601 - ASPHALT APPLICATION TEMPERATURES
600-1 Section 601
ASPHALT APPLICATION TEMPERATURES 601.1 DESCRIPTION The application temperatures for the va rious type and grades of asphalts sh all be within the ranges listed in TABLE 601-1 or as specified on the aspha lt producer’s Bill of Lading. TABLE 601-1: ASPHALT A PPLICATION TEMPERATURES TYPE AND GRADE TEMPERATURE RANGE (ºF) Spraying Plant Mixing Min. Max. Min. Max. Asphalt Binder 275 340 * * Asphalt Cement (AC-20-5TR) 325 350 NA NA Asphalt Cement (AC-20-XP) 325 350 NA NA Asphalt Cement (AC-10-2TR) 300 350 NA NA Asphalt Cement (AC-10-XP) 300 350 NA NA Cutback Asphalt, MC 30 88 125 88 125 Cutback Asphalt, MC & RC 70 &250 125 200 125 200 Cutback Asphalt, MC & RC 800 & 3000 150 250 150 250 Asphalt Rejuvenating Agent, ARA-1P 70 150 70 150 Emulsified Asphalt, CRS-1H, RS-1H, SS-1HP, CMS-1, MS-1, HFMS-1, RS-1HP, CRS-1HP 100 180 100 180 Emulsified Asphalt, SS-1H, CSS-1H None 150 None 150 Emulsified Asphalt, C SS-1HM, CSS-Special None 120 None 120 EBL 120 180 NA NA * Use the Producer’s recommended mixing temperature range. All asphalt binders and cutback asphalts reheated to temperatures 50ºF more than the maximum in TABLE
601-1 will be considered overheated and may be rejected pe nding re-sampling and re-testing of the material at the
discretion of the Engineer. All emulsified asphalts reheated to temperatures above the maximum shown above will be considered overheated and may be rejected pending re-sampling and re-testing of the material at the discretion of the Engineer. 602 - HOT MIX ASPHALT (HMA) CONSTRUCTION (Quality Control/Quality Assurance (QC/QA))
600-2 Section 602
HOT MIX ASPHALT (HMA) CONSTRUCTION (Quality Control/Quality Assurance (QC/QA)) 602.1 DESCRIPTION Mix and place 1 or more courses of plant produced HMA mixture on a prepared surface as shown in the Contract Documents. Demonstrate quality control by providing the quality control testing. BID ITEMS UNITS HMA Base (*)(**)(***) Ton HMA Surface (*)(**)(***) Ton HMA Overlay (*)(**)(***) Ton HMA Pavement (#) (##) Square Yard HMA Pavement (#) Shoulder Square Yard Emulsified Asphalt (****) Ton Asphalt Core (Set Price) Each Material for HMA Patching (Set Price) Ton Quality Control Testing (HMA) Ton *Mix Designation **Grade of Asphalt Binder ***Shoulder ****Type and Grade of Emulsified Asphalt # Thickness ##Type of surface course HMA mixture 602.2 CONTRACTOR QUALITY CONTROL REQUIREMENTS
a.General. Provide qualified personnel and sufficient equi pment complying with the requirements listed in Part V to conduct quality control testing that complies w ith Appendix B, Sampling and Testing Frequency Chart for Asphalt Construction Items for Quality Control/Quality Assurance Projects. Allow the Engineer access to the Contractor’s laborato ry to observe testing procedures, calculations, test documentation and plotting of test results. Calibrate and correlate the testing equipment with pr escribed procedures, and co nduct tests in compliance with specified testing procedures as listed in Part V. Maintain a Quality Manual in the field laboratory show ing the calibrations performed on all test equipment and when the next calibration is due for that equipment. As a minimum, follow the calibration/verification interval established in Table 2: HMA Materials Test Equipment in Section 5.2.7.1-HMA: Contractor’s Quality Control Plan, Part V. See also, Section 5.2.7.3-Example of a Laboratory Quality Manu al for HMA, Part V. Store and retain the most recent 2 lots per mix designation of quality control samples for KDOT. KDOT will retain the most recent 2 lots per mix designation gyratory compacted air voids (Va) verification samples and the remaining material not previously used for testing (back half of sample). Do not retain more than the previous 3 lots per mix designation of quality control or verification samples. When the hot mix plant shuts down for the winter, discard the samples after 7 days.
b.Quality Control Plan (QCP). At the pre-construction conference, submit to the Engineer for approval, a QCP as outlined in Section 5.2.7-Contractor’s Quality C ontrol Plan, Part V. Follow 5.2.7.1-HMA: Contractor’s Quality Control Plan in Part V as a general guideline. Th e Contractor’s laboratory and equipment will be inspected and approved as outlined in Section 5.2.7-Contractor’s Quality Control Plan, Part V. Include a listing of the names and phone numbers of indi viduals and alternates responsible for quality control administration and inspection. On the Contractor’s organizational chart, show the specified lines of authority relating both to mix design and quality control ope rations during production. Post the organizational chart in the Contractor’s test facility. Provide a quality control organization or private testing firm having pe rsonnel certified according to the Policy and Procedures Manual for The Certified Inspection a nd Testing (CIT) Training Program. The testing for this 602 - HOT MIX ASPHALT (HMA) CONSTRUCTION (Quality Control/Quality Assurance (QC/QA))
600-3 type of construction will require personnel certified in Ag gregate Field Tester (AGF), Aggregate Lab Technician
(AGL), Superpave Field (SF), Profilograph (PO) and Nuclear Moisture Density Gauge Tester (NUC) classifications. Provide a minimum of 1 employee on the project certified in the QC/QA Asphalt Specs (QCA) classification. Only persons certified in the approp riate classifications covering the specific tests required shall perform such testing. At the beginning of the project, provide the Engineer with the list of certified technicians and alternates, phone numbers and tests/inspection they will be performing. As personnel changes and certifications may expire, continue to provide the Engineer with an accurate list. Provide an organizational chart showing the specified lines of authority relating to both mix design and quality control operations during production. Identify the company official acting as liaison with KDOT, and the Certified Technician who will direct inspection and testing. Post the chart in the test facility.
c.Required Duties of Certified Technicians. Be available on the project site whenever HMA is being produced and being placed on the project site. Perform and utilize quality c ontrol tests and othe r quality control practices to assure that delivered materials and propor tioning meet the requirements of the mix designs. Periodically inspect all equipment utilized in transporting, proportioning, mixing, placing and compacting to assure it is operating properly and that placement and compaction comp ly with the contract requirements.
d.Contractor’s Testing Facilities. Describe the testing facility an d its accreditation in the QCP. Locate the testing facility either at the plant site or at the project. Obtain approval of the testing facilities and location from the DME before the commencement of mixture production. Provide suitable space for the required testing equipment. Also, equi p the testing facility with these items for the exclusive use of the testing facility’s quality control personnel and the Engineer: A telephone with a private line for the exclusive use of the testing facility’s quality control personnel; and A copying machine for use by the Cont ractor’s personnel and the Engineer. Broadband internet connection (for 1 computer). If the E ngineer determines that broadband internet service is not available, provide a fax machine, at no additional cost. An air conditioner capable of maintaining a temperature below 77 F in the main part of the Field Office and Laboratory. Locate the KDOT field laboratory near the Contract or’s testing facility and have it fully functional 2 working days before placement of the pre-production mix.
e.Documentation. Include in the QCP procedures, charts and fo rms to be used to provide the required documentation. Record all original documentation in a bound field book or other KDOT approved bound record and turn over to KDOT at the end of the project. At all times, have complete records of all inspections and tests available on site for the Engineer. All records documenting the Contractor’s quality control inspections and tests become the property of KDOT upon completion of the work. Indicate the nature and number of observations made, the number and type of deficiencies found, the quantities approved and rejected, and the corrective action taken in the records. Examples of quality control forms and charts are available in Part V, or Contractors may design their own. Documentation procedures are subject to approval by the Engineer before the start of the work an d to compliance checks during the progress of the work. Maintain control charts on an ongoing basis. Provide the following test data to the KDOT Project Representative: Copies of all test results and control charts on a weekly basis, representing the prior week’s production; Copies of the quality control summary sheet on a daily basis. Include, as a minimum, mix gradation, binder content, theoretical maximum specific gravity (G mm), air voids (V a) at N des, percent G mm at N ini and N max, voids in mineral aggregate (VMA), voids fille d with asphalt (VFA) and dust to effective binder content (D/B) ratio; and Copies of all failing test results (based on a moving average of 4 tests, when appropriate). Include all applicable sieves, VMA, VFA, density at N ini and N max, and D/B ratio.
f.Testing Requirements. In the QCP, identify test methods, procedures and equipment proposed for use. Use standard KDOT test methods and properly calibrated m easuring and testing equipment as outlined in Part V. 602 - HOT MIX ASPHALT (HMA) CONSTRUCTION (Quality Control/Quality Assurance (QC/QA))
600-4 Detail any alternative sampling method, procedure or inspec tion equipment proposed to be used. Such alternatives
are subject to review and approval by the DME. Take all samples for tests and perform in-place test s at random locations, se lected according to the Contractor’s QCP and at the rates specified in the Sampling and Testing Frequency Chart for Hot Mix Asphalt for Quality Control/Quality Assurance Pr ojects in Appendix B, Part V.
g.Pre-Production Testing Requirements.
1.The Engineer will observe the Contractor obtaining and splitting the pre-production test section sample into 3 representative portions. Each sample set shall consis t of enough material for 2 gyratory specimens, theoretical G mm and ignition burnoff.
2.Mold 2 gyratory specimens from the 1st sample set immediately, while still hot. Additional heating may be required to raise the temperature of the sample to compaction temperature. Determine G mm, perform ignition burnoff and complete calculations.
3.Provide the KDOT Field Representative with the 2nd sample set. The KDOT Field Representative will mold 2 gyratory specimens, determine G mm, perform ignition burnoff and complete calculations.
4.Retain or provide the 3rd sample set to the KDOT 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. This sample will be transported to the District Materials Laboratory, after it has cooled to ambient air temperature. KDOT personnel will reheat the sample to compaction temperature, mo ld 2 gyratory specimens, determine G mm, perform ignition burnoff and complete calculations. If the 3rd sample set is collected, transported while hot to the District Materials Laboratory and compacted in less than 2 hours, then, at the DME’s discretion, the requirement to cool the sample may be waived. If results are not acceptable to either party, repeat the above steps in subsections 602.2g.(1) through (5) for the Contractor’s Field Laboratory, KDOT ’s Field Laboratory, and District Materials 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 th e random 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 the same truckload as selected for the Contractor’s sublot A, B, C or D. KDOT field personnel will: provide the random spots to sample from behind the paving operations before compaction (KT-25); not supply the Contractor the identity of the truckload to be sampled ahead of time; notify the Contractor’s laboratory of which truck to sample 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 supply ⅓ of the sample to the KDOT District Materials Laboratory for testing.
3.Results. At a minimum, compare G mm and V a results. The acceptable differences are 0.019 and 0.5%, respectively. If the results exceed these differences, take an additional split sample in Lot 1 from sublot C or D, as time permits. If test results do not compare favorably, KDOT and th e 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 and District Materials Labora tory test results will be reported as "information only" samples. 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 .
Source: Kansas Standard Specifications for State Road and Bridge Construction, 2015 Edition. Pages 238–242 of 978.