611 - HOT MIX ASPHALT (HMA)-COMMERCIAL GRADE
600-65 Use equipment that complies with DIVISION 150 to produce, haul, spread and compact the HMA-
Commercial Grade mixture. Lift Thickness. Except for leveling courses or when shown otherwise in the Contract Documents, TABLE
602-9 applies. The Engineer may adjust lift thickness to utilize the most efficient method of acquiring specified
density and surface quality. The minimum lift thickness fo r any HMA mixture is 3 times the nominal maximum aggregate size, unless otherwise designated in the Contract Documents or approved by the Engineer. TABLE 602-9: NOMINAL COMPACTED THICKNESS Lift Maximum Nominal Compacted Thickness Surface 2 inches Base 4 inches Use a minimum of 2 rollers to compact the mixture to the maximum density before the mixture temperature falls below 175°F. When using WMA, achieve the maximum density before the temperature of the WMA falls below 165°F. Do not crush the aggregate. On incidental or miscellaneous work, the Engineer may waive the minimum roller requirement if conditions warrant. Roller ma rks may be removed with a self-propelled static roller when the pavement surface temperature falls below 175°F or 165°F for WMA, roller ma rks may be removed from the mat with a self-propelled static steel roller.
b.Weather Limitations. Do not place asphalt mixtures on any wet or frozen surface or when weather conditions otherwise prevent the proper handling and finishing of the mixture. Only place asphalt mixtures when e ither the ambient air temperature or the road surface temperature is equal to or greater than that shown in TABLE 611-4 . TABLE 611-4: ASPHALT PLACEME NT TEMPERATURE LIMITATIONS Paving Course Thickness (inches) Air Temperature (ºF) Surface Temperature (ºF) HMA WMA Foam WMA Chem HMA WMA Foam WMA Chem Surface All 50 45 40 55 50 45 Subsurface <1.5 50 45 40 55 50 45 Subsurface ≥1.5 and < 3 40 35 30 45 40 35 Subsurface ≥ 3 30 30 30 35 32 32
c.Pavement Smoothness. Evaluate pavement smoothness according to SECTION 603 and the following: Excluding side roads, entrances an d non-traffic areas, the Engineer ma y test the completed surface with a 10 foot straightedge, and the maximum a llowable surface variation is 3/16 inch in 10 feet. Correct areas that exceed the allowable variation as directed by the Engineer. HMA Commercial Grade is not eligible for pay adjustments. 611.4 MEASUREMENT AND PAYMENT The Engineer will measure HMA-Comm ercial Grade and HMA-Commercial Grade (Patching) by the ton. Payment for "HMA-Commercial Grade (Class*)" at the contract unit prices is full compensation for the specified work (including emulsified asphalt for tack). Payment for and "HMA-Commercial Grade (Class *) (Patching)" includes all excavation, compaction of subgrade or subbase if required, disposal of waste material and all material (including emulsified asphalt for tack), all labor, equipment, tools, supplies, incidentals and mobilization necessary to complete the work. If the gradation test results or air void test results indi cate there is non-compliant material, the Engineer will compute and assess either an Aggregate Price Adjustment or an Air Void Price Adjustment that will be an item added to the contract.
1.Aggregate Price Adjustment. Use TABLE 611-5 , on each Lot of asphalt mixture represented by non- compliant cold-feed gradation (acceptance) tests: Determine the absolute value of the deviation be tween the acceptance test re sults (rounded to the nearest 0.01%) and the design virgin aggregate single point for the No. 4, No. 8, No. 30 and the No 200 pay sieves. Use the 1 Test Column in TABLE 611-5 to determine payment for the Lot. Use the deviation from the sieve that produces the greatest price adjustment. 611 - HOT MIX ASPHALT (HMA)-COMMERCIAL GRADE
600-66 Table 611-5: Schedule of Adjus Ted Payment for Asphalt Mixes
Accumulated Deviation of the Acceptance Tests from the Design Job-Mix Single Point Tolerance Pay Factor 1 Test 2 Tests 3 Tests 4 Tests ± 7 1.00 0.00 - 7.00 0.00 - 9.00 0.00 - 12.12 0.00 - 14.00 0.98 7.01 -7.50 9.91 - 10.60 12.13 - 12.99 14.01 - 15.00 0.95 7.51 - 8.00 10.61 - 11.32 13.00 - 13.86 15.01 - 16.00 0.92* 8.01 - 8.50 11.33 - 12.02 13.87 - 14.73 16.01 - 17.00 0.88* over 8.50 over 12.02 over 14.73 over 17.00 ± 6 1.00 0.00 - 6.00 0.00 - 8.48 0.00 - 10.38 0.00 - 12.00 0.98 6.01 - 6.50 8.49 - 9.20 10.39 - 11.25 12.01 - 13.00 0.95 6.51 - 7.00 9.21 - 9.90 11.26 - 12.12 13.01 - 14.00 0.92* 7.01 - 7.50 9.91 - 10.60 12.13 - 12.99 14.01 - 15.00 0.88* over 7.50 over 10.60 over 12.99 over 15.00 ± 5 1.00 0.00 - 5.00 0.00 - 7.08 0.00 - 8.61 0.00 - 10.00 0.98 5.01 - 5.50 7.09 - 7.78 8.62 - 9.54 10.01 - 11.00 0.95 5.51 - 6.00 7.79 - 8.48 9.55 - 10.38 11.01 - 12.00 0.92* 6.01 - 6.50 8.49 - 9.20 10.39 - 11.25 12.01 - 13.00 0.88* over 6.50 over 9.20 over 11.25 over 13.00 ± 4 1.00 0.00 - 4.00 0.00 - 5.66 0.00 - 6.93 0.00 – 8.00 0.98 4.01 - 4.50 5.67 - 6.36 6.94 - 7.80 8.01 – 9.00 0.95 4.51 - 5.00 6.37 - 7.08 7.81 - 8.67 9.01 - 10.00 0.92* 5.01 - 5.50 7.09 - 7.78 8.68 - 9.54 10.01 - 11.00 0.88* over 5.50 over 7.78 over 9.54 over 11.00 ± 3 1.00 0.00 - 3.00 0.00 - 4.24 0.00 - 5.19 0.00 – 6.00 0.98 3.01 - 3.20 4.25 - 4.52 5.20 - 5.55 6.01 – 6.40 0.95 3.21 - 3.40 4.53 - 4.80 5.56 - 5.97 6.41 – 6.80 0.92* 3.41 - 3.80 4.81 - 5.38 5.98 - 6.57 6.81 – 7.60 0.88* over 3.80 over 5.38 over 6.57 over 7.60 ± 2.5 1.00 0.00 - 2.50 0.00 - 3.54 0.00 - 4.32 0.00 – 5.00 0.98 2.51 - 2.70 3.55 - 3.82 4.33 - 4.68 5.01 – 5.40 0.95 2.71 - 2.90 3.83 - 4.10 4.69 - 5.01 5.41 – 5.80 0.92* 2.91 - 3.30 4.11 - 4.66 5.02 - 5.73 5.81 – 6.60 0.88* over 3.30 over 4.66 over 5.73 over 6.60 ± 2 1.00 0.00 - 2.20 0.00 - 3.12 0.00 - 3.81 0.00 – 4.40 0.95 2.21 - 2.40 3.13 - 3.40 3.82 - 4.17 4.41 – 4.80 0.92* 2.41 - 2.75 3.41 - 3.88 4.18 - 4.77 4.81 – 5.56 0.88* over 2.75 over 3.88 over 4.77 over 5.56 *If approved by the Engineer, the Contractor may accept th e indicated partial pay. KDOT may require removal and replacement at no additional cost. At any time, the C ontractor may remove and re place at no cost to KDOT.
2.Air Void Price Adjustment. The Engineer will assess an Air Void Price Adjustment (negative price adjustment only), as outlined in SECTION 602 , on the asphalt material (taken from each QC/QA Lot) represented by non- compliant QC/QA (acceptance) tests. 612 - MILLING
600-67 Section 612
MILLING 612.1 DESCRIPTION Remove the existing surface to the depth and limits show n in the Contract Documents or established by the Engineer. Load and stockpile the milled material, when required. Provide transitions at transverse joints and raised st ructures to create a smooth longitudinal riding surface before opening the milled surface to traffic. Remove transitions prior to resurfacing. B I D I T E M U N I T S Milling * * Unit of Measurement Shown in the Contract Documents 612.2 MATERIALS – None specified. 612.3 CONSTRUCTION REQUIREMENTS Remove the existing surface to the required grade line as established by the Engineer. Use equipment that is automatically controlled with regard to grade and slope. Operate the automatic grade and slope control from a traveling stringline, a minimum of 30 f eet long, attached to the milling machine and operating parallel to the line of travel. Extend the cross slope of the pavement by milling across the shoulder to the point where this line intersects the existing shoulder surface or to the edge of the s houlder, whichever is less, unless shown otherwise in the Contract Documents or directed by the Engineer. When sh oulders are to be milled (daylighted out), mill them the same day as the adjacent traveled way pavement is milled. When milling multiple passes, mill so the longitudinal joint between passes is flush. When milling asphalt down to an existing concrete pavement, keep the final milling operation a maximum of 2 miles ahead of the laydown operation, unless approved otherwise by the Engineer. Do not track the milling machine across span bridges if the operatin g weight of the machine exceeds 80,000 pounds. Limit the operating weight of the milling machine to 80,000 pounds when removing existing asphalt material from, or performing machine preparation on a bridge deck. If the milled area will be opened to traffic prior to resurfacing, perform the following: At transverse joints, either feather transitions between milled and unmilled surfaces by milling or placing a wedge of hot mix asphalt (n o steeper than 1 vertical, 24 horizontal), for the entire width of the transverse joint. After removal of existing material around manholes , utility valves inlets and other appurtenances, place a temporary wedge around the appurtenance (no steeper than 1 ver tical, 12 horizontal). Use hot mix asphalt or other approved material of a thickness and design that the material remains intact while under traffic. Remove transitions prior to resurfacing. Do not open the milled area to traf fic unless all transverse joints, manhol es, utility valves, inlets and other appurtenances have wedges in place to provi de for a smooth longitudinal riding surface. 612.4 MEASUREMENT AND PAYMENT When milling is a bid item in the contract, the Engineer will measure milling as shown in the Contract Documents. This shall include th e removal, hauling, if required, and stockpiling of existing surface. When shown by the Station, the Engin eer will measure the Station along the centerline of the lanes, regardless of the pavement width. When shown by the square yard, the Engineer will measure the s quare yards of surface milled. When shown by the ton, the Engineer will measure the tons of material milled. Payment for "Milling" at the contract unit pri ce is full compensation for the specified work. 613 – ULTRATHIN BONDED ASPHALT SURFACE
600-68 Section 613
ULTRATHIN BONDED ASPHALT SURFACE 613.1 DESCRIPTION Construct the ultrathin bonded asphalt surface (UBAS) as designated in the Contract Documents. B I D I T E M S U N I T S HMA Surface (Ultrathin Bonded) (*) (**) Ton Emulsified Asphalt (Emulsion Bonding Liquid) Ton Quality Control Testing (HMA) Ton * Type of mix gradation ** Grade of Asphalt Binder 613.2 CONTRACTOR QUALITY CONTROL REQUIREMENTS
a.General. Provide qualified personnel and sufficient equipment complying with the requirements listed in Part V to conduct quality control testing that complie s with Appendix B - Sampling and Testing Frequency Chart for Asphalt Construction Items for Qua lity 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 Section 5.2.7- Contractor’s Quality Control Plan, Part V. Store and retain the most recent 2 lots per mix desi gnation of quality control samples for KD OT. KDOT will retain the most recent 2 lots per mix designation gyra tory compacted 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 mi x plant shuts down for the winter, discard the samples after 7 days. Maintain control charts on an ongoing basis. At the completion of the project, all do cumentation becomes the property of KDOT. 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) and film thickness; and Copies of all failing test results (based on a moving average of 3 tests, when appropriate).
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 Control Plan, Part V. Follow Appendix A of the Contractor’s Quality Control Plan in Part V as a genera l guideline. The 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 individuals 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 oper ations during production. Post the organizational chart in the Contractor’s test facility. Provide a quality control organization or private te sting firm having personnel certified according to the Policy and Procedure Manual for the Certified Inspection and Testing (CIT) Training Program. The testing for this type of construction will require personnel certified in Ag gregate Field Tester (AGF), Aggregate Lab Technician, Profilograph (PO), and Superpave Field (SF) classifications. 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. 613 – ULTRATHIN BONDED ASPHALT SURFACE
600-69 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 UBAS 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. Provide Broadband internet connection (for 1 computer). If the Engineer 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) and film thickness; and Copies of all failing test results (based on a moving average of 3 tests, when appropriate). Include all applicable sieves, binder content and film thickness.
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. 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, selected according to the Contractor’s QCP and at the rates specified in the Sa mpling and Testing Frequency Chart for UBAS for Quality Control/Quality Assurance Projects in Appendix B, Part V.
g.Pre-Production Testing Requirements.
1.The Engineer will observe the Contractor obtaini ng and splitting the pre-production test section samples into 3 representative portions. Each sample set shall consist of enough material for G mm and ignition burnoff testing.
2.Determine G mm, perform ignition burnoff, evaluate the mix gradation and complete calculations. 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
Source: Kansas Standard Specifications for State Road and Bridge Construction, 2015 Edition. Pages 302–307 of 978.