613 – ULTRATHIN BONDED ASPHALT SURFACE
600-70 (3) Provide the KDOT Field Representative with the 2nd sample set. The KDOT Field Representative will
determine G mm, perform ignition burnoff, evaluate the mix gradation and complete calculations.
4.Retain or provide the 3rd sample set to the KDOT Field or District Materials Representative.
5.The results of the testing will be compared. If Contractor and KDOT field laboratory test results do not compare favorably, the District Materials Laboratory will test their ⅓ of the sample. KDOT personnel will determine G mm, perform ignition burnoff and complete calculations. If results are not acceptable to either party, repeat the above steps in subsections 613.2g.(1) through (4) for the Contractor’s Field Laboratory, KDOT’s Field Laborato ry, and KDOT’s Dist rict Laboratory until the issues may be resolved satisfactorily by all parties.
h.Lot 1 Testing Requirements.
1.Sequence of Sampling. KDOT field personnel will determine the ra ndom truckload for the Contractor for sublots A, B, C and D, and the KDOT verification test. The verification sample will be sampled and tested by KDOT field personnel. The verification sample shall be randomly taken within the lot and shall not be from the same truckload as selected for the Contractor’s sublot samples A, B, C or D. Obtain sampling using KT-25 procedure C.1 Plant Discharge or C.2 Truck Bed. KDOT field personnel will: • not supply the Contractor the identity of the truckload to be sampled ahead of time; • notify the Contractor’s laboratory of which truck to sa mple after the aggregate has left the cold feeds, and before the truck is finished loading; and • determine whether the split sample will be taken from sublot A or B and notify the Contractor.
2.Split Samples. The Contractor shall: • obtain a sample large enough to split 3 ways for testing; • retain and test ⅓ of the sample; • supply ⅓ of the sample to the KDOT field laboratory for testing; and • retain or supply ⅓ of the sample for the KDOT District Materials Laboratory.
3.Results. At a minimum, compare the KDOT Field Laboratory’s and the Contractor’s G mm, binder content, and film thickness results. The acceptable difference for the G mm results is 0.019. If the results exceed this difference, take an additional split sample in Lot 1 from sublot C or D, as time permits. If Contractor and KDOT field laboratory test results do not compare favorably, KDOT and the Contractor will investigate the differences in test results together and take appropriate action. The Contractor’s test results will be used for quality control. KDOT Field Laboratory test results an d District Materials Laboratory test results will be reported as "information only" samples.
i.Testing Requirements for Lots 2 and Greater.
1.Take all samples for tests randomly as designated in the approved QCP at the rates specified in Appendix B - Sampling and Testing Frequency Chart, Part V. Provide the Engineer with the random locations before obtaining the sample. The Engineer reserves the right to generate the random locations. If the Engineer generates the random locations, the Contractor will be notified of which truck to sample after the aggregate has left the cold feeds, and before the truck is finished loading.
2.Conduct the tests for mixture properties, aggreg ate 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 using a method to retain heat to facilitate sample quartering procedures.
3.Record and document all test results and cal culations 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 3 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 - Sampling and Testing Frequency Chart, Part V shows the accuracy to "record to" for the tests listed. Include a description of quality control actions taken (adjustment of cold feed percen tages, changes in Job Mix Formulas (JMF), etc.) in the Daily Quality Control Summary Sheet. In addition, post and keep current quality c ontrol charts, showing both individual test results and moving average values. As a minimum, plot the single test values on KDOT approved control charts for the mix characteristics shown in TABLE 613-5 .
4.If the Contractor and Engineer agree, the procedures shown for sampling, testing and evaluation of Lot 613 – ULTRATHIN BONDED ASPHALT SURFACE
600-71 1 in subsection 613.2h. may be used for any other Lot produced on the project.
j.Corrective Action. In the QCP, identify procedures for notifying the Engineer when corrective measures must be implemented, and for halting production.
k.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. 613.3 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 in the Contractor’s Field Lab. 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. Provide Emulsion Bonding Liquid (EBL) that complies with DIVISION 1200 .
b.Reclaimed Asphalt Pa vement (RAP) and Recycled Asphalt Shingles (RAS). Do not use RAP or RAS in the UBAS.
c.Aggregates . Provide aggregates that comply with SECTION 1103 .
d.Combined Aggregates. Provide combined aggregates for the mixes required in the Contract Documents as shown in TABLE 613-1 . Mixes may use any combination (except as noted be low) of aggregate and mineral filler supplements complying with the applicable requirements in TABLES 1103-1 and 1103-2 . When coarse aggregates are blended from 1 or more sources, or if more than 1 type, each source or type shall meet the coar se aggregate properties (CAA, LA Abrasion, and micro-deval) in TABLE 1103-3 . The minimum Uncompacted Void Cont ent of the Fine Aggregate “U” Valu e, of the combin ed aggregate is 45%. The minimum sand equivalency (SE) of the combined aggregates is 45%. 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. No natural sand will be used in the UBAS. 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 material in the mixture shall be from the primary aggregate; a minimum of 45% of the plus No. 8 mesh sieve material 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 requirements do not apply to the mixture on the shoulder.
e.Contractor Trial Mix Design. A minimum of 10 working days before the start of UBAS 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 613-1 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 individual coarse aggregate properties listed in TABLE 1103-3 , the fine aggregate 613 – ULTRATHIN BONDED ASPHALT SURFACE
600-72 properties listed in TABLE 1103-4 , and the mix properties listed in TABLE 613-2 . Contact the DME to determine
if additional material is needed for additional design checks. 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 re quired to submit material to KDOT fo r a new Official Quality test report since the time the Contractor ran the speci fic gravity tests, then perform KT-6 on the aggregate currently produced. Do not use the specific gravity values obtained 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. TABLE 613-1: COMBINE AG GREGATE REQUIREMENTS FOR ULTRATHIN BONDED ASPHALT SURFACE* Mix Designation / Nom Thickness Percent Retained – Square Mesh Sieves Asphalt Content (%) ¾" ½" ⅜" No. 4 No. 8 No. 16 No. 30 No. 50 No. 100 No. 200 Type A - ⅝" 0 0-7 45-60 68-78 75-85 82-90 87-92 90-94 94.0-96.0 5.0 to 6.2 Type B - ⅝" 0 0-7 0-25 62-75 73-83 77-85 82-90 87-92 90-94 94.0-96.0 4.8 to 6.2 Type C - ⅝" 0 0-25 20-50 62-75 73-83 77-85 82-90 87-92 90-94 94.0-96.0 4.6 to 6.2 *For flat and elongated particles in the combined coarse aggregate, use the ratio of 3:1 in lieu of 5:1 shown in KT-59. Do not exceed 25% for the total sample. TABLE 613-2: MIX PROPERTIES Property Test Method Limits Total Amine Value of Antistrip Agent, (mg/g of KOH, min)a ASTM D2074 500 Design Film Thickness ( m, min.) KDOT Construction Manual 9.0 b Drain Down (% max.) KT-63 0.10 Gyratory Compacted Revolutions, Ndes KT-58 100 c Emulsion Bonding Liquid (EBL),(gal/sy) Equation 1 (0.20 ± 0.07)d a – The asphalt binder used in the mix will contain a minimum of 0.25% of an amine based antistripping agent by weight of the asphalt binder. b – Calculate using the film thickness equation in Section 5.10.4-Calcs for Marshall Mix Design of Bituminous Mixtures, Part V. c – Compact gyratory specimen to 100 gyrations. Calculate the percent air voids using KT-15, Procedure IV. d – Calculate the target EBL Shot Rate (S ebl (gal.sy)), using Equation 1; however, the value must be within the limits in this table. Equation 1: 100)MF V(*P*93.3 Sa s ebl The particle size (P s), and the mix factor (MF) are based on the mix designation as shown in the TABLE 613-3 . TABLE 613-3: VARIABLES IN EBL SHOT RATE EQUATION Mix Designation Particle Size (Ps) Mix Factor (MF) Type A 0.250 3.2 Type B 0.375 3.2 Type C 0.500 3.2 613 – ULTRATHIN BONDED ASPHALT SURFACE
600-73 Consider adjusting the EBL spray rate based on th e condition of the existing surface as listed in the
TABLE 613-4 . Consult the supplier of the EBL to obtain the recommended adjustment to the spray rate. TABLE 613-4: EBL ADJUSTM ENT CONSIDERATIONS Existing Pavement Type Condition Adjustment Rate (gal/sy) PCCP Smooth 0.00 Textured +0.02 to +0.04 HMA Flushed -0.02 to -0.04 New 0.00 Matte and OGFC +0.02 Dry +0.03 Milled +0.02 to +0.04 Surface Recycle & Cold Recycle Flushed -0.02 to -0.04 Black +0.02 Dry +0.03 Chip Seal Flushed -0.02 to -0.04 Black +0.02 Dry +0.03 613.4 CONSTRUCTION REQUIREMENTS
a.Plant Operation. Adjust all plant operations to operate continuously.
1.Preparation of the Asphalt Bi nder. Heat the asphalt binder to within a range as specified in SECTION 601. When heating the asphalt binder to the specified temperat ure, avoid local overheating. At all times, provide a continuous supply of the as phalt binder to the mixer at a uniform temp erature. Asphalt binder received from the refinery at temperatures less than 37 5°F may be used as received, if the requirements regardin g the reheating of asphalt binder in SECTION 601 are met.
a.Commingling of Asphalt Binders. Do not a dd or commingle asphalt binders from 2 or more sources into a storage tank. If this occurs, th e contents of the storage tank are considered contaminated. Do not use the contents of the st orage tank on the project, except as follows: It is permissible, at the Contractor’s option, to thoroughly mix the contents of the tank and request sampling of the mixture. Submit the sample to the MRC for testing. Do not use the asphalt binder until approved, and when needed, a new mix design evaluation is completed.
b.Asphalt Binder Sources. Before changing as phalt binder sources on a project, obtain approval from the DME. A new JMF may be required. (c) Anti-Strip Additives. If liquid anti-strip additives are added at the Contractor’s plant, install a “totalizer” to monitor the quantity of anti-strip additive being added. The Engineer may approve alternative methods for including anti- strip additives in a batch plant. If added at the plant, the anti- strip will be added in line with the asphalt binder as it is being transferred from the transit unit to the asphalt binder storage tank. Provide a method for the Engineer to monitor the percent of additive being added.
2.Preparation of Mineral Aggregate. When the mineral aggregate is composed of 2 or more ingredients, combine as shown in the approved JMF. Temperature Requirements. Dry the aggregate for th e mixture and heat to a temperature to obtain an asphalt-aggregate mixture temperature immediately after mixing within the 75 to 150 second Saybolt viscosity range of the asphalt binder used. Obtain the temperature for this viscosity range from the MRC or the Asphalt Binder Producer. No mixing or compaction temperatures are to exceed 340ºF without approval from the Field Materials Engineer. The minimum temperature may be revised by the DME provided it is demonstrated that satisfactory results may be obtained at a lower temperature. In such event, de liver the HMA to the paver at a temperature sufficient to allow the material to be satisfactorily placed and compacted to the speci fied density and surface tolerance requirements.
3.Preparation of HMA. Introduce asphalt binder into the prepared aggregate in the proportionate amount determined by the P br in the JMF.
Source: Kansas Standard Specifications for State Road and Bridge Construction, 2015 Edition. Pages 307–310 of 978.