405CAPE SEAL

Cape Seal Art. 405.02 191

405.01Description. This work shall consist of constructing a single

bituminous surface treatment (A-1) and a micro-surfacing on existing hot-mix asphalt

405.02Materials. Materials shall be according to the following

according to the following.

Item Article/Section

Note 1. The seal coat aggregate shall be either fine or coarse aggregate.

When fine aggregate is used, it shall be stone sand, wet bottom boiler slag, slag sand, or steel slag sand. The aggregate quality shall be Class C. The aggregate gradation shall be FA 1 (Special), FA 4 (Special), or FA 22 as specified on the plans and shall meet the following.

FINE AGGREGATE GRADATIONS Grad. No. Sieve Size and Percent Passing 3/8 in. (9.5 mm) No. 4 (4.75 mm) No. 8 (2.36 mm) No. 16 (1.18 mm) No. 40 (425 um) No. 200 (75 um) FA 1 (Special) 100 90 ± 10 62.5 ± 17.5 32.5 ± 7.5 7.5 ± 7.5 1.5 ± 1 FA 4 (Special) 100 -- -- 2 ± 2 -- 1.5 ± 1 FA 22 100 1/ 1/ 8 ± 8 -- 2 ± 2

1/ For the fine aggregate gradation FA 22, the aggregate producer shall set the midpoint percent passing, and the Department will apply a range of ± 10 percent. The midpoint shall not be changed without Department approval.

When coarse aggregate is used, it shall be crushed gravel, crushed stone, wet bottom boiler slag, crushed slag, crushed sandstone, or crushed steel slag. The aggregate quality shall be Class C and the total chert count shall be no more than 25.0 percent by weight (mass) as determined by the Illinois Test Procedure 203. The aggregate gradation shall be CA 15, CA 16, or CA 20 as specified on the plans.

Note 2. The bituminous material shall be either a CRS-2P or HFRS-2P according to Article 1032.06(e).

Art. 405.02 Cape Seal 192

Article 404.02.

the following.

Item Article/Section

405.03Equipment. Equipment shall be according to the following

according to the following.

Item Article/Section

Note 1. There shall be a minimum of two rollers, with the final number of rollers determined by the rollers’ abilities to maintain proper spacing with the aggregate spreader as directed by the Engineer.

Note 2. The mechanical sweeper shall be power driven and self- propelled with the broom located between the axles. The mechanical sweeper shall not use a cantilever-mounted broom and the broom rotation shall not be operated by forward movement.

Note 3. The aggregate spreader shall be a self-propelled mechanical type with the receiving hopper in the rear and shall pull the aggregate truck. The spreader shall be fitted with an automated system which provides positive interconnected control of the aggregate flow with the forward speed of the spreader. The automated system shall provide uniform and consistent aggregate application at the rate specified.

The Engineer will check the spread roll of the aggregate spreader for straightness each day before operations begin. Should the surface of the spread roll vary off a straight line along its longitudinal dimension by more than 1/16 in. (1.5 mm), the Engineer will inspect the application of aggregate for corrugations and, should these occur, the machine shall be repaired or replaced. The forward speed of the spreader during calibration shall be the same as is to be used during construction. The equipment required for aggregate spreader calibration may consist of several sheets of canvas, each being exactly 1 sq yd (0.8 sq m), and a weight scale. By making several runs at different gate openings over the sheets of canvas, placed to cover the full width applied by the spreader, and carefully measuring the aggregate on each canvas sheet, the gate opening at the pre-established speed required to apply aggregate at the specified rate may be determined.

Cape Seal Art. 405.04 193

Note 4. The pressure distributor shall have a minimum capacity of 3000 gal (11,500 L). The application rate control shall be automated and shall control the application rate regardless of ground speed or spray bar width. The computer shall have the capability of recording the application rate, gallons sprayed, square yards, and feet traveled. The pressure distributor shall be capable of maintaining the asphalt emulsion at the specified temperature. The spray bar nozzles shall produce a uniform triple lap application fan spray, and the shutoff shall be instantaneous, with no dripping. The pressure distributor shall be capable of maintaining the specified application rate within  0.015 gal/sq yd (  0.070 L/sq m) for each load. The spray-bar nozzles shall be turned to make the same angle with the longitudinal axis of the spray bar as recommended by the manufacturer.

Application rates shall be determined by the procedures listed in ASTM D 2995, except the sample may be taken on three 8 x 12 in. (200 x 300 mm) metal plates. The three plates shall be positioned as directed by the Engineer.

following.

Item Article/Section

the following.

Item Article/Section

CONSTRUCTION REQUIREMENTS

405.04Weather Limitations. Placement of the A-1 bituminous surface

treatment shall be done between May 1 and August 31, with the micro-surfacing being placed according to the timeframe specified herein. Bituminous materials shall be applied only when the temperature of the air in the shade is above 55 ºF (13 ºC). No work shall be started if local conditions indicate rain is imminent.

The A-1 bituminous surface treatment may be done between September 1 and September 15 provided both of the following conditions are met:

temperature of the surface to which the asphalt will be applied is 70 ºF (20 ºC) or above, and

Art. 405.05 Cape Seal 194

or any temperatures below 55 ºF (13 ºC) for the day the work is to be done or for the following five days.

405.05Micro-Surfacing Mix Design. The mix design for the micro-surfacing

mixture shall be developed and approved according to Article 404.06.

405.06Micro-Surfacing Test Strip. The requirements for test strips shall be

according to Article 404.07.

405.07Surface Preparation. The pavement surface shall be prepared

according to Article 404.08, and prior to applying the A-1 bituminous surface treatment, the pavement surface shall be cleaned.

Manholes, valve boxes, drop inlets, and other service entrances shall be protected from the cape seal by a suitable method. The surface preparation shall be approved by the Engineer prior to application of the A-1 bituminous surface treatment. No dry aggregate either spilled from the lay-down machine or existing on the road, will be permitted.

405.08Calibration. The working day prior to starting construction of the A-1

bituminous surface course, the pressure distributor and aggregate spreader shall be calibrated and adjusted according to the manufacturer's recommendations. At least three days prior to starting the work the Contractor shall provide the Engineer with a copy of the manufacturer's recommendations for the equipment to be used. All calibrations and adjustments shall be made in the presence of the Engineer on a level surface at a location approved by the Engineer. The Contractor shall maintain proper calibration and adjustment of the equipment and the Engineer reserves the right to check application rates as the work progresses. Should the equipment fail to consistently apply the specified rates, the work shall be stopped and the Contractor shall recalibrate and readjust the equipment.

405.09Application. The cape seal shall be applied as shown on the plans

and the following.

shall be applied according to the following.

the following table, the Contractor shall determine the application rates of bituminous material and seal coat aggregate. The application rates along with the seal coat gradations shall be submitted to the Engineer for approval prior to the start of work. Application rates shall be according to the following table for the aggregate type shown on the plans, and shall result in aggregate embedment between 50 and 70 percent behind the roller. Changes in the application rate of greater than 15 percent shall be resubmitted to the Engineer for approval.

Cape Seal Art. 405.09 195

Aggregate Type Bituminous Material Rate Aggregate Rate CA 15 0.38 – 0.46 gal/sq yd (1.7 – 2.1 L/sq m) 22 – 30 lb/sq yd (12 – 16 kg/sq m) CA 16 0.36 – 0.40 gal/sq yd (1.6 – 1.8 L/sq m) 18 – 26 lb/sq yd (8 – 14 kg/sq m) CA 20 0.36 – 0.40 gal/sq yd (1.6 – 1.8 L/sq m) 18 – 26 lb/sq yd (8 – 14 kg/sq m) FA 1 (Special) 0.26 – 0.30 gal/sq yd (1.2 – 1.4 L/sq m) 16 – 20 lb/sq yd (9 – 11 kg/sq m) FA 4 (Special) 0.28 – 0.36 gal/sq yd (1.3 – 1.6 L/sq m) 18 – 24 lb/sq yd (10 – 13 kg/sq m) FA 22 0.32 – 0.40 gal/sq yd (1.5 – 1.8 L/sq m) 15 – 22 lb/sq yd (8 – 12 kg/sq m)

material at the time of application shall be such that it shall spray uniformly without clogging the spraying nozzles and shall be applied within the temperature ranges of 150 – 190 ºF (65 – 90 ºC).

jobsite according to Article 1003.01(e) or 1004.01(e). The aggregate used shall contain no free moisture. Slightly damp aggregate may be used with the approval of the Engineer.

applied with a pressure distributor. The entire length of the spray bar shall be set at the height above the surface recommended by the manufacturer for even distribution of the bituminous material.

The distributor shall be operated in a manner such that missing or overlapping of transverse joints is avoided. To prevent overlapping of successive applications of bituminous material at transverse joints, heavy paper shall be spread over the previously applied bituminous material and aggregates. In order to obtain a uniform application of the bituminous material, the distributor shall be traveling at the speed required for the specified rate of application when the spray bar crosses the paper.

Adjacent construction, such as concrete pavement, curb and gutter, bridge floors, raised reflective pavement markers, and bridge handrails, shall be protected by shields, covers or other means. If bituminous material is applied to adjacent construction, the Contractor shall remove such material to the satisfaction of the Engineer.

The emulsified asphalt shall not be applied when the wind conditions will inhibit uniform coverage from the fans of asphalt being applied.

Art. 405.09 Cape Seal 196

evenly with an aggregate spreader over the entire surface being treated. When treating one-half of the pavement width at a time, an inside strip of uncovered emulsified asphalt 3 in. (75 mm) wide shall be left during construction of the first half to provide center joint overlap when the second half of the treatment is placed. In all cases, the aggregate shall be applied ahead of the truck or spreader wheels. Hand spreading will be permitted only when approved by the Engineer and, when so permitted, the aggregate shall be spread uniformly and at the approximate rate specified. Any ridges of aggregate left by the aggregate spreader shall be smoothed out with hand brooms immediately behind the aggregate spreader.

All equipment involved in the work shall operate as close to each other as practical. The aggregate shall cover the asphalt emulsion within 30 seconds of applications. At no time shall the aggregate spreader trail the pressure distributor by more than 150 ft (45 m) to ensure proper asphalt/aggregate adhesion.

Each aggregate truck shall be equipped with a suitable hitch for connection to the aggregate spreader while unloading. The trucks shall avoid contact between the truck body or bed and the aggregate spreader. The body or bed of the truck shall be modified, if necessary, to empty cleanly and completely into the receiving hopper of the aggregate spreader. No aggregate shall be allowed to spill onto the road surface when the truck is emptying into this hopper.

The aggregate shall be rolled following spreading. A maximum time of five minutes will be allowed between the spreading of aggregate and completion of the initial rolling of the aggregate. The rollers shall proceed in a longitudinal direction at a speed less than or equal to 5 mph (8 km/h). Each roller shall travel over the aggregate a minimum of two times. The entire surface shall be rolled immediately with a self- propelled pneumatic-tired roller. Rolling shall proceed in a longitudinal direction beginning at the edges and progressing toward the center, overlapping on successive trips by at least 1/2 the width of the roller. The aggregate shall then be rolled with a separate pneumatic-tired roller until the aggregate is properly seated in the bituminous material.

The Contractor shall use the appropriate sweeping equipment to perform an initial sweeping after a minimum of two hours curing and not less than one hour before sunset on the day the A-1 surface treatment is placed. The initial sweeping shall remove excess aggregate by lightly sweeping each pavement lane. The sweeping shall be sufficient to prevent migration of loose aggregate back onto any part of the pavement.

The Contractor shall sweep the pavement surface as needed to remove excess aggregate.

within a maximum of 12 calendar days of placing the A-1 bituminous surface

Cape Seal Art. 405.09 197

treatment. The Contractor shall sweep the pavement surface immediately prior to applying the micro-surfacing.

The surface shall be prewetted by water fogging ahead of the spreader box when road conditions require, as determined by the Engineer. The rate of fogging shall be adjusted during the day based on pavement temperature, surface texture, and dryness.

of each lane in a single pass at a rate of 24 lb/sq yd (13 kg/sq m). The application rate shall be verified from daily readings taken from the proportioning devices during the progress of the work.

The paving mixture shall be spread to fill minor cracks and shallow potholes and leave a uniform surface. A sufficient amount of material shall always be carried in all parts of the spreader box to ensure complete coverage. Overloading of the spreader shall be avoided. No lumps or uncoated aggregate will be permitted in the finished surface.

Adjustments to the mix design may be required during construction, based on field conditions. The percent of cement in the mix design may be increased or decreased by less than 0.5 percent when the micro- surfacing is being placed if it is found to be necessary for better consistency or set times. The Engineer will give final approval for all adjustments.

composition. No streaks, such as those caused by oversized aggregate, shall be left in the finished surface. If excess streaking develops, the job shall be stopped until the Contractor proves to the Engineer that the situation has been corrected. Excessive streaking is defined as more than four drag marks greater than 1/2 in. (13 mm) wide and 4 in. (100 mm) long, or 1 in. (25 mm) wide and 3 in. (75 mm) long, in any 30 sq yd (25 sq m) area. No transverse ripples or longitudinal streaks of 0.25 in. (6 mm) in depth will be permitted, when measured by placing a 10 ft (3 m) straightedge over the surface.

that premature breaking of the material in the spreader box does not occur. The mixture shall be homogeneous during and following mixing and spreading. It shall be free of excess water or emulsified asphalt and free of segregation of the emulsified asphalt and aggregate fines from the coarser aggregate. Under no circumstances shall water be sprayed directly into the lay-down box while placing micro-surfacing material.

ISSA A143 and submit to the Engineer for approval. When practical, the surface course joint shall be at least 10 in. (255 mm) away from the nearest edge of any subsequent permanent pavement markings.

Art. 405.09 Cape Seal 198 Micro-surfacing edges shall be parallel with the existing pavement edges. If the existing pavement edge cannot be used to give a straight edge, a stringline or other guide will be required. Edge lines shall not vary by more than ± 2 in. (± 50 mm) horizontally in any 100 ft (30 m) of length.

A smooth, neat seam shall be provided where two passes meet. Excess material shall be immediately removed from the ends of each run. Any damage to, or irregularities in, the micro-surfacing shall be repaired, as directed by the Engineer. All repairs shall be made with a paver box, except areas designated as hand work areas.

areas approved by the Engineer shall be designated as hand work areas. Adjustments to the additive will be permitted to provide a slower setting time when hand spreading is needed. If hand spreading is necessary, the mixture shall be poured in a small windrow along one edge of the surface to be covered and then spread uniformly by a hand squeegee or lute. Hand work areas shall have an appearance consistent with that being placed with a spreader box.

405.10Clean-Up. All areas, such as manholes, gutters, and intersections,

shall have the cape seal removed as specified by the Engineer. The Contractor shall, on a daily basis, remove any debris associated with the performance of the work.

405.11Slurry Systems Sampling and Testing. The Contractor shall check

yield of the application after the first 1,000 ft (300 m), and throughout each day’s paving, with a minimum of three tests per day. Yield check results shall be furnished to the Engineer daily.

The Contractor shall submit a daily “run sheet” for each day’s work as soon as all the data is available. The run sheet shall provide a breakdown of the actual meter numbers and quantities of all materials actually used each day, as well as the respective locations.

The Contractor shall provide a copy of the paver calibration to the Engineer for verification and approval. The calibration shall be performed a minimum of once per job mix formula (JMF), per contract.

The Contractor shall collect a minimum of one sample per JMF in the presence of the Engineer. Material for the sample shall be collected from the loading shoot of the pug mill prior to being deposited into the drag box. The sample shall be placed in a 1 gal (3.8 L) sealed plastic bag. Enough material shall be collected, evenly distributed in the plastic bag, and laid flat to form approximately 1/2 in. (13 mm) of material. The bag shall be squeezed to remove excess air, sealed, and placed on a hard, flat surface. After allowing the bag to sit flat for 15 minutes, pick up the bag and evaluate the sample. The material should have turned black and should show positive signs of setting up (stiffening). The results at 15 minutes should be noted and the sealed bag placed into a 1 gal (3.8 L) friction top container and sent to the Department for AB content testing.”

Cape Seal Art. 405.15 199

405.12Opening to Traffic. The A-1 bituminous surface treatment portion

shall be opened to traffic according to Article 701.17(c)(4).

The micro-surfacing shall be opened to traffic within one hour of its application.

405.13Slurry Systems Curing. The micro-surfacing shall cure for a

minimum of seven days before placement of the permanent pavement markings.

405.14Method of Measurement. This work will be measured for payment as

follows.

shall conform to Article 202.07(a).

feet (meters), measured along the crack.

Pavement marking removal and pavement marker removal will be measured for payment according to Article 783.05.

The cape seal will be measured for payment in place and the area computed in square yards (square meters). The width for measurement will be the width of the top surface as shown on the plans or as directed by the Engineer.

405.15Basis of Payment. Crack/joint sealing will be paid for at the contract

unit price per foot (meter) for FIBER-MODIFIED ASPHALT CRACK SEALING.

Bump removal will be paid for at the contract unit price per each for BUMP REMOVAL.

Pavement marking removal and pavement marker removal will be paid for according to Article 783.06.

Cape seal will be paid for at the contract unit price per square yard (square meter) for CAPE SEAL.

Art. 406.01 Hot-Mix Asphalt Binder and Surface Course 200

SECTION 406. HOT-MIX ASPHALT BINDER AND SURFACE COURSE

406.01Description. This work shall consist of constructing hot-mix asphalt

406.02Materials. Materials shall be according to the following

Item Article/Section

Note 1. The bituminous material used for tack or prime coat shall be one of the types listed in the following table.

Type of Construction Bituminous Materials Tack Coat on Brick, Concrete, or HMA Bases SS-1, SS-1h, SS-1hP, NTEA, RS-1, RS-2, CSS-1, CSS-1h, CSS-1hP, CRS-1, CRS-2, HFE-90, RC-70, PG 58-22, PG 58-28, PG 64-22 Prime Coat on Aggregate Bases MC-30, PEP

When emulsified asphalts are used, any dilution with water shall be performed by the emulsion producer. The emulsified asphalt shall be thoroughly agitated within 24 hours of application and show no separation of water and emulsion. The use of RC-70 shall be limited to air temperatures below 60 ºF (15 ºC).

406.03Equipment. Equipment shall be according to the following

Item Article/Section