394 QC TESTING Test Frequency1,2 Depth of Laydown 1 per 500 ft Pulverized Material Gradation 1 per 1,000 tons of production Pulverized Material Moisture Content 1 per 500 tons of production Asphalt Emulsion Content3 1 per 500 tons of production Water Content3 1 per 500 tons of production Compacted In-Place Field Density 1 per 1,000 ft Field Moisture Content for Curing 1 per each day of production Optimum Field Density 1 per 2 days of production
1.The Contractor shall perform all QC tests within the first 500 ft after startup and after any change in the mix design.
2.Testing frequency is based upon either linear feet of CCPR laydown or tons of CCPR mixture processing.
3.Asphalt emulsion content and water content shall be taken from the readings of the control settin gs of the mixin g unit. MATERIALS
417.04 Materials CCPR shall consist of a homogenous blend of RAP combined with asphalt 40
emulsion, water, and when required, recycling additives such as corrective aggregate or cement. Cement recycling additives used in asphalt emulsion stabilized CCPR may be dry powder or slurry with a minimum dry solids content of 60%. The actual materials used are dependent on the CCPR mix design and project requirements. Materials for use in CCPR shall be in accordance wi th the following: Asphalt Emulsi on ........................................................ 902.01(b)3 Corrective Aggregate to adjust gradation or supplement material volume: 50
1.Coarse or Dense Graded Aggregate, Class C or Higher .......................................... 904.03
2.Fine Aggregate .............................................. 904.02
3.RAP shall be the product resulting from the cold milling or crushing of existing asphalt pavement and processed so that 100% passes the 1 1/2 in. (37.5 mm) sieve. Portland Cement, Type I .............................................. 901.01(b) Water ........................................................................... 913.01 A Type D certification in accordance with 916 and the Frequency Manual shall be provided for the CCPR. 417.04 395 417.05 Mix Design CCPR mix designs shall be in accordance with ITM 592 and shall be comprised of existing RAP, asphalt emulsion, and recycling additives, if necessary. The mix design and all associated te sting shall be performed using samples of each proposed material. RAP samples shall either be coll ected from the existing pavement at the project site representing the milling depth or from the RAP stockpile to be used during construction. The mix design shall be completed by a design laboratory that is 70 AASHTO re:source accredited in HMA and asphalt emulsion. Additional mix designs shall be developed when the proposed material changes significantly to establish representative mixes for the entire job. The Contractor shall be responsible for obtaining all samples required to develop the mix design. One sample per lane mile of planned CCPR shall be the minimum sampling frequency for mix design preparation. The mix design, or designs, shall be submitted to the Engineer for approval at least five calendar days prior to the JITT and shall include results of all tests performed. If new materials are added, a new mix design, including the updated test results, shall be submitted at least one day prior to implementation. 80 CONSTRUCTION REQUIREMENTS
417.06 Roadway Preparation
Snowplowable raised pa vement markers shall be removed in accordance with 808.11(e) prior to CCPR operations. Grass and other vegetation shall be re moved from the edge of the existing pavement to prevent contamination of the pulverized asphalt material during milling operation. 90 All areas of soft or yielding subgrade shall be corrected prior to CCPR operations. If the CCPR mix is to be placed on a prepared subgrade or aggregate base, the Contractor shall ensure the subgrade soils and base have been properly prepared, moisture treated, and compacted to the minimum density as specified, immediately prior to placement of the CCPR mix to cr eate an evenly graded, unyielding surface.
417.07 Pavement Removal The existing asphalt pavement shall be milled in accordance with 306 to the 100
length, depth, and width as specified. The RAP shall be free of contamination of dirt, base, concrete or other deleterious materials such as silt and clay. When paving fabric is encountered during the pulverization operation, the Contractor shall make necessary changes in equipment or operations so incorporation of shredded fabric into the CCPR does not affect the performance parameters or inhibit placement or compaction of the CCPR. The Contractor shall remove and properly dispose of oversized pieces of paving fabric. The Contractor shall make the necessary adjustments in equipment or operations so that the shredded fabric in the recycled 417.07 396 material is no more than 5 sq in. No fa bric piece shall have a dimension exceeding a 110 length of 4 in. Rubberized crack filler, durable pavement markings, loop wi res, and other non- pavement materials shall be removed as observed from the roadway. Residual materials that cannot be completely removed may be incorporated into the mixture if the Contractor can demonstrate that those added materials will not adversely affect performance. Any such materials retained in the mix shall be appropriately sized and blended so as not to adversely affect the strength of the recycled pavement. 120
417.08 Equipment The equipment shall consist of the following major components:
a.Milling Machine/Pavement Cold Planer Milling equipment shall be in accordance with 306.03(a). The equipment shall be capable of pulverizing the existing asphalt material in a single pass to the depth shown on the plans. The machine shall have automatic depth controls to maintain the cutting depth to within ±1/4 in. of that shown on the plans. The milling operation shall not disturb or damage the underlying material. The use of a heating device to soften the 130 pavement will not be allowed. (b) Additive Slurry Storage and Supply Equipment Slurry shall be produced using a batch or continuous-flow type stationary mixer equipped with calibrated metering and feeding devices that introduce the cement, water and additives into the mixer in the specified quantities. Additive slurry storage and supply equipment shall have agitators or similar equipment to keep the slurry in suspension when held in the slurry batch or storage tanks. Slurry shall be kept in suspension during transport using agitator equipment. 140
c.Sizing Equipment A material-sizing unit shall be capable of sizing using a scalping screen or crushing capabilities to reduce RAP to a maximum size of 1 1/2 in. (37.5 mm) or to the maximum size requirements specified prior to mixing with the asphalt emulsion. (d) Mixing and Proportioning Equipment The equipment shall be capable of processing sized RAP, asphalt emulsion, water, and any additives stipulated in the mix design into a homogenous and uniformly coated CCPR mixture. The CCPR mixing unit shall be a twin shaft pugmill or other approved mixer, including the drum type capable of producing a consistent uniform mixture. 150 The outlet of the mixer shall be such that it prevents segregation of the material when discharged. The equipment shall display automatic digital readings for the flow rate of both the RAP and asphalt emulsion in appropriate units of weight and time. The mixing apparatus shall have cold feed hopper equipped with vibrators on the 417.08 397 hopper walls to assist the free flow of materials to a variable speed belt conveyor. Control of the RAP shall be by mechanically adjustable gate valves at the point of discharge or a RAP belt scale for the continuous weighing of the RAP. The variable speed belt conveyor or RAP belt scale shall be interlocked to the asphalt emulsion metering device. 160 The asphalt emulsion metering device shall be capable of automatically adjusting the flow of asphalt emulsion to compensate for any variation in the amount of RAP introduced into the mixing apparatus. Aspha lt emulsion shall be metered by weight of RAP using a calibrated meter that will accurately measure the amount of asphalt emulsion to within a tolerance of ±2.0% of the specified rate. (e) Hauling Equipment Hauling equipment shall be in accordance with 409.03(b).
f.Laydown Equipment Laydown equipment shall be in accordance with 409.03(c). The paver screed shall be controlled by electronic grade and cross slope control. Heating of the screed shall not be allowed. CCPR material shall either be loaded directly into the paver hopper from transport trucks or loaded by a pickup device. If utilizing a pickup device, it shall be capable of removing and transferring the entire windrow of recycled mix in a single pass. 180 The equipment used for placement of the CCPR mixture shall be capable of the placement in accordance with 105.03. (g) Compaction Equipment Compaction equipment shall be in accordance with 409.03(d). The number, weight, and types of rollers shall be as necessary to obtain required compaction. At a minimum, the following rollers shall be used:
1.At least one pneumatic tired roller in accordance with 409.03(d)3 with a minimum weight of not less than 20 t. 190
2.At least one double drum vibratory roller in accordance with 409.03(d)4 with a minimum weight of not less than 10 t.
417.09 Weather Limitations CCPR operations shall be performed when the RAP temperature, or pavement surface temperature, is above 50ºF with ambient temperatures above 35ºF for seven
days. The Engineer may restrict work when the heat index is greater than 100°F. The CCPR shall not be performed before May 1 or after October 1. 200 417.09 398 417.10 Material Sizing and Stockpiling The gradation of the RAP shall have 100% passing the 1 1/2 in. (37.5 mm) sieve, or be sized to meet specific contract requirements. RAP that has been crushed and screened shall be stockpiled and maintained to prevent reconsolidation. Water may be added to RAP as it is screened and crushed to abate dust and mitigate reconsolidation. Corrective aggregate, if required, sha ll either be mixed with RAP to produce a homogenous mixture during stockpiling or fed into the mixing apparatus at the rate 210 determined by the mix design. 417.11 Processing and Mixing Operation The sized RAP shall be processed throug h a mixing unit capable of combining the sized RAP, asphalt emulsion, and any additives to produce a homogenous recycled mixture. An additive used in asphalt emulsion stabilized CCPR may be dry powder or slurry. The Contractor shall address the application methods and fugitive dust control procedures in the QCP when dry powder materials are used. 220 The asphalt emulsion shall be injected into the CCPR materials at the initial rate determined by the mix design and approved by the Engineer. Sampling and mix design may determine different levels of asphalt emulsion at various portions of the project. The asphalt emulsion shall have an application tolerance determined by adding ±0.25% to the percent total asphalt emulsion content. The Contractor can request the asphalt emulsion percentage to exceed the upper tolerance provided the mix design requir ements are satisfied at the requested 230 percentage. The request will be subject to approval by the Engineer.
417.12 Placement The depth of CCPR shall be as indicated on the plans. The hauling equipment shall deliver the blended CCPR material into the paver within one hour of mixing or before the asphalt emulsion begins to break and set.
CCPR single lift thickness shall be a minimum compacted depth of 3 in. and shall not exceed a maximum compacted depth of 5.5 in. Tack coat in accordance with 406 240 shall be applied between the lifts.
417.13 Control Strip and Compaction
A minimum 500 ft long control strip shall be conducted on the first day of production to verify the construction process meets the requirements as specified. The control strip shall allow the Contractor to: 417.10
a.demonstrate the equipment, materials, and processes proposed to produce a CCPR layer in accordance with specification requirements, 250
b.determine the optimal rates for the asphalt emulsion, water and any additives recommended for the material, and
c.determine the sequence and manner of rolling necessary to obtain specified density requirements in one uniformly compacted layer. The CCPR density shall be achieved w ith the same equipment, materials, construction methods, and dens ity requirements used on the accepted control strip. A 260 new control strip shall be constructed if changes are made outside of the tolerances of the original mix design, equipment, or construction methods. A rolling pattern that produces the maximum obtainable density, or optimum field density, shall be determined during the control strip using a roller in accordance with 409.03(d)4. The Contractor shall provide a sequence and manner of rolling by establishing a roller pass versus density chart that shows the progress of densification from initial lay down through optimum field density using a properly calibrated nuclear gauge in accordance with AASHTO T 310. Production may continue after approval of the control strip. 270 The Contractor shall perform compaction testing in accordance with AASHTO T 310 during production to ensure compaction is between 97% and 102% of the optimum field density established during th e control strip. If two successive tests indicate compaction is over 102% or below 97% of the optimum field density, a new rolling pattern and roller pass versus density chart shall be established. The QC technician shall be on site, observing all compaction efforts, and approving areas as they reach minimum rela tive compaction. Care shall be taken not to over compact the mat. 280 Any type of rolling effort that causes cr acking, displacement, or other type of pavement distress shall be discontinued until such time as the problem can be resolved as approved by the Engineer. Rollers shall not be started or stopped on recycled material unless when changing direction during the compaction process. All tests shall be conducted at the stated QC testing frequencies throughout CCPR operations. 290 417.13 400 417.14 Opening to Traffic Opening to traffic shall occur after sufficient cure time has been applied to the CCPR so traffic will not initiate raveling or permanent deformation. All loose particles that may develop on the pavement surface sh all be removed by a rotary power broom in accordance with 409. After opening to traffic, the surface of the recycled pavement shall be maintained in a condition suitable for the safe movement of traffic.
417.15 Maintenance
The Contractor shall mainta in the recycled pavement in a manner satisfactory to the Engineer until the surface course has been constructed. Any damage to the completed recycled material shall be repaired by the Contractor prior to the placement of new asphalt concrete or final surface sealing. Patching shall be in accordance with 304. The excavated patch areas shall be filled and compacted with HMA or CCPR material as directed by the Engineer. No direct payment will be made for damage re pair unless approved by the Engineer.
417.16 Curing
Before placing the final surfacing, the recycled surface shall remain in-place for a minimum of three days and meet one of the following conditions:
a.there is less than 3.0% moisture remaining in the mixture, or
b.the material has cured for a minimum of 10 consecutive days without rainfall. The planned method and duration of curi ng for CCPR shall be in accordance with 320 the QCP. The specified surface course sha ll be placed within two weeks of the CCPR final cure, but no later than November 1.
417.17 Milling and Pavement Smoothness When the CCPR material is placed in a single lift, the entir e surface of the CCPR
shall be scarified in accordance with 306.04 in preparation for the overlay, except liquidated damages will not apply. Construction engineering in accordance with 105.08(b) shall be provided. Pavement smoothness of the cured CCPR mat shall meet the requirements of 330 401.18(b) The Contractor shall correct humps or depressions exceeding the tolerances in accordance with 401.18(c).
417.18 CCPR Surface Course
The CCPR shall be swept of all loose material and standing water with a rotary power broom in accordance with 409 immediately prior to placing the tack coat. A tack coat shall be required and shall be app lied to the CCPR in accordance with 406. 417.14 Monuments shall be reestablished in accordance with 615.10 after the surface course is placed. 340
417.19 Method of Measurement
The CCPR will be measured by the square yard, complete in place. Asphalt emulsion will be measured by the ton. Aggr egate used to adjust the CCPR gradation will be measured by the ton. HMA Patching will be measured in accordance with
304.06 Re-established monuments will be measured in accordance with 615.13.
Grade adjustment of existing structures wi ll be measured in accordance with 720.06. Removal of snowplowable raised pavement markers will be measured in accordance with 808.12. Portland cement w ill be measured by the ton.
417.20 Basis of Payment
The CCPR will be paid for at the contract unit price per square yard, complete in place. Asphalt emulsion will be paid for at the contract unit price per ton, complete in place. Aggregate used to adjust the CCPR gradation will be paid for at the contract unit price per ton, complete in place. HMA patching will be paid for in accordance with 304.07 for the thickness shown on the plans. Re-established monuments will be paid for in accordance with 615.14. Grade adjustment of existing structures will be paid for in accordance with 720.07. Removal of snowplowable raised pavement markers will be paid for in accordance with 808.13. 360 Portland cement will be paid for in accordance with 104.03. The change order will include direct material costs, delivery costs, and shall not include any other markups. Payment will be made under: Pay Item Pay Unit Symbol Cold Central Plant Recycling .................................................... SYS Corrective Aggregate, CCPR .................................................... TON Stabilizing Material, As phalt Emulsion ..................................... TON 370 Stabilizing Material, Portland Cement ...................................... TON The costs associated with the CCPR mix design and quality control testing shall be included in the cost of the cold central plant recycling. The costs associated with the removal of grass and vegetation, rubberized crack filler, durable pavement markings, loop wire s and other non-pavement materials shall be included in the cost of the CCPR. The costs associated with pulverizing, stabilizing, compacting, curing and 380 maintenance of the CCPR not related to failing subgrade shall be included in the cost of the CCPR. 417.20 402 The cost associated with mixing water fo r cold central plant material shall be included in the cost of the co ld central plant recycling. The cost associated with aggregate used to supplement material volume shall be included in the cost of the corrective aggregate pay item. When portland cement is a required stabilizing material, costs associated with 390 mixing, installation, compaction, curing, and maintenance shall be included in the cost of the CCPR. The cost associated with aggregate used to adjust the CCPR gradation shall be included in the cost of the corrective aggregate pay item. The costs of the asphalt emulsion stabilizing material shall be included in the cost of the stabilizing material pay item. In the locations of failing subgrade, removal of the CCPR shall be included in the 400 cost of subgrade treatment. 417.20 403 DIVISION 500 – CO NCRETE PAVEMENT
Source: Indiana Standard Specifications, 2024 Edition. Pages 394–403 of 1,248.