611Hot Mix Asphalt (Hma)-Commercial Grade

- HOT MIX ASPHALT (HMA)-COMMERCIAL GRADE HOT MIX ASPHALT (HMA)-COMMERCIAL GRADE

611.1DESCRIPTION

Construct the designated class of HMA-Commercial Gr ade asphalt pavement, as shown in the Contract Documents. Class A HMA-Commercial Grade is intended for all areas that are not Class B locations. Class A includes permanent traffic areas and temporary tr affic areas with moderate to high volumes of vehicular traffic such as driving lanes, auxiliary lanes and shoulders. Class B HMA-Commercial Grade is in tended for non-traffic areas and sh ort-term temporary traffic areas with a low volume of vehicular traffic. B I D I T E M S U N I T S HMA–Commercial Grade (Class *) Ton HMA–Commercial Grade (Class *) (Patching) Ton *A or B

611.2MATERIALS

Provide asphalt for tack coat suitable for th e intended use and approved by the Engineer.

Commercial Grade to the DME for revi ew and approval. When requested by the Engineer, submit a sufficient quantity of materials to verify the mix design. Submit a mix design that complies with these requirements:

approves otherwise or shown elsewhere in the Contract Documents, use a SM-12.5A or SR-12.5A ( TABLE 611-2) for Class A. Use any mix designation listed in TABLE 611-2 for Class B. TABLE 611-1: HMA-COMMERCIAL GRADE CLASS A and CLASS B MIX CRITERIA CLASS A CLASS B AGGREGATE: Coarse Angularity (min.%) 75 50 Uncompacted Voids-Fine (min. %) 42 40 Sand Equivalent (min. %) 40 40 Natural sand (max. %) 35 - Reclaimed Asphalt Pavement (RAP) (max. %) 25 50 Binder: PG64-22 or PG58-281 PG58-28 or PG64-22 COMPACTION REVOLUTIONS: (A)3 (B) 3 Nini 7 6 7 Ndes 75 50 75 Nmax 115 75 115 Level of Compaction at Nini ≤90.5 ≤91.5 ≤91.5 MIX: VFA 65 – 78 66-80 65 – 78 Tensile Strength Ratio (TSR) (min. %) 802 - - 1In permanent locations with an asphalt mixture containing Recycled Asphalt Shingles (RAS) or 16% to 25% RAP, use PG58-28. In all other locations, the Contractor may use either grade of binder. 2Meet the minimum TSR requirement for design only. Depending on the anticipa ted exposure to the environment, the DME may waive the TSR requirement. 3Use either column A or B, Contractor’s option. - HOT MIX ASPHALT (HMA)-COMMERCIAL GRADE If RAP or RAS is used, inform the Engineer as to the source and type of RAP and RAS. Provide RAP that is reasonably free of contamination, uniform in composition (similar to RAP gradation shown on mix design) and has passed through a 2 ¼" screen or grizzly. The Engin eer will accept the RAP and RAS based on a visual inspection. The Engineer may approve the use of an asphalt mixture (listed in TABLE 611-2) that is produced, tested and complies with SECTION 602. If used, QC/QA testing is required.

TABLE 611-2: MIX DESIGN REQUIREMENTS (Master Grading Limits and VMA) Nominal Maximum Size & Mix Designation Percent Retained - Square Mesh Sieves Min. VMA (%)1" 3/4 " 1/2 " 3/8 " No. 4 No. 8 No. 200 SM-9.5A 0 0-10 10 min. 33-53 90.0-98.0 14.5 SR-9.5A 0-2 0-10 10 min. 33-53 90.0-98.0 14.5 SM-9.5T 0 0-10 10 min. 53-68 90.0-98.0 14.5 SR-9.5T 0-2 0-10 10 min. 53-68 90.0-98.0 14.5 SM-12.5A 0 0-10 10 min. 42-61 90.0-98.0 13.5 SR-12.5A 0-2 0-10 10 min. 42-61 90.0-98.0 13.5 SM-19A 0 0-10 10 min. 51-65 92.0-98.0 13.0 SR-19A 0-2 0-10 10 min. 51-65 92.0-98.0 13.0 • Meet the minimum VMA requirements with design only. • Use an air void target of 4% (at Ndes) to establish binder content. • Using the combined gradation (RAP and RAS, if any, and virgin aggr egate), select a single point for each sieve within the master gradin g limits and the No. 16, No. 30, No. 50 and No. 100 sieves. Also, provide the combined virgin aggregate gradation. • When controlling a virgin mix by cold feed gradation testing, apply single point tolerances in TABLE 611-3 to the design single points for the virgin aggregate. Do not ex ceed the tolerances for the Master Grading Limits. • When controlling a mix that contains RAP or RAS by cold feed virgin gradation testing, apply single point tolerances in TABLE 611-3 to the design single points for the virgin aggregate. The tolerances may exceed the Master Grading Limits. • If RAP is used, calculate the Effective Specific Gravity (Gse) of the RAP as shown in subsection 5.10.4 – Calculations for the Marshall Mix Design of Bituminous Mixtures, Part V and used as the G sb of the RAP. If RAS is used, calculate the Effective Specific Gravity (G se) of the RAS as shown in subsection 5.10.4, Part V and use as the Gsb of the RAS. TABLE 611-3: SINGLE POINT TOLERANCES Nominal Maximum Size & Mix Designation Percent Retained - Square Mesh Sieves 3/8" No. 4 No. 8 No. 16 No. 30 No. 50 No. 100 No. 200 SM-9.5A or SR-9.5A ±5 ±5 ±5 ±4 ±4 ±3 ±2 SM-9.5T or SR-9.5T ±6 ±5 ±5 ±4 ±3 ±3 ±2 SM-12.5A or SR-12.5A ±6 ±6 ±5 ±5 ±4 ±4 ±3 ±2 SM-19A or SR-19A ±6 ±6 ±5 ±5 ±4 ±4 ±4 ±2 Comply with the certification requirements for the appropriate categories listed in the Policy and Procedure Manual for the Certified Inspection and Testing Training (CIT 2) Program. Use calibrated testing equipment with prescribed procedures in the KDOT Construction Manual, Part V, Section 5.2.7. - HOT MIX ASPHALT (HMA)-COMMERCIAL GRADE

Engineer. Depending upon the change, the Engineer may require another mix design before granting approval. On the first Lot only of production of any mix designation, any gradation penalty for the entire Lot will be assessed on the basis of the revised design job-mix (if any), provided no change in asphalt content is required as a result of the revision. For changes made in the design job-mix on subsequent Lots, computation of adjusted payment will not be retroactive within the Lots. Make any gradation change for the Lot before starting the gradation testing for that Lot. During mix production on non-QC/QA projects, the Engineer may conduct tests (randomly located) to verify compliance with the approved mix design, and make adjustments to the binder content (Note: Plant produced mix may have a lower VMA and require a reduction in binder content.). On projects with less than 500 tons of commercial grade asphalt mixture, testing (QC/QA or cold-feed gradations) is at the Engineer’s discretion. On projects with 500 tons or more, testing of the asphalt mixture is required: • The Engineer will test the combined virgin gradatio n at a frequency of 1 test for each 500 ton Lot or fraction thereof. • On projects with more than 2000 tons of HMA–Commercial Grade mixture the Contractor may request the lot be increased to 750 ton provided the following criteria are met: • The plant is producing more than 500 tons of HMA–Commercial Grade mixture per day; • Previous 3 consecutive lots were produced without penalty; and • Provide immediate notification of lot size change to the Engineer any time a change is made. • If any lot fails to meet all of the above criteria, the lot size shall resort to 500 tons until such time that the aforementioned criteria are met. • Or, the Contractor and Engineer will test (QC/QA respectively) the asphalt mixture according to the testing requirements and frequencies in Part V, Appendix B. KDOT will perform tests at the Contractor’s lab or at a location agreed to by the Engineer and Contractor. Testing will be completed and the results reported to the Contractor within 24 hours. If the test results indicate there is non-compliant material, make the appropriate adjustments to the mix proportions to comply with the approved mix design.

the single point tolerances, or QC/QA test results fail to comply with SECTION 602, suspend the production of that mix pending satisfactory results of a pre-production sample. Such suspension will constitute Lot termination.

added. 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 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. Provide Warm Mix Asphalt (WMA) additives or processes that comply with DIVISION 1200 . The Contractor is permitted to use WMA unless otherwise shown on the plans. For mixes containing Warm Mix Asphalt (WMA) ad ditives, submit for the Engineer’s review and approval, the additive or process used, the recommended rate of application, and the temperature ranges for mixing and compaction. Mixing temperature range is provided by the Asphalt Binder Supplier. When using WMA, the mixing temperature may be reduced no more than 30 oF for WMA water foaming processes, and no more than 70 oF for WMA chemical and organic additives. The minimum mixing temperature for WMA is 220oF.

611.3CONSTRUCTION REQUIREMENTS

- HOT MIX ASPHALT (HMA)-COMMERCIAL GRADE 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.

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 PLACEMENT 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

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 allowable 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.

611.4MEASUREMENT AND PAYMENT

The Engineer will measure HMA-Commercial 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 indicate 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.

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. - HOT MIX ASPHALT (HMA)-COMMERCIAL GRADE TABLE 611-5: SCHEDULE OF ADJUSTED 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 Contractor may remove and replace at no cost to KDOT.

only), as outlined in SECTION 602, on the asphalt material (taken from each QC/QA Lot) represented by non- compliant QC/QA (acceptance) tests.