602 - HOT MIX ASPHALT (HMA) CONSTRUCTION (Quality Control/Quality Assurance (QC/QA))
600-5 i. Testing Requirements for Lots 2 and Greater.
1.Take all samples for tests at ra ndom locations as designated in the approved QCP at the rates specified in Appendix B, Part V. Provide the Engineer with the random locations before going to the roadway to determine density or sample the HMA. The Engineer reserves the right to generate the random locations. If the Engineer generates the random locations, the Contractor will be notified before going to the roadway to sample the HMA or determine density.
2.Conduct the tests for mixture properties, aggregate gradation and binder content on representative portions of the HMA, quartered from the larger sample of HMA. Take a random sample weighing a minimum of 55 pounds from behind the paver and transport it to the test facility, usi ng a method to retain heat to facilitate sample quartering procedures. (3) Record and document all test results and calcula tions on data sheets provided by KDOT. Record specific test results on a daily summary sheet provided by KDOT to facilitate the computation of moving test averages. Base moving averages on 4 consecutive test resu lts. Calculations are to be based on the precision displayed on the data sheets. Use "precision displayed" when calculating within Excel. Appendix B, Part V shows the accuracy to "record to " for the tests listed. Include a description of quality control actions taken (adjustment of cold feed percentages, changes in Job Mix Formulas (JMF), etc.) in the Daily Quality Control Summary Sheet. In addition, post and keep current quality control charts, sh owing both individual test results and moving average values. As a minimum, plot the single test values and the 4 test moving average values, as applicable, on KDOT approved control charts for th e mix characteristics shown in TABLE 602-12 .
4.If the Contractor and Engineer agree, the procedures shown for sampling, testing and evaluation of Lot 1 in subsection 602.2h. may be used for any other Lot produced on the project.
g.Corrective Action. In the QCP, identify procedures fo r notifying the Engineer when corrective measures must be implemented, and for halting production.
h.Non-Conforming Materials. In the QCP, specifically address how non-conforming materials will be controlled and identified. Establish and maintain an e ffective and positive system for controlling non-complying material, including procedures for its identification, isolation and disposition. Reclaim or rework non-complying materials according to procedures acceptable to the Engin eer. This could include removal and replacement of in- place pavement. Positively identify all non-conforming materials and produc ts to prevent use, shipment and intermingling with complying materials and products. Provide holding areas, mutually agreeable to the Engineer and Contractor. 602.3 MATERIALS
a.Asphalt Binder. Provide Asphalt Binder that complies with DIVISION 1200 . Post a legible copy of the latest bill of lading for the Asphalt Binder on or near the gyratory compactor. Use the mixing and compaction temperatures shown on the bill of lading; however, th e maximum mixing or compaction temperature is 340ºF, unless otherwise approved by the Fiel d Materials Engineer. Notify the En gineer if the mixing or compaction temperature changes. Exception: The mixing temperature may be increased no more than 10 oF above the maximum mixing temperature shown on the bill of lading provided all the following are met: The air temperature is below 70oF. The plant has not produced mix earlier in the day. Do not exceed a mix temperature of 350oF. No truck has returned for its second load of the day. Once a previously loaded truck returns for its next load, reduce the temperature to not higher than the maximum mix temperature shown on th e bill of lading, not to exceed 340oF.
b.Reclaimed Asphalt Pave ment (RAP) and Recycled As phalt Shingles (RAS). Provide RAP and RAS that comply with SECTION 1103 .
c.Aggregates . Provide aggregates that comply with SECTION 1103 .
d.Combined Aggregates. Provide combined aggr egates for the mixes requ ired in the Contract Documents as shown in TABLE 602-1 . 602 - HOT MIX ASPHALT (HMA) CONSTRUCTION (Quality Control/Quality Assurance (QC/QA))
600-6 Mixes may use any combination of aggregate and mineral filler supplements complying with the applicable
requirements in TABLES 1103-1 and 1103-2 . Provide materials with less than 0.5% moisture in the final mixture. The maximum quantity of crushed steel slag used in the mix is 50% of the total aggregate weight. For all mixes used on the traveled way, the maximum quantity of natural sand is 35%. Natural sand shall be called SSG-1, SSG-2, etc. in the mix design. Additional requirements for SM-9.5T and SR-9.5T: Traveled way mixes shall include a minimum of 40% primary aggregate based on total aggregate weight; A minimum of 50% of the plus No. 4 mesh sieve ma terial in the mixture shall be from the primary aggregate; A minimum of 45% of the plus No. 8 mesh sieve ma terial in the mixture shall be from the primary aggregate; and Primary aggregates are designated as CS-1 (excludi ng limestone), CS-2 (excluding limestone), CG, CH-1 and CSSL as described in subsection 1103.2a.(1) . Primary aggregate requ irements do not apply to the mixture used on the shoulder.
e.Contractor Trial Mix Design. A minimum of 10 working days before the start of HMA production, submit in writing to the DME for review and approval, a proposed JMF for each combin ation of aggregates. For each JMF submitted, include test data to demonstrate that mixtures comply ing with each proposed JMF shall have properties specified in TABLE 602-1 for the designated mix type at the Recommended Percent Asphalt (P br). Submit the proposed JMF on forms provided by KDOT. Submit the worksheets used in the design process to include at a minimum the mix properties listed in TABLE 602-2 . Contact the DME to determine if additional information should be submitted. Provide sufficient material as identified in TABLE 602-3 . Contact the DME to determine if additional material is needed for additional de sign checks such as the modi fied Lottman test (KT-56). When more than 25% of the mix is comprised of siliceous virgin aggregates and/or RAP, add anti-strip to the mix. The minimum amount of anti-strip required in the mix is 0.01% for every percent of natural sand and RAP in the mix. Thus, if 25% natural sand and 10% RAP is in a mix, then 0.35% anti-strip by weight of virgin asphalt binder is required in the mix. If during production, the Tensile Strength Ratio (TSR) values (both KDOT and Contractor) exceed 85%, then the Contractor and the DME, working together, may decide on a lower amount of anti-strip. Submit for the Engineer’s review an d approval, the test data listed in TABLE 602-4 for each blend and the proposed JMF. In addition, for mixes containing RAP or RAS, submit for the Engineer’s review and approval, the test data listed in TABLE 602-5 for each blend and the proposed JMF. Submit a mix design for each blend and the proposed JMF as outlined in TABLE 602-6 . For each aggregate used in the mix design, determine the specific gravity using KT-6. This may be accomplished while the project is being constructed or anytime during the 12 months preceding the start of construction on a project. If construction has not yet begun, notify the DME 5 working days prior to obtaining the material for the specific gravity test so that companion samples may be obtained at the same time. If construction has already begun on the project, then determine the specific gravity values of the individual aggregates before 10,000 tons of HMA is produced. Provide the test results to the DME within 14 days of sampling the material. If the producer of the aggregate has been required to submit material to KDOT for a new Official Quality test, since the time the Contractor ran the specific gravity tests, th en perform KT-6 on the aggr egate currently produced. Do not use the specific gravity values obta ined from these tests in the mix design calculations for current projects, unless mutually agreeable to both parties. Use the information, as soon as it becomes available, as part of the process to verify and update the “Mon thly Hot Mix Aggregate Specific Grav ity Values” posted on KDOT’s Internet site.
Source: Kansas Standard Specifications for State Road and Bridge Construction, 2015 Edition. Pages 242–243 of 978.