Art. 406.01 Hot-Mix Asphalt Binder and Surface Course SECTION 406. HOT-MIX ASPHALT BINDER AND SURFACE COURSE
406.01 Description. This work shall consist of constructing hot-mix asphalt
(HMA) binder and/or surface course on a prepared base.
406.02 Materials. Materials shall be according to the following.
Item Article/Section
a.Fine Aggregate .................................................................................. 1003.03
b.Hot-Mix Asphalt ...................................................................................... 1030
c.Bituminous Materials (Note 1) ................................................................ 1032
d.Longitudinal Joint Sealant (LJS) ......................................................... 1032.12
e.Full Lane Sealant (FLS) ...................................................................... 1032.13
f.Temporary Rubber Ramps and Temporary Plastic Ramps ..................... 1033 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).
406.03 Equipment. Equipment shall be according to the following.
Item Article/Section
a.Self-Propelled Pneumatic-Tired Roller ............................................... 1101.01
b.Three-Wheel Rollers .......................................................................... 1101.01
c.Tandem Rollers ................................................................................. 1101.01
d.Vibratory Roller .................................................................................. 1101.01
e.Spreading and Finishing Machine ...................................................... 1102.03
f.General Use Pressure Distributor .................................................. 1102.05(a)
g.LJS Pressure Distributor ................................................................ 1102.05(b)
h.FLS Pressure Distributor ............................................................... 1102.05(c)
i.LJS Melter Kettle ........................................................................... 1102.05(d)
j.Trench Roller ..................................................................................... 1101.01
k.Pavement Surface Test Equipment ............................................... 1101.10(a)
l.Spray Paver ....................................................................................... 1102.06
m.Oscillatory Roller ................................................................................ 1101.01 Hot-Mix Asphalt Binder and Surface Course Art. 406.05 CONSTRUCTION REQUIREMENTS
406.04 Keeping Road Open to Traffic. The road shall be kept open to traffic
according to Article 701.17(c)(3).
406.05 Preparing, Prime Coat for Aggregate Bases, and Tack Coat or Full
Lane Sealant. The base shall be prepared and primed, tacked, or full lane sealed according to the following.
a.Preparing. Aggregate base shall be prepared according to Section 358. On existing pavements, excess crack filler and HMA patches which contain an excess of bitumen or which are unstable in hot weather shall be removed. Bitumen shall be removed from expansion joints and cracks more than 1 1/2 in. (38 mm) wide. Open cracks and open expansion joints having a width of 1/2 in. (13 mm) or more, expansion joints and cracks that have been cleaned, and flangeways, shall be filled with mixture for cracks, joints, and flangeways. The mixture shall be hand tamped in place with hand tools. Depressions 3/4 to 1 1/4 in. (19 to 31 mm) in the surface of the existing pavement shall be tacked and filled with IL-4.75 or IL-9.5FG binder (hand method). Depressions greater than 1 1/4 in. (31 mm) and spot locations where heavy disintegration and deep spalling exists, the area shall be cleaned of all loose and unsound material, tacked, and filled with IL-4.75, IL-9.5, or IL-9.5FG binder (hand method). Binder placed other than with a finishing machine will be designated as binder (hand method) and shall be compacted with a roller to the satisfaction of the Engineer. Hand tamping will be permitted when approved by the Engineer. Waste material produced during pavement preparation operations shall be removed at the close of each day’s work and shall be disposed of according to Article 202.03.
b.Prime Coat for Aggregate Bases. The bituminous material shall be applied uniformly with a general use pressure distributor on the prepared surface at a residual asphalt rate of 0.25 ± 0.01 lb/sq ft (1.21 ± 0.05 kg/sq m). A hand spray wand shall be used at places not covered by the 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. To prevent missing or overlapping at transverse joints, heavy paper shall be spread over the previously applied bituminous material and aggregate. 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, and raised Art. 406.05 Hot-Mix Asphalt Binder and Surface Course reflective pavement markers shall be protected by shields, covers, or other means. The prime coat shall be permitted to cure until the penetration has been approved by the Engineer, but at no time shall the curing period be less than 24 hours for MC-30 or 4 hours for PEP. Pools of prime occurring in depressions shall be removed by brooming or squeegeeing the excess material over the surrounding surface the same day the prime coat is applied.
c.Tack Coat or Full Lane Sealant. The base or previous lift shall be cleaned of dust, debris, and any substance that will prevent the bituminous material from adhering to the base. Cleaning shall be accomplished by sweeping to remove large particles followed by air blasting or vacuum sweeping to remove dust. The bituminous material shall be applied according to
Article 406 — 05(b), except as specified below.
1.Tack Coat for Brick, Concrete, or HMA Bases. The base shall be free of standing water at the time of application. The tack coat shall be applied to the base and between each lift of HMA uniformly and at a rate that will provide a residual asphalt rate on the prepared surface as specified in the following table. Type of Surface to be Tacked Residual Asphalt Rate lb/sq ft (kg/sq m) Concrete, Existing HMA, and Milled HMA 0.05 (0.244) New HMA and Brick 0.025 (0.122) The bituminous material for the tack coat shall be placed one lane at a time. If a spray paver is not used, the tacked lane shall remain closed until the tack coat is fully cured and does not pickup under traffic. When placing tack coat through an intersection where it is not possible to keep the lane closed, the tack coat may be covered immediately following its application with fine aggregate mechanically spread at a uniform rate of 2 to 4 lb/sq yd (1 to 2 kg/sq m).
2.Full Lane Sealant (FLS) for HMA Bases. The base shall be dry for 24 hours prior to application of FLS and no rain in the forecast for 24 hours following application. If rain is anticipated but cannot be avoided, the FLS shall be covered immediately following its application with fine aggregate mechanically spread at a uniform rate of 2 to 4 lb/sq yd (1 to 2 kg/sq m). The FLS shall be applied uniformly with a FLS pressure distributor at a rate that will provide the residual rate on the prepared surface as specified in the following table. Type of Surface Placed Above FLS Residual Asphalt Rate lb/sq ft (kg/sq m) IL-9.5 0.30 (1.464) IL-9.5FG 0.25 (1.221) Hot-Mix Asphalt Binder and Surface Course Art. 406.06 FLS shall fully cure in less than 5 minutes. HMA may be placed once the FLS has cured. The Contractor shall furnish to the Engineer a bill of lading for each tanker supplying material to the project. The residual asphalt rate will be verified a minimum of once per type of surface to be tacked, primed, or full lane sealed as specified herein for which at least 2,000 tons (1,800 metric tons) of HMA will be placed. The test will be according to the Manual of Test Procedures for Materials “Determination of Residual Asphalt in Prime and Tack Coat Materials”. Tack or prime coat shall be fully cured prior to placement of HMA to prevent pickup by haul trucks or paving equipment. If pickup occurs, paving shall cease in order to provide additional cure time, and all areas where the pickup occurred shall be repaired. If after five days, loss of tack, prime, or FLS is evident prior to covering with HMA, additional tack, prime, or FLS shall be placed as determined by the Engineer at no additional cost to the Department. .
406.06 Placing. The HMA shall be placed according to the following.
a.Pre-Production Meeting. When HMA is placed under the Pay for Performance (PFP) or Quality Control for Performance (QCP) Quality Management Program, the Contractor shall schedule a pre-production meeting prior to the start of production of the mixture specified. The HMA QC Plan, test frequencies, and responsibilities of all parties involved in testing will be addressed. The Engineer will provide the random locations, tonnages, and sublot selected from each lot in a sealed envelope for the Contractor to sign at the pre-production meeting or prior to paving. The locations, tonnages, and sublot selected from each lot may be adjusted due to field conditions according to the documents “Hot-Mix Asphalt PFP and QCP Random Jobsite Sampling” and “Hot-Mix Asphalt PFP and QCP Procedure for Determining Random Density Locations”. The signed, sealed envelope will be given to the Contractor after paving is complete, along with documentation of any adjustments. Personnel attending the meetings may include: Resident Engineer, District Mixtures Control Representative, QC Manager, Contractor Paving Superintendent, and Consultants involved in any part of the HMA sampling or testing.
b.Start of HMA Production and Job Mix Formula (JMF) Adjustments. Test strip construction shall be according to Article 1030.10.
c.Placement Conditions. HMA shall be placed on a clean, dry base and when weather conditions are suitable. Binder course shall be placed only when the air temperature in the shade is at least 40 °F (5 °C) and the forecast is for rising temperatures. Surface course shall be placed only when the air temperature in the shade is at least 45 °F (8 °C) and the forecast is for rising temperatures. Art. 406.06 Hot-Mix Asphalt Binder and Surface Course In all cases, the mixture temperature shall never exceed 350 °F (180 °C). For mixes placed under QC/QA criteria, the HMA and WMA shall be delivered at a minimum temperature of 250 °F (120 °C) and 215 °F (102 °C), respectively, except as specified below.
1.Special Conditions for Mixture IL-4.75.
a.The surface shall be dry for at least 24 hours, and clean, prior to placement of the mixture.
b.Work shall not begin when local conditions indicate rain is imminent.
c.The mixture shall be placed only when the temperature in the shade is at least 50 °F (10 °C) and the forecast is for rising temperatures.
d.Mixes placed under QC/QA criteria shall be delivered at a minimum temperature of 310 °F (155 °C) and measured in the truck just prior to placement.
e.The mixture shall be overlaid within 5 days of being placed.
2.Special Conditions for SMA.
a.SMA mixture shall be placed only when the temperature of the surface is above 50 °F (10 °C).
b.Mixes placed under QC/QA criteria shall be placed at a minimum temperature of 310 °F (155 °C) when using SBS PG 76-28 and 300 °F (149 °C) when using SBS PG 76-22. The mixture temperature shall be measured immediately behind the paver screed. Intermingling of different mixture designs, or the same mixture design produced at more than one HMA plant, in one paver will not be permitted.
d.Field Conditions. HMA shall be placed and compacted during daylight, unless artificial light satisfactory to the Engineer is provided. In the event of sudden rain, the loading of trucks at the plant or from storage bins shall immediately stop. Material in transit will be permitted to be laid at the Contractor's risk providing the pavement is free of standing water and the proper temperature of the HMA is maintained. Approval to unload the trucks in transit shall in no way relax the requirements for quality, density, or smoothness of the HMA being placed.
e.Lift Thickness. The minimum compacted lift thickness for HMA binder and surface courses shall be as follows. Hot-Mix Asphalt Binder and Surface Course Art. 406.06 Mixture Composition Type of Lift Minimum Compacted Lift Thickness, in. (mm) IL-4.75 Binder only 3/4 (19) over HMA surfaces 1/ 1 (25) over PCC surfaces 1/ IL-9.5FG Surface or Binder 1 1/4 (31) IL-9.5, IL-9.5L Surface or Binder 1 1/2 (38) SMA-9.5 Surface or Binder 1 1/2 (38) SMA-12.5 Surface or Binder 2 (50) IL-19.0, IL-19.0L Binder only 2 1/4 (56) 1/ The maximum compacted lift thickness for mixture IL-4.75 shall be 1 1/4 in. (31 mm).
f.Spreading and Finishing. The HMA shall be placed with a spreading and finishing machine to the typical section and grade shown on the plans or as established by the Engineer. In areas where irregularities, inaccessibility, or unavoidable objects make the use of the spreading and finishing machine impractical, the HMA may be spread, raked, and luted by hand. When placing HMA within 200 ft (60 m) of a bridge abutment, the automatic electronic grade control on the paver shall be operated from a preset grade control stringline. At all other locations, a preset grade control stringline or a grade reference device traveling on the adjacent pavement surface shall be used. When traffic interference or sharp curves make the minimum 30 ft (9 m) device impractical, the grade reference device may be shortened to no less than 10 ft (3 m) as directed by the Engineer. For HMA mixes placed under QC/QA criteria, the operating speed of the paver shall not exceed that speed which is necessary to produce a uniformly spread and struck off mat having a smooth texture without tearing or segregation. The paver speed shall be mated with the required roller speed and shall not exceed that which coincides with the average rate of delivery of HMA to the paver to provide, as nearly as possible, continuous operation of the paver. In no case shall the speed of the paver exceed 50 ft (15 m) per minute for High and Low ESAL mixes or 30 ft (9 m) per minute for SMA. A stringline shall be used as a guide for the finishing machine in order to maintain a uniform edge alignment; if any other method is proposed, it shall meet the approval of the Engineer before being used. Irregularities in the alignment of the outside edges and along the longitudinal joint shall be corrected by adding or removing HMA before the edges are rolled. Excess HMA deposited on the existing base, binder course, or surface course outside the limits of the lane being laid shall be removed immediately and disposed of as directed by the Engineer.
g.Segregation Control. Paving operations shall be conducted in a manner to prevent medium or high segregation. Plant operations, hauling of the mix, paver operations, and the compacted mat shall be continually monitored for segregation. Art. 406.06 Hot-Mix Asphalt Binder and Surface Course The in-place HMA shall be evaluated daily for segregation according to the document “Segregation Control of Hot-Mix Asphalt”. The Contractor’s Annual Quality Control Plan or Addendum shall identify the individual(s) responsible for performing and documenting the daily evaluations. Quality Control Plans and Addendums for subsequent projects shall reflect the corrective actions taken, whether the corrective action was initiated by the Contractor or the Engineer.
h.Construction Joints. Transverse and longitudinal construction joints shall be constructed according to the following. Joints between old and new pavements or between successive days’ work shall be made so as to ensure thorough and continuous bond between the old and new mixtures.
1.Transverse Joints. Transverse construction joints in previously laid material may be constructed by cutting the material back for its full depth to expose a fresh surface. Where a wooden header is used at a construction joint, the cutting may be omitted provided the joint conforms to the specified thickness.
2.Longitudinal Joints. Unless prohibited by stage construction, any HMA lift shall be complete before construction of the subsequent lift. The longitudinal joint in all lifts shall be at the centerline of the pavement if the roadway comprises two lanes in width, or at lane width if the roadway is more than two lanes in width. When stage construction prohibits the total completion of a particular lift, the longitudinal joint in one lift shall be offset from the longitudinal joint in the preceding lift by not less than 3 in. (75 mm). The longitudinal joint in the surface course shall be at the centerline of the pavement if the roadway comprises two lanes in width, or at lane width if the roadway is more than two lanes in width. A notched wedge longitudinal joint shall be used between successive passes of HMA binder course that has a difference in elevation of greater than 2 in. (50 mm) between lanes on pavement that is open to traffic. The notched wedge longitudinal joint shall consist of a 1 to 1 1/2 in. (25 to 38 mm) vertical notch at the lane line, a 9 to 12 in. (230 to 300 mm) wide uniform taper sloped toward and extending into the open lane, and a second 1 to 1 1/2 in. (25 to 38 mm) vertical notch at the outside edge. The notched wedge longitudinal joint shall be formed by the strike off device on the paver. The wedge shall then be compacted by the joint roller. Tack coat shall be applied to the entire surface of the notched wedge joint immediately prior to placing the adjacent lift of binder. The material Hot-Mix Asphalt Binder and Surface Course Art. 406.06 shall be uniformly applied at a residual rate of 0.05 to 0.1 gal/sq yd (0.2 to 0.5 L/sq m). When longitudinal joint sealant (LJS) is specified, the surface to which the LJS is applied shall be thoroughly cleaned and dry. The LJS may be placed before or after the tack coat. When placed after the tack coat, the tack shall be fully cured prior to placement of the LJS. The LJS shall be applied in a single pass with a LJS pressure distributor, LJS melter kettle, or from a pre-formed roll. At the time of installation, the pavement surface temperature and the ambient temperature shall be a minimum of 40 °F (5 °C) and rising. The LJS shall be applied at a width of 18 ± 1 1/2 in. (450 ± 38 mm) and centered ± 2 in. (± 50 mm) under the joint of the next HMA lift to be constructed. If the LJS flows more than 2 in. (50 mm) from the initial placement width, LJS placement shall stop and remedial action shall be taken. When resuming placement of LJS, suitable release paper shall be placed over the previous application of LJS to prevent doubling the thickness of LJS. The application rate of LJS shall be based on the HMA mixture and thickness placed above the LJS according to the following. LJS Application Rate, lb/ft (kg/m) 1/ 2/ Lift Thickness, in. (mm) Coarse Graded Mixture (IL-19.0, IL-19.0L, IL-9.5, IL-9.5L, IL-4.75) Fine Graded Mixture (IL-9.5FG) SMA Mixture (SMA-9.5, SMA-12.5) 3/4 (19) 0.88 (1.31) 1 (25) 1.15 (1.71) 1 1/4 (31) 1.31 (1.95) 0.88 (1.31) 1 1/2 (38) 1.47 (2.19) 0.95 (1.42) 1.26 (1.88) 1 3/4 (44) 1.63 (2.43) 1.03 (1.54) 1.38 (2.06) 2 (50) 1.80 (2.68) 1.11 (1.65) 1.51 (2.25) ≥ 2 1/4 (56) 1.96 (2.92) 1/ The application rate includes a surface demand for liquid. The thickness of the LJS may taper from the center of the application to a lesser thickness on the edge of the application, provided the correct width and application rate are maintained. 2/ If different mixture types are placed adjacent, the lower of the two application rates shall be used. The Contractor shall furnish to the Engineer a bill of lading for each tanker supplying material to the project. The application rate of LJS shall be verified within the first 1,000 ft (300 m) of the day’s placement Art. 406.07 Hot-Mix Asphalt Binder and Surface Course and every 12,000 ft (3,600 m) thereafter. A suitable paper or pan shall be placed at a random location in the path of the LJS. After application of the LJS, the paper or pan shall be picked up, weighed, and the application rate calculated. The tolerance between the application rate shown in the LJS Application Table and the calculated rate shall be ± 10 percent. The LJS shall be replaced in the area where the sample was taken. A 1 qt (1 L) investigative (INV) sample shall be taken from the LJS pressure distributor or LJS melting kettle at the jobsite once for each contract and sent to the Central Bureau of Materials. The LJS shall be suitable for construction traffic to drive on without pickup or tracking of the LJS within 30 minutes of placement. If pickup or tracking occurs, LJS placement shall stop and damaged areas shall be repaired. LJS in a pre-formed roll may also be used for small areas or for repairing damaged areas. Prior to paving, the Contractor shall ensure the paver end plate and grade control device is adequately raised above the finished height of the LJS.
406.07 Compaction. The HMA shall be compacted according to the following
requirements.
a.Rollers. Immediately after each lift of binder or surface course mixture is placed, each lift shall be compacted with equipment meeting the requirements listed in the following Table 1. TABLE 1 - MINIMUM ROLLER REQUIREMENTS FOR HMA Breakdown/Intermediate Roller (one of the following) Final Roller (one or more of the following) Density Requirement IL-9.5, IL-9.5FG, IL-19.0 and IL-19.0L 1/ VD, P, TB, 3W, OT, OB VS, TB, TF, OT As specified in Section 1030. IL-4.75 and SMA 3/ 4/ TB, 3W, OT TF, 3W, OT As specified in Section 1030. Mixtures on Bridge Decks 2/ TB TF As specified in Articles 582.05 and 582.06. 1/ If the average delivery at the job site is 85 ton/hr (75 metric ton/hr) or less, any roller combination may be used provided it includes a steel wheel roller and the required density and smoothness is obtained. 2/ One TB may be used for both breakdown and final rolling on bridge decks 300 ft (90 m) or less in length, except when the air temperature is less than 60 ºF (15 ºC). Hot-Mix Asphalt Binder and Surface Course Art. 406.07 3/ Pneumatic-tired and vibratory rollers will not be allowed. 4/ The Contractor shall provide a minimum of two steel wheel tandem rollers (T B), and/or oscillatory rollers (O T), and/or three-wheel (3W) rollers for breakdown. 3W, T B, and T F rollers shall be a minimum of 280 lb/in. (50 N/mm). The 3W, O T, and TB rollers shall be operated at a uniform speed not to exceed 3 mph (5 km/h), with the drive roll for T B rollers nearest the paver, and maintain an effective rolling distance of not more than 150 ft (45 m) behind the paver. EQUIPMENT DEFINITION Vs Vibratory roller, static mode, minimum 125 lb/in. (2.2 kg/mm) of roller width. Maximum speed = 3 mph (5 km/h) or 264 ft/min (80 m/min). If the vibratory roller in static mode does not eliminate roller marks, its use shall be discontinued and a tandem roller, adequately ballasted to remove roller marks, shall be used. VD Vibratory roller, dynamic mode, operated at a speed to produce not less than 10 impacts/ft (30 impacts/m). P Pneumatic-tired roller, maximum speed = 3 1/2 mph (5.5 km/h) or 308 ft/min (92 m/min). The pneumatic-tired roller shall have a minimum tire pressure of 80 psi (550 kPa) and shall be equipped with heat retention shields. The self-propelled pneumatic-tired roller shall develop a compression of 300 to 500 lb/in. (53 to 88 N/mm) per width of the tire tread in contact with the HMA surface. TB Tandem roller for breakdown rolling, 8 to 12 tons (7 to 11 metric tons), 250 to 400 lb/in. (44 to 70 N/mm) of roller width, maximum speed = 3 1/2 mph (5.5 km/h) or 308 ft/min (92 m/min). TF Tandem roller for final rolling, 200 to 400 lb/in. (35 to 70 N/mm) of roller width with minimum roller width of 50 in. (1.25 m). Ballast shall be increased if roller marks are not eliminated. Ballast shall be decreased if the mat shoves or distorts. 3W Three-wheel roller, maximum speed = 3 mph (5 km/h) or 264 ft/min (80 m/min), 300 to 400 lb/in. (53 to 70 N/mm) of roller width. The three- wheel roller shall weigh 10 to 12 tons (9 to 11 metric tons). OT Oscillatory roller, tangential impact mode. Maximum speed = 3.0 mph (4.8 km/h) or 264 ft/min (80 m/min). OB Oscillatory roller, tangential and vertical impact mode, operated at a speed to produce not less than 10 vertical impacts/ft (30 impacts/m). When initial rolling causes undue displacement, hairline cracking, or checking in either the binder course or surface course, the time of rolling shall be adjusted to correct these conditions. Art. 406.07 Hot-Mix Asphalt Binder and Surface Course In all places inaccessible to the rollers, such as locations adjacent to curbs, gutters, headers, manholes, and similar structures, the required compaction shall be secured with tampers. HMA that becomes loose, broken, mixed with foreign material, or is in any way defective shall be removed and replaced with fresh HMA and compacted to conform to the surrounding area.
b.Rolling HMA Placed Under QC/QA Criteria. Rolling of the first lane of binder and surface course shall start longitudinally at the edge having the lower elevation and progress to the other edge, overlapping on successive trips to obtain uniform coverage. The roller shall not pass over an unprotected edge of the freshly laid HMA, unless directed by the Engineer. When directed by the Engineer, the edge shall be rolled with a pneumatic-tired roller. When laying the HMA adjacent to a previously placed lane, the first pass of the roller shall be along the longitudinal joint on the fresh mixture with the compression wheel not more than 6 in. (150 mm) from the joint. The second pass of the roller shall overlap the longitudinal joint not more than 12 in. (300 mm) on the previously placed lane, after which the rolling shall proceed from the low side of the transverse slope to the high side, overlapping uniformly. Each stop shall be regulated to prevent trapping of water on the rolled surface. The steel wheel rollers shall be operated with the compression wheels toward the direction of paving. The speed of the roller at all times shall be slow enough to avoid displacement of the HMA. If displacement occurs, it shall be corrected at once by raking and applying fresh HMA where required. To prevent adhesion of the HMA to the roller, the wheels shall be kept properly moistened without an excess of water. Rolling of the binder and surface courses shall be continued until all roller marks are eliminated and the HMA is satisfactorily compacted. When required by the Engineer, the surface course shall be rolled diagonally in two directions with a tandem roller, the second rolling crossing the lines of the first, and, if the width of the pavement permits, it shall also be rolled at right angles to the centerline.
406.08 Butt Joints. Butt joints shall be constructed according to the details
shown on the plans. The surface removal shall be performed according to Section 440. Construction of butt joints shall not begin prior to beginning general operations on the project. When butt joints are to be constructed under traffic, temporary ramps shall be constructed and maintained at both upstream and downstream ends of the surface removal areas immediately upon completion of the surface removal operation. The temporary ramps shall be constructed by the following methods.
a.Temporary HMA Ramps. Temporary HMA ramps shall have a minimum taper rate of 1:40 (V:H). The HMA material used shall meet the approval of the Engineer. Cold-milled HMA tailings will not be acceptable. Hot-Mix Asphalt Binder and Surface Course Art. 406.11
b.Temporary Rubber and Temporary Plastic Ramps. Temporary rubber and temporary plastic ramps shall only be used on roadways with permanent posted speeds of 55 mph or less. The ramps shall have a minimum taper rate of 1:30 (V:H). The leading edge of the ramp shall have a maximum thickness of 1/4 in. (6 mm) and the trailing edge shall match the height of the adjacent pavement ± 1/4 in. (± 6 mm). Temporary rubber and temporary plastic ramps shall be installed according to the manufacturer’s specifications and fastened with anchors meeting the manufacturer’s recommendations. Temporary rubber or temporary plastic ramps that fail to stay in place or create a traffic hazard shall be replaced immediately with temporary HMA ramps at the Contractor’s expense. Temporary ramps shall be removed just prior to placing the proposed surface course. If work is suspended for the winter season prior to completion of surface course construction, precut butt joints shall be filled to the elevation of the existing pavement surface with compacted HMA.
406.09 Approaches, Intersections, and Entrances. The thickness of the
HMA surface at the ends of the proposed resurfacing and adjacent to railroad grade crossings shall be diminished uniformly to a featheredge at a rate of 1:240 (V:H). At paved intersections, the HMA shall be feathered out in a distance of 10 ft (3 m), unless otherwise directed by the Engineer. At these locations, the thickness of the surface course shown on the plans shall be maintained to a point where the binder course has been reduced to 1 in. (25 mm) in thickness. Beyond this point, surface course only shall be used. At these locations where the HMA surface is diminished uniformly to a featheredge, the last 5 ft (1.5 m) shall receive an additional application of bituminous tack coat, just prior to placing the HMA. Unpaved intersections and entrances shall be constructed as shown on the plans or designated by the Engineer. The existing surface shall be prepared according to Section 358 and receive an application of bituminous prime coat.
406.10 Multi-Lane Pavement Resurfacing. For multi-lane pavement
resurfacing, the lift(s) of binder course shall be placed and compacted prior to start of placement of the surface course mixture. When HMA shoulder resurfacing is not being constructed simultaneously with the mainline pavement, a HMA wedge at least 3 ft (1 m) wide shall be placed on the shoulder simultaneously with binder placement on the mainline pavement. The wedge shall be constructed according to the details shown on the plans or as directed by the Engineer.
406.11 Surface Tests. The completed surface course will be tested for
smoothness in the wheel paths with a 16 ft (5 m) straightedge. Surface variations of the mainline pavement shall not exceed 3/16 in. (5 mm). Mainline pavement is defined as all pavement, except the following: ramps which will be posted for speeds of 40 mph (70 km/h) or less, acceleration and deceleration lanes, crossovers, side street turns, and other miscellaneous pavement surfaces as determined by the Engineer. In all areas other than mainline pavement, surface variations shall not exceed 3/8 in. (10 mm). Art. 406.12 Hot-Mix Asphalt Binder and Surface Course The smoothness test will not be performed on binder courses, but the Engineer reserves the right to require corrective measures when obvious surface variations are evident. For each variation in the surface course that exceeds the maximum permissible specified above but is less than 3/4 in. (19 mm), a deduction will be made in the tonnage of surface course mixture measured for payment as specified in the following table. Binder and/or Surface Course Plan Thickness, in. (mm) Surface Course Mixture Deduction Per Variation, ton (metric ton) (Existing Surface Not Reprofiled) 2 3/4 (69) or more Less than 2 3/4 (69) 2 (2) 1 (1) (Existing Surface Reprofiled) All 2 (2) In all cases where the variation in surface course equals or exceeds 3/4 in. (19 mm), the entire area affected shall be removed and replaced with fresh surface course mixture at the expense of the Contractor. The Contractor shall furnish a 16 ft (5 m) straightedge and shall provide for its jobsite transportation at no additional cost to the Department.
406.12 Protection of Pavement. The Contractor shall protect all sections of
newly compacted HMA from traffic until they have hardened to the satisfaction of the Engineer.
406.13 Method of Measurement. This work will be measured for payment as
follows.
a.Contract Quantities. The requirement for the use of contract quantities shall be according to 202.07(a).
b.Measured Quantities. Bituminous material for tack, prime, or full lane sealant (FLS) will be measured for payment as specified in Section 1032. Aggregate for covering tack or FLS will not be measured for payment. Longitudinal joint sealant (LJS) will be measured for payment in place in feet (meters). Mixture for cracks, joints and flangeways, binder (hand method), binder course, and surface course mixtures will be measured for payment in tons (metric tons) on approved platform scales, surge bin scales, or surge bin hopper scales equipped with automatic printers as specified in
Article 1102 — 01(a)(7). HMA produced by a batch-type mixing plant may be
measured by batch weights only when surge or storage bins are not used. An occasional check to verify the accuracy of the batch weights or automatic printers, will be made by weighing full truckloads of the HMA on an approved platform scale at the plant or on a commercial scale approved by the Hot-Mix Asphalt Binder and Surface Course Art. 406.13 Engineer. If it becomes apparent that the batch weights or automatic printers are not accurate in measuring the HMA, the scales and/or printers shall be repaired immediately. Quantities of materials wasted or disposed of in a manner not called for in the contract will be deducted from the final total measured quantities. The Contractor shall furnish a load ticket which records the net weight of the HMA in each truck, as specified in
Article 1102 — 01(a)(7). In addition, the load ticket shall have sufficient space
for signatures, identification of the HMA, date of delivery, and any other data which the Engineer may require. The Contractor shall submit the load ticket to the Engineer at the work site when the truck arrives. Mixture for cracks, joints, and flangeways, binder (hand method), and binder course in excess of 103 percent of the quantity specified by the Engineer will not be measured for payment. Surface course mixture in excess of 103 percent of the adjusted plan quantity will not be measured for payment. The adjusted plan quantity for surface course mixtures will be calculated as follows. Adjusted Plan Quantity = C x quantity shown on the plans or as specified by the Engineer where C : English: U 8 . 46 GC mb metric: U 99 . 24 GC mb and where: G mb = average bulk specific gravity from approved mix design U = unit weight of surface course shown on the plans in lb/sq yd/in. (kg/sq m/25 mm), used to estimate plan quantity 46.8 = English constant
24.99 = metric constant
If project circumstances warrant a new surface course mix design, the above equations shall be used to calculate the adjusted plan quantity for each mix design using its respective average bulk specific gravity. Surface removal for butt joints will be measured for payment in place and the area computed in square yards (square meters). Temporary ramps will be measured for payment in place and area computed in square yards (square meters). When the option of placing HMA binder and surface course mixtures on shoulders is used, and shoulders at 6 ft (1.8 m) or less in width are placed simultaneously with the traffic lane as specified in Section 482, the quantity of HMA placed on the traffic lane will be limited to a calculated tonnage based upon actual mat width and length, plan thickness, or a revised thickness authorized by the Engineer, and design mix weight per inch (millimeter) of thickness. The difference between the total actual tonnage Art. 406.14 Hot-Mix Asphalt Binder and Surface Course placed and the calculated tonnage used on the traffic lane will be measured and paid for as HMA shoulders according to Section 482. When a HMA wedge is placed simultaneously with the binder course as specified in Article 406.10, the quantity of binder course placed on the traffic lane will be limited to 103 percent of the quantity specified by the Engineer. The difference between the total actual tonnage placed and 103 percent of the tonnage specified by the Engineer will be measured and paid for as HMA shoulders according to Section 482.
406.14 Basis of Payment. Prime coat, tack coat, and full lane sealant (FLS)
will be paid for at the contract unit price per pound (kilogram) of residual asphalt for BITUMINOUS MATERIALS (PRIME COAT), BITUMINOUS MATERIALS (TACK COAT), POLYMERIZED BITUMINOUS MATERIALS (TACK COAT), and BITUMINOUS MATERIALS (FULL LANE SEALANT). Longitudinal joint sealant (LJS) will be paid for at the contract unit price per foot (meter) for LONGITUDINAL JOINT SEALANT. HMA binder and surface courses will be paid for at the contract unit price per ton (metric ton) for MIXTURE FOR CRACKS, JOINTS, AND FLANGEWAYS; HOT-MIX ASPHALT BINDER COURSE (HAND METHOD), of the Ndesign specified; HOT-MIX ASPHALT BINDER COURSE, of the mixture composition and Ndesign specified; HOT-MIX ASPHALT SURFACE COURSE, of the mixture composition, friction aggregate, and Ndesign specified; POLYMERIZED HOT-MIX ASPHALT BINDER COURSE (HAND METHOD), of the Ndesign specified; POLYMERIZED HOT-MIX ASPHALT BINDER COURSE, of the mixture composition and Ndesign specified; POLYMERIZED HOT-MIX ASPHALT SURFACE COURSE, of the mixture composition, friction aggregate, and Ndesign specified; POLYMERIZED HOT-MIX ASPHALT BINDER COURSE, STONE MATRIX ASPHALT, of the mixture composition and Ndesign specified; POLYMERIZED HOT-MIX ASPHALT SURFACE COURSE, STONE MATRIX ASPHALT, of the mixture composition, friction aggregate, and Ndesign specified:
a.QCP Pay Adjustments. When the work is performed under QCP criteria, the following pay adjustments shall apply.
1.Composite Pay Factor. Payment for the above pay items will be based on the calculation of the composite pay factor using QA test results for each mixture according to the document “Hot-Mix Asphalt QCP Pay Adjustments”.
2.Dust/AB Ratio. A monetary deduction will be made as specified in
Article 1030 — 08 and the table below for dust/AB ratios that deviate from
the 0.6 to 1.2 range. Hot-Mix Asphalt Binder and Surface Course Art. 406.14 Dust/AB Ratio Deduction Table 1/ Range Deduct / Sublot 0.6 ≤ X ≤ 1.2 $0 0.5 ≤ X < 0.6 or 1.2 < X ≤ 1.4 $1,000 0.4 ≤ X < 0.5 or 1.4 < X ≤ 1.6 $3,000 X < 0.4 or X > 1.6 Shall be removed and replaced 1/ Does not apply to SMA.
b.PFP Pay Adjustments. When the work is performed under PFP criteria, the following pay adjustments shall apply.
1.Composite Pay Factor. Payment for the above pay items will be based on the calculation of the composite pay factor for each mixture according to the document “Hot-Mix Asphalt PFP Pay Adjustments”.
2.Dust/AB Ratio. A monetary deduction will be made as specified in
Article 1030 — 07 and the table above for dust/AB ratios that deviate from
the 0.6 to 1.2 range.
3.Unconfined Edge Density. A monetary deduction will be made as specified in Article 1030.07 and the table below for densities less than 90 percent. Unconfined Edge Density Deduction Table Density Deduction / Sublot ≥ 90 % $0 89.0 - 89.9 % $1,000 88.0 - 88.9 % $3,000 < 88.0 % Outer 1.0 ft (300 mm) will require remedial action acceptable to the Engineer Surface removal for butt joints will be paid for at the contract unit price per square yard (square meter) for HOT-MIX ASPHALT SURFACE REMOVAL - BUTT JOINT and PORTLAND CEMENT CONCRETE SURFACE REMOVAL - BUTT JOINT. Temporary ramps will be paid for at the contract unit price per square yard (square meter) for TEMPORARY RAMP. The cost of furnishing and introducing anti-stripping additives in the HMA shall be included in the contract unit price of the HMA item involved. If provided as a payment item, the preparation of base will be measured and paid for as specified in Section 358. If not provided as a payment item, the cost of the preparation of the base will be paid for according to Article 109.04. Art. 407.01 Hot-Mix Asphalt Pavement (Full-Depth) The HMA test strip will be evaluated for payment according to one of the following options. OPTION 1. If the HMA placed during the initial test strip is determined to be acceptable, the mixture will be paid for at the contract unit price. OPTION 2. If the HMA placed during the initial test strip (1) is determined to be unacceptable to remain in place by the Engineer, and (2) was not produced within 2.0 to 6.0 percent air voids or within the individual control limits of the JMF according to the Department’s test results, the mixture will not be paid for and shall be removed at no additional cost to the Department. An additional test strip shall be constructed and the mixture will be paid for in full, if produced within 2.0 to 6.0 percent air voids and within the individual control limits of the JMF. OPTION 3. If the HMA placed during the initial test strip (1) is determined to be unacceptable to remain in place by the Engineer, and (2) was produced within 2.0 to 6.0 percent air voids and within the individual control limits of the JMF according to the Department’s test results, the mixture shall be removed. Removal will be paid for according to Article 109.04. This initial mixture will be paid for at the contract unit price. An additional test strip shall be constructed and the mixture will be paid for in full, if produced within 2.0 to 6.0 percent air voids and within the individual control limits of the JMF. SECTION 407. HOT-MIX ASPHALT PAVEMENT (FULL-DEPTH)
407.01 Description. This work shall consist of constructing a full-depth hot-
mix asphalt (HMA) pavement on a prepared subgrade.
407.02 Materials. Materials shall be according to Article 406.02.
407.03 Equipment. Equipment shall be according to Articles 406.03,
1101.04, and 1101.10. Pavement thickness cores shall be taken utilizing an approved coring machine. The cores shall have a diameter of 2 in. (50 mm). The cores will be measured with a device supplied by the Department. CONSTRUCTION REQUIREMENTS
407.04 General. HMA Pavement (Full-Depth) shall be constructed according
to the applicable portions of Section 406 with binder and surface course mixtures as shown on the plans.
407.05 Subgrade. The subgrade shall be prepared according to Section 301,
except Articles 301.05 and 301.06 will not apply, or according to Section 302 when soil modification is used.
407.06 Placing and Compacting. Prior to placing the initial lift of the HMA
binder course, trimmings and other loose material shall be removed from the prepared subgrade.
Referenced in this section
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Source: Illinois Standard Specifications for Road and Bridge Construction, 2022 Edition. Pages 217–233 of 1,217. View official source ↗