WARRANTED
414.01Description
This work shall consist of furnishing materials and the placement of warranted ultrathin bonded wearing course, UBWC, in accordance with 105.03. The UBWC shall consist of surface preparation, application of asphalt emulsion and asphalt mixture. Asphalt mixture shall be produced by a Certified Hot Mix Asphalt Producer.
The Contractor shall be responsible fo r the warranted UBWC in accordance with 10
414.14
MATERIALS
414.02Materials
Materials shall be in acco rdance with the following:
Asphalt Emulsion ........................................................ 902.01(b)2 Asphalt Materials PG Binder, PG 64- 22, PG 76-22 .......................... 902.01(a) 20 PG Binder Grade .................................................. 414.02(b) Coarse Aggregates, Class A or Higher ........................ 904.03 and 414.02(c) Fine Aggregates ........................................................... 904.02 Mineral Filler ............................................................... 904.02(f)
The PG binder grade shall be selected based on the following requirements:
PG Binder ESAL 64-22 < 10,000,000 76-22
Additional requirements for the PG 76-22 binder as follows:
Characteristic Test Method Min. Max. Separation, % prepared by ASTM D 7173 AASHTO T 53 6qC Elastic Recovery, @ 39qF (4qC), % AASHTO T 301 60
Additional requirements for coarse aggregate shall also be as follows:
Characteristic Method Min. Max. Coarse Aggregate Angularity ASTM D5821 95/85* Micro-Deval Abrasion, % loss AASHTO T 327 18 * Denotes two faced crush requirements.
414.03Design Mix Formula
The DMF shall be determined for each mixture prepared by a Qualified Mix Design Laboratory selected from the Department's list of Qualified Mix Design Laboratories. The Contractor shall submit a DMF for each mixture to the Engineer one week prior to use. The DMF shall state the maximum particle size in the mixture, the 414.03
mixture gradation, the total aggregate bulk specific gravity, the maximum and bulk specific gravity of the UBWC mixture and the application rate for any anti-stripping additives. No mixture shall be used until the DMF has been reviewed by the DTE.
414.04Mix Design
The binder content and the percentage of aggregate passing each sieve shall be in accordance with the following requirements:
MIXTURE DESIGNATION – CONTROL POINT (Percent Passing) Sieve Size 12.5 mm 9.5 mm 4.75 mm 3/4 in. (19.0 mm) 100.0 1/2 in. (12.5 mm) 85.0 - 100.0 100.0 3/8 in. (9.5 mm) 55.0 - 80.0 85.0 - 100.0 100.0 No. 4 (4.75 mm) 22.0 - 38.0 22.0 - 38.0 40.0 - 55.0 No. 8 (2.36 mm) 19.0 - 32.0 19.0 - 32.0 20.0 - 32.0 No. 16 (1.18 mm) 15.0 - 24.0 15.0 - 24.0 15.0 - 24.0 No. 30 (600 μm) 11.0 - 18.0 11.0 - 18.0 11.0 - 18.0 No. 50 (300 μm) 8.0 - 14.0 8.0 - 14.0 8.0 - 14.0 No. 100 (150 μm) 5.0 - 10.0 5.0 - 10.0 5.0 - 10.0 No. 200 (75 μm) 4.0 - 5.5 4.0 - 5.5 4.0 - 5.5 Binder Content, % 4.6 - 6.1 4.8 - 6.1 5.0 - 6.3 Plan Lay Rate (lb/sq yd)* 90 75 65 * Plan lay rates are based on 100 lb/sq yd/in. using a mixture with a specific gravity of 2.5. Mixtures with different specific gravity will require an adjusted equivalent lay rate.
The binder film thickness shall be a minimum of 0.4 mil. The binder content of the mix shall be determined by calculating the binder film thickness in accordance with ITM 589.
The maximum specific gravity of the UBWC mixture shall be mass determined in water in accordance with AASHTO T 209.
The bulk specific gravity of the UBWC mi xture shall be determined in accordance with AASHTO T 331.
Draindown from the loose mixture shall not exceed 0.10% when tested in accordance with AASHTO T 305.
The TSR shall meet or exceed 80% wh en tested in accordance with AASHTO T 70 283(1). Specimens for AASHTO T 283 shall be 6 in. in diameter by 3 3/4 ±1/4 in. height and compacted in accordance with AASHTO T 312, except the specimens shall be compacted to 100 gyrations and resultant air voids reported for information purposes only.
414.04
The compaction temperatures shall be 300 ±10°F.
30, Section 7.1.
to 100 gyrations.
sample.
need to be repeated unless th e difference in tensile strength between duplicate specimens is greater than 25 lb/sq in.
414.05Use of Recycled Materials
Recycled materials shall be in accordance with 401.06 for dense graded surfaces, except RAP for use in the UBWC mixture shall be 100% passing the 3/8 in. (9.5 mm) sieve and 95 to 100% passing the No. 4 (4.75 mm) sieve. 100
414.06Quality Control
The Contractor shall produce a mixture in compliance with the DMF within the limits of the quality control tolerances. The Contractor shall maintain all quality control documentation and make a copy available to the Engineer upon request or at completion of work.
The Contractor shall sample the mix a minimum once per day in accordance with ITM 580, section 8.6 Truck Samples, Dense Graded HMA Mixture. The sample shall be tested for binder content and gradation prior to the next day’s production. 110
The Contractor shall take corrective action when the binder content exceeds r0.5% from that stated in the DMF as tested in accordance with ITM 586.
The Contractor shall take corrective ac tion when the aggregate gradation exceeds the following values from that stated in the DMF as tested in accordance with AASHTO T 30.
414.06
Sieve Size Quality Control Tolerances (r), % Mixture Designation - Tolerances 12.5 mm 9.5 mm 4.75 mm 3/4 in. (19.0 mm) 1/2 in. (12.5 mm) 5.0 3/8 in. (9.5 mm) 5.0 No. 4 (4.75 mm) 4.0 4.0 5.0 No. 8 (2.36 mm) 4.0 4.0 4.0 No. 16 (1.18 mm) 4.0 No. 200 (75 μm) 1.0 1.0 1.0
CONSTRUCTION REQUIREMENTS 120
414.07Equipment
The equipment shall be in accordance with 409.01, 409.02, 409.03(b), 409.03(d)1, and as follows:
The paver shall be self-priming, designed and built for applying the UBWC. The paver shall have:
The paver shall be capable of spraying the asphalt emulsion, applying the asphalt mix and leveling the surface of the mat in one pass. The screed shall have the ability to crown the pavement at the center.
414.08Preparation of Surface
The Contractor shall be responsible for all surface preparation to meet the requirements for warranted UBWC. All castings and detector housings not identified on the plans as being reset shall be protected prior to the application of material in accordance with 404.07, except that raised pavement markers shall be removed.
414.09Asphalt Emulsion
The asphalt emulsion shall be applied at a temperature recommended by the emulsion supplier. The asphalt emulsion shall be applied uniformly across the entire width of pavement to be overlaid. Equipm ent shall not operate on the applied asphalt 150 emulsion before the asphalt mix is placed.
414.07
The recommended plan application rates of the asphalt emulsion are as shown in the table below. Determination of actual application rates shall be the responsibility of the Contractor.
Recommended Asphalt Emulsion Application Rate and Adjustment Factors for Surface Conditions Mixture Designation 12.5 mm 9.5 mm 4.75 mm General application rate, gal./sq yd 0.20 0.17 0.14 Existing Surface Condition Recommended adjustment to application rate, gal./sq yd PCCP, smooth or polished -0.03 -0.03 -0.03 PCCP, broomed or textured 0 0 0 Flushed asphalt concrete surface -0.02 -0.03 -0.03 Dense, unaged asphalt concrete surface 0 0 0 Open textured, dry, aged or oxidized asphalt concrete surface +0.02 +0.01 +0.01 Milled asphalt concrete surface +0.02 +0.01 +0.01
414.10Pre-Paving Meeting
A pre-paving meeting between the Engineer and Contractor will be held on-site 160 prior to beginning work. The following shall be reviewed:
equipment, including units for transport of materials
414.11Mixture Placement
The UBWC shall be prepared and placed at temperatures recommended by the binder supplier. Fracturing of aggregates shall be avoided.
414.12Mixture Finishing
Three passes of rollers capable of exerting at least 150 lb/in. and in conformance with 409.03(d)1 shall be applied to the UBWC before the material has cooled below 185qF. A release agent may be added to the water system of the rollers to prevent 180 adhesion of the material to the roller drum. Rollers shall not operate in vibratory mode.
414.12
414.13Smoothness
Pavement smoothness shall be controlled by the Contractor with a 16 ft straightedge longitudi nally and will be controlled by the Department with a 10 ft straightedge transversely. The 16 ft straightedge shall be in accordance with 306.03(d). The 10 ft straightedge will be in accordance with 306.03(d). Smoothness correction shall be in accordance with 401.18(e).
The lane edge shall have no more than 2 in. of horizontal variance in 100 ft. 190
Warranty
A warranty bond is to insure completion of required warranty work, including payments for all labor, materials, equipment, and incidentals necessary or convenient to the successful completion of the project and the carrying out of the duties and obligations imposed by the contract used to remediate any warranted distresses.
The Contractor shall furnish to the Engineer a warranty bond at the pre- construction conference or prior to beginning any work on the contract. The warranty bond shall be equal to 100% of the contract total for the warranted UBWC pay items, 200 and shall be properly executed by a surety satisfactory to the Department, and shall be payable to the State of Indiana. The warranty bond shall be in effect for three years from the date of substantial completion.
Upon the final acceptance of the project , the contractual obligations of the Contractor are satisfied as long as the UBWC continues to meet or exceed the warranted values as defined herein.
All warranty work shall be accomplished in accordance with 414.16. At the end of the warranty period, the Contractor will be released from further warranty work or 210 responsibility, provided all previous warranty work has been satisfactorily completed and approved by the Department.
414.15Conflict Resolution Team
The scope of work for the conflict resolution team includes all issues concerning the warranted pavement relative to the quality control plan, material selection, warranted pavement evaluations, distress indicators, remedial action, and remediation plans.
The team will consist of two Contractor representatives, two Department 220 representatives, and an additional person mutually agreed upon by both the Department and the Contractor. All costs for the additional person will be equally
shared by the Department and the Contractor.
The team members will be identified in writing when needed and will be
knowledgeable in the terms and conditions of this warranty and the methods used in
the measurement and calculation of pavement distress. The team will render a final
recommendation to the Chief Engineer by a majority vote. Each member has an equal
vote.
414.13
381
230
414.16Warranty Work
Elective work is performed by the Contractor at its discretion to meet the
performance requirements of warranted UBWC prior to direction from the Department
for the Contractor to perform remedial work.
Remedial work is performed as a result of pavement distress surveys performed
by the Department.
During the warranty period, elective work and remedial work shall be performed
at no cost to the Department. Elective work shall be at the Contractor’s option. The240
scope of all elective work or remedial work to be performed as well as materials to be
used shall be proposed by the Contractor and shall be subject to approval by the
Department. Prior to proceeding with any warranty work or monitoring, all necessary
permits shall be obtained from the Department.
Elective work during the warranty period will not be assessed a lane closure fee.
For remedial work, costs for closure periods will be as shown in the contract.
During the warranty period, the Contractor may monitor the warranted UBWC
using non-destructive procedures.250
Coring, milling, or other destructive procedures may not be performed by the
Contractor without prior consent of the Department. The Contractor will not be
responsible for damages to the pavement as a result of coring, milling, or other
destructive procedures conducted by the Department.
The Contractor has the first option to perform the remedial work. If the problem
requires immediate attention, as determined by the Engineer, for safety of the traveling
public and the Contractor cannot perform the remedial work within 24 h of
notification, the Department will perform the remedial work. The Contractor shall be260
responsible for all costs incurred by the Department for remedial work performed by
the Department. Remedial work performed by the Department will not alter the
requirements, responsibilities, or obligations of the warranty.
414.17Pavement Distress Indicators, Thresholds, and Remedial Action
The Department will use the following pavement distress indicators throughout
the warranty period:
the underlying surface.270
and ASTM E524.
414.17
382
The pavement threshold values for the pavement distress indicators will be
evaluated for the entire length of the project for each lane. The threshold values for the
pavement distress indicators are listed below:
Distress Single Location Multiple Locations
Delamination/Raveling 1/2 sq yd 1 sq yd/mi
Rut Depth 1/4 in. average 1/4 in./mi
Friction Number* no less than 30 average 35
* Individual friction tests will be performed in each lane every 1/2 mi for the
length of the project.
280
The Department may evaluate the warranted UBWC during the warranty period.
A final condition survey will be made by the Department and the Contractor will be
notified in writing of all sections exceeding the warranty threshold at least 90 days in
advance of the expiration of the warranty period.
If the Department determines that any threshold level has been met or exceeded
and remedial work is required, the Contractor shall submit a work plan and schedule
to the Engineer for approval. The Contractor shall perform the remedial work within
30 calendar days of notification of approval by the Engineer.290
If, anytime during the warranty period, 30% or more of the project requires, or
has received remedial work, remedial work as determined by the Department shall be
performed on the entire project.
If remedial or elective work performed by the Contractor necessitates repair or
replacement of pavement markings, adjacent lanes or roadway shoulders, the required
work shall be the responsibility of the Contractor.
Warranty requirements for all elective and remedial work will be limited to the300
life of the original contract warranty.
414.18Department Maintenance
The Department may perform routine maintenance operations during the warranty
period including, but not limited to, plowing, applying de-icing chemicals, repairs to
safety appurtenances, pavement markings, mowing, and sign maintenance.
The Department will perform no routine pavement surface maintenance activities
during the warranty period.
310
414.19Method of Measurement
Ultrathin bonded wearing course, of the type specified, will be measured by the
square yard in accordance with 109.01.
414.18
383
414.20Basis of Payment
Ultrathin bonded wearing course, of the type specified, will be paid for at the
contract unit price per square yard.
Payment will be made under:
320
Pay Item Pay Unit Symbol
Ultrathin Bonded Wearing Course for Approaches, _____ ....... SYS
size
Ultrathin Bonded Wearing Course, _____ ................................ SYS
size
The cost of all incidentals including, but not limited to, surface preparation,
asphalt emulsion, meeting smoothness requirements, and warranty bond shall be
included in the cost of the pay items.330
414.21Final Warranty Acceptance
The Engineer will review the project in the field for any general defects not
addressed in the indicators and recommend a Final Warranty Acceptance. The
Department will issue the Contractor a Final Warranty Acceptance letter upon
completion of the warranty period and all required remedial work.
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