401Hot Mix Asphalt Pavement

401.01 Description The Contractor shall furnish a uniformly blended, homogeneous

mixture placed as one or more courses of Hot Mix Asphalt Pavement (HMA) on an approved base in accordance with the contract documents and in reasonably close conformity with the lines, grades, thickness, and typical cross sections shown on the plans or established by the Resident. The Department will accept this work under Quality Assurance provisions, in accordance with these specifications and the requirements of Section 106 – Quality, the provisions of AASHTO M 323 except where otherwise noted in sections 401 and 703 of these specifications, and the MaineDOT Policies and Procedures for HMA Sampling and Testing.

401.02 Materials Materials shall meet the requirements specified in Section 700 -

Materials: Asphalt Cement 702.01 Aggregates for HMA Pavement 703.07 RAP for HMA Pavement 703.08 HMA Mixture Composition 703.09

401.03 Composition of Mixtures The Contractor shall compose the Hot Mix Asphalt

Pavement with aggregate, Performance Graded Asphalt Binder (PGAB), and mineral filler if required. HMA shall be designed and tested according to AASHTO R35 and the volumetric criteria in Table 1. The Contractor shall size, uniformly grade, and combine the aggregate fractions in proportions that provide a mixture meeting the grading requirements of the Job Mix Formula (JMF). Unless otherwise noted in Special Provision 403 - Hot Mix Asphalt Pavement, the design, verification, Quality Control, and Acceptance tests for this mix will be performed at 65 gyrations. TABLE 1: VOLUMETRIC DESIGN CRITERIA Design ESAL’s (Million s) Required Density (Percent of Gmm) Voids in the Mineral Aggregate (VMA)(Minimum Percent) Voids Filled with Binder (VFB) (Minimum %) Fines/Eff. Binder Ratio Nominal Maximum Aggregate Size (mm) Ninitial N design N max 25 12.5 9.5 4.75 <0.3 <91.5 96.0 <98.0 13.0 14.0 15.0 16.0 16.0 70-80 0.6-1.2 0.3 to <3 <90.5 65-80 3 to <10 <89.0 65-80* 10 to <30 > 30 *For 9.5 mm nominal maximum aggregate size mixtures, the maximum VFB is 82. For 4.75 mm nominal maximum aggregate size mixtures, the maximum VFB is 84. 4-2 The Contractor shall submit for Department approval a JMF to the Asphalt Pavement Engineer for each mixture to be supplied. The JMF will be approved by the Department in accordance with the MaineDOT HMA Policies and Procedures for HMA Sampling and Testing Manual. At the time of JMF submittal, the Contractor shall identify and make available the stockpiles of all proposed aggregates at the plant site. There must be a minimum of 150 ton for coarse aggregate stockpiles and 75 ton for fine aggregate stockpiles before the JMF may be submitted. The Contractor shall provide aggregate samples to the Department unless otherwise required. The Contractor shall also make available to the Department the PGAB proposed for use in the mix in sufficient quantity to test the properties of the asphalt and to produce samples for testing of the mixture. The first day’s production shall be monitored, and the approval may be withdrawn if the mixture exhibits undesirable characteristics such as checking, shoving or displacement. The Contractor shall be allowed to submit aim changes for a JMF as outlined in the MaineDOT HMA Policies and Procedures for HMA Sampling and Testing Manual: Mix Design Approval Section. The Contractor shall submit a new JMF for approval each time a change in material source or materials properties is proposed. The same approval process shall be followed. The cold feed percentage of any aggregate may be adjusted up to 10 percentage points from the amount listed on the JMF, however no aggregate listed on the JMF shall be eliminated. The cold feed percentage for RAP may be reduced up to 10 percentage points from the amount listed on the JMF and shall not exceed the percentage of RAP approved in the JMF or for the specific application under any circumstances. 401.031 Warm Mix Technology The Contractor may place Hot Mix As phalt Pavement produced with an accepted WMA technology if approved by the Department. Methods or technologies shall generally be at the Contractors option, but will be limited to proven, Agency and Industry accepted practice. Mixture production, placement and volumetric testing details, including temperatures, shall be included in the project specific QCP, and submitted to the Department for approval prior to any work.

401.04 Temperature Requirements The temperature of the mixture shall conform to the

tolerances in Table 2 as measured at the truck at the mixing plant and at the paver unless otherwise authorized by the Department. TABLE 2: ALLOWABLE TEMPERATURE RANGES PGAB Grade(s) Temperature Range (°F) PG58-28 / PG64-28 275-325 PG64E-28 / PG70E-28 285-335

401.05 Performance Graded Asphalt Binder The Contractor shall utilize either a PG58-

28, PG64-28, PG64E-28, PG70E-28, or other grade as specified in the 403 Special Provision. The Contractor shall utilize a PG64-28 if no liquid grade is specified within the 403 Special Provision.

401.06 Weather and Seasonal Limitations The State is divided into two paving zones as

follows: 4-3

401.07 Hot Mix Asphalt Plant

401.071 General Requirements HMA plants shall conform to AASHTO M156, Standard Specification for Requirements for Mixing Plants for Hot-Mixed, Hot-Laid Bituminous Paving Mixtures with exception of Section 4.2.1, 4.2.2, 4.3.4, 4.3.5, and 4.12.2. All HMA plants will be inspected annually by the Department prior to producing HMA for Department projects. The Contractor shall provide the Department at least 72 hour’s notice that the plant is ready for inspection. The HMA plant will be equipped with ladders and platforms that are accessible and safe to obtain belt and binder samples. The HMA plant 4-4 will have a sampling platform to perform HMA sampling from the back of haul units. Silo storage time of mixtures shall not exceed 36 hours. 401.072 Stockpiles HMA plants shall have sufficient space for stockpiles, with a minimum of supply for 2 days production of all aggregate products used in MaineDOT approved mix designs currently under production for the facility at all times. A minimum stockpile supply of 100 ton (70 yards) shall be maintained always no matter the production rate for the HMA plant. Stockpiles shall be separated and built to minimize segregation. All aggregate stockpiles of products used in MaineDOT approved mix designs shall be labelled with signage made of weather-proof material. Stockpile identification signs shall be a minimum size of 12” high and 24” wide with reflective lettering that is a minimum of 2” in height. The sign shall be placed so that it is easily readable from outside the stockpile area. 401.073 Cold Feeds Cold Feed Bins will have bin dividers to keep aggregate from intermingling between bins. Adequate means must be provided for obtaining samples of the complete and combined flow of all Cold feed bins. Cold feed bins will not be required to have individual sampling locations. 401.074 Dryer Dryer shall be capable of heating aggregate to required mixing temperature and shall be in good operation and condition. Dryer shall be subject to annual inspection prior to start-up. The Contractor shall dry and heat the aggregates for the HMA to the required temperature. The Contractor shall properly adjust flames to avoid physical damage to the aggregate and to avoid depositing soot on the aggregate. The Contractor shall provide the Department the opportunity to inspect the dryer prior to the annual inspection. The Contractor shall provide the Department a minimum period of 72 hours to inspect the dryer and provide at least 24 hour’s notice that the dryer is ready for inspection. 401.075 Asphalt Binder Asphalt binder heating system shall heat binder to proper mixing temperature. A thermometer shall be provided in the asphalt binder line. Indirect asphalt binder heating system shall be used and no direct flame may come in contact with tank. The temperature of asphalt binder shall be uniformly maintained using insulation or another approved method. An asphalt binder sampling valve shall be provided in the circulation line. The sampling valve shall be provided downstream of any binder additive used. The use of a different sampling location may be approved by the Department. The Contractor shall drain down the asphalt as low as safely possible in any tank that will be switched to a new source or grade prior to adding the new PGAB. 401.076 Additives Additives (WMA, anti-strip, etc.) not directly introduced into the binder at the terminal shall be introduced into the HMA plant per the supplier’s recommendations and shall be approved by the Asphalt Pavement Engineer, Pavement Quality Manager, or their authorized representative. The system for introducing additives shall be interlocked with the aggregate feed or weigh system to maintain correct proportions for all rates of production and batch sizes. Additive introduction systems shall be controlled by a proportioning device to the amount required on the JMF plus or minus 0.1% of the target. Additive introduction systems shall be interlocked with the plant and the recordation (batch tickets or drum recordation) shall display the additive and the weight and percentage 4-5 added. A means for sampling any mixture additives will be provided. The sampling point shall be after the additive is mixed with the PGAB before entering the drum or mixer unit. 401.077 Batch Plants Hot Bins Hot bins shall provide uniform continuous operation and be in good working condition. The plant shall be able to provide samples of hot bins upon request. Overflow shall be provided for each hot bin. Hot bin gates shall close without leaking. Bin walls must prevent intermingling between bins. Each hot bin shall have telltale devices (“low level indicator”) which will alter the operator when the bin is empty. Mixer Unit Clearance between blades and liner shall be adjusted to 1” maximum, unless the aggregate exceeds 1 ¼” then the clearance shall be 1 ½”. The spray bar length shall be at least 75% of the mixer length. The mixer unit shall be a twin pug mill-type mixer capable of mixing continuously for at least 45 seconds after all materials have been introduced into the mixer. The blades in the mixer shall be of sufficient number and size, capable of producing a homogenous mixture. If the mixer is not enclosed, it shall be equipped with an adjustable hood to prevent loss of dust by dispersion. The mixer unit shall be subject to annual inspection prior to removal of safety features and being readied for service. The Contractor shall provide the Department the opportunity to inspect the mixer unit prior to the annual inspection. The Contractor shall provide the Department a minimum period of 72 hours to inspect the mixer unit and provide at least 24 hour’s notice that the mixer unit is ready for inspection. Mineral Filler Mineral filler and fiber shall utilize separate bins and feed systems to store and proportion the required quantity into the mixture. The feed systems shall be accurate to no more than 10% of the required weight with a convenient and accurate means of calibration. Mineral filler and fiber shall be introduced in the weigh hopper and uniformly distributed prior to the injection of the asphalt binder. Automation The HMA batch plant shall automatically batch materials, mixes and discharges mixes. The batch plant shall accurately proportion the various materials in the proper order by weight. The entire batching and mixing cycle shall be continuous and shall not require any manual operations. The batch plant shall use auxiliary interlock circuits to trigger an audible alarm whenever an error exceeding the acceptable tolerance occurs. Along with the alarm, the printer shall print an asterisk on the delivery slip in the same row containing the out-of-tolerance weight. The automatic proportioning system shall be capable of consistently delivering material within the full range of batch sizes. When RAP is being used, the plant must be capable of automatically compensating for the moisture content of the RAP. The HMA batch plant shall be operated within the following tolerances: 4-6 Each aggregate component +/-1.5% cumulative, per bin Mineral Filler + / - 0.5% Bituminous Material + / - 0.1% Zero return (aggregate) +/- 0.5% Z e r o R e t u r n ( A C ) + / - 0.1% Additives + / - 0.1% Recordation All plants shall be equipped with an approved digital recording device. The printer shall mark any weight on the ticket that exceeds tolerance. The delivery slip load ticket shall contain information required under Section 108.1.3 - Provisions Relating to Certain Measurements, Mass and paragraphs a, b, and c of Section 401.078. 401.078 Drum Plants Cold Feeds and Delivery System A scalper screen shall be used to remove oversize material. The accuracy of the belt scale shall be within +/- 1.0% of the actual weight being measured. The HMA drum plant shall be capable of correcting for aggregate moisture. Mineral filler and fiber shall utilize separate bin(s) and feeder systems to store and proportion the required quantity into the mixture. The feed systems shall be accurate to no more than +/- 10% of the required weight with a convenient and accurate means of calibration. The plant shall be equipped with a single control to change all feed rates. Mineral filler and fiber shall be introduced such that dry mixing is accomplished no less than 18 inches prior to the injection of the asphalt binder. The Contractor shall ensure that the mineral filler does not become entrained in the exhaust stream of the dryer. Binder System The flow of asphalt binder shall adjust automatically with dry aggregate weights. The Department will conduct an asphalt flow meter check annually and after each plant change of location. The flow meter check must be performed prior to receiving approval to produce for Department projects. The plant must be configured to provide a convenient means to check accuracy of the flow meter. The flow meter will be considered accurate if the measured weight is within 1% of actual weight. Drum Mixer The HMA drum plant shall be equipped with a diversion system where mix can be diverted at startup/shutdown and any time. The drum mixer shall be subject to annual inspection prior to removal of safety features and being readied for service. The Contractor shall provide the Department a minimum period of 72 hours to inspect the drum mixer while providing at least 72 hour’s notice that the drum mixer is ready for inspection. Recordation An approved automatic ticket printer system shall be used with all approved HMA drum plants. The requirements for delivery slips for payment of materials measured by weight, as given in the following Sections, shall be waived: 108.1.3 a., 108.1.3 b., 108.1.3 c., and 108.1.3 d. The automatic printed ticket will be considered as the Weight 4-7 Certificate. The dry aggregate weights and binder flow shall be recorded as well as mineral filler and all binder additives. The recordation of materials shall be printed a minimum of every ten minutes while in production. The requirements of Section 108.1.3 f. - Delivery Slips, shall be met by the weigh slip or ticket, printed by the automatic system, which accompanies each truckload, except for the following changes:

401.08 Hauling Equipment Units hauling HMA shall have tight, clean, and smooth

metal bodies, which have been thinly coated with a small amount of approved release agent to prevent the mixture from adhering to the bodies. Release agents that dissolve or strip asphalts, including diesel fuel, will not be allowed. All mix haul units shall have a cover of canvas or other water repellent material capable of heat retention, which completely covers the mixture. The cover shall be securely fastened on the truck, unless unloading. All mix haul units shall have an opening on both sides, which will accommodate a thermometer stem. The opening shall be located near the midpoint of the body, at least 12 in above the bed.

401.09 Pavers The Contractor shall use pavers meeting the requirements of this section

unless otherwise authorized by the Department. Pavers shall be self-contained, self- propelled units with an activated heated screed capable of placing courses of Hot Mix Asphalt Pavement in full lane widths specified in the contract on the main line, shoulder, or similar construction. Pavers shall be of sufficient class and size to place Hot Mix Asphalt Pavement over the full width of the mainline travel way with a 10 ft minimum main screed with activated extensions. The Contractor shall place Hot Mix Asphalt Pavement on the main line with a paver using an automatic grade and slope controlled screed, unless otherwise authorized by the Department. The controls shall automatically adjust the screed and increase or decrease the layer thickness to compensate for irregularities in the preceding course. The controls shall maintain the proper transverse slope and be readily adjustable so that transitions and superelevated curves can be properly paved. The controls shall operate from a fixed or moving reference such as a grade wire or ski type device (floating beam) with a minimum length of 30 ft, a non-contact grade control with a minimum span of 24 ft, except that a 40 ft reference shall be used on Expressway projects. The Contractor shall operate the paver in such a manner as to produce a visually uniform surface texture and a thickness within the requirements of Section 401.11 - Surface Tolerances. The paver shall have a receiving hopper with sufficient capacity for a uniform spreading operation and a distribution system to place the mixture uniformly, without segregation in front of the screed. The screed assembly shall produce a finished surface of the required evenness and texture without tearing, shoving, or gouging the mixture. Pavers with extendible screeds shall have auger extensions and tunnel extenders as per the manufacturer’s recommendations, a copy of which shall be available if requested. The Contractor shall have the paver at the project site sufficiently before the start of paving operations to be inspected and approved by the Department. The Contractor shall repair or replace any paver found worn or defective, either before or during placement, to 4-9 the satisfaction of the Department. Pavers that produce an unevenly textured or non- uniform mat will be repaired or replaced before continuing to place HMA on MaineDOT projects. On a daily basis, the Contractor shall perform density testing across that mat as detailed in Section 401.191 Quality Control - Method A, B & C.

401.10 Rollers Rollers shall be static steel, pneumatic tire, oscillatory, or approved

vibrator type. Rollers shall be in good mechanical condition, capable of starting and stopping smoothly, and be free from backlash when reversing direction. Rollers shall be equipped and operated in such a way as to prevent the picking up of hot mixed material by the roller surface. The use of rollers, which result in crushing of the aggregate or in displacement of the HMA will not be permitted. Any Hot Mix Asphalt Pavement that becomes loose, broken, contaminated, shows an excess or deficiency of Performance Graded Asphalt Binder, or is in any other way defective shall be removed and replaced at no additional cost with fresh Hot Mix Asphalt Pavement, which shall be immediately compacted to conform to the adjacent area. The Contractor shall repair or replace any roller found to be worn or defective, either before or during placement, to the satisfaction of the Department. Rollers that produce grooved, unevenly textured or non-uniform mat will be repaired or replaced before continuing to place HMA on MaineDOT projects. The type of rollers to be used and their relative position in the compaction sequence shall generally be the Contractor’s option, provided specification densities are attained and with the following requirements:

401.11 Surface Tolerances The Department will check the following surface tolerances:

a.) Longitudinally: The pavement surface profile shall be free of deviations in excess of +/- ¼ inches from the required pavement surface profile grade. To verify the surface tolerance a straight plane shall be established using 16 foot straight edge or a taught string 4-10 line placed parallel to the direction of travel and checked continuously across the width of the lane. b.) Transversely: The pavement surface profile shall be free of deviations in excess of 0 inches below and ¼ inches above the required cross sectional profile grade. To verify the surface tolerance a straight plane shall be established using a 10 foot straight edge or taught string line placed perpendicular to the direction of travel and checked continuously along the length of the lane. The Contractor shall correct defective areas by removing defective work and replacing it with new material as directed by the Department. The Contractor shall furnish a 10 foot straightedge for the Department’s use.

401.12 Preparation of Existing Surface The Contractor shall thoroughly clean the

surface upon which Hot Mix Asphalt Pavement is to be placed of all objectionable material. When the surface of the existing base or pavement is irregular, the Contractor shall bring it to uniform grade and cross section. All surfaces shall have a tack coat applied prior to placing any new HMA course. Tack coat shall conform to the requirements of Section 409 – Bituminous Tack Coat, Section 702 – Bituminous Material, and all applicable sections of the contract.

401.13 Spreading and Finishing On areas where irregularities or unavoidable obstacles

make the use of mechanical spreading and finishing equipment impracticable, the Contractor shall spread, rake, and lute the HMA with hand tools to provide the required compacted thickness. Release agents that dissolve or strip asphalts, including diesel fuel, will not be allowed. On roadways with adjoining lanes carrying traffic, the Contractor shall place each course per the conditions in Table 4, unless otherwise noted by the Department in Section 403 - Hot Mix Asphalt Pavement. 4-11 TABLE 4: PLACEMENT CONDITIONS FOR ADJOINING LANES Depth (at centerline) Placement Conditions Vertical Longitudinal Joint ¾” and less (incl. shim) The Contractor may place the HMA course over the full single travel lane width for each production day. 1” to 1 ¼” The Contractor may place the HMA course over the full single travel lane width for each production day and will be required to place a matching course of HMA over the adjacent section of travel lane before weekend or holiday suspension. 1 ½” to 2” The Contractor may place the HMA course over the full single travel lane width for each production day and will be required to place a matching course of HMA over the adjacent section of travel lane before the end of the following calendar day. Greater than 2” The Contractor shall place each course over the full width of the traveled way section being paved that day. Notched-Wedge Longitudinal Joint 1 ½” to 2” The Contractor may place the HMA course over the full single travel lane width for each production day and will be required to place a matching course of HMA over the adjacent section of travel lane before weekend or holiday suspension. A maximum unmatched centerline joint length of 0.5 miles will be permitted over the weekend. Greater than 2” The Contractor may place the HMA course over the full single travel lane width for each production day and will be required to place a matching course of HMA over the adjacent section of travel lane before the end of the following calendar day. The Contractor will be required to place the specified course over the full width of the mainline traveled way being paved, regardless of use, depth, or longitudinal joint type prior to Memorial Day, July 4th, Labor Day, paving suspensions exceeding three days, or other dates as specified by special provision. The Contractor shall install additional warning signage that clearly defines the centerline elevation differential hazard. Unless otherwise addressed in the contract, the Contractor shall install additional centerline delineation such as a double RPM application at 100 foot intervals, or temporary painted line. For any exposed vertical edge between the shoulder and traveled way, at a minimum, the use of temporary painted line, or RPMs placed along the edge of traveled way at 200 foot intervals is required. The Traffic Control Plan shall be amended to include this option and the additional requirements. All signs and traffic control devices will conform to Section 719.01, and Section 652, and will be installed prior to the work, at a maximum spacing of 0.50 mile for the entire length of effected roadway section. If this option is utilized, all additional signing, labor, traffic control devices, or incidentals will not be paid for directly, will be considered incidental to the appropriate 652 items.

401.14 Hot Mix Asphalt Placement on Bridge Decks Hot mix asphalt pavement placed

on bridges shall also conform to Section 508.04 and the following requirements.

401.15 Compaction Immediately after the Hot Mix Asphalt Pavement has been spread,

struck off, and any surface irregularities adjusted, the Contractor shall thoroughly and uniformly compact the HMA by rolling. The Contractor shall roll the surface when the mixture is in the proper condition and when the rolling does not cause undue displacement, cracking, or shoving. The Contractor shall prevent adhesion of the HMA to the rollers or vibrating compactors without the use of fuel oil or other petroleum based release agents. Solvents designed to strip asphalt binders from aggregates will not be permitted as release agents on equipment, tools, or pavement surfaces. The Contractor shall immediately correct any displacement occurring as a result of the reversing of the direction of a roller or from other causes to the satisfaction of the Department. Any operation other than placement of variable depth shim course that results in breakdown of the aggregate shall be discontinued. Any new pavement that shows obvious cracking, checking, or displacement shall be removed and replaced for the full lane width as directed by the Resident at no cost to the Department. Along forms, curbs, headers, walls, and other places not accessible to the rollers, the Contractor shall thoroughly compact the HMA with mechanical vibrating compactors. The Contractor shall only use hand tamping in areas inaccessible to all other compaction equipment. On depressed areas, the Contractor may use a trench roller or cleated compression strips under a roller to transmit compression to the depressed area. 4-13 Any HMA that becomes unacceptable due to cooling, cracking, checking, segregation or deformation as a result of an interruption in mix delivery shall be removed and replaced with material that meets contract specifications at no cost to the Department.

401.16 Joints The Contractor shall construct wearing course transverse and longitudinal

joints in such a manner that minimum tolerances shown in Section 401.11 - Surface Tolerances are met when measured with a straightedge. The paver screed shall maintain a uniform head of HMA during transverse and longitudinal joint construction. The HMA shall be free of segregation and meet temperature requirements outlined in Section 401.04. Transverse joints of the wearing course shall be straight and neatly trimmed. The Contractor may form a vertical face exposing the full depth of the course by inserting a header, by breaking the bond with the underlying course, or by cutting back with hand tools. The Contractor shall apply a coating of emulsified asphalt immediately before paving all joints to the vertical face and 3 in of the adjacent portion of any pavement being overlaid except those formed by pavers operating in echelon. The Contractor shall use an approved spray apparatus designed for covering a narrow surface. The Department may approve application by a brush for small surfaces, or in the event of a malfunction of the spray apparatus, but for a period of not more than one working day. Where pavement under this contract joins an existing pavement, or when the Department directs, the Contractor shall cut the existing pavement along a smooth line, producing a neat, even, vertical joint. The Department will not permit broken or raveled edges. The cost of all work necessary for the preparation of joints is incidental to related contract pay items. Longitudinal joints shall be generally straight to the line of travel and constructed in a manner that best ensure joint integrity. Methods or activities that prove detrimental to the construction of straight, sound longitudinal joints will be discontinued. The Contractor may utilize an approved notched wedge joint device on all HMA layers 1 ½ inches in depth or greater. A notched wedge joint shall be constructed as shown in Figure 1 using a device that is attached to the paver screed and is capable of independently adjusting the top and bottom vertical notches. FIGURE 1: Notched Wedge Joint Notes

401.17 Hot Mix Asphalt Documentation The Contractor and the Department shall agree

on the amount of Hot Mix Asphalt Pavement that has been placed each day. All delivery slips shall conform to the requirements of 401.078.

401.18 Prepave Meeting Prior to placing any mix, the Department and the Contractor

shall hold a Pre-paving conference to discuss the paving schedule, source of mix, type and amount of equipment to be used, sequence of paving pattern, rate of mix supply, random sampling, project lots and sublots and traffic control. A copy of the density QC random numbers to be used on the project shall be provided to the Resident. The Departments’ random numbers for Acceptance testing shall be generated and on file with the Resident and the Project Manager. All personnel of the Department and the Contractor who have significant information relevant to the paving items shall attend, including the responsible onsite paving supervisor for the Contractor. The Resident will prepare minutes of the conference and distribute them to all attendees. Any requests to revise the minutes must be made to the Resident within 7 Days of Receipt. These minutes will constitute the final record of the Pre-paving conference. On the first day of paving and whenever there is a change in the onsite paving foreman or paving inspector, the Department and the Contractor shall hold an informal onsite meeting to review the minutes of the Pre-paving conference, Project Specific QCP, Plans, Typicals, Special Provisions and communication process. This meeting shall be held prior to placing any mix. The onsite paving supervisor, QCT, Superintendent, Resident and/or paving inspector shall attend. Prepave meetings shall not be required on projects designated as Acceptance Method D unless otherwise noted in Section 403 - Hot Mix Asphalt Pavement. 4-15

401.19 Contractor Quality Control The Contractor shall operate in accordance with the

approved Quality Control Plan (QCP) to assure a product meeting the contract requirements. The Contractor shall not begin paving operations until the Department approves the QCP in writing. 401.191 Quality Control - Method A, B & C The QCP shall meet the requirements of Section 106.6 - Acceptance and this Section. The QCP shall address any items that affect the quality of the Hot Mix Asphalt Pavement including, but not limited to, the following:

401.20 Acceptance Method A, B & C These methods utilizes Quality Level Analysis

and pay factor specifications. For Hot Mix Asphalt Pavement designated for acceptance under Quality Assurance provisions, the Department will sample once per sublot on a statistically random basis, test, and evaluate in accordance with the following Acceptance Properties: TABLE 7: ACCEPTANCE PROPERTIES Properties Point of Sampling Test Method Gradation Paver Hopper AASHTO T30 PGAB Content Paver Hopper AASHTO T308 % TMD (In-Place Density) Mat behind all Rollers AASHTO T269 Voids at Ndesign Paver Hopper AASHTO T 312 VMA at Ndesign Paver Hopper AASHTO T 312 Fines to Effective Binder Paver Hopper AASHTO T 312 VFB Paver Hopper AASHTO T 312 The Department will obtain samples of Hot Mix Asphalt Pavement in conformance with AASHTO R 97, Sampling Asphalt Mixtures, and the MaineDOT Polici es and Procedures for HMA Sampling and Testing. The Contractor shall transport the sa mples in containers provided by the Department to the designated MaineDOT Laboratory within 48 hours except when otherwise noted in the project specific QCP or as directed by t he Resident. Failure to deliver an acceptance sample to the designated acceptance laboratory will be considered the second incident under 106.4.6–QCP Non-Compliance. 4-20 Target values shall be as specified in the JMF. The Department will withhold reporting of the test results for the Acceptance sample until 7:00 AM, on the se cond working day of receipt of the sample, or after receipt of the Contractors results of the Acceptance sample split. Upon conclusion of each lot, where there is a minimum of four sublot s, results shall be examined for statistical outliers, as stated in Section 106.7.2 - Statistical Outliers. TABLE 8: ACCEPTANCE METHODS Property USL and LSL Method A Method B Method C Lot Size* Entire production per item per contract up to 6000 ton Entire production per item per contract Entire production per item per contract up to 6000 ton Maximum Sublot Size – Mix 750 ton Lot quantity divided by three 750 ton Maximum Sublot Size – Density Surface Layers – 250 ton Base / Intermediate Layers – 500 ton Lot quantity divided by five Surface Layers – 250 ton Base / Intermediate Layers – 500 ton Minimum Number of Samples – Mix Four Three Four Minimum Number of Samples – Density Five *Unless otherwise agreed upon at the Prepave Meeting If there is less than one-half of a sublot remaining at the end, then it shall be combined with the previous sublot. If there is more than one-half sublot remaining at the end, then it shall constitute the last sublot and shall be represented by test results. If it becomes apparent partway through a Lot that, due to an underrun, there will be insufficient mix quantity to obtain the minimum number of sublots needed, the Resident may adjust the size of the remaining sublots and select new sample locations based on the estimated quantity of material remaining in the Lot. Unanticipated over-runs of up to 1500 ton shall be rolled into the last lot. Cases where the lot is terminated prior to reaching completion shall be handled in accordance with Section 106.7.3 Early Termination of Lots. In cases where density incentive/disincentive provision apply, additional cores shall be taken to attain a minimum of three for the Lot. Isolated Areas During the course of inspection, should it appear that there is an isolated area that is not representative of the lot based on a lack of observed compactive effort, excessive segregation, a change in process or any other questionable practice, that area may be isolated and tested separately. An area so isolated that has a calculated pay factor below 0.80 for Method A and C or below 0.86 for Method B, based on three random tests shall be removed and replaced at the expense of the Contractor for the full lane width and a length not to be less than 150 ft. Pavement Density The Department will measure pavement density using core samples tested according to AASHTO T 166. The Contractor shall cut 6-inch diameter cores at no additional cost to the Department by the end of the working day following paving. Cores 4-21 shall be cut such that the nearest edge at least 9 inches from any joint. Pre-testing of the cores will not be allowed. If the Contractor and the Department mutually determine that a core is damaged, the Contractor shall cut new core(s) at the same offset and within 3 ft of the initial sample. The Contractor and the Department will mutually determine if underlying material is adhered to the core and if so will mark the core at the point where sawing is needed. The Department will place the cores in a secure container and the Contractor shall transport the cores to the designated MaineDOT lab. The cores will be saw cut by the Department to remove underlying layers. No recuts are allowed at a test location after the core has been tested. Upon conclusion of each lot, density results shall be examined for statistical outliers as stated in Section 106.7.2. On all sections of overlay with wearing courses designed to be 1 in or less in thickness, there shall be no pay adjustment for density otherwise noted in Section 403 - Hot Mix Asphalt Pavement. For overlays designed to be 1 in or less in thickness, density shall be obtained by the same rolling train and methods as used on mainline travelway surface courses with a pay adjustments for density, unless otherwise directed by the Department. There shall be no pay adjustment for density on shoulders unless otherwise noted in Section 403 - Hot Mix Asphalt Pavement. Density for shoulders shall be obtained by the same rolling train and methods as used on mainline travelway, unless otherwise directed by the Department. Efforts to obtain optimum compaction will not be waived by the Department unless it is apparent during construction that local conditions make densification to this point detrimental to the finished pavement surface course. TABLE 9: ACCEPTANCE LIMITS Property USL and LSL Method A Method B Method C Percent Passing 4.75 mm and larger sieves Target +/-7% Percent Passing 2.36 mm to 1.18 mm sieves Target +/-4% Target + /-5% Target +/-5% Percent Passing 0.60 mm sieve Target +/-3% Target +/-4% Target +/-4% Percent Passing 0.30 mm to 0.075 mm sieve Target +/-2% Target + /-3% Target +/-2% PGAB Content Target +/-0.4% Target +/-0.5% Target +/-0.4% Voids at Ndesign 4.0% +/-1.5% 4.0% +/-2.0% N/A Fines to Effective Binder 0.9 +/-0.3 0.9 +/-0.3 N/A VMA at Ndesign LSL from Table 1 LSL from Table 1 N/A VFB Table 1 plus a 4% production tolerance for USL Table 1 plus a 4% production tolerance for USL N/A % TMD (In-place Density) 95.0% +/- 2.5% The Contractor shall cease paving operations whenever one of th e following occurs on a lot in progress: 4-22 TABLE 10: CEASE PRODUCTION CONDITIONS Property Percent Within Limits (PWL) Method A / Method B Method C Percent Passing NMAS sieve* <60 <60 Percent Passing 2.36 mm sieve* Percent Passing 0.30 mm sieve* Percent Passing 0.075 mm sieve* PGAB Content Voids at Ndesign N/A Fines to Effective Binder* VMA at Ndesign VFB % TMD (In-place Density) <60 *Paving operations shall not be required to cease if the mean test value is equal to the LSL or USL and s = 0. In cases where the Contractor is to cease paving operations based upon an Acceptance result or payfactor, the Contractor will submit a corrective action plan to the Department. The Department will only allow the continuation of paving operations when it is satisfied the corrective action will result in an improvement in results. The Department may require the submittal of a passing verification sample to allow further production. The Department will sample, test, and evaluate Hot Mix Asphalt Pavement in accordance with Section 106 - Quality and Section 401.20 - Acceptance, of this Specification. The Department will use the following criteria for pay adjustment at the completion of the Lot using the pay adjustment factors under Section 106.7 - Quality Level Analysis: Density If the pay factor for Density falls below 0.80 for Method A or C or 0.86 for Method B, all of the cores will be randomly re-cut by Sublot. A new pay factor will be calculated that combines all initial and retest results. If the resulting pay factor is below 0.80 for Method A or C or below 0.86 for Method B, the entire Lot shall be removed and replaced with material meeting the specifications at no additional cost to the Department, except that the Department may, when it appears that there is a distinct pattern of defective material, isolate any defective material by investigating each mix sample sublot and require removal of defective mix sample sublots only, leaving any acceptable material in place if it is found to be free of defective material. Pay factors equal to or greater than the reject level will be paid accordingly. Mix Properties The Department will determine a pay factor (PF) using the applicable Acceptance Limits. If any single pay factor for PGAB Content, VMA at Ndesign, or Voids at Ndesign falls below 0.80 for Method A, then the composite pay factor for PGAB Content, VMA at Ndesign, and Voids at Ndesign shall be 0.55. If any single pay factor for PGAB Content, VMA at Ndesign, or Voids at Ndesign falls below 0.86 for Method B, then the composite pay 4-23 factor for PGAB Content, VMA at Ndesign, and Voids at Ndesign shall be 0.70. If the PGAB content falls below 0.80 for Method C, then the PGAB pay factor shall be 0.55. The following variables will be used for pay adjustment: PA = Pay Adjustment Q = Quantity represented by PF in ton P = Contract price per ton PF = Pay Factor The Department will determine a pay adjustment using Table 11: Pay Adjustment Calculations as follows: TABLE 11: PAY ADJUSTMENT CALCULATIONS Acceptance Method Mix Properties / Gradation Density Method A PA = (Voids @ Nd PF- 1.0)(Q)(P)x0.20 + (VMA at Ndesign PF- 1.0)(Q)(P)x0.20 + (PGAB Content PF- 1.0)(Q)(P)x0.10 PA = (density PF- 1.0)(Q)(P)x0.50 Method B Method C PA = (% Passing Nom. Max PF-1.0)(Q)(P)x0.05+(% passing 2.36 mm PF- 1.0)(Q)(P)x0.05+(%passing 0.30 mm PF-1.0)(Q)(P)x0.05+(%passing 0.075 mm PF-1.0)(Q)(P)x0.10+(PGAB Content PF-1.0)(Q)(P)x0.25 In addition, for 9.5 mm NMAS mixtures the following pay adjustment shall also apply: The average percent passing for the 0.075 mm sieve shall be evaluated for each Lot. If the average is greater than 6.5%, a pay adjustment according to Table 12 below shall apply in addition to the other pay adjustments for the given method of testing. TABLE 12: 0.075 MM SIEVE PAY ADJUSTMENT Average Percent Passing 0.075 mm Sieve Pay Adjustment 6.6% - 7.0% -5% > 7.0% -10% The Department shall notify the Contractor whenever the average of at least three samples in a given Lot is greater than 6.5%.

401.21 Acceptance Method D Unless otherwise stated in the 403 special provision, one

sample will be taken from the paver hopper or the truck body per 250 ton per pay item. The mix will be tested for gradation and PGAB content. Disputes will not be allowed. If the mix is within the tolerances listed in Table 13, the Department will pay the contract unit price. Contractor shall cut two 6 in cores, which shall be tested for percent TMD per AASHTO T- 269 unless otherwise noted in Section 403 - Hot Mix Asphalt Pavement. If the average for the two tests falls below 92.5% the disincentive shall apply. If the test results for each 250 ton increment are outside these limits, the following deductions shall apply to the HMA quantity represented by the test. 4-24 TABLE 13: METHOD D ACCEPTANCE LIMITS AND PAY ADJUSTMENTS Property USL and LSL Pay Adjustment Percent Passing 4.75 mm and larger sieves Target +/-7% N/A Percent Passing 2.36 mm sieve Target +/-7% -2.0% Percent Passing 1.18 mm sieve Target +/-5% N/A Percent Passing 0.60 mm sieve Target +/-4% N/A Percent Passing 0.30 mm sieve Target +/-3% -1.0% Percent Passing 0.075 mm sieve Target +/-3% -2.0% PGAB Content Target +/-0.5% -5.0% % TMD (In-place Density) LSL of 92.5% -10.0% If test results do not meet the Table 13 requirements, deducts as shown shall be applied to the quantity of mix represented by the test.

401.22 Method of Measurement The Department will measure Hot Mix Asphalt

Pavement by the ton in accordance with Section 108.1 - Measurement of Quantities for Payment.

401.23 Basis of Payment The Department will pay for the work, in place and accepted, in

accordance with the applicable sections of this Section, for each type of HMA specified. The Department will pay for the work specified in Section 401.12, for the HMA used, except that cleaning objectionable material from the pavement and furnishing and applying bituminous material to joints and contact surfaces is incidental. Payment for this work under the appropriate pay items shall be full compensation for all labor, equipment, materials, and incidentals necessary to meet all related contract requirements, including design of the JMF, implementation of the QCP, obtaining core samples, transporting cores and samples, filling core holes, applying emulsified asphalt to joints, and providing testing facilities and equipment. The Department will make a pay adjustment for quality as specified in Section

401.20 Acceptance Method A, B & C or 401.21 Acceptance Method D.

401.24 Process for Dispute Resolution (Methods A, B, & C only) At the time of Hot-

Mix Asphalt sampling, the Department will obtain a split sample of each Acceptance test random sample for possible dispute resolution testing. The Contractor shall also obtain a split sample of the HMA at this same time. If the Contractor wishes to retain the option of requesting dispute testing of the initial Acceptance sample, the Contractor will test their split of the Acceptance sample and shall report their results to the Resident, with a copy to Contractor.mainedot@maine.gov by 7:00 AM, on the second working day from time of QA sampling, otherwise dispute resolution will not be initiated. The Department’s dispute resolution split sample will be properly labeled and stored for a period of at least two weeks after it has been reported, or until the sample is tested. The properties eligible for dispute and the respective variances are shown in Table 14. The Contractor may dispute the Department’s Acceptance results and request that the dispute resolution split sample be tested by notifying the Department’s Resident and QA 4-25 Engineer in writing within two working days after the results of the Acceptance test are reported. The following shall be provided in the request:  Acceptance sample reference number  The specific test result(s) or property(ies) being disputed, and  The complete, signed report of the Contractor’s testing (In a lab certified by the NETTCP and MaineDOT) of their split of the Acceptance sample indicating that the variances in Table 14 for the specific test result(s) or property(ies) were exceeded. TABLE 14: DISPUTE RESOLUTION VARIANCE LIMITS Property Disputable on Method A/B Disputable on Method C Variance Limits PGAB Content Yes Yes +/-0.4% Gmb Yes No +/-0.030 Gmm Yes No +/-0.020 Voids at Ndesign Only if Gmb or Gmm is not disputable No +/-0.8% VMA at Ndesign Only if Gmb or Gmm is not disputable No +/-0.8% Percent Passing 4.75 mm and larger sieves No Yes +/- 4.0% Percent Passing 2.36 mm to 0.60 mm sieves No Yes +/- 3.0% Percent Passing 0.30 mm to 0.15 mm sieves No Yes +/- 2.0 % 0.075 mm sieve Only for 9.5 mm NMAS mixes Yes +/- 0.8% The value of any disputed result or property reported for the initial Acceptance sample shall stand if the value reported for the dispute resolution sample is not closer to the value the Contractor reported for their split sample than to the value reported for the initial Acceptance sample. If the value reported for the dispute resolution falls precisely half-way between the other two values the value reported for the dispute resolution will replace the original acceptance value. Otherwise, the value reported for the dispute resolution sample will replace the value reported for the initial Acceptance sample and will be used to re- calculate any other affected results or properties.

Hot Mix Asphalt Pavement in other states

• Alaska 401 · HOT MIX ASPHALT PAVEMENT
• Wisconsin 460 · Hot Mix Asphalt Pavement