture Composition. The Job Mix Formula (JMF) represents the mix design comprised of aggregate gradation and asphalt binder content that produce the desired mix criteria in the laboratory. The ingredients of the mix design shall be combined in such proportions as to produce a mixture conforming to the composition limits by weight unless by volume is specified. The JMF shall fall within the following limits. MIXTURE COMPOSITION (% PASSING) 1/ Sieve Size IL-19.0 IL-19.0L 2/ SMA-12.5 3/ SMA-9.5 3/ IL-9.5 IL-9.5L 2/ IL-9.5FG IL-4.75 min max min max min max min max min max min max min max min max 1 1/2 in. (37.5 mm) 1 in. (25 mm) 100 100 3/4 in. (19 mm) 90 100 95 100 100 100 1/2 in. (12.5 mm) 75 89 90 99 95 100 100 100 100 100 3/8 in. (9.5 mm) 50 85 70 95 90 100 95 100 90 100 100 #4 (4.75 mm) 40 60 38 65 20 40 30 50 32 69 52 80 60 75 7/ 90 100 #8 (2.36 mm) 26 42 16 24 4/ 20 30 32 52 5/ 38 65 45 60 7/ 70 90 #16 (1.18 mm) 15 30 21 10 32 25 40 50 65 #30 (600 µm) 18 15 30 #50 (300 µm) 6 15 15 4 15 8 15 15 30 #100 (150 µm) 4 9 3 10 6 10 10 18 #200 (75 µm) 3.0 6.0 3.0 7.0 8.0 11.0 6/ 8.0 11.0 6/ 4.0 6.0 4.0 8.0 4.0 6.5 7.0 9.0 6/ #635 (20 µm) ≤ 3 ≤ 3 Dust/Asphalt Binder Ratio 1.0 1.0 1.0 1.0 1.0 1.0 Notes: 1/ Based on percent of total aggregate weight. 2/ Percent passing the #30 (600 µm) sieve shall be less than 50 percent of the percentage passing the #4 (4.75 mm) sieve for IL- 19.0L and #8 (2.36 mm) for the IL-9.5L. 3/ When the bulk specific gravity (Gsb) of the component aggregates vary by more than 0.2 0, the blend gradations shall be based on percent by volume. 4/ When establishing the Adjusted Job Mix Formula (AJMF) the percent passing the #8 (2.36 mm) sieve shall not be adjusted above 24 percent. 5/ The mixture composition shall not exceed 44 percent passing the #8 (2.36 mm) sieve for surface courses with Ndesign = 90. 6/ Additional minus #200 ( 75 µm) material required by the mix design shall be mineral filler, unless otherwise approved by the Engineer. 7/ When the mixture is used as a binder, the maximum shall be increased by 5 percent passing. Art. 1030.05 A rt. 1030.05 Hot-Mix Asphalt (b) Volumetric Requirements. The target value for the air voids of the HMA shall be 4.0 percent at the design number of gyrations. The voids in the mineral aggregate (VMA) of the HMA design shall be based on the nominal maximum size of the aggregate in the mix, and shall conform to the following requirements. Voids in the Mineral Aggregate (VMA), % Minimum for Ndesign Mix Design 30 50 70 80 90 IL-19.0 13.5 13.5 13.5 IL-9.5 15.0 15.0 15.0 IL-9.5FG 15.0 15.0 15.0 IL-4.75 1/ 18.5 SMA-12.5 1/ 16.0 17.0 SMA-9.5 1/ 16.0 17.0 IL-19.0L 13.5 IL-9.5L 15.0 1/ Maximum draindown shall be 0.3 percent according to Illinois Modified AASHTO T 305. (c ) Contractor Determination of Tensile Strength and Tensile Strength Ratio (TSR). The mixture designer shall determine if the proposed mix design meets minimum tensile strength requirements and is resistant to stripping. These determinations shall be made based on tests performed according to Illinois Modified AASHTO T 283. The proposed mix design shall have a minimum conditioned tensile strength of 60 psi (415 kPa) for non-polymer modified performance graded (PG) asphalt binders and 80 psi (550 kPa) for polymer modified PG asphalt binders except modified PG 64-28 or lower asphalt binders which shall have a minimum tensile strength of 70 psi (485 kPa). The conditioned to unconditioned TSR shall be equal to or greater than 0.85 for 6 in. (150 mm) specimens. Mixtures, either with or without an additive, with TSRs less than 0.85 for 6 in. (150 mm) specimens will be considered unacceptable. Also, the conditioned tensile strength for mixtures containing an anti-strip additive shall not be lower than the conditioned tensile strength of the same mixture without the anti-strip additive. I f it is determined that an additive is required, the additive may be hydrated lime, slaked quicklime, or a liquid additive. Dry hydrated lime shall be added at a minimum rate of 1.0 percent by weight of total dry aggregate. Slurry shall be added in such quantity as to provide the required amount of hydrated lime solids by weight of total dry aggregate. The method of application shall be according to Article 1102.01(a)(8). Hot-Mix Asphalt Art. 1030.05
d.Mix Design Verification Testing. Mix designs shall be submitted for verification according to the document “Hot-Mix Asphalt Mixture Design Verification Procedure”. High ESAL mixture designs shall meet the following requirements for tensile strength, TSR, Hamburg wheel, and I-FIT criteria. Low ESAL mixture designs shall meet TSR and I-FIT criteria. If a mix fails the Department’s verification testing, the Contractor shall make necessary changes to the mix and provide passing volumetric, tensile strength, TSR, Hamburg wheel, and I-FIT procedure results before resubmittal. The Department will verify the passing results.
1.Tensile Strength. The minimum allowable conditioned tensile strength shall be according to Article 1030.05(c).
2.TSR. The minimum TSR shall be according to Article 1030.05(c).
3.Hamburg Wheel Test. The maximum allowable rut depth shall be 0.5 in. (12.5 mm). The minimum number of wheel passes at the 0.5 in. (12.5 mm) rut depth is based on the high temperature binder grade of the mix as specified in the mix requirements table on the plans and shall be according to the following. Illinois Modified AASHTO T 324 Requirements 1/ PG Grade Minimum Number of Wheel Passes PG 58-xx (or lower) 5,000 PG 64-xx 7,500 PG 70-xx 15,000 2/ PG 76-xx (or higher) 20,000 2/ 1/ When WMA is produced at temperatures of 275 ± 5 °F (135 ± 3 °C) or less, loose mix shall be oven aged at 270 ± 5 °F (132 ± 3 °C) for two hours prior to gyratory compaction of Hamburg wheel specimens. 2/ For IL-4.75 binder course, the minimum number of wheel passes shall be reduced by 5,000.
4.I-FIT. The minimum flexibility index (FI) shall be as follows. Illinois Modified AASHTO T 393 Mixture Short Term Aging, Minimum FI Long Term Aging, Minimum FI 2/ HMA 1/ 8.0 5.0 3/ SMA 16.0 10.0 IL-4.75 12.0 - 1/ All mix designs, except for SMA and IL-4.75 mixtures. Art. 1030.06 Hot-Mix Asphalt 2/ Required for surface courses only. 3/ Production long term aging FI for HMA shall be a minimum of 4.0.
1030.06 Quality Management Program. The Quality Management Program
(QMP) will be shown on the plans as Pay for Performance (PFP), Quality Control for Performance (QCP), or Quality Control / Quality Assurance (QC/QA) for each HMA mixture or full-depth pavement according to the following. PFP shall be used on interstate, freeway, and expressway resurfacing and full- depth projects having a minimum quantity of 8,000 tons (7,260 metric tons) per mix. QCP shall be used on mainline mixture quantities between 1,200 and 8,000 tons (1,016 and 7,620 metric tons) as well as shoulder applications greater than 8 ft (2.4 m) wide and at least 1,200 tons (1,016 metric tons). QC/QA shall be used for mixtures less than 1,200 tons (1,016 metric tons), shoulder applications 8 ft (2.4 m) wide or less, hand method, variable width shoulders, incidental surfacing, intermittent resurfacing, driveways, entrances, minor sideroads, sideroad returns, patching, turn lanes less than 500 ft (152 m) in length, temporary pavement, and shared-use paths or bike lanes unless paved with the mainline pavement. The following shall apply to PFP, QCP, and QC/QA.
a.Laboratory. The Contractor shall provide a laboratory, at the plant, according to the Bureau of Materials Policy Memorandum, “Minimum Private Laboratory Requirements for Construction Materials Testing or Mix Design”. The requirements for the laboratory and equipment for production and mix design are listed in the document "Hot-Mix Asphalt Laboratory Equipment". The Engineer may inspect measuring and testing devices at any time to confirm both calibration and condition. If laboratory equipment becomes inoperable, the Contractor shall cease mix production. If the Engineer determines the equipment is not within the limits of dimensions or calibration described in the appropriate test method, the Engineer may stop production until corrective action is taken.
b.Annual QC Plan and QC Addenda. The Contractor shall submit, in writing to the Engineer, a proposed Annual QC Plan following the format of the document “Model Annual Quality Control Plan for Hot-Mix Asphalt Production" for each HMA plant for approval before each construction season. This shall include documentation that each HMA plant has been calibrated and approved by the Department. Job-specific QC Addenda to the Annual QC Plan must be submitted in writing to the Engineer following the format of the document "Model Quality Control Addendum for Hot-Mix Asphalt Production" for approval before the pre-construction conference. The Annual QC Plan and the QC Addenda shall address all elements involved in the production and quality control of the HMA incorporated in the project. Hot-Mix Asphalt Art. 1030.06 Production of HMA shall not begin without written approval of the Annual QC Plan and QC Addenda by the Engineer. The approved Annual QC Plan and QC Addenda shall become part of the contract between the Department and the Contractor but shall not be construed, in itself, as acceptance of any HMA produced. Failure to execute the contract according to the approved Annual QC Plan and QC Addenda shall result in suspension of HMA production or other appropriate actions as directed by the Engineer. The Annual QC Plan and QC Addenda may be amended during the progress of the work, by either party, subject to mutual agreement. Revisions shall require proper justification and be provided to the Department by the Contractor to ensure product quality. Any revision in the Annual QC Plan or QC Addenda must be approved in writing by the Engineer.
c.General Quality Control (QC) by the Contractor. The Contractor’s quality control activities shall ensure mixtures meet contract requirements.
1.Inspection and Testing. The Contractor shall perform or have performed the inspection and testing required to conform with contract requirements. QC includes the recognition of obvious defects and their immediate correction. QC may require increased testing, communication of test results to the plant or the job site, modification of operations, suspension of HMA production, rejection of material, or other actions as appropriate. The Engineer shall be immediately notified of any failing tests and subsequent remedial action. Passing tests shall be reported to the Engineer prior to the start of the next day’s production.
2.Personnel. The Contractor shall provide a QC Manager who shall have overall responsibility and authority for quality control. This individual shall have successfully completed the Department's “Hot-Mix Asphalt Level II” course. In addition to the QC Manager, the Contractor shall provide sufficient personnel to perform the required visual inspections, sampling, testing, and documentation in a timely manner. Mix designs shall be developed by personnel who have successfully completed the Department's “Hot- Mix Asphalt Level III” course. Technicians performing mix design testing and plant sampling/testing shall have successfully completed the Department's “Hot-Mix Asphalt Level I” course. The Contractor may also provide a Gradation Technician who has successfully completed the Department's "Gradation Technician Course" to run gradation tests only under the supervision of a Hot-Mix Asphalt Level II Technician. The Contractor shall provide a Hot-Mix Asphalt Density Tester who has successfully completed the Department's "Nuclear Density Testing” course to run all nuclear density tests on the job site. Art. 1030.07 Hot-Mix Asphalt Only quality control personnel shall perform the required QC duties. The Contractor is referred to the document "Hot-Mix Asphalt QC Personnel Responsibilities and Duties Checklist" for a description of personnel qualifications and duties.
d.Additional Contractor and Department Duties.
1.The Engineer will initiate and witness asphalt binder sampling by the Contractor at a minimum frequency of one injection line-sample per week, per HMA plant. Sample containers will be furnished by the Department. The Engineer will take possession of and submit the properly identified samples, according to Policy Memorandum 1-08, to the Central Bureau of Materials for testing.
2.Immediately upon completion of coring for density samples or thickness checks, the Contractor shall remove water from the core holes and fill the holes with packaged, dry, rapid hardening mortar or concrete. The cementitious material shall be mixed in a separate container, placed in the hole, consolidated by rodding, and struck-off flush with the adjacent pavement. Depressions in the surface of filled core holes greater than 1/4 in. (6 mm) at the time of final inspection shall require removal and replacement of the fill materials.
1030.07 Pay for Performance (PFP). PFP is a program that evaluates pay
parameters using percent within limits to determine a pay adjustment. Monetary deductions for dust/AB ratios and unconfined edge densities may also apply.
a.Definitions.
1.Quality Control (QC). QC includes all production and construction activities by the Contractor necessary to achieve a level of quality.
2.Quality Assurance (QA). QA includes all monitoring and testing activities by the Engineer necessary to assess product quality, to identify acceptability of the product, and to determine payment.
3.Percent Within Limits (PWL). PWL is the percentage of material within the quality limits for a given quality characteristic.
4.Quality Characteristic. The characteristics that are evaluated by the Department to determine payment using PWL. The quality characteristics (i.e. pay parameters) for this program are air voids, field VMA, and density. Field VMA will be calculated using the combined aggregates bulk specific gravity (Gsb) from the mix design.
5.Quality Level Analysis (QLA). QLA is a statistical procedure for determining the amount of in-place mixture within specification limits.
6.Mixture Lot. A mixture lot will begin once an acceptable test strip has been completed and the adjusted job mix fomula (AJMF) has been determined. If the test strip is waived, the mixture lot will begin with the start of production. A mixture lot consists of ten mixture sublots. If Hot-Mix Asphalt Art. 1030.07 seven or fewer mixture sublots remain at the end of production of a mixture, the test results for these sublots will be combined with the previous lot for evaluation of PWL and pay factors.
7.Mixture Sublot. A mixture sublot for air voids and field VMA will be a maximum of 1,000 tons (910 metric tons). If the project quantity is less than 8,000 tons (7,260 metric tons), the sublot size will be adjusted to achieve a minimum of 8 tests.
a.If the remaining quantity is greater than 200 tons (180 metric tons) but less than 1,000 tons (910 metric tons), the last mixture sublot will be that quantity.
b.If the remaining quantity is 200 tons (180 metric tons) or less, the quantity shall be combined with the previous mixture sublot.
8.Density Lot. A density lot consists of 30 density intervals. If 19 or fewer density intervals remain at the end of production of a mixture, the test results for these sublots will be combined with the previous lot for evaluation of percent within limits and pay factors.
9.Density Interval. A density interval will be every 0.2 miles (320 m) for lift thicknesses of 3 in. (75 mm) or less and 0.1 miles (160 m) for lift thicknesses greater than 3 in. (75 mm). In cases where paving is completed over multiple lanes in a single pass of one or more pavers to eliminate unconfined edges or cold joints between lanes, the paving lane is defined as the total combined width of the lanes paved in that single pass. If the paving lane width is greater than 20 ft (6 m), the density intervals will be every 0.1 mi. (160 m) for lift thicknesses of 3 in. (75 mm) or less and 0.05 mi. (80 m) for lift thicknesses greater than 3 in. (75 mm). If the last density interval for a lift is less than 200 ft (60 m), it will be combined with the previous density interval.
10.Density Specimen. A density specimen shall consist of a 4 in. (100 mm) core taken at a random test location within each density interval.
11.Density Test. A density test shall consist of testing a density specimen according to Illinois Modified AASHTO T 166. When establishing the target density, the HMA maximum theoretical specific gravity (G mm) will be based on the running average of four Department test results including the current day of production. Initial Gmm will be based on the average of the first four test results.
12.Unconfined Edge Density. The location of the unconfined edge density test sample will be randomly selected within each 0.5 mile (800 m) sublot for each mixture with an unconfined edge according to the document “Hot-Mix Asphalt PFP and QCP Calculations of Monetary Deductions”. The last sublot may be less than 0.5 mile (800 m) but at least 200 ft (60 m). If longitudinal joint sealant (LJS) is used at a joint, the joint will not be included in the unconfined edge density testing. Art. 1030.07 Hot-Mix Asphalt
13.Pay Adjustment. The pay adjustment is calculated using the test results of the pay parameters (air voids, field VMA and density).
14.Combined Full-Depth Pay Adjustment. For full-depth pavements, the composite pay factors for all incorporated mixtures are combined to determine the combined full-depth pay adjustment.
15.Monetary Deduction. In addition to the pay adjustment for the pay parameters air voids, field VMA, and density for each mix or full-depth pavement, it will be determined if there is a monetary deduction for dust/AB ratio and/or unconfined edge density.
b.Quality Control (QC) by the Contractor. The Contractor’s QC plan shall include the schedule of testing for both quality characteristics used to determine pay and other quality characteristics required to control the product. The schedule shall include sample time and location. The minimum test frequency shall be according to the following. Minimum Quality Control Sampling and Testing Requirements Quality Characteristic Minimum Test Frequency Sampling Location Mixture Gradation 1/day per QC Plan Asphalt Binder Content Gmm Gmb Density per QC plan per QC Plan The Contractor shall submit QC test results to the Engineer within 48 hours of sampling.
c.Initial Production Testing. The Contractor shall split and test the first two samples with the Department for comparison purposes. The Contractor shall complete all tests and report all results to the Engineer within two working days of sampling. The Engineer will make Department test results of the initial production testing available to the Contractor within two working days from the receipt of the samples.
d.Additional Contractor Duties. The Contractor shall obtain the random mixture samples identified by the Engineer according to the document “Hot- Mix Asphalt PFP and QCP Random Jobsite Sampling”. One composite sample per sublot shall be collected in the presence of the Engineer. The composite sample shall be split into four equal mix samples. The Contractor shall transport the Department’s mix sample to the location designated by the Engineer. The Contractor shall provide personnel and equipment to collect density specimens for the Engineer. Core locations will be determined by the Engineer following the document “Hot-Mix Asphalt PFP and QCP Procedure for Determining Random Density Locations”. The Contractor shall cut the cores within the same day and prior to opening to traffic unless otherwise Hot-Mix Asphalt Art. 1030.07 approved by the Engineer. The Contractor shall transport the Department’s secured density specimens to the location designated by the Engineer.
e.Quality Assurance (QA) by the Engineer. The Department’s laboratories which conduct PFP testing will participate in the AASHTO re:source’s (formerly AMRL) Proficiency Sample Program. The Engineer will test each mixture sublot for air voids, field VMA, and dust/AB ratio; and each density interval for density to determine payment according to the document “Hot- Mix Asphalt PFP Pay Adjustments”. A sublot shall begin once an acceptable test-strip has been completed and the AJMF has been determined.
1.Air Voids, Field VMA, and Dust/AB Ratio. For each sublot, the Engineer will determine the random tonnage for the sample and the Contractor shall be responsible for obtaining the sample according to the document “Hot-Mix Asphalt PFP and QCP Random Jobsite Sampling”. The Engineer will not disclose the random location of the sample until after the truck containing the random tonnage has been loaded and en-route to the project.
2.Density. For each density interval, the Engineer will determine the random location for the density test according to the document “Hot-Mix Asphalt PFP and QCP Procedure for Determining Random Density Locations”. The Engineer will not disclose the random location of the sample until after the final rolling. The Engineer will witness and secure all mixture and density samples.
f.Test Results. The Department’s test results for the first mixture sublot and density interval, of every lot will be available to the Contractor within three working days from the receipt of secured samples. Test results for remaining sublots will be available to the Contractor within ten working days from receipt of the secured sample that was delivered to the Department’s testing facility or a location designated by the Engineer. The Engineer will maintain a complete record of Department test results. Copies will be furnished upon request. The records will contain, at a minimum, all the Department test results, raw data, random numbers used and resulting calculations for sampling locations, and QLA calculations.
g.Dispute Resolution. Dispute resolution testing will only be permitted when the Contractor submits their split sample test results prior to receiving Department split sample test results and meets the requirements listed in the document “Hot-Mix Asphalt PFP Dispute Resolution”. If dispute resolution is chosen, the Contractor shall submit a request in writing within four working days of receipt of the Department results of the QLA for the lot in question. The Engineer will document receipt of the request. The request shall specify Method 1 (pay parameter dispute) or Method 2 (individual parameter dispute) as defined in the document “Hot-Mix Asphalt PFP Dispute Resolution”. The Central Bureau of Materials laboratory will be used for dispute resolution testing. Art. 1030.08 Hot-Mix Asphalt
h.Acceptance by the Engineer. To be considered acceptable, all the Department’s test results shall be within the acceptable limits listed below. Acceptable Limits Parameter Acceptable Range Air Voids 2.0 – 6.0 % Field VMA -1.0 – +3.0 % 1/ Density IL-19.0, IL-9.5, IL-9.5FG, IL-4.75 90.0 – 98.0 % SMA 12.5, SMA 9.5 92.0 – 98.0 % Dust / AB Ratio 0.4 – 1.6 2/ 1/ Based on minimum required field VMA as stated in the mix design volumetric requirements in Article 1030.05(b). 2/ Does not apply to SMA. In addition, the PWL for any quality characteristic shall be 50 percent or above for any lot. No visible pavement distress shall be present such as, but not limited to, segregation, excessive coarse aggregate fracturing or flushing.
1030.08 Quality Control for Performance (QCP). QCP is a program that
uses step-based pay without an incentive to determine pay adjustment. A monetary deduction for dust/AB ratios also applies.
a.Definitions.
1.Quality Control (QC). QC includes all production and construction activities by the Contractor necessary to achieve a level of quality.
2.Quality Assurance (QA). QA includes all monitoring and testing activities by the Engineer necessary to assess product quality, to identify acceptability of the product, and to determine payment.
3.Pay Parameters. Pay parameters are air voids, field VMA and density. Field VMA will be calculated using the combined aggregates bulk specific gravity (Gsb) from the mix design.
4.Mixture Lot. A mixture lot will begin once an acceptable test strip has been completed and the AJMF has been determined. If the test strip is waived, a mixture lot will begin with the start of production. A mixture lot will consist of four sublots unless it is the last or only lot, in which case it may consist of as few as one sublot.
5.Mixture Sublot. A mixture sublot for air voids, field VMA, and dust/AB ratio will be a maximum of 1,000 tons (910 metric tons).
a.If the remaining quantity is greater than 200 tons (180 metric tons) but less than 1,000 tons (910 metric tons), the last mixture sublot will be that quantity. Hot-Mix Asphalt Art. 1030.08
b.If the remaining quantity is 200 tons (180 metric tons) or less, the quantity will be combined with the previous mixture sublot.
6.Density Interval. Density intervals will be every 0.2 miles (320 m) for lift thicknesses of 3 in. (75 mm) or less and 0.1 miles (160 m) for lift thicknesses greater than 3 in. (75 mm). In cases where paving is completed over multiple lanes in a single pass of one or more pavers to eliminate unconfined edges or cold joints between lanes, the paving lane is defined as the total combined width of the lanes paved in that single pass. If the paving lane width is greater than 20 ft (6 m), the density intervals will be every 0.1 mi. (160 m) for lift thicknesses of 3 in. (75 mm) or less and 0.05 mi. (80 m) for lift thicknesses greater than 3 in. (75 mm). If the last density interval for a lift is less than 200 ft (60 m), it will be combined with the previous density interval.
7.Density Sublot. A density sublot will be the average of five consecutive density intervals.
a.If fewer than three density intervals remain outside a density sublot, they will be included in the previous density sublot.
b.If three to five density intervals remain, they will be considered a density sublot.
8.Density Specimen. A density specimen shall consist of a 4 in. (100 mm) core taken at a random location within each density interval.
9.Density Test. A density test shall consist of testing a density specimen according to Illinois Modified AASHTO T 166. When establishing the target density, the HMA maximum theoretical specific gravity (G mm) will be based on the running average of four Department test results. Initial G mm will be based on the average of the first four test results. If less than four G mm results are available, an average of all available Department Gmm test results will be used.
10.Pay Adjustment. The pay adjustment is calculated using the test results of the pay parameters (air voids, field VMA and density).
11.Combined Full-Depth Pay Adjustment. For full-depth pavements, the composite pay factors for all incorporated mixtures are combined to determine the combined full-depth pay adjustment.
12.Monetary Deduction. In addition to the pay adjustment for the pay parameters air voids, field VMA, and density for each mix or full-depth pavement, it will be determined if there is a monetary deduction for dust/AB ratio.
b.Quality Control (QC) Testing by the Contractor. The Contractor’s QC plan shall include the schedule of testing for both pay parameters and non-pay Art. 1030.08 Hot-Mix Asphalt parameters necessary to control the product. The minimum test frequency shall be according to the following table. Minimum Quality Control Mixture Sampling and Testing Requirements Quality Characteristic Minimum Test Frequency Air Voids Gmb 1 per sublot Gmm Washed Mixture Gradation Asphalt Binder Content Dust/AB Ratio 1/ Field VMA 1/ Dust/AB ratio is not used in the calculation of the pay adjustment but is used to verify the mix is within acceptable limits and determine if there are monetary deductions for this parameter. The Contractor’s results from mix sample testing of split samples, in conjunction with additional quality control tests, shall be used to control production. The Contractor shall submit their mix sample test results from the split sample to the Engineer within 48 hours of the time of sampling.
c.Additional Contractor Duties. The Contractor shall obtain the random mixture samples at locations identified by the Engineer according to the document, “Hot-Mix Asphalt PFP and QCP Random Jobsite Sampling”. One composite sample per sublot shall be collected in the presence of the Engineer. The composite sample shall be split into four equal mix samples. The Contractor shall transport the Department’s mix sample to the location designated by the Engineer. The Contractor shall provide personnel and equipment to collect density specimens for the Engineer. Core locations will be determined by the Engineer following the document “Hot-Mix Asphalt PFP and QCP Procedure for Determining Random Density Locations”. The Contractor shall cut the cores within the same day and prior to opening to traffic unless otherwise approved by the Engineer. The Contractor shall transport the Department’s secured density specimens to the location designated by the Engineer.
d.Quality Assurance (QA) by the Engineer. The Department’s laboratories which conduct QCP testing will participate in the AASHTO re:source’s (formerly AMRL) Proficiency Sample Program. Quality Assurance by the Engineer will be as follows.
1.Air Voids, Field VMA, and Dust/AB Ratio. The Engineer will determine the random tonnage for the sample and the Contractor shall be responsible for obtaining the sample according to the document “Hot- Mix Asphalt PFP and QCP Random Jobsite Sampling Procedure”. The Engineer will not disclose the random location of the sample until after Hot-Mix Asphalt Art. 1030.08 the truck containing the random tonnage has been loaded and en-route to the project.
2.Density. For each density interval, the Engineer will determine the random location for the density test according to the document “Hot-Mix Asphalt PFP and QCP Procedure for Determining Random Density Locations”. The Engineer will not disclose the random location of the sample until after the final rolling. The Engineer will witness and secure all mixture samples to be tested by the Department. The Engineer will select at random one sublot mixture sample from each lot for testing of air voids, field VMA and dust/AB ratio. The Engineer will test a minimum of one mixture sample per project. The Engineer will test all pavement cores for density. QA test results will be available to the Contractor within ten working days from receipt of split mixture samples and cores from the last sublot from each lot. The Engineer will maintain a complete record of all Department test results and copies will be provided to the Contractor with each set of sublot results. The records will contain, at a minimum, the originals of all Department test results and raw data, random numbers used and resulting calculations for sampling locations, and pay calculations. When the QA mixture test results are compared to QC results for a sublot and they are within the precision limits listed in the following table, the QA sublot results will be defined as the final mixture results for that sublot. When QA results are compared to QC results for a sublot and they do not meet the precision limits listed in the following table, the Department will verify the results by testing the retained split sample. The retest results will replace all of the original results and will be defined as the final mixture results for that sublot. If the final mixture QA results for the random sublot do not meet the 100 percent sublot pay factor limits listed in the document “Hot-Mix Asphalt QCP Pay Adjustments” or do not compare to QC results within the precision limits in the following table, the Engineer will test all sublot split mixture samples for the lot. Test Parameter Limits of Precision Gmb 0.030 Gmm 0.026 Field VMA 1.0 % If the dust/AB ratio results for the random sublot do not fall within 0.6 and 1.2, the Department will test the remaining sublots for that lot to determine the dust/AB ratio monetary deductions.
e.Acceptance by the Engineer. To be acceptable, all of the Department’s test results will be within the acceptable limits listed in the following table. Art. 1030.09 Hot-Mix Asphalt Test Parameter Acceptable Limits Air Voids 2.0 – 6.0 % Field VMA -1.0 – +3.0 % 1/ Density IL-19.0, IL-9.5, IL-9.5FG, IL-4.75 90.0 – 98.0 % SMA 12.5, SMA 9.5 92.0 – 98.0 % Dust / AB Ratio 0.4 – 1.6 2/ 1/ Based on minimum required VMA as stated in the mix design volumetric requirements in Article 1030.05(b). 2/ Does not apply to SMA. In addition, no visible pavement distresses shall be present such as, but not limited to, segregation, excessive coarse aggregate fracturing or flushing.
1030.09 Quality Control / Quality Assurance (QC/QA). QC/QA is a method
specification acceptance program with no pay adjustments or deductions.
a.Required Mixture Tests. The Contractor shall complete testing of all required mixture samples within 3 1/2 hours of sampling.
1.Mixture Sampling. The Contractor shall obtain required mixture samples according to the document, “Hot-Mix Asphalt QC/QA Initial Daily Plant and Random Samples”.
2.Frequency. The Contractor shall use the test methods identified to perform the following mixture tests at a frequency not less than that indicated. Hot-Mix Asphalt Art. 1030.09 Frequency of Mixture Tests 3/, 4/ Parameter Production Tons (Metric Tons) Per Day Initial Daily Plant Tests Daily Random Tests Test Method Aggregate Gradation of Washed Ignition Oven or Solvent Extraction All 1 1 Illinois Modified AASHTO T 30 Asphalt Binder Content All 1 1 Illinois Modified AASHTO T 164, T 287, T 308 1/ Field VMA 2/ < 1200 (1090) 1 1 for first 2 days Illinois Modified AASHTO R 35 ≥ 1200 (1090) 1 1 Air Voids Bulk Specific Gravity of Gyratory Sample < 1200 (1090) 1 1 for first 2 days Illinois Modified AASHTO T 312 ≥ 1200 (1090) 1 1 Maximum Specific Gravity of Mixture < 1200 (1090) 1 1 for first 2 days Illinois Modified AASHTO T 209 ≥ 1200 (1090) 1 1 Draindown IL-4.75, SMA-12.5 and SMA-9.5 All 1 Illinois Modified AASHTO T 305 1/ The ignition oven shall not be used if the calibration factor exceeds 1.5 percent. 2/ The combined G sb used in the VMA calculation shall be listed in the approved mix design. 3/ If the day's production is less than 250 tons (225 metric tons) per mix, gradation analysis, air voids, field VMA and asphalt binder content tests will not be required on a specific mixture. A minimum of one set of mixture tests for each mix shall be performed for each five consecutive production-day period when the accumulated tonnage produced in that period exceeds 500 tons (450 metric tons). A Hot-Mix Asphalt Level II Technician shall oversee all QC operations. 4/ If the required tonnage of any mixture for a single pay item is less than 250 tons (225 metric tons) in total, the Contractor may propose intentions of waiving the "Required Mixture Tests" in the QC Addenda. The mixture shall be produced using a mix design that has been verified as specified and validated by the Department's recent acceptable field test data. A Hot-Mix Asphalt Level II Technician shall oversee all quality control operations for the mixture. Art. 1030.09 Hot-Mix Asphalt
3.Dust/AB Ratio and Moisture Content. During production, the dust/AB ratio and the moisture content of the mixture at discharge from the mixer shall meet the following. Parameter All Mixtures Dust/AB Ratio 1/ 0.6 to 1.2 Moisture, max. 0.3 % 1/ Does not apply to SMA. If at any time the dust/AB ratio or moisture content of the mixture falls outside the stated limits, production of the HMA shall cease. The cause shall be determined and corrective action satisfactory to the Engineer shall be initiated prior to resuming production.
4.Additional HMA Samples. The Contractor shall, when necessary, take and test additional samples (designated "check" samples) at the plant during HMA production. These samples in no way replace the required plant samples described above. Check samples shall be tested only for the parameters deemed necessary by the Contractor. Check sample test results shall be noted in the Plant Diary but shall not be plotted on the control charts. The Contractor shall detail the situations in which check samples will be taken in the Annual QC Plan.
b.Required Density Tests. The Contractor shall control the compaction process by testing the mix density at random locations as determined according to the document "Hot-Mix Asphalt QC/QA Procedure for Determining Random Density Locations", and recording the results on forms approved by the Engineer. The Contractor shall follow the density testing procedures detailed in the document "Illinois Modified ASTM D 2950, Standard Test Method for Density of Bituminous Concrete In-Place by Nuclear Method". When required, the Contractor shall be responsible for establishing the correlation to convert nuclear density results to core densities according to the document "Procedure for Correlating Nuclear Gauge Densities with Core Densities for Hot-Mix Asphalt”. The Engineer may require a new nuclear/core correlation if the Contractor’s gauge is recalibrated during the project.
1.Paving. For paving, density tests shall be performed at randomly selected locations within 0.5 mile (800 m) intervals for each lift of 3 in. (75 mm) or less in thickness. For lifts in excess of 3 in. (75 mm) in thickness, a test shall be performed within 0.25 mile (400 m) intervals. In no case shall more than one-half day's production be completed without performing QC density testing. Longitudinal joint density testing shall also be performed at each random density test location. Longitudinal joint testing shall be located at a distance equal to 4 in. (100 mm) from each pavement edge. Hot-Mix Asphalt Art. 1030.09
a.Confined Edge. Each confined edge density shall be represented by a one-minute nuclear density reading or a core density and shall be included in the average of density readings or core densities taken across the mat which represent the Individual Test.
b.Unconfined Edge. Each unconfined edge joint density shall be represented by an average of three one-minute nuclear density readings or a single core density at the given density test location and shall meet the density requirements specified in the Density Control Limits table below. The three one-minute nuclear density readings shall be spaced 10 ft (3 m) apart longitudinally along the unconfined pavement edge and centered at the random density test location. Density testing will not be required on longitudinal joints treated with longitudinal joint sealant (LJS).
2.Patching. For patching, density tests shall be performed each day on randomly identified patches following the document “Hot-Mix Asphalt QC/QA Procedure for Determining Random Density Locations”. Density testing frequency shall be a minimum of one test per half day of production per mix.
c.Control Limits. The AJMF values shall be plotted on the control charts within the following control limits. CONTROL LIMITS Parameter IL-19.0, IL-9.5, IL-9.5FG, IL-19.0L, IL-9.5L SMA-12.5, SMA-9.5 IL-4.75 Individual Test Moving Avg. of 4 Individual Test Moving Avg. of 4 Individual Test Moving Avg. of 4 % Passing: 1/ 1/2 in. (12.5 mm) ± 6 % ± 4 % ± 6 % ± 4 % 3/8 in. (9.5mm) ± 4 % ± 3 % # 4 (4.75 mm) ± 5 % ± 4 % ± 5 % ± 4 % # 8 (2.36 mm) ± 5 % ± 3 % ± 4 % ± 2 % # 16 (1.18 mm) ± 4 % ± 2 % ± 4 % ± 3 % # 30 (600 µm) ± 4 % ± 2.5 % ± 4 % ± 2.5 % Total Dust Content # 200 (75 µm) ± 1.5 % ± 1.0 % ± 1.5 % ± 1.0 % Asphalt Binder Content ± 0.3 % ± 0.2 % ± 0.2 % ± 0.1 % ± 0.3 % ± 0.2 % Air Voids ± 1.2 % ± 1.0 % ± 1.2 % ± 1.0 % ± 1.2 % ± 1.0 % Field VMA 2/ -0.7 % -0.5 % -0.7 % -0.5 % -0.7 % -0.5 % 1/ Based on washed ignition oven or solvent extraction gradation. Art. 1030.09 Hot-Mix Asphalt 2/ Allowable limit below minimum design VMA requirement DENSITY CONTROL LIMITS Mixture Composition Ndesign Individual Test (includes confined edges) Unconfined Edge Joint Density, minimum IL-4.75 50 93.0 – 97.4 % 91.0 % IL-9.5FG 50 – 90 93.0 – 97.4 % 91.0 % IL-9.5 90 92.0 – 96.0 % 90.0 % IL-9.5, IL-9.5L, < 90 92.5 – 97.4 % 90.0 % IL-19.0 90 93.0 – 96.0 % 90.0 % IL-19.0, IL-19.0L < 90 93.0 1/ – 97.4 % 90.0 % SMA-9.5, SMA-12.5 50 or 80 93.5 – 97.4 % 91.0 % 1/ 92.0 percent when placed as first lift on an unimproved subgrade.
d.Control Charts. Standardized control charts shall be maintained by the Contractor at the laboratory and shall be accessible at all times for review by the Engineer. Control limits for each required parameter, both individual tests and the average of four tests, shall be plotted on control charts as described in the document "Hot-Mix Asphalt QC/QA Control Charts”. The results of individual required tests listed in Article 1030.09(c) obtained by the Contractor shall be recorded on the control chart immediately upon completion of a test, but no later than 24 hours after sampling. Only the required tests and resamples shall be recorded on the control chart. Control Chart Requirements All Mixtures Gradation 1/ 3/ % Passing Sieves: 1/2 in. (12.5 mm) 2/ # 4 (4.75 mm) # 8 (2.36 mm) # 30 (600 µm) Total Dust Content 1 # 200 (75 µm) Volumetric Asphalt Binder Content Bulk Specific Gravity Maximum Specific Gravity of Mixture Air Voids Density Field VMA 1/ Based on washed ignition oven or solvent extraction. 2/ Does not apply to IL-4.75. Hot-Mix Asphalt Art. 1030.09 3/ SMA also requires the 3/8 in. (9.5mm) sieve.
e.Corrective Action for Required Mixture Tests.
1.Individual Test Results. When an individual test result exceeds its control limit, the Contractor shall immediately resample and retest. If at the end of the day no material remains from which to resample, the first sample taken the following day shall serve as the resample as well as the first sample of the day. This result shall be recorded as a retest. If the retest passes, the Contractor may contine the required test frequency. Additional check samples should be taken to verify mix compliance.
a.If the retest for air voids, field VMA, or asphalt binder content exceeds control limits, HMA production shall cease and immediate corrective action shall be instituted by the Contractor. After corrective action, HMA production shall be restarted, the HMA production shall be stabilized, and the Contractor shall immediately resample and retest. The corrective action shall be documented.
b.Gradation. For gradation retest failures, immediate corrective action shall be instituted by the Contractor. After corrective action, the Contractor shall immediately resample and retest. The corrective action shall be documented.
2.Moving Average. When the moving average values trend toward the moving average control limits, the Contractor shall take corrective action and increase the sampling and testing frequency. The corrective action shall be documented. The Contractor shall notify the Engineer whenever the moving average values exceed the moving average control limits. If two consecutive moving average values fall outside the moving average control limits, the Contractor shall cease mixture production. Corrective action shall be immediately instituted by the Contractor. Mixture production shall not be reinstated without the approval of the Engineer.
3.Dust Control. If the washed ignition oven or solvent extraction gradation test results indicate fluctuating dust, corrective action to control the dust shall be taken. If the Engineer determines that positive dust control equipment is necessary, the equipment as specified in
Article 1102 — 01(c)(7) shall be installed prior to the next construction
season.
f.Corrective Action for Required Nuclear Density Tests. When an individual nuclear density test exceeds the control limits, the Contractor shall immediately retest in a location that is halfway between the failed test site and the finish roller. If the retest passes, the Contractor shall continue the normal density test frequency. An additional density check test should be performed to verify the mix compaction. Art. 1030.09 Hot-Mix Asphalt If the retest fails, the Contractor shall immediately conduct one of the following procedures.
1.Low Density. If the failing density retest indicates low densities, the Contractor shall immediately increase the compaction effort, review all mixture test results representing the HMA being produced, and make corrective action as needed. The Contractor shall immediately perform a second density retest within the area representing the increased compaction effort and mixture adjustments.
2.High Density. If the failing density retest indicates high densities, the Contractor shall cease production and placement until all mixture test results are reviewed and corrective action is taken. If the high density failure is a result of a change in the mixture, existing material in the surge bin may be subject to rejection by the Engineer. After restart of HMA production, a second density retest shall then be performed in the area representing the mixture adjustments. If the second retest from either procedure passes, production and placement of the HMA may continue. The increased compaction effort for low density failures shall not be reduced to that originally being used unless it is determined by investigation that the cause of the low density was unrelated to compaction effort, the cause was corrected, and tests show the corrective action has increased the density within the required limits. If the second retest fails, production and placement of the HMA shall cease until the Contractor has completed an investigation and the problem(s) causing the failing densities has/have been determined. If the Contractor's corrective action is approved by the Engineer, production and placement of the HMA may then be resumed. The Contractor shall increase the frequency of density testing to show, to the satisfaction of the Engineer, that the corrective action taken has corrected the density problem.
g.Additional Contractor Duties.
1.The Contractor shall complete the sampling as required for the Department’s random mixture verification tests. One sample weighing approximately 150 lb (70 kg) shall be collected for each 3,000 tons (2,720 metric tons) of mix, with a minimum of one per mixture for mixtures with less than 3,000 tons (2,720 metric tons). The mixture shall be sampled according to the document, “Hot-Mix Asphalt QC/QA Initial Daily Plant and Random Samples”.
2.The Contractor shall complete split verification sample tests listed in the Limits of Precision table in Article 1030.09(h)(2).
3.The Contractor shall provide personnel and equipment to collect density verification cores for the Engineer. Core locations will be determined by the Engineer following the document “Hot-Mix Asphalt QC/QA Procedure for Determining Random Density Locations” at density verification intervals defined in Article 1030.09(b). After the Engineer identifies a density verification location and prior to opening to traffic, Hot-Mix Asphalt Art. 1030.09 the Contractor shall cut a 4 in. (100 mm) diameter core. With the approval of the Engineer, the cores may be cut at a later time.
h.Verification by the Engineer. The Engineer will observe the Contractor’s quality control processes and complete testing of the test strip samples, identify random verification mixture sample locations, conduct mixture verification testing, identify random density verification locations, conduct density verification testing, and identify asphalt binder samples for testing.
1.The Engineer will determine the random verification mixture sample locations according to the document “Hot-Mix Asphalt QC/QA Initial Daily Plant and Random Samples”. The Engineer will randomly identify one sample for each 3,000 tons (2,720 metric tons) of mix, with a minimum of one sample per mix. The Engineer will witness, secure and take possession of the verification mixture sample. Department mixture testing will be completed on asphalt binder content, bulk specific gravity, maximum specific gravity and field VMA. If an anti-strip additive was used in the mixture, the Department will also test for stripping according to Illinois Modified AASHTO T 283. If the mixture fails to meet the minimum tensile strength and TSR criteria as specified in
Article 1030 — 05(d), no further mixture will be accepted until the
Contractor takes such action as is necessary to furnish a mixture meeting the criteria. Differences between the Contractor's and the Department's split verification sample test results will be considered acceptable if within the following limits. Test Parameter Limits of Precision Asphalt Binder Content 0.3 % Maximum Specific Gravity of Mixture 0.026 Bulk Specific Gravity 0.030 Field VMA 1.0 % If comparison of the mixture verification test results are outside the above limits of precision, the Engineer will complete an investigation. The investigation may include review and observation of the Contractor's and the Department’s technician performance, testing procedure, and equipment.
2.After final rolling and prior to paving subsequent lifts, the Engineer will identify the random density verification test locations. Cores will be used for density verification for all paving greater than or equal to 3 ft (1 m) in width when the paving length exceeds 300 ft (90 m). The Engineer may utilize nuclear gauges for paving less than 3 ft (1 m) in width, for any paving 300 ft (90 m) or less in length, and for patches. Additional items or locations where nuclear gauges will be used will be shown in the plans. Density verification test locations will be determined according to the document “Hot-Mix Asphalt QC/QA Procedure for Determining Random Art. 1030.09 Hot-Mix Asphalt Density Locations”. The density testing interval for paving wider than or equal to 3 ft (1 m) will be 0.5 miles (800 m) for lift thicknesses of 3 in. (75 mm) or less and 0.2 miles (320 m) for lift thicknesses greater than 3 in. (75 mm). The density testing interval for paving less than 3 ft (1 m) wide will be 1 mile (1,600 m). If a day’s paving will be less than the prescribed density testing interval, the length of the day’s paving will be the interval for that day. The density testing interval for mixtures used for patching will be 50 patches with a minimum of one test per mixture per project. The Engineer will witness the Contractor coring, and secure and take possession of all density samples at the density verification locations. The Engineer will test the cores collected by the Contractor for density according to Illinois Modified AASHTO T 166 or AASHTO T 275. A density verification test will be the result of a single core or the average of the nuclear density tests at one location. The results of each density test must be within acceptable limits. The Engineer will promptly notify the Contractor of observed deficiencies.
i.Acceptance by the Engineer. Final acceptance will be based on the following.
1.Acceptable limits. To be considered acceptable, the Department’s verification test results shall be within the following acceptable limits. Parameter Acceptable Limits Field VMA -1.0 – +3.0 % 1/ Air Voids 2.0 – 6.0 % Density IL-9.5, IL-19.0, IL-4.75, IL-9.5FG 90.0 – 98.0 % SMA 12.5, SMA 9.5 92.0 – 98.0 % Dust / AB Ratio 0.4 – 1.6 2/ 1/ Based on minimum required VMA as stated in the mix design volumetric requirements in Article 1030.05(b). 2/ Does not apply to SMA.
2.The Contractor’s process control charts and actions. In addition, no visible pavement distress such as, but not limited to, segregation, excessive coarse aggegate fracturing, or flushing shall be present. If any of the above is not met, the work will be considered in non- conformance with the contract.
j.Documentation. The Contractor shall be responsible for maintaining the Annual QC Plan and QC Addendum. Hot-Mix Asphalt Art. 1030.10 The Contractor shall be responsible for documenting all observations, records of inspection, adjustments to the mixture, test results, retest results, and corrective actions in a bound hardback field book or bound hardback diary which will become the property of the Department. The Contractor shall be responsible for the maintenance of all permanent records whether obtained by the Contractor, the Contractor's consultants, or the producer of the HMA. The Contractor shall provide the Engineer full access to all documentation throughout the progress of the work. Adjustments to mixture production and test results shall be recorded and sent to the Engineer on forms approved by the Engineer.
1030.10 Start of HMA Production and Job Mix Formula (JMF)
Adjustments. The start of HMA production and JMF adjustments shall be as follows. For each contract, a 300 ton (275 metric ton) test strip will be required at the beginning of HMA production for each mixture with a quantity of 3,000 tons (2,750 metric ton) or more according to the document “Hot-Mix Asphalt Test Strip Procedures”. An off-site preliminary test strip may be required for new mixture types according to the document “Off-Site Preliminary Test Strip Procedures for Hot-Mix Asphalt”. When a test strip is constructed, the Contractor shall collect and split the mixture according to the document “Hot-Mix Asphalt Test Strip Procedures”. Within two working days after sampling the mixture placed in the test strip, the Contractor shall deliver prepared samples to the District laboratory for verification testing. The Contractor shall complete mixture tests stated in Article 1030.09(a). The Department will complete testing of loose mixture samples and gyratory cylinders provided by the Contractor. Mixture sampled shall include enough material for the Department to conduct mixture tests detailed in Article 1030.09(a) and in the document “Hot-Mix Asphalt Mixture Design Verification Procedure” Section 3.3. The mixture test results shall meet the requirements of Articles 1030.05(b) and 1030.05(d), except tensile strength and TSR testing will only be conducted on the first use of a mix design for the year and Hamburg wheel tests will only be conducted on High ESAL mixtures. If the test strip mixture fails to meet the requirements for tensile strength or TSR, a resample shall be provided by the Contractor to the Department. Failure of a resampled mixture test shall result in the Contractor stopping production. The Contractor shall take corrective action and re-submit for testing according to
Article 1030 — 05(d), substitute an approved mix design, or submit a new mix design for
mix verification testing according to Article 1030.05(d). Based on the test results from the test strip, if any JMF adjustment or plant change is needed, the JMF shall become the Adjusted Job Mix Formula (AJMF). If an adjustment/plant change is made, the Engineer may require a new test strip to be constructed. Upon completion of the first acceptable test strip, the JMF shall become the AJMF regardless of whether or not the JMF has been adjusted. Art. 1030.10 Hot-Mix Asphalt If the HMA placed during the initial test strip is determined to be unacceptable to remain in place by the Engineer, it shall be removed and replaced. In no case shall the target for the amount passing be outside the mixture composition limits stated in
Article 1030 — 05(a).
The limitations between the JMF and AJMF are as follows. Parameter High ESAL Adjustment Low ESAL Adjustment 1/2 in. (12.5 mm) ± 5.0 % ± 6.0 % # 4 (4.75 mm) ± 4.0 % ± 5.0 % # 8 (2.36 mm) ± 3.0 % # 30 (600 µm) 1/ # 200 (75 µm) 1/ ± 2.5 % Asphalt Binder Content ± 0.3 % ± 0.5 % 1/ In no case shall the target for the amount passing be greater than the JMF. Adjustments outside the above limitations will require a new mix design. Production is not required to stop after a growth curve has been constructed for PFP and QCP mixtures. For QC/QA mixtures, volumetric test results that are within Acceptable Limits shall be available to the Engineer before production may resume. Upon notification by the Engineer of a failing Hamburg wheel or I-FIT test, the Contractor shall immediately resample and the Department will test. Paving may continue as long as all other mixture criteria is being met. If the second set of Hamburg wheel or I-FIT tests fail, no additional mixture shall be produced until the Engineer receives both passing Hamburg wheel and I-FIT tests. During production, the Contractor and Engineer shall continue to evaluate test results and mixture laydown and compaction performance. Adjustments within the above requirements may be necessary to obtain the desired mixture properties. If an adjustment/plant change is made, the Engineer may request additional growth curves and supporting mixture tests.
1030.11 Preparation of Mixture for Cracks, Joints, and Flangeways. When
the mixture is prepared in a batch-type mixing plant, the heated aggregate and the asphalt binder shall be measured separately and accurately by weight or by volume. The heated aggregate and asphalt binder shall be mixed in a pug mill mixer. When the aggregate is in the mixer, the asphalt binder shall be added and mixing continued until a homogeneous mixture is produced in which all particles of aggregate are coated uniformly. The mixing time will be determined by the Engineer. When the mixture is prepared in a dryer drum plant, the heated aggregate and asphalt binder shall be accurately proportioned and mixed in the dryer drum plant. For all types of plants, the ingredients shall be combined in such proportions as to produce a mixture according to the following composition limits by weight. Reclaimed Asphalt Pavement Art. 1031.01 Mixture Composition Fine Aggregate (FA 1, FA 2 or FA 3) 93 - 96 % Asphalt Binder (PG 58-28, PG 64-22) 6 - 9 % With the permission of the Engineer, an approved cold-lay sand asphalt mixture may be used in lieu of the above mixture.
1030.12 Transportation. Vehicles used in transporting HMA shall have clean
and tight beds. The beds shall be sprayed with asphalt release agents from the Department’s qualified product list. In lieu of a release agent, the Contractor may use a light spray of water with a light scatter of manufactured sand (FA 20 or FA 21) evenly distributed over the bed of the vehicle. After spraying, the bed of the vehicle shall be in a completely raised position and it shall remain in this position until all excess asphalt release agent or water has been drained. When the air temperature is below 60 °F (15 °C), the bed, including the end, endgate, sides and bottom shall be insulated with fiberboard, plywood, or other approved insulating material and shall have a thickness of not less than 3/4 in. (19 mm). When the insulation is placed inside the bed, the insulation shall be covered with sheet steel approved by the Engineer. Each vehicle shall be equipped with a cover of canvas or other suitable material meeting the approval of the Engineer which shall be used if any one of the following conditions is present.
a.Ambient air temperature is below 60 °F (15 °C).
b.The weather is inclement.
c.The temperature of the HMA immediately behind the paver screed is below 250 °F (120 °C).
d.The mixture being placed is SMA. The cover shall extend down over the sides and ends of the bed for a distance of approximately 12 in. (300 mm) and shall be fastened securely. The covering shall be rolled back before the load is dumped. SECTION 1031. RECLAIMED ASPHALT PAVEMENT AND RECLAIMED ASPHALT SHINGLES
1031.01 Description. Reclaimed asphalt pavement and reclaimed asphalt
shingles shall be according to the following.
a.Reclaimed Asphalt Pavement (RAP). RAP is the material produced by cold milling or crushing an existing hot-mix asphalt (HMA) pavement. The Contractor shall supply written documentation that the RAP originated from roadways or airfields under federal, state, or local agency jurisdiction.
b.Reclaimed Asphalt Shingles (RAS). RAS is the material produced from the processing and grinding of preconsumer or post-consumer shingles. RAS shall be a clean and uniform material with a maximum of 0.5 percent Art. 1031.01 Reclaimed Asphalt Pavement unacceptable material by weight of RAS, as defined in Bureau of Materials Policy Memorandum, “Reclaimed Asphalt Shingle (RAS) Sources”. RAS shall come from a facility source on the Department’s “Qualified Producer List of Certified Sources for Reclaimed Asphalt Shingles” where it shall be ground and processed to 100 percent passing the 3/8 in. (9.5 mm) sieve and 93 percent passing the #4 (4.75 mm) sieve based on a dry shake gradation. RAS shall be uniform in gradation and asphalt binder content and shall meet the testing requirements specified herein. In addition, RAS shall meet the following Type 1 or Type 2 requirements.
1.Type 1. Type 1 RAS shall be processed, preconsumer asphalt shingles salvaged from the manufacture of residential asphalt roofing shingles.
2.Type 2. Type 2 RAS shall be processed post-consumer shingles only, salvaged from residential, or four unit or less dwellings not subject to the National Emission Standards for Hazardous Air Pollutants (NESHAP).
1031.02 Stockpiles. RAP and RAS stockpiles shall be according to the
following.
a.RAP Stockpiles. The Contractor shall construct individual RAP stockpiles meeting one of the following definitions. Stockpiles shall be sufficiently separated to prevent intermingling at the base. Stockpiles shall be identified by signs indicating the type as listed below (i.e. “Homogeneous Surface”). Prior to milling, the Contractor shall request the Department provide documentation on the quality of the RAP to clarify the appropriate stockpile.
1.Fractionated RAP (FRAP). FRAP shall consist of RAP from Class I, HMA (High and Low ESAL) mixtures. The coarse aggregate in FRAP shall be crushed aggregate and may represent more than one aggregate type and/or quality, but shall be at least C quality. FRAP shall be fractionated prior to testing by screening into a minimum of two size fractions with the separation occurring on or between the No. 4 (4.75 mm) and 1/2 in. (12.5 mm) sieves. Agglomerations shall be minimized such that 100 percent of the RAP in the coarse fraction shall pass the maximum sieve size specified for the mixture composition of the mix design.
2.Homogeneous. Homogeneous RAP stockpiles shall consist of RAP from Class I, HMA (High and Low ESAL) mixtures and represent: 1) the same aggregate quality, but shall be at least C quality; 2) the same type of crushed aggregate (either crushed natural aggregate, ACBF slag, or steel slag); 3) similar gradation; and 4) similar asphalt binder content. If approved by the Engineer, combined single pass surface/binder millings may be considered “homogeneous” with a quality rating dictated by the lowest coarse aggregate quality present in the mixture.
3.Conglomerate. Conglomerate RAP stockpiles shall consist of RAP from Class I, HMA (High and Low ESAL) mixtures. The coarse aggregate in this RAP shall be crushed aggregate and may represent more than one
Referenced in this section
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Source: Illinois Standard Specifications for Road and Bridge Construction, 2022 Edition. Pages 886–915 of 1,217. View official source ↗