2365Stone Matrix Asphalt

2365.1DESCRIPTION

This Work consists of constructing a stone matrix asphalt wearing course mixture (SMA) placed on a prepared surface in accordance with these Specifications. Construct the SMA to the lines, grades, thicknesses, and typical cross -sections shown on the Plans or established by the Engineer. Stone matrix asphalt mixture designation code: SMWEE640H.

2365.2MATERIALS

A Aggregates Use only virgin Aggregates. A.1 Aggregate Requirements Provide mineral Aggregate meeting the requirements of Table 2365.2-1 and Table 2365.2-2. Table 2365.2-1 Stone Matrix Asphalt Aggregate Gradation Broad Bands (percent passing of total washed gradation) Sieve Size percent Passing 3/4 inch 100 1/2 inch 86-96 3/8 inch 60-85 No. 4 25-35 No. 8 15-25 No. 200 8.0-12.0

Table 2365.2-2 Stone Matrix Asphalt Mixture Aggregate Requirements Aggregate Blend Property Requirements Coarse Aggregate angularity (one face/two face), percent wear, Laboratory Manual Method 1214 100/90 Fine Aggregate Angularity Use manufactured sand Coarse Aggregate absorption, percent, Laboratory Manual Method 1204 < 2 Voids in coarse Aggregate (VCADRC), Laboratory Manual Method 1211 & AASHTO T19 Standard Method for Bulk Density (“Unit Weight”) and Voids in Aggregate VCAmix<VCADRC Flat and elongated particles, max percent by weight, Laboratory Manual Method 1208 10 (3:1 ratio) Clay content (MnDOT 1215) 45 Total spall in fraction retained on the No. 4 Sieve, Laboratory Manual Method 1209 1.0 Maximum spall content in total sample, Laboratory Manual Method 1209 1.0 Maximum percent lumps in fraction retained on the No. 4 Sieve 0.5 Class B Carbonate restrictions: maximum percent -No. 4 Sieve 50 Class B Carbonate restrictions: maximum percent +No.4 Sieve 0 A.2 Los Angeles Rattler The Los Angeles Rattler loss on the coarse Aggregate fraction Material retained on the No. 4 Sieve cannot exceed 35 percent for any individual source used within the mix (Laboratory Manual Method 1210). A.3 Magnesium Sulfate loss on coarse aggregate fraction for each source ............3139.2C.2 A.4 Mineral Filler ............................................................................................. AASHTO M17 B Additives An additive is any Material added to an asphalt mixture or Material , such as mineral filler, asphalt additives, anti-strip, stabilizers, and similar products that do not have a specific Pay Item. When the Contract requires additives, compensation is included with the Pay Items for the appropriate mixture. If directed to incorporate additives, the compensation will be as Extra Work, at the U nit Price specified in the Proposal. No compensation will be made for additives incorporated at the Contractor's option .

Do not incorporate additives into the mixture without approval of the Engineer. Add anti-foaming agents to asphalt cement at the manufacturer's recommended dosage rate. C SMA Asphalt Stabilizer ............................................................................................. AASHTO 305 Use a cellulose fiber asphalt stabilizer additive to control drain-down in the SMA mixture. Feed the stabilizing additive through a separate system that proportions the required amount of stabilizer in uniform distribution at a dosage rate within 0.2-0.4 percent by weight of the total mix. The system must have low-level and no-flow indicators and a printout of the feed rate in pounds/minute. Additionally, the stabilizer supply line must include a section of transparent pipe for observing consistency of flow or feed. Use PG 58V-28, meeting the requirements of AASHTO MP 19 Standard Specification for Performance-Graded Asphalt Binder Using Multiple Stress Creep Recovery (MSCR) Test . E Mixture Design E.1 General Design Design the mixture in conformance with AASHTO R 46 Standard Practice for Designing Stone Matrix Asphalt (SMA). Additional information on SMA mix design is found in Appendix B of the National Asphalt Pavement Association quality information Series 122, Designing and Constructing SMA Mixtures State-of-the-Practice. Use Laboratory Manual Method 1816 (Corelok) to determine mixture bulk specific gravity. E.2 Aggregate At least 15 Calendar Days before beginning production, submit to the District Materials Laboratory a minimum of 100 pounds for Aggregate quality testing. At least 30 Calendar Days prior to production, submit to the District Materials Laboratory 100 pounds of each Aggregate that require magnesium sulfate soundness testing. At least 7 Working Days prior to the start of asphalt production, submit a minimum of 150 pounds of the coarse Aggregate fraction from the selected design blend (JMF). This fraction will be tested for the voids in coarse Aggregate (VCAdrc) (Laboratory Manual Method 1211 & AASHTO T19 Standard Method of Test for Buk Density (“Unit Wight”) and Voids in Aggregate). E.3 Mixture Sample At least 7 Working Days before the start of asphalt production, submit the proposed job mix formula (JMF) in writing and signed by a Level II Quality Management Mix Designer for each combination of Aggregates to be used in the mixture. Include test data to demonstrate conformance to mixture properties as specified in Table 2365.2-1, Table 2365.2-2 and Table 2365.2-5. Use forms approved by the Department for the submission . Submit the design as a laboratory mix design (Option 1). Submit an uncompacted mixture sample plus briquettes, in conformance with the JMF, compacted at the optimum asphalt content and required compactive effort for laboratory examination and evaluation. Provide a mixture sample size and the number of compacted briquettes and in accordance with the following:

Table 2365.2-3 Stone Mastic Asphalt Mixture Sample Requirements Item Gyratory Design Uncompacted mixture sample size 75 pounds Number of compacted briquettes 2 Coarse Aggregate fraction 150 pounds F Mixture Moisture Sensitivity F.1 Tensile Strength Ratio At least 7 Working Days before actual production, submit sample to the District Materials Laboratory for verification of moisture sensitivity retained tensile strength ratio (TSR) . The Engineer may test Material submitted for TSR verification for maximum specific gravity

the tested Material fails to meet the Gmm tolerance. If the Engineer rejects a mix design, resubmit a new mix design as described above. The Contractor may use one of the following options to verify that the TSR meets the requirements in Table 2365.2-5. F.1.a Option A Batch Material at the design proportions including optimum asphalt . Split the sample before curing and allow samples to cool to room temperature, approximately 77°F. Submit 80 pounds of mixture to the District Materials Laboratory for curing and test verification. Use a cure time of 2 hours ±15 minutes at 290°F cure time for both groups and follow Laboratory Manual Method 1813 procedures. F.1.b Option B Batch and cure in accordance with Option A. Compact and submit briquettes and uncompacted mixture in accordance with Table 2365.2-4. Table 2365.2-4 Option B Mixture Requirements Item Gyratory Design Uncompacted mixture sample size 8,200 G Number of compacted briquettes* 6 Compacted briquette air void content 5.5 – 6.5 percent * 6-inch specimens.

G Mixture Requirements The Department will base initial mixture evaluation on the trial mix tests in accordance with Table 2365.2-5 and Table 2365.2-6.

Table 2365.2-5 Stone Matrix Asphalt Mixture Requirements Item Gyratory Design Gyrations for Ndesign 75 Air Voids, percent -- wear 4.0 percent Fines/effective asphalt 1.2-2.0 Tensile strength ratio, min percent 70 VMA, percent 17.0 VFA, percent -- wear 70-80 Draindown - based on a 1 hour reading at the anticipated production temperature < 0.3 percent Stabilizer by weight of total mix, percent 0.2 – 0.4 VCA ratio VCAMIX<VCADRC Minimum asphalt requirement, percent by weight of mix See Table 2365.2-6 G.1 Minimum Asphalt Content Asphalt content is established based on the combined Aggregate bulk specific gravity, (Gsb). Use Table 2365.2-6 to determine the minimum asphalt content. Table 2365.2-6 Stone Matrix Asphalt Minimum Asphalt Content Combined Aggregate Bulk Specific Gravity Minimum Asphalt Content, Percent <2.400 6.8 2.401-2.450 6.7 2.451-2.500 6.6 2.501-2.550 6.5 2.551-2.600 6.3 2.601-2.650 6.2 2.651-2.700 6.1 2.701-2.750 6.0 2.751-2.800 5.9 2.801-2.850 5.8 2.851-2.900 5.7 2.901-2.950 5.6 2.951-3.000 5.5 G.2 Documentation Include the following documentation and test results for each JMF submitted for review.

production

0.1 percent) of Aggregate passing each of the specified Sieves for each Aggregate to be incorporated into the mixture

Aggregate

dry Aggregate) of both coarse and fine Aggregate, for each product used in the mixture (including RAP/RAS). Use Laboratory Manual Method 1204 and 1205. The tolerance allowed between the Contractor's and the Department's specific gravities are Gsb (individual) = 0.040 (+4 and -4) and Gsb (combined) = 0.020

proportions showing compliance with Table 2365.2-2:

(pound/feet cubed), voids in the Coarse Aggregate-Dry Rodded Condition (VCADRC) according to AASHTO T19. The VCA ratio (VCAmix/VCADRC) shall be less than 1.0, i.e. VCAmix< VCADRC

the mixture and the PG grade

contents in increments of 0.5 percent with at least one point above and one point below the optimum asphalt binder percentage

Determination of Draindown Characteristics in Uncompacted Asphalt Mixtures) on loose mix

content based on the average of the effective specific gravities measured by using at least two maximum specific gravity tests at the asphalt contents above and below the expected optimum asphalt binder content

for the individual and average bulk specific gravities, density, and heights

0.1 percent

VCA ratio of less than 1.0

G.3 Mixture Design Report The Department will issue an initial Mixture Design Report (MDR) consisting of the JMF after review of the submitted design. The review will include the Department’s test results submitted Aggregate and mixture. A preliminary MDR will provide the JMF limits to begin production of a test strip. G.4 Initial SMA Test Strip Verification Do not begin full-scale production of the SMA mixture until it is shown, in a test strip, that the mixture can be produced, placed, and compacted to the requirements of this Specification. Limit the test strip to 500 tons with a minimum requirement of 200 tons placed at the specified thickness and width indicated in the Contract. During construction of the test strip take a minimum of 2 mixture samples to determine mixture properties as shown in the Production Start-Up Testing Rate table shown above. Take 1 sample within the first 100 tons of mixture produced and the other randomly within the remaining mixture produced. After both samples are obtained cease production of the SMA until mixture properties are tested and evaluated by both the Contractor and the Department. Resume production when:

testing tolerances shown in Table 2365.2-7

as indicated on the Mixture Design Report. Air voids must fall within 1.5 times the JMF limit

in the table for SMA mixture requirements If the Material in the test strip does not meet the requirements listed above another test strip will be required. With the approval of the Engineer, the test strip may be placed within the Project limits. A final MDR will be issued once the test strip meets Specification requirements. H Mixture Quality Management H.1 Quality Control Perform Quality Control (QC) as part of the production process. QC is the process control of the operations related to mixture production and determining the quality of the mixture being produced. The QC sample is the Contractor’s sample taken and tested during production and used to control the production process . Provide and maintain a QC program for stone matrix asphalt pavement production, including mix design, process control inspection, sampling and testing, and adjustments in the process related to t he production of the stone matrix asphalt pavement. H.2 Plant Certification Provide the following to obtain certification:

passed as documented by Asphalt Plant Inspection Report (TP 02142-02, TP 02143-02). The inspection report must also include documentation showing plant and laboratory Equipment has been calibrated and is being maintained to the tolerance shown in the Bituminous Manual and sections 1200, 1800, and 2000 of the Laboratory Manual.

H.3 Quality Assurance The Engineer will perform Quality Assurance (QA) as part of the acceptance process. QA is the process of monitoring and evaluating various aspects of the Contractor’s testing as described below. The QA sample is the Department’s companion sample to the Contractor’s QC sample. QA testing is performed to accept the Work. The Engineer will perform the following:

basis

H.4 Verification Sample The Department will take at least one random sample daily and call this the verification sample. The Department will provide the Contractor a verification companion, which is defined as a companion sample to the verification sample Department uses. Take all verification samples from the truck box at the plant site. Test and use this verification companion sample as part of the QC program. Use the verification companion sample to replace the next scheduled QC sample. The Department recommends sampling enough Material to accommodate retesting in case the samples fail. Perform verification testing on at least one set of production tests daily to verify the requirements of Table 2365.2-1, Table 2365.2-2, and Table 2365.2-5. Compare the verification companion sample to the verification sample for compliance with allowable tolerances in Table 2365.2-7. The Department will consider the verification process complete if the Contractor’s verification companion meets the tolerances in Table 2365.2-7. If the tolerances between the Contractor’s verification companion and the Department’s verification sample do not meet the requirements of Table 2365.2-7, the Department will retest the Material. If the retests fail to meet tolerances, the Department will substitute the Department's verification test results for the Contractor’s results in the QC program and use those results for acceptance. Table 2365.2-7 Allowable Differences between Contractor and Department Test Results Item Allowable Difference Mixture bulk specific gravity (Gmb) 0.030 Mixture maximum specific gravity (Gmm) 0.019 VMA 1.2 Coarse Aggregate angularity, percent fractured faces (percent P) 15 Asphalt binder content: Ignition oven percent 0.3 Gradation Sieve, percent passing: 3/4 inch, 1/2 inch, 3/8 inch 6 No. 4 5 No. 8 4 No. 200 2.0

I Contractor Quality Control Provide QC technicians certified as a Level I Bituminous Quality Management (QM) Tester meeting the requirements of the MnDOT Technical Certification Program for QC testing and Level II Bituminous QM Mix Designer to make process adjustments. Provide at lea st one person per paving operation certified as a Level II Bituminous Street Inspector. Provide a laboratory with Equipment and supplies for Contractor Quality Control testing and maintain with the following:

of Equipment

machine if internet and email are available

Laboratory Equipment needs to meet the requirements listed in Section 430.1 of the Bituminous Manual, Laboratory Manual, and these Specifications, including having extraction capabilities. Before beginning production, the laboratory Equipment needs to be calibrated and operational. J Sampling and Testing Take QC/QA samples from the truck box at the plant site. Sample randomly and in accordance with the Schedule of Materials Control and this provision. QC/QA samples are to be quartered from a larger sample of mixture. In order to account for asphalt absorption, the sample needs to be kept heated at the compaction temperature for 30 minutes before splitting and batching into test portions. The procedure for truck box sampling is on the Bituminous Office website. Store compacted QC mixture specimens and loose QC and Department’s QA mixture companion samples for 10 Calendar Days. Label these split companion samples with companion numbers. Determine random numbers and locations using the Bituminous Manual, Section 720 or ASTM D3665, Standard Practice for Random Sampling of Construction Materials, Section 5. K Start-Up and Production Test Rates K.1 Start-Up Testing Rates At the start of production, for the first 2,000 tons of mix, perform testing at the following frequencies:

Table 2365.2-8 Stone Matrix Asphalt Production Start-Up Testing Rates Production Test Testing Rates Lab Manual Method & AASHTO number Bulk specific gravity 1 test per 500 tons 1816 (Corelok) ǁ Maximum specific gravity 1 test per 500 tons 1807 ǁ Air voids (calculated) 1 test per 500 tons 1808 ǁ Asphalt content 1 test per 500 tons 1852 & 1853 ǁ VMA (calculated) 1 test per 500 tons AASHTO R46 & SP 2 Gradation 1 test per 500 tons 1203 ǁ Fines to effective AC (calculation) 1 test per 500 tons Fine Aggregate angularity* 1206 ǁ Coarse Aggregate angularity 1 test per 1000 tons 1214 ǁ VCA ratio (calculation) 1 test per 500 tons AASHTO R46 & T19 Draindown 1 test per 500 tons AASHTO T305 * No FAA requirement, however, fine Aggregate shall be 100 percent crushed. ǁ Laboratory Manual Method K.2 Production Test Rates After producing the first 2,000 tons of each mix type test at the following frequencies: Table 2365.2-9 Stone Matrix Asphalt Production Testing Rates Production Test Sampling/Testing Rates Lab Manual Method & AASHTO number Bulk specific gravity 1 test per 1000 tons 1816 (Corelok) ǁ Maximum specific gravity 1 test per 1000 tons 1807 ǁ Air voids (calculated) 1 test per 1000 tons 1808 ǁ Asphalt content 1 test per 1000 tons 1852 & 1853 ǁ VMA (calculated) 1 test per 1000 tons AASHTO R46 & SP 2 Gradation 1 test per 1000 tons 1203 ǁ Fines to effective AC (calculated) 1 test per 1000 tons AASHTO R46 & SP 2 Coarse Aggregate angularity 2 tests/day for a minimum of 2 Working Days, then 1 per day if CAA is met. If CAA >8 percent of requirement, 1 sample/day but test 1/week. 1214 ǁ Fine Aggregate angularity (FAA)* 1206 ǁ TSR As directed by the Engineer 1813 ǁ Aggregate SpG & absorption As directed by the Engineer 1204, 1205 ǁ Mixture moisture content As directed by Engineer 1855 ǁ Asphalt binder Sample 1st load then 1 per 250,000 gallon -sample size 1 quart

5-693.920ǁ

Draindown 1 test per day AASHTO T305 VCA ratio (calculated) 1 test per 1000 tons AASHTO R46 * No FAA requirement, however, fine Aggregate shall be 100 percent crushed. ǁ Laboratory Manual Method

L Documentation: Maintain documentation, including test summary sheets and control charts, on an ongoing basis . File reports, records, and diaries developed during the Work as directed by the Engineer. These documents become the property of the Department. Number test results in accordance with the MDR and record on forms approved and provided by the Department. Include the following production test results and mixture information on the Department approved test summary sheet:

Submit copies of failing test results to the Engineer on a daily basis. Provide the Engineer with asphalt manifests or bill of ladings (BOL) on a daily basis. Provide a daily plant diary, including a description of QC actions taken. Include changes or adjustments on the test summary sheets. Provide an automated weigh Scale and computer generated weigh ticket. Ensure the ticket indicates the Project number, mix designation (including binder grade), mixture design report number, truck identification and tare, net mass, and date and time of loading. Furnish an electronic printout (long form recordation) from an automated plant blending control system at 20 minute intervals when the plant is producing mixture. The Engineer may waive this requirement if the plant does not have the capability to produce the automated blending control information; however, the Contractor must then perform daily spotchecks to determine percent new asphalt added. L.1 Drum Plant Requirements Include the following information on the plant control printout for d rum plants:

produced at time of printout Provide a daily electronic printout of the plant calibration (SPAN) numbers for each bin and meter. M JMF Limits Table 2365.2-10 Stone Matrix Asphalt JMF Limits (N=4) Item JMF Limits Production air voids, percent ±1.0 Asphalt binder content, percent ±0.4 VMA -0.3 Sieve - percent Passing 3/4 inch, 1/2 inch, 3/8 inch ± 4 No. 4, No. 8 ± 3 No. 200 ± 2.0

The mixture production targets and JMF limits are listed on the Mixture Design Report. JMF limits are used as the criteria for acceptance of Materials based on individual (single) test results. Gradation JMF limits are not allowed outside the broadband requirements in Table 2365.2-1 M.1 Moving Average Calculation Calculate a moving average as the average of the last four test results . Continue the calculation without interruption, except begin new summary sheets and charts annually for winter carry-over Projects and if an asphalt plant is reset up in the same site after it has been moved out. M.2 JMF Bands JMF Bands are the area between the target, as identified on the Mixture Design Report, and the JMF limits. N JMF Adjustment Begin mixture production with Materials within 5 percent of the design proportions and other mixture parameters within the JMF limits in accordance with Table 2365.2-10 for gradation, asphalt content, and Aggregate proportions meeting the requirements of the reviewed Mixture Design Report . Use all Aggregate proportions meeting the requirements of the Mixture Design Report unless the Aggregate proportion is 0 percent. O JMF Request for Adjustment Make a request to the Bituminous Engineer or District Materials Engineer for a JMF adjustment to the mix design if the QC test results indicate a necessary change to achieve the specified properties . Do not use Aggregates or Materials not part of the original mix design to make adjustments unless otherwise approved by the Engineer, in conjunction with the District Materials Engineer or the Department Bituminous Engineer. A Certified Level II Bituminous QM Mix Designer will review the requested change for the Department. If the request meets the design requirements in Table 2365.2-1, Table 2365.2-2, and Table 2365.2-5, the Department will issue a revised Mixture Design Report .

Use an interactive communication process with the Engineer before making JMF adjustments . Make JMF adjustments only within the mixture specification gradation design broadbands in accordance with Table 2365.2-1. Submit a new JMF if redesigning the mixture. The Department will not allow consecutive requests for a JMF adjustment without production data. P Failing Materials – Gradation, Coarse Aggregate Angularity, Air Voids, VMA, and Percent Asphalt Binder Material acceptance is based on individual and moving average test results . Use isolated test results for acceptance of air voids and VMA at the start of mixture production . The Department will consider individual test results greater than two times the JMF bands as failing . The Department will fail moving average test results exceeding the JMF limits. Stop production and make adjustments if the moving average values exceed the JMF limits . Restart production after performing the adjustments and notifying the Engineer . Resume testing at the accelerated rates and for the tests listed in Table 2365.2-8, for the next 2,000 tons of mixture produced. Continue calculating the moving average after the stop in production. The Department will consider mixture produced where the moving average of four exceeds the JMF limits as unsatisfactory in accordance with 2365.2P.3, “Moving Average Failure at Mixture Start-Up – Production Air Voids,” 2365.2P.4, “Moving Average Failure at Mixture Start-Up — VMA,” 2365.2P.5, “Moving Average Failure - Production Air Voids,” and 2365.2P.6, “Moving Average Failure — Percent Asphalt Binder Content, VMA, and Gradation.” P.1 Isolated Failures at Mixture Start-Up – Production Air Voids At the start-up of mixture production, use the first three isolated test results for production air voids before establishing a moving average of four. Calculate isolated production air voids using the maximum mixture specific gravity and the corresponding bulk specific gravity from that single test. After testing four samples and establishing a moving average of four, the Department will base acceptance on individual and moving average production air voids. The Department will not accept the Material if any of the first three isolated test results for production air voids exceeds twice the JMF bands from the target listed on the Mixture Design Report at the start of production. P.2 Individual Failure at Mixture Start-Up– VMA At the start-up of mixture production, before a moving average of four can be established, the first three individual test results for VMA will be used for acceptance. After four samples have been tested and a moving average of four can be established, acceptance will be based on individual and moving average VMA. If, at the start of production, any of the first three individual VMA test results exceeds twice the JMF bands from the target listed on the Mixture Design Report, the Material is considered unsatisfactory or unacceptable. P.3 Moving Average Failure at Mixture Start-Up – Production Air Voids If a moving average failure occurs within any of the first three moving average results after mixture start-up (tests four, five, and six), the Department will accept the mixture if the individual air void, corresponding to the moving average failure meets the JMF limits . The Department will not accept Material if the individual air void fails to meet the JMF limit. The Department may apply a monetary deductions for unacceptable Material unless the Engineer determines that the isolated air void corresponding to the individual air void meets the JMF limit.

P.4 Moving Average Failure at Mixture Start-Up – VMA When a moving average failure occurs within any of the first 3 moving average results after mixture start-up (tests 4, 5, and 6), the mixture will be considered acceptable if the individual VMA, corresponding to the moving average failure is within the JMF limits . If the individual VMA is not within the JMF limit, the mixture will be considered unacceptable and the Engineer will decide whether the mixture is subject to removal and replacement or a monetary deduction. If the mixture is to be removed and replaced, the Contractor will perform the Work at Contractor’s expense. P.5 Moving Average Failure – Production Air Voids A moving average production air void failure occurs when the individual production air void moving average of four exceeds the JMF limit. The Department will consider the mixture unacceptable and subject to a monetary deduction. P.6 Moving Average Failure – Percent Asphalt Binder Content, VMA, and Gradation For mixture properties including asphalt binder content, VMA, and gradation, where the moving average of four exceeds the JMF limits, the mixture is considered unacceptable and the Engineer will decide whether the mixture is subject to removal and replacement or reduced payment. If the mixture is to be removed and replaced, the Contractor will perform the Work at Contractor’s expense. P.7 Coarse Aggregate Crushing Failure If any CAA test results do not meet the requirements specified in Table 2365.2-2, the Department may reduce payment for the placed Material in accordance with Table 2365.5-1.

2365.3CONSTRUCTION REQUIREMENTS

A Restrictions A.1 Asphalt Release Agents Do not use petroleum distillates to prevent adhesion of asphalt mixtures to E quipment. An asphalt release agent must meet the criteria for “Effect on Asphalt” as described in the most recent Asphalt Release Agent on file in MnDOT’s Office of Environmental Services . Drain excess release agents from truck boxes prior to loading. A.2 Edge Drop Off Protect traffic from drop-off conditions when traffic is carried during construction. Drop - off conditions are covered in the most current Minnesota Temporary Traffic Control Field Manual. A.3 Surge and Storage Bins Store the asphalt mixture for no more than 1 hour at storage facilities that prevent segregation of the mix and drainage of asphalt from the mix. Maintain the mixture at within 9°F of the temperature when discharged from the silo or mixer and prevent excessive cooling or overheating. A.4 Weather Limitations and Paving Date Do not perform Work within the Roadway in the spring until removal of seasonal load restrictions on roads in the vicinity unless otherwise approved by the Engineer . Do not place SMA when weather or Roadbed conditions or moisture conditions of the Roadway surface are judged unfavorable by the Engineer. Place SMA mixtures only when the ambient air temperatures are at least 50 °F.

A.5 Mixing and Discharge of Materials Notify the Engineer of the recommended mixing temperatures as provided from the asphalt supplier. Unless authorized by the Engineer, do not produce the mixture more than 30 °F above the recommended maximum mixing temperature. Use the automated plant control printout to monitor discharge temperature. The Department will not pay for or allow placement of any mixture produced at more than 30°F above the recommended maximum mixing temperature unless authorized by the Engineer. A.6 Asphalt Binder Sampling Valve Obtain asphalt binder samples from a sampling valve located between the pump and the drum. Sample each type of asphalt binder used in mixture production after 50 tons of mixture has been produced, then sample at a rate of one per 250,000 gal. A minimum of 1 gallon of binder must be drawn and wasted from the sampling valve before the actual sample is drawn . Provide a 1-quart sized sample. The Inspector will monitor the sampling the Contractor performs . Record sample information on an Asphalt Sample Identification Card. Submit the sample to the Central Materials Laboratory. Contact the Chemical Laboratory Director for disposition of failing asphalt binder samples. B Distributor ................................................................................................................. 2360.3B.2.d C Tack Coat Apply a uniform asphalt tack coat to the clean and dry existing asphalt or concrete surface and to the surface of each course or Lift constructed, except for the final course or Lift, in accordance with 2357, “Bituminous Tack Coat.” Coat the contact surfaces of all fixed Structures and the edge of the in-place mixture in all courses at transverse joints and in the wearing course at longitudinal joints . A uniform application will not have streaks (corn rows), bare spots, puddles, or other irregular patterns . Allow emulsified asphalt tack coats to break, as indicated by a color change from brown to black, before placing subsequent Lifts. Take tack coat samples from the asphalt distributor according to rates provided in the Schedule of Materials Control. The Inspector will monitor the sampling the Contractor performs. D Rollers D.1 Steel-Wheeled Rollers Use self-propelled steel wheeled compacting Equipment weighing at least 8 tons. D.2 Pneumatic Tired Rollers Self-propelled pneumatic tired compacting Equipment is only allowed when approved by the Engineer. E Compaction After spreading each course, compact in accordance with the Maximum Density method as described below, unless the ordinary compaction method is otherwise specified in the S pecial Provisions. Do not allow rollers to stand on the uncompacted mixture or newly rolled pavement with a surface temperature greater than 140°F. To maintain a true surface, correct the following by removing and replacing the Material in the defective areas as directed by the Engineer at no additional cost to the Department:

operations

E.1 Maximum Density Compact the pavement to at least the minimum required Maximum Density values in accordance with Table 2365.3-1. Table 2365.3-1 Required Minimum SMA Lot Density All SMA Mixtures percent Gmm 93.0 E.1.a Density Determination (Core Bulk Density) Calculate each individual lot’s Maximum Density by averaging the results of the cores within the lot expressed as the percentage of the maximum specific gravity . Use Laboratory Manual Method 1816, Corelok, to determine core density. E.1.b Timeline Complete compaction within 8 hours of mixture placement and before obtaining core samples. Only use pneumatic tired or static steel rollers for compaction performed between 6 hours and 8 hours after mixture placement. Do not reroll compacted mixtures with deficient densities. E.1.c Stop Production If all the lots in a day’s production or greater than 50 percent of the lots on multiple days fail to meet the minimum density requirement stop production and determine the source of the problem. Discuss with the Engineer what corrective action will be taken to bring the Work into compliance with specified minimum required density. E.1.d Lot Determination Table 2365.3-2 Lot Determination Daily Production, tons Lots 300* – 600 1 601 – 1,000 2 1,001 – 1,600 3 1,601 – 2,600 4 2,601 – 4,600 5 > 4,600 ǁ * If producing no greater than 300 tons of mix, establish the first lot when the total weight is greater than 300 tons. ǁ Add one lot for each additional 900 tons or part thereof. E.1.e Mat Density Cores Obtain four cores in each lot. Take two cores from random locations as directed by the Engineer. Take the third and fourth cores, the companion cores, within one foot longitudinally from the first two cores. Submit the companion cores to the Engineer immediately after coring and sawing. If the random core location falls on a longitudinal joint, cut the core with the outer edge of the core barrel one foot away laterally from the edge of the top of the mat. Do not take cores for compacted mat density within one foot of any longitudinal joint. The Contractor is responsible for maintaining traffic, coring, patching the core holes within 24 hours, and sawing the cores to the paved lift thickness before density testing.

The Engineer may require additional density lots to isolate areas affected by Equipment malfunction, heavy rain, or other factors affecting normal compaction operations. E.1.f Contractor Core Testing Take and test cores at least 4 inches in diameter at locations determined and marked by the Engineer. Mark samples with the lot number and core number or letter. Transport the cores to the laboratory daily taking care to prevent damage to them . Schedule the approximate time of testing during normal Project Work Hours to allow the Engineer to observe the test and to record the Corelok testing of the cores. Determine the density by the end of the next Working Day after compaction. Measure each core three times for thickness before saw cutting. Report the average Lift thickness on the core sheet. If placing multiple Layers in a single day, saw and separate cores for each Layer, test, and report by the end of the next Working Day. The Contractor is responsible for maintaining traffic, coring, patching the core holes within 24 hours, and sawing the cores to the paved Lift thickness before density testing. E.1.g Companion Core Testing The Department will select at least one of the two companion cores per lot to test for verification. E.1.h Tolerance Comparison E.1.h(1) Tolerance Comparison – Individual Compare the individual core bulk specific gravities obtained by the Contractor and by the Department. If the bulk specific gravity between the Contractor and the Department cores differ by more than 0.030, use the Department’s bulk specific gravity. E.1.h(2) Tolerance Comparison – Day’s Shrinking Tolerance For a second comparison of the cores that pass the individual tolerance criteria, compare the average of the Contractor’s bulk specific gravities with the average of the Department’s bulk specific gravities . Determine the tolerance by dividing 0.030 by the square root of the number of samples compared. Use all the Department’s results for the day’s paving if the cores do not fall within the determined tolerance. E.1.i Recoring The Engineer may allow the Contractor to recore a sample if the sample was damaged in the coring process or damaged in transit to the laboratory through no fault of the Contractor. F Surface Requirements After compaction, the finished surface of each Lift shall be reasonably free of segregated, open and torn sections, and shall be smooth and true to the grade and cross -section shown on the Plans with the following tolerances:

Table 2365.3-3 Surface Requirements Course/Location Description Tolerance Wear Tolerance of final 2 lifts from the edge of a 10 foot straightedge laid parallel to or at right angles to the centerline. 1/4 inch Transverse joints/construction joints Tolerance from the edge of a 10 foot straightedge centered longitudinally across the transverse joint. Correction by diamond grinding required unless approved by the Engineer. 1/4 inch 20 foot pavement section excluded from IRI and ALR testing in Table 2399.3-2 Tolerance from the edge of a 10 foot straightedge placed parallel to or at right angles to centerline. Does not include measurement at terminal header, Bridge deck, and approach panels. Corrective Work required unless approved by the Engineer. 1/4 inch Transverse Slope Tolerance for surface of each Lift exclusive of final Shoulder wear. Not to vary by more than 0.4 percent from Plans Distance from edge of each Lift and established centerline No less than the Plan distance or more than 3 inches greater than the Plan distance. The edge alignment of the wearing Lift on tangent sections and on curve sections of 3 degrees or less cannot deviate from the established alignment by more than 1 inch in any 25 foot section. See Description Final wear adjacent to concrete pavements After compaction the final Lift wear adjacent to concrete pavements must be slightly higher but not to exceed 1/4 inch than the concrete surface. See Description Final wear adjacent to fixed Structures After compaction the final Lift wear adjacent to gutters, manholes, pavement headers, or other fixed Structures must be slightly higher but not to exceed 1/4 inch higher than the surface of the Structure. See Description Finished surface of each Lift Must be free of segregated, open and torn sections and deleterious material. See Description Finished surface No flushing or “fat” spots See Description

Cut or saw and then remove and replace Material placed outside the described limitations at no additional cost to the Department. F.1 Lift Thickness After compaction, the thickness of the SMA will be within a tolerance of 1/4 inch of the thickness shown on the Plans. The Engineer may require removal and replacement of any part of any Lift that is constructed to less than the minimum required thickness, at no additional cost to the Department. Measure cores taken for density determination for thickness also . Measure each core three times for thickness before sawing. Report the average of these three measurements. Document each lot's average core thickness and submit to the Engineer. If the average of the two Contractor cores exceed the specified tolerance, an additional two cores may be taken in the lot in question. The Engineer will use the average of all core thickness measurements per day per L ift to determine daily compliance with thickness Specifications.

On that portion of any Lift constructed to more than the maximum permissible thickness, the Materials used in the excess mixture above that required to construct that portion of the Lift to the Plan thickness plus 1/4 inch may be excluded from the pay quantities or at the discretion of the Engineer and at the Contractor's expense may be required to be removed and replaced.

2365.4METHOD OF MEASUREMENT

When paying for Material by weight, the Engineer will measure separately asphalt mixture of each type by weight based on the total quantity of Material hauled from the mixing plant. The Engineer will not make deductions for the asphalt Materials.

2365.5BASIS OF PAYMENT

The Contract Unit Price for asphalt mixture used in each course includes the cost of constructing the asphalt surfacing and providing and incorporating asphalt binder, mineral filler, and asphalt stabilizer. The Department will pay for additives required by the Contract at the relevant Contract Unit Price for the mixture. The Department will pay for additives incorporated as directed by the Engineer as Extra Work in accordance with 1402, “Contract Revisions.” If the Plans do not show a Contract Pay Item for Shoulder surfacing and other special construction, the Department will include payment for the quantities of Material used for these purposes in the payment for the wearing course Materials. Complete yield checks and monitor thickness determinations to construct the W ork as shown on the Plans. Use the tolerances for Lift thickness in accordance with Table 2365.3-3 for occasional variations and not for continuous over-running or under-running, unless otherwise required by the Engineer. A Monetary Adjustments The Department must apply Incentives and Disincentives and may apply monetary deductions for Stone Matrix Asphalt. The amounts of these adjustments are deemed reasonable. A.1 Isolated Failures at Mixture Start-Up – Production Air Voids The Department may apply monetary deductions for unacceptable Material in accordance with Table 2365.5-1. The Engineer will calculate the quantity of unacceptable Material on the tonnage placed from the sample point of the failing test to the sample point when the isolated test result is back within twice the JMF bands. If the failure occurs at the first test after the start of production, the Engineer will calculate the ton nage subject to monetary deduction as described above, including the tonnage from the start of production. If isolated air voids are less than 1.0 percent or greater than 7.0 percent, the Engineer will either calculate a monetary deduction or order the Material removed and replaced at no additional cost to the Department. The Engineer may require the Contractor to test in- place mixture to better define the removal and replacement limits. The Engineer may require the Contractor to test in-place mixture placed before the failing test result. If the Department applies a monetary deduction, the Department will pay for the Material at 50 percent of the Contract Unit Price.

A.2 Individual Failure – Gradation, Percent Asphalt Binder, Production Air Voids, and VMA Table 2365.5-1 Payment Schedule for Individual Test Results Item Payment Factor, percent * Gradation 95 VMA 85 Coarse Aggregate crushing 90 Asphalt binder content 90 Production air voids, individualǁ and isolated† 80 * Apply the lowest payment factor when using multiple reductions on a single test. ǁ Calculate individual air voids using the moving average maximum specific gravity and the bulk specific gravity from that single test. † Calculate the isolated air voids from the maximum specific gravity and the bulk specific gravity from that single test. The Engineer will only use isolated void test results for acceptance for the first three tests after mixture production start -up.

A.3 Individual Failure at Mixture Start-Up – VMA Monetary deductions as outlined in Table 2365.5-1 shall apply to all tonnage placed from the sample point of the failing test until the sample point when the test results are back within twice the JMF limits. When the failure occurs at the first test, after the start of production, the tonnage subjected to monetary deduction shall be calculated as described above and shall include the tonnage from the start of production. A.4 Moving Average Failure at Mixture Start-Up – Production Air Voids The Department may apply monetary deductions for unacceptable Material at 30 percent of the relevant Contract Unit Price. The Engineer will calculate the quantity of Material subject to monetary deduction as the tons placed from the sample point of the failing moving average result and corresponding individual air void beyond the JMF limit to the sampling point when the individual test result is back within the JMF limit. If the failure occurs at the first test after the start of daily production, the Engineer will include tonnage from the start of production that day with the tonnage subjected to the monetary deduction. A.5 Moving Average Failure at Mixture Start-Up – VMA Monetary deduction will be 25 percent of the Contract bid price. Tonnage subjected to replacement or monetary deduction shall be calculated as the tons placed from the sample point of the failing moving average result and corresponding individual VMA beyond the JMF limit to the sampling point when the individual test result is back within the JMF limit. A.6 Moving Average Failure – Production Air Voids The Department may apply monetary deductions for unacceptable mixture at 30 percent of the Contract Unit Price. The Engineer will calculate the quantity of mixture subject to monetary deduction as the tons placed from the sample point of all individual test results beyond the JMF limits, which contributed to the moving average value that exceeded the JMF limit, to the sampling point where the individual test result meets the JMF limits. If the failure occurs at the first test after the start of daily production, the Engineer will include the tonnage from the start of production that day with the tonnage subject to the monetary deduction.

Table 2365.5-2 Payment Schedule for Moving Average Test Results Item Monetary Deductions, percent * Gradation 10 Coarse and fine Aggregate crushing Not Applicable (individual failures only) VMA 20 Asphalt binder content 20 Production air voids 30 * Lowest Pay Factor applies when there are multiple reductions on a single test. A.7 Moving Average Failure – Percent Asphalt Binder Content, VMA, and Gradation Payment, percent of the Contract bid price, is shown in Table 2365.5-2. Tonnage subjected to replacement or monetary deduction is calculated as the tons placed from the sample point of all individual test results beyond the JMF limits which contributed to the moving average value that exceeded the JMF limit, to the sampling point when the individual test result is back within the JMF limits. When the failure occurs at the first test after the start of daily production, tonnage subjected to monetary deduction shall include the tonnage from the start of production that day. A.8 Coarse Aggregate Crushing Failure The Engineer will calculate the quantity of Material subject to monetary deduction as the tons placed from the sample point of the failing test until the sampling point where the test result meets the Specifications. If the failure occurs at the first test after the start of daily production, the Engineer will include the tonnage from the start of production that day with the tonnage subjected to the monetary deduction. A.9 Mat Density Cores The Department may apply monetary deduction of $100 per Working Day per lot until surface is restored. A.10 Maximum Density Determine Pay Factor for density in accordance with Table 2365.5-3. Table 2365.5-3 Pay Factor Schedule for Maximum Density Percent of Maximum Specific Gravity Pay Factor, Percent Above 97.0 98 93.0 – 97.0 100 91.0 – 92.9 98 89.0-90.9 95 Less than 89.0 remove and replace

A.11 Surface Requirements If the Engineer determines the Material can remain in-place outside the limits, the Department will pay for the Material at a monetary deduction of $10 per square yard. The Department will consider any single occurrence of Material outside the limitations to have a minimum dimension of at least 1 square yard in any dimension.

B Schedule The Department will pay for plant mixed SMA on the basis of the following schedule: Item No. Item Unit

2365.509 Type SM 12.5 Wearing Course Mixture (6,H) ton