614Hma Base (Reflective Crack Interlayer (Rci))

– HMA BASE (REFLECTIVE CRACK INTERLAYER (RCI) HMA BASE (REFLECTIVE CRACK INTERLAYER (RCI))

614.1DESCRIPTION

Construct the HMA-reflective crack interlayer (RCI) as designated in the Contract Documents. BID ITEMS UNITS HMA-RCI (PG 70-28 RCI) Ton Quality Control Testing (HMA) Ton

614.2CONTRACTOR QUALITY CONTROL REQUIREMENTS

Perform quality control testing according to subsection 602.2 . Develop control charts for the mix characteristics listed in Table 614-7.

614.3MATERIALS

exception: Post a legible copy of the latest bill of lading fo r the Asphalt Binder on or near the gyratory compactor. Use the mixing and compaction temperatures shown on the bill of lading; however, the maximum mixing or compaction temperature is 340ºF, unless otherwise approved by the Field Materials Engineer. Notify the Engineer 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:

Once a previously loaded truck returns for its next load, reduce the temperature to not higher than the maximum mix temperature shown on the bill of lading, not to exceed 340oF.

RAS in the RCI.

Documents as shown in TABLE 614-1. 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. Natural sand shall be called SSG-1, SSG-2, etc. in the mix design.

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 complying with each proposed JMF shall have properties specified in TABLE 614-1 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 614-2. Contact the DME to determine if additional information should be submitted. Provide sufficient material as identified in TABLE 614-3. Submit for the Engineer’s review and approval, the test data listed in TABLE 614-4 for each blend and the proposed JMF. Provide a mix that meets the requirements in TABLE 614-5. – HMA BASE (REFLECTIVE CRACK INTERLAYER (RCI) 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 “Monthly Hot Mix Aggregate Specific Gravity Values” posted on KDOT’s Internet site. For RCI mixes, the optimum percentage of asphalt mate rial is the percentage that yields the design air voids at Ndes (50 gyrations) and complies with the other requirements of the specifications. Submit test results for all design criteria. The values from the approved mix design become the values in the initial job mix formula (JMF) for the RCI. These values remain in effect for the JMF un til a written request by the Contractor for a change is approved by the Engineer. Provide a new mix design when any change in materials occurs from those used in the mix design, unless waived by the DME. TABLE 614-1: COMBINED AGGREGATE REQUIREMENTS Mix Designation Percent Retained - Square Mesh Sieves ⅜" No. 4 No. 8 No. 16 No. 30 No. 50 No. 100 No. 200 RCI 0 0-15 1-25 13-47 41-68 74-91 88-99 94.0-99.0

the Job Mix Formula (JMF). Submit a new mix design when requesting a change beyond this limit.

TABLE 614-2: MIX PROPERTIES Property Abbreviation Test Method Additional Information Air Voids V a KT-15 & KT-58 Calculated from Gmm and Gmb. Run at the Pbr. Recommended Percent Asphalt Pbr Produce a mix with a Va of 4.5%. Theoretical Maximum Specific Gravity G mm KT-39 Rice Test. Sand EquivalentSE KT-55 Bulk Specific Gravity of HMA Gmb KT-15 Compacted Mix Property. Percent Gmm at Ndes %Gmm @ Ndes % KT-15 Use Gmm value from KT-39. Calculated from Gyratory Compaction height data, Gmm, and Gmb. Voids in Mineral Aggregate VMA KT-15 & KT-6 Calculated from Gmb, Gsb, Pb. Voids Filled with Asphalt VFA Calculated from VMA and V a @ Ndes. Formulas for calculations are in the Superpave Volumetric Mixture Design and Analysis Handbook. – HMA BASE (REFLECTIVE CRACK INTERLAYER (RCI) TABLE 614-3: MATERIAL SUBMITTALS Submittal Quantity Descriptio n Additional Information Aggregate for KT-15 3 Samples Sized for 6 inch Plugs Comply with Job Mix Gradation. Aggregate for KT-39 2 Samples Sized for Gmm Testing Comply with Job Mix Gradation. Binder for KT-15 As Needed Sized for 3 Plugs at P br Binder for KT-39 As Needed Sized for 2 Gmm Tests Each Aggregate for KT-6 As N eeded Specific Gravity Test Uncompacted HMA Sample 35 lbs Cool sample to room temperature If transported hot and compacted within 2 hours, then requirement to cool sample may be waived by the DME. Gyratory Plugs at Ndes 2 Plugs Compacted at P br Compacted to N des TABLE 614-4: TEST DATA SUBMITTALS Submittal Information Asphalt Binder Source, Grade, Specific Gravity, Mixi ng and Compaction Temperature from the Producer of the asphalt binder. Each Aggregate Source and Producer, including Legal Description. Gradation of Each Aggregate Percentage Retained to nearest 1% (except nearest 0.1% for No. 200 sieve) Material Proportioning Proportion of each material is shown in percentage of aggregate. Composite Gradation Based on Gradation of Each Aggregate and Material Proportioning. Composite Gradation Plot Plotted on KDOT Form 712 (0.45 power graph paper). Asphalt Binder Added Percentage to nearest 0. 01% based on total weight of the mixture. Aggregate Percentage of flat and elongated particles in the coarse aggregate Sand EquivalentSE for the combined virgin aggregates. TABLE 614-5: RCI MIX REQUIREMENTS FOR DESIGN SUBMITTAL MIX CHARACTERISTIC CRITERIA Sand Equivalent (SE), minimum, % 45 Gyratory Compaction Revolutions, Ndes 50 Air Voids (Va) target, %(1) 4.5 (2) VMA, minimum, %(1) 18.0 VFA, minimum, %(1) 70 Hveem Stability (AASHTO T-246) @ 140oF), 4" (100 mm) molds, minimum(1) 18.0 Flexural Beam Fatigue (AASHTO T-321) (3), 2000 microstrain, 10 Hz., 98% ± 1.0 of Gmb @ Ndes, 59oF (Age samples for 4 hours at 275oF before compaction, reference AASHTO R30 Section 7.2) 200,000 cycles

then change the target air voids to correlate to the mix that does meet all the test requirements. Use this for all target air voids during production. The target asphalt binder c ontent during production (JMF) will be the asphalt binder content from the approved mix design that yields the target air voids. Submit a new mix design to include the Hveem Stability and Flexural Beam Fatigue Testing when a new target asphalt binder content or target air voids is requested.

Section 8.7 Replace the last sentence with the following: This stiffness is the Initial Beam Modulus, which is used as a reference for determining the specimen failure. Section 8.8: Delete the second sentence. Section 8.9: Delete the last sentence. Section 9.1.3: Change “Flexural Stiffness” to “Beam Modulus” Section 9.1.6: Replace this section with the following: Normalized Modulus = (Beam Modulus x Cycle Number) / (Initial Beam Modulus x 50) Figure 6 - Plot the Normalized Modulus x Cycles versus Load Cycles (Repetitions) Section 9.1.7 and Section 9.1.8: Delete Section 9.1.9: Replace with the following: – HMA BASE (REFLECTIVE CRACK INTERLAYER (RCI) Failure Point – Failure is defined at the maximum or peak Normalized Modulus when Normalized Modulus x Cycles is plotted versus Load Cycles. Section 9.1.10: Delete respectively Section 10.7: Delete Section 10.8: Replace with the following: Prepare a plot of Normalized Modulus x Cycles versus load cycles TABLE 614-6: MIX DESIGN TEST DATA SUBMITTALS Submittal Information Minimum of 1 Mix Design As a minimum, 1 mix design at the Pbr Gmm Determined at each binder content. Individual and Bulk Specific Gravity Tests Provide results for a minimum of 2 specimens at each binder content. Percent Air Voids Provide % Va in the mixture for each binder content when compacted to Ndes gyratory revolutions along with copies of the Gyratory graphs. Percent VMA Provide %VMA at each binder content.

614.4CONSTRUCTION REQUIREMENTS

601. When heating the asphalt binder to the specified temperature, 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 regarding the reheating of asphalt binder in SECTION 601 are met.

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.

from the DME. A new JMF may be required.

combine as shown in the approved JMF.

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, deliver the HMA to the paver at a temperature sufficient to allow the material to be satisfactorily placed and compacted to the specified density and surface tolerance requirements.

determined by the P br in the JMF.

the pugmill, contains sufficient moisture to cause foaming of the mixture, or if the temperature of the aggregate is such that the as phalt-aggregate mixture temperature is outside the range specified in SECTION 601.

continuous operation. For batch and continuous ty pe plants, the minimum wet mixing time is 40 seconds. In all cases, mix a sufficient time to produce a uniform mixture in which all the aggregate – HMA BASE (REFLECTIVE CRACK INTERLAYER (RCI) particles are thoroughly coated. On batch plants, begin the timing at the start of the asphalt binder introduction into the pugmill, and end upon the opening of the discharge gate. For continuous flow plants, mixing time in seconds shall equal: [pugmill dead capacity in pounds] divided by [pugmill output in pounds per second].

limits specified by the manufacturer, unless it can be demonstrated to the satisfaction of the Engineer that such limits may be exceeded without detriment to the HMA.

all times so the hopper is more than ¾ full before the gates open, and the gates close before material can drop through the gob hopper directly into the surge bin, weigh hopper or truck.

If after an interruption of production, the drum-mixer contains cold, uncoated or otherwise unsuitable material, waste material through a diversion chute. In a continuous or batch plant drier, waste unsuitable material through the pugmill. At the end of a production run, waste any segregated material in the cone of the storage bin.

signed by the Plant Foreman or the Project Manager listing the dry weight of each aggregate, mineral filler and the tons of asphalt binder. The dry weight is the tons of the material less the water content.

pavement. Clean and fill cracks and joints, and construct surface leveling as shown in the Contract Documents. Prior to placing the HMA, apply a t ack coat to the existing surface, as shown in the Contract Documents. When warranted by weather conditions, the Engineer may authorize a change in the asphalt for tack coat. When such changes are made, the price per ton of material being used will be the unit price bid for the material designated in the contract plus or minus the difference in the invoice price per ton of the 2 materials at the refinery as determined at the time of application.

Deliver HMA to the paver at a temper ature sufficient to allow the material to be placed and compacted to the specified density and surface tolerance.

irregularities. Make every effort to prevent or correct any irregularities in the pavement, such as changing pavers or using different and additional equipment. Do not raise (dump) the wings of the paver receiving hopper at any time during the paving operation. The Engineer may waive this requirement if it is determined that raising (dumping) the wings will not produce detrimental segregation. If segregation or irregularities in the pavement surface or de nsity are noted, review the plant, hauling and paving operations and take corrective action. The recommendations made in KDOT’s "Segregation Check Points" sh ould reduce the segregation and irregular ities to an acceptable level. Copies of KDOT’s "Segregation Check Points" may be obtained from the KDOT District Office or Field Engineer. Spread the HMA and finish to the specified crown and grade using an automatically controlled HMA paver. Operate the paver at a speed to provide a uniform rate of placement without undue interruption. At all times, keep the paver hopper sufficiently full to prevent non-uniform flow of the HMA to the augers and screed. If the automatic grade control devices break down, the E ngineer may allow the paver to operate to the close of the working day, provided the surface is satisfactory.

segregation, true to cross section, uniform in density and texture and free from surface irregularities. If the pavement does not comply with all of these requirements, plant production and paving will be suspended until the deficiency is corrected. The Engineer may verify segregation and uniformity of density requirements in TABLE 602-7 are met by using methods outlined in Section 5.8.3 – Segregation Check Using the Nuclear Density Gauge, Part V.

Approval of any of these devices will be based upon satisfactory performance.

30 feet, to the paver and operate parallel with its line of travel. – HMA BASE (REFLECTIVE CRACK INTERLAYER (RCI)

matching surface grades along longitudinal joints.

from and parallel to the pavement edge on 1 or both sides. Erect the stringline parallel to the established pavement surface grade and support at intervals as necessary to maintain the established grade and alignment.

Documents. Use electronic guidance systems that meet the requirements and tolerances listed in SECTION 802. Horizontal control is guided by GPS. Vertical control is guided by Total Stations. GPS will not be allowed for Vertical control.

possible without shoving or tearing. Use self-propelled rollers operated at speeds slow enough to avoid displacement of the HMA. Equipment and rolling procedures whic h result in excessive crushing of the aggregate are prohibited. Use a sufficient number and weight of rollers to compact the HMA to the required density. Perform final rolling with a steel roller unless otherwise specified. On the final pass, operate finishing, vibratory rollers in the static mode. Coordinate the frequency, amplitude and forward speed of the vibratory roller to achieve satisfactory compaction without objectionable undulations. For HMA lifts with a compacted thickness less than 1¼ inch, operate vibratory rollers in the static mode. Keep rollers in operation as necessary so all parts of the pavement receive substantially equal compaction at the proper time. The Engineer will suspend HMA delivery to the project at any time proper compaction is not being performed. Remove, replace with suitable material and finish acco rding to these specifications any mixture that becomes loose, broken, mixed with foreign material or which does not comply in all respects with the specifications.

approved rolling procedure with random nuclear gauge de nsity determinations. Incl ude a method for controlling density in the QCP. Designate a "Compaction Foreman". This person sh all control compaction procedures, review nuclear gauge results as they are obtained, ad just compaction procedures as needed to optimize compaction and report any changes in the compaction process and results of nuclear gauge testing to the Engineer. The compaction foreman may also be the nuclear gauge operator. The nuclear gauge operator shall continuously monitor compaction procedures. As a minimum, take 10 random nuclear gauge density determinations per day and report results to the Engineer. Throughout the day, nuclear gauge results shall be available for review by the Engineer. The compaction foreman shall document at a minimum of once every 2 hours that the approved rolling sequence is being followed. Documentation shall include roller passes, the mat temperature at each pass, amplitude setting of rollers and roller speed. Provide the documentation to the Engineer. Determine and periodically update an approved rolling procedure as outlined in this section. As a minimum, evaluate the initial rolling procedure using 3 rollers. If the hot mix plant is operating at over 275 tons per hour, use a minimum of 4 rollers in the initial evaluation. The number of rollers may be reduced to 2 (or 3 if the plant is operating at over 275 tons per hour) provided cores (minimum of 3 sets of 3) are taken from both a segment (single truck load) using 3 rollers and a segment (single truck load) using 2 rollers (4 and 3 rollers, respectively if plant is running over 275 tons per hour). Determine the G mb of the cores using KT-15. If the G mb of the segment with less rollers is equal to or greater than the G mb of the segment with more rollers, then the minimum number of rollers may be reduced by 1. Operate vibratory rollers in the static mode only. Evaluate RCI paver screed operation with the nuclear gauge at various vibration settings. For screed evaluation, take the nuclear gauge readings directly behind the screed and before rolling. The Compaction Foreman and Engineer will evaluate the densities obtained with the various roller combinations and screed settings to determine the initial approved rolling procedure. Together, the Compaction Foreman and Engineer will determine when new rolling procedures are required. RCI production may be stopped by the Compaction Foreman or Engineer when ever rolling is not being performed according to the approved rolling procedure. For all lots, achieve the maximum density before the temperature of the HMA falls below 175 F. Do not crush the aggregate. When the mat temperature falls below 175F, roller marks may be removed from the mat with a self-propelled static steel roller.

uniform coating of asphalt material. Place the HMA uniformly high near the contact surfaces so that after compaction it shall be approximately ¼ inch above the edge of such structures. – HMA BASE (REFLECTIVE CRACK INTERLAYER (RCI)

SECTION 816.

provide a thorough and c ontinuous bond, provide an acceptable surface texture and meet density requirements. Do not vary the surface elevation more than 3/16 inch in 10 feet, when tested longitudinally across the joint. When required, repair the joints or paving operations will be suspended.

compaction at the joint. If deemed necessary by the Engineer to properly seal the joint, apply a light coat of asphalt emulsion or asphalt binder to the exposed edge before the joint is made. Before placing the fresh HMA against a cut joint or against old pavement, spray or paint the contact surface with a thin uniform coat of asphalt emulsion or asphalt binder. Where a finishing machine is used, make the longitudinal joint by depositing a sufficient amount of HMA to form a smooth and tight joint. Offset the longitudinal joint in successive courses by 6 to 12 inches. Comply with traffic lane edges for the width of the surface of top course placement.

Maintain one-way traffic, and restrict traffic speeds to 20 miles per hour in the vicinity of workers, unless otherwise designated. Use pilot cars to lead traffic through the area of paving and rolling operations, and if directed, through a curing area. The use of flaggers is allowed through patching operations, unless the patching area or distance between flaggers exceeds ½ mile, in which case the use of a pilot car shall be required. On overlay projects with 2 lanes or more in each direction for traffic use, the Engineer may waive the pilot car requirements. Station one flagger ahead of the application of the tack coat and one flagger ahead of the area being protected from traffic. Take adequate protection for traffic on side roads approaching the tack area.

Contract Documents. Overlay all widening areas designated in the Contract Documents or ordered by the Engineer.

Technical Support: Personnel familiar with the process will provide technical support for production and placement of the RCI. Tack Coat: Place a tack coat pr ior to the placement of the RCI. Thickness: Compact the RCI, as a minimum, to the depth shown in the Contract Documents. Thicknesses less than the plan thickness are not acceptable and may resu lt in removal and replacement at no additional cost to KDOT. Longitudinal Joint: Overlap the PCCP or HMA longitudinal joint with the RCI by at least 6 inches. Compaction and Density: Control the in-place density of all lots of the RCI using an approved rolling procedure as outlined in subsection 614.4e. If cores are taken use extreme care when handling the cores. Use a solid flat and un-textured surface to transport and store the cores prior to testing. Release to Traffic and Overlay Placement: Cover the RCI with a hot mixture over lay within 10 days after placement. The RCI may be opened to traffic or covered w ith the hot mix overlay after cooling to less than 140°F or as determined by the Engineer. Unacceptable work: Remove and replace areas dete rmined unacceptable by the Engineer, in accordance with this specification, at no additional cost to KDOT. Damaged Areas: Replace any traffic-damaged or marred areas at no additional cost to KDOT. Blisters: Perforate blisters that are a minimum of 8” in diameter or a minimum of 1” high that have not disappeared by the time of the overlay using a method approved by the Engineer.

614.5PROCESS CONTROL

Specify the limits and proportions such that the material produced complies with the applicable requirements of the – HMA BASE (REFLECTIVE CRACK INTERLAYER (RCI) designated mix type. The Contractor is responsible for all process control operations including testing. At no time will KDOT’s representative issue instructions to the Contractor or producer as to setting of dials, gauges, scales and meters. KDOT will collect and test verification samples an d assurance samples and inspect the Contractor’s quality control operations.

JMF to obtain the specified properties when compacted. If, during production, results from quality control tests demonstrate a need to make adjustments to the mix design, then make adjustments to the design JMF single point gradation and binder content to achiev e the specified properties. The JMF adjustments shall produce a mix that complies with TABLE 614-1 for the specified mix designation. When necessary, adjust on a sublot basis. Report the new JMF to KDOT’s field representative and the DME before making such changes, and submit a new mix design for review and approval if required by the DME.

tolerances shown in TABLE 614-7 to the JMF or adjusted JMF for binder content and air voids. Establish acceptable limits for the other listed mix charact eristics by applying the tolerances shown in TABLE 614-7 to the requirements of TABLE 614-1. TABLE 614-7: SPECIFICATION WORKING RANGES (QC/QA) Mix Characteristics Tolerance from JMF Single Test Value Plot 4 Point Moving Average Value Plot Binder Content ±0.5% * ±0.3% * Air Voids @ Ndes gyrations ±1.0% * ±1.0% * Mix Characteristics Toleranc e for Specification Limits Single Test Value Plot 4 Point Moving Average Value Plot Gradation (applicable sieves shown in TABLE 614-1) ** * zero tolerance * Voids in Mineral Aggregate 1.0% below min. * zero tolerance * Voids Filled with Asphalt zero tolerance n/a Sand Equivalent zero tolerance n/a *Values to plot. For gradations, as a minimum, plot the No. 8, No. 16, No. 50, and No. 200 sieves. ** The maximum deviation from the JMF shall be ±4% for No. 16 sieve and ±1.0% for No. 200 sieve.

614.6WEATHER LIMITATIONS

Do not place HMA on any wet or froz en surface or when weather conditi ons otherwise prevent the proper handling and finishing of the mixture. Only place HMA when either the mi nimum ambient air temperature or the road surface temperature shown in TABLE 614-8 is met. TABLE 614-8: MINIMUM RCI PLACEMENT TEMPERATURES Paving Course Thickness (inches) Air Temperature (ºF) Road Surface Temperature (ºF) RCI All 50 55

614.7MIXTURE ACCEPTANCE

lot by lot basis contingent upon satisfactory test results. Obtain quality control and verification samples of the RCI using KT-25 sampling procedure D.2 Truc k Bed. The sampling device and procedures used to obtain and split the samples must be approved by the Engineer. The Contract or’s quality control tests will be used for acceptance provided those results are verified by KDOT. – HMA BASE (REFLECTIVE CRACK INTERLAYER (RCI) A load or loads of mixture which, in the opinion of the Engineer, are unacceptable for reasons such as being segregated, aggregate being improperly coated, foaming aggregate or being outside the mixing temperature range may be rejected. The Engineer will take verification samples using the same sampling and splitting procedure as approved for the Contractor’s quality control tests. The P b test values will also be used to determine P b pay adjustments according to subsection 614.8b. P b pay adjustments apply to the RCI placed on the traveled way and shoulders (including ramps and acceleration and deceleration lanes).

specified material produced from a single source or operation. Each lot shall normally be represented by 4 contiguous test results. A lot may be represented by test results on samples taken from 1 or more day’s production.

beyond the Contractor’s normal quality control testing variation. The investigation may be based on either Contractor or KDOT test results. The information from additional testing (including testing of in-place RCI) may be used to define unacceptable work according to subsection 105.5. The Engineer may apply appropriate price reductions or initiate corrective action. For any test, if a dispute exists between the Engineer and Contractor about the validity of the other’s test results, the KDOT District Materials Laboratory or the MRC will perfo rm referee testing, except for P b dispute resolution. If the disputed KDOT test results were genera ted at the District Laboratory, the MRC will perform the referee tests. If the disputed KDOT test result was generated at the MRC, an independent laboratory agreeable to both parties will be selected. The Laboratory shall be accredited by the AASHTO Accreditation Program in the appropriate testing category. If referee testing indicates that KDOT test results are co rrect, the Contractor pays for the additional testing, including referee testing performed at the MRC. This will be paid using the bid item Contract Deduct which will be an item added to the contract. If the referee testing indicates that C ontractor test results are correct, KDOT pays for the additional testing. Pay the independent lab for the testing and submit the pa id invoice to KDOT. The Engineer will reimburse the Contractor (based on the invoice price) as Extra Work, SECTION 104. For Pb dispute resolution (the statistical comparison fails and the Contractor questions KDOT results), the following procedure applies for the lots in question:  Determine which lots to dispute. Only dispute the lot produced immediately prior to the lot currently under production and being tested. Notify the Engineer, prior to the completion of all Contractor P b testing for this lot. (When production is completed for any mix, the last lot may be challenged the day production is completed).  Discard Pb and Pb pay adjustment factors previously determined within the lots being questioned.  All back halves of samples within the lot in question will be taken by KDOT to the District Materials Laboratory. All back halves of samples shall be a minimum of 35 pounds. Failing to obtain enough material removes the right to dispute resolution. Copies of all paperwork, including work sheets, associated with previous P b calculations for the disputed lots will also be taken to the District Materials Laboratory. The following retesting will be completed by KDOT:  Determine the P b using the back half of all samples within the lot being questioned using KT-57. Normally, there will be 5 back halves (4 Contractor’s and 1 KDOT) to test within each lot.  Using the retest P b results, a statistical comparison will be ma de. If the t-test passes, the Contractor’s retest results will be used to calculate the pay factor and KDOT will pay for all retesting. Use the procedures shown in subsection 614.8b. If the t-test fails, KDOT’s retest results will be used to calculate the pay factor, and the Contractor will pay for all retesting. When a deficiency within a lot is determined to exist for properties other than P b (P b deficiencies are addressed elsewhere in the specification), the Engineer will decide on the disposition of each lot as to the acceptance, rejection or acceptance at an adjusted payment. The Engineer’s decision is final.

subsection 614.7c. – HMA BASE (REFLECTIVE CRACK INTERLAYER (RCI)

over the lots at each hot mix plant from project to project.

3,000 tons). It is anticipated that lot size shall be as specified. However, with the Engineer’s approval, the Contractor may re-define lot size for reasons such as, but not limited to, change in contract quantities or interruption of the work. Take 1 sample during production of each sublot and utilize it to determine disposition of the lot in which it occurs.

mix characteristics listed in TABLE 614-7 and without a P b penalty, the sublot size may be increased to 1,000 tons (lot size of 4,000 tons), provided the normal production rate of the plant is greater than 250 tons per hour. Provide immediate notification of lot size changes to the Engineer any time a change is made. If subsequent test results fall outside the tolerances shown for any mix characteristic listed in TABLE 614- 7 or a Pb penalty is incurred, the sublot size shall be decrease d to 750 tons. When the increased lot size criteria are again met, the sublot size may be increased to the limits given above.

tons) of RCI will be used. Use the plan quantity for the lot size. Reduce the sublot size below 750 tons by dividing the lot into 3 or 4 equal sublots. Before beginning production, provide the Engineer with the number and size of the sublots.

each plant and type of mix before production of that mix. Evaluate the pre- production mix at in itial start-up and after suspension of production resulting from failing test results. P b payment shall not be adjusted for pre- production mixes. Provide a pre-production mix that complies with the gradation, P b, VMA, and laboratory V a requirements prior to starting or resuming production. For P b, Va, and VMA, use the "Single Test Value" listed in TABLE 614-7 for comparison. For the other tests listed, use the values listed in TABLE 614-1 for each mix. Except for initial start-up, normal delivery of material to the project before completion of certain test results on pre- production mixes may be authorized by the DME. Place the material produced for the pre-production mix in locations approved by the DME. The Engineer will pay for material as the material produced. At the direction of the Engineer, remove the pre-production mix if it is both out of specification and the material shortens the pavement life or changes the intended function. The Engineer will pay for the replacement of one pre-production mix at 100% of the contract unit price for the RCI. The payment will be full compensation to the Contractor for the placement a nd removal of that pr e-production mix. KDOT will not be financially responsible for any subseque nt failed pre-production mixes (that require removal) for the RCI. The removed material is the property of the Contractor. The Engineer will not pay for pr e-production mixes that are required to be replaced due to poor workmanship or equipment failure. The Engineer will make the final decision to remove a failed pre-production mix with input from the Contractor.

made, if 2 consecutive test results for any single mix characte ristic fail to fall within the limits established by the tolerances shown in the single test value column of TABLE 614-7. Additionally, suspend production of the mix until appropriate corrections have been made, if any 4-po int moving average value for any single mix characteristic fails to fall within the limits established by the toleran ces shown in the 4-point moving average value column of TABLE 614-7. Production remains suspended pending the satisfactory results of a pre-production mix, unless waived by the DME. The Engineer may stop production of RCI at any time the mix or process is determined to be unsatisfactory. Make the necessary corrections before production will be allowed to resume. Failure to stop production of RCI shall subject all subsequent material to rej ection by the Engineer or acceptance at a reduced price, as determined by the Engineer. – HMA BASE (REFLECTIVE CRACK INTERLAYER (RCI)

614.8BASIS OF ACCEPTANCE

KDOT. The Engineer will routinely compare the variances (F -test) and the means (t-test) of the verification test results with the quality control test results for P b using a spreadsheet provided by KDOT. If KDOT verification test results do not show favorable comparison with the Contract or’s quality control test results, then KDOT test results will be used for material acceptance, material rejection and the determination of any pay adjustment on the P b. Disputed test results will be handled according to subsection 614.7c. KDOT will use a spreadsheet program to calculate pay adjustments for P b, and to compare Contractor QC and KDOT QA test results. KDOT will provide a copy of this program to the Contractor, when requested. Microsoft Excel software is required to run this program; it is the Contractor’s responsibility to obtain the correct software. Values computed using equations referenced in this specification may vary slightly from the spreadsheet values due to rounding of numbers. In such cases, the numbers computed by the spreadsheet will govern. The comparison of quality control and verification tests will be completed using the t-tests to compare their population means and the F-test to compare their variances. The F & t tests, along with the Excel Spreadsheet used to compare the Contractor’s QC results and KDOT’s QA results, are described in Section 5.2.6, Part V. Additional information on the program may be obtained from the Bureau of Construction and Materials.

based on measured P b from samples of plant produced material. The P b pay adjustment factor ( PB) (positive or negative) will be determined and used to compute the Pb pay adjustment by multiplying PB times the number of tons included in the lot times $40 per ton. This adjustment will be paid for under the bid item Asphalt Binder Pay Adjustment. When the statistical comparison between the quality control and the verification tests pass, use the procedures in subsection 614.8b.(1) to compute P

procedures in subsection 614.8b.(2). Asphalt Binder Lot Size: A lot shall normally be comprised of the results of 4 contiguous individual P b tests as determined from the ignition oven burn-off procedure (KT-57).

(QUB and QLB) for each lot using Equations 3 and 4, respectively and round to hundredths. Locate the QUB value in the left column of the Percent Within Limits (PWL) Table in Section 5.2.1, Part V. Select the appropriate upper percent within limit value (PWLUB) by moving across the selected quality index row to the column representing the number of samples (N) in the lot. Repeat the process using the QLB value and select the ap propriate value for the lower percent within limits ( PWLLB). If the QUB or QLB value is greater than the largest quality index value shown in the table, then a value of 100.00 is assigned as the value for PWLUB or PWLLB, respectively. If both QUB and QLB exceed the values shown in the table, a value of 100.00 is assigned as the value for both PWLUB and PWLLB. If either QUB or QLB is a negative value or PWLUB + PWLLB is less than 150.00, the Engineer will determine if the material in the lot may remain in place. If the Engineer determines that th e material may remain in place then the maximum value of PB for the lot will be equal to –0.060. The Engineer may establish lower values for PB (-0.100, -0.200, etc.) in such instances. Otherwise, calculate PB using Equation 3 and round to thousandths. Equation 1: S XUSL Q UB Equation 2: S LSLX Q LB X is the average measured Pb of all samples within a lot rounded to hundredths. USL is the upper specification limit for Pb, and is defined as 0.30% higher than the JMF Pb. LSL is the lower specification limit for Pb, and is defined as 0.30% lower than the JMF Pb. S is the standard deviation of the measured P b for all samples within a lot and is calculated using equation

Equation 3: PB = ((PWLUB + PWLLB - 100)(0.0015)) – 0.135 PWL UB is the upper percent within limits value for Pb. PWL LB is the lower percent within limits value for Pb. – HMA BASE (REFLECTIVE CRACK INTERLAYER (RCI)

calculate the PB for the lot. Follow the procedures given in subsection 614.8b.(1) to determine the PB or disposition of the lot. Use the values from TABLE 614-9 to calculate QUB, QLB, PWLUB and PWLLB in Equations 1, 2 and 3 in subsection 614.8b.(1). TABLE 614-9: Statistical Values for Asphalt Binder Pay Adjustment for Failing t-Test Term Definition Value X Average or Mean KDOT’s test result for the lot S Standard Deviation 0.20 USL Upper Specification Limit 0.50% + JMF Pb LSL Lower Specification Limit JMF Pb - 0.50% N Sample Size 3

614.9MEASUREMENT AND PAYMENT

delivery to the road. Batch weights will not be allowed as a method of measurement unless all the following conditions are met:  the plant is equipped with an automatic printer system approved by the Engineer;  the automatic printer system prints the weights of material delivered; and  the automatic printer system is used in conjunction with an automatic batching and mixing control system approved by the Engineer. Provide a weigh ticket for each load. Due to possible va riations in the specific gravity or weight per cubic foot of the aggregates, the tonnage used may vary from the proposal quantities and no adjustment in contract unit price will be made because of such variances. Payment for "HMA -RCI" at the contract unit prices is full compensation for the specified work. Any pay adjustments will both be applied and the payment adjusted accordingly.

for "Emulsified Asphalt" at the contract unit price is full compensation for the specified work.

performed by the Contractor on a per t on basis of HMA-RCI placed on the project . No adjustment in the bid price will be made for overruns or underruns in the contract quantity. The bid price will constitute payment for all necessary mix design testing, field process control testing, the testing laboratory and all necessary test equipment. Payment for "Quality Control Testing (HMA)" at the contract unit price is full compensation for the specified work.