NJDOT Standard Specifications Section 902: Asphalt

SECTION 902 – ASPHALT

902.01 Bituminous Materials

Use the following temperature-volume correction (TVC) factors to convert the volume of bituminous materials, measured at the temperature at the point of use, to the volume at 60 °F:

1.For PG Binder, use the following equation: TVC = 1.0211326242 − 3.548988118  10−4 [T (F)] + 4.49881  10−8 [T (F)]2

2.For emulsified asphalts, use Table 902.01-1. Table 902.01-1 TVC Factors for Emulsified Asphalt Material (40 – 103 °F) Temp (°F) Factor Temp (°F) Factor Temp (°F) Factor Temp (°F) Factor 40 1.0050 56 1.0010 72 0.9970 88 0.9930 41 1.0048 57 1.0008 73 0.9968 89 0.9928 42 1.0045 58 1.0005 74 0.9965 90 0.9925 43 1.0043 59 1.0003 75 0.9953 91 0.9923 44 1.0040 60 1.0000 76 0.9960 92 0.9920 45 1.0038 61 0.9998 77 0.9958 93 0.9918 46 1.0035 62 0.9995 78 0.9955 94 0.9915 47 1.0033 63 0.9993 79 0.9953 95 0.9913 48 1.0030 64 0.9990 80 0.9950 96 0.9910 49 1.0028 65 0.9988 81 0.9948 97 0.9908 50 1.0025 66 0.9985 82 0.9945 98 0.9905 51 1.0023 67 0.9983 83 0.9943 99 0.9903 52 1.0020 68 0.9980 84 0.9940 100 0.9901 53 1.0018 69 0.9978 85 0.9938 101 0.9899 54 1.0015 70 0.9975 86 0.9935 102 0.9896 55 1.0013 71 0.9973 87 0.9933 103 0.9884 104 0.9891 123 0.9845 142 0.9799 161 0.9754 105 0.9889 124 0.9843 143 0.9797 162 0.9751 106 0.9886 125 0.9840 144 0.9794 163 0.9749 107 0.9884 126 0.9838 145 0.9792 164 0.9747 108 0.9881 127 0.9835 146 0.9790 165 0.9744 109 0.9879 128 0.9833 147 0.9787 166 0.9742 110 0.9876 129 0.9830 148 0.9785 167 0.9739 111 0.9874 130 0.9828 149 0.9782 168 0.9737 112 0.9872 131 0.9826 150 0.9780 169 0.9735 113 0.9869 132 0.9823 151 0.9778 170 0.9732 114 0.9867 133 0.9821 152 0.9775 171 0.9730 115 0.9864 134 0.9818 153 0.9773 172 0.9728 116 0.9862 135 0.9816 154 0.9770 173 0.9725 117 0.9860 136 0.9814 155 0.9768 174 0.9723 118 0.9857 137 0.9811 156 0.9766 175 0.9721 119 0.9855 138 0.9809 157 0.9763 176 0.9718 120 0.9852 139 0.9806 158 0.9761 177 0.9716 121 0.9850 140 0.9804 159 0.9758 178 0.9713 122 0.9847 141 0.9802 160 0.9756 179 0.9711

902.01.01 Asphalt Binder

Use an asphalt binder that is storage-stable and conforms to AASHTO M 332. Include compliance with the elastic response requirement in Figure 1 of AASHTO R 92, if applicable. The asphalt binder producer shall provide the asphalt binder quality control plan annually to the ME for approval. Ensure that the quality control plan conforms to AASHTO R 26. Submit to the ME a certification of compliance, as specified in 106.07, for the asphalt binder. The ME will perform quality assurance sampling and testing of each asphalt binder lot as defined in the approved quality control plan.

902.01.02 Emulsified Asphalts

Use undiluted anionic emulsified asphalts of the rapid -setting (RS) and medium -setting (MS) types conforming to AASHTO M 140. Use undiluted cationic emulsified asphalts of the rapid -setting (CRS), quick -setting (CQS), and medium-setting (CMS) types conforming to AASHTO M 208. For prime coats, use an anionic emulsified asphalt of the slow-setting (SS) type conforming to AASHTO M 140 or cationic emulsified asphalt of the slow-setting (CSS) type confirming to AASHTO M 208. The emulsified asphalt producer shall provide the emulsified asphalt quality control plan annually to the ME for approval. Ensure that the quality control plan conforms to AASHTO R 77. Submit to the ME a certification of compliance, as specified in 106.07, for the emulsified asphalt. The ME will perform quality assurance sampling and testing of each emulsified asphalt lot as defined in the approved quality control plan.

902.01.03 Polymer Modified Emulsified Asphalt

Use undiluted polymer modified emulsified asphalt of the rapid-setting (RS), cationic rapid-setting (CRS), medium-setting (MS), and cationic quick-setting (CQS) types conforming to AASHTO M 316. The polymer modified emulsified asphalt producer shall provide the polymer modified emulsified asphalt quality control plan annually to the M E for approval. Ensure that the quality control plan conforms to AASHTO R 77. Submit to the ME a certification of compliance, as specified in 106.07, for the polymer modified emulsified asphalt. The ME will perform quality assurance sampling and testing of each polymer modified emulsified asphalt lot as defined in the approved quality control plan.

902.01.04 Warm Mix Asphalt (WMA) Additives and Processes

Use a WMA additive or process that is listed on the Northeast Asphalt User/Producer Group (NEAUPG) Qualified WMA Technologies List which can be found at the following website: http://www.neaupg.uconn.edu/. If an approved HMA mix design is used, a separate mix design with WMA additives or processes is not required. Submit information on the WMA additive or process with the Paving Plan required in 401.03.07.A. For controlled foaming systems, also submit the operating parameters of the system including accuracy of the meter, operating range, and temperature of the binder. Provide the target and operating tolerances for the percent water injection and temperatures for the binder. Provide a method for validating this with changing production rates. Ensure that a technical representative of the manufacturer is on-site or available for consultation for the first day or night of production.

902.02 Hot Mix Asphalt (Hma)

902.02.01 Mix Designations

The requirements for specific HMA mixtures are identified by the abbreviated fields in the Item description as defined as follows: HOT MIX ASPHALT 12.5ME SURFACE COURSE

1.“HOT MIX ASPHALT” “Hot Mix Asphalt” is located in the first field in the Item description for the purpose of identifying the mixture requirements.

2.“12.5” The second field in the Item description designates the nominal maximum size aggregate (in millimeters) for the job mix formula (sizes are 4.75, 9.5, 12.5, 19, 25, and 37.5 mm).

3.“M” The third field in the Item description de signates the design compaction level for the job mix formula based on traffic forecasts as listed in Table 902.02.03-2 (levels are L=low and M=medium).

4.“E” The fourth field in the Item description designates the high temperature designation of the performance - graded binder. Options are “64” for PG 64S-22 and “E” for PG 64E-22.

5.“SURFACE COURSE” The last field in the Item description designates the intended use and location within the pavement structure (options are surface, intermediate, or base course).

902.02.02 Composition of Mixtures

Provide materials as specified: Aggregates for Hot Mix Asphalt ................................ ................................ ................................ ................... 901.05 Asphalt Binder ................................ ................................ ................................ ................................ ......... 902.01.01 Warm Mix Asphalt (WMA) Additives and Processes (optional) ................................ ................................ 902.01.04 If a WMA additive is pre -blended in the asphalt binder, ensure that the asphalt binder meets the requirements of the specified grade after the addition of the WMA additive. If a WMA additive is added at the HMA plant, ensure that the addition of the additive will not negatively impact the grade of asphalt binder. Follow the manufacturer’s recommendations for percentage of WMA additive needed. Mix HMA in a plant that is listed on the QPL and conforms to the requirements for HMA Plants as specified in 1009.01. Composition of the mixture for HMA surface course is coarse aggregate, fine aggregate, and asphalt binder, and may also include mineral filler, WMA additive, and up to 15 percent Reclaimed Asphalt Pavement (RAP). For controlled asphalt foaming system WMA, the Department may require an anti -stripping additive. Ensure that the finished mix does not contain more than a total of 1 percent by weight contamination from Crushed Recycled Container Glass (CRCG). The composition of the mixture for HMA base or intermediate course is coarse aggregate, fine aggregate, and asphalt binder, and may also include mineral filler, WMA additive and up to 35 percent of recycled materials. For controlled asphalt foaming system WMA, the Department may require an anti -stripping additive. The 35 percent of recycled materials may consist of a combination of RAP, CRCG, Ground Bituminous Shingle Material (GBSM), and RPCSA, with the following individual limits: Table 902.02.02-1 Use of Recycled Materials in HMA Base or Intermediate Course Recycled Material Maximum Percentage RAP 25 CRCG 10 GBSM 5 RPCSA 20 Combine the aggregates to ensure that the resulting mixture meets the grading requirements specified in Table 902.02.03-1. In determining the percentage of aggregates of the various sizes nec essary to meet gradation requirements, exclude the asphalt binder. Ensure that the combined coarse aggregate, when tested according to ASTM D 4791, has less than 10 percent flat and elongated pieces retained on the No. 4 sieve and larger. Measure aggregat e using the ratio of 5:1, comparing the length (longest dimension) to the thickness (smallest dimension) of the aggregate particles. Ensure that the combined fine aggregate in the mixture conforms to the requirements specified in Table 902.02.02-2. Ensure that the material passing the No. 40 sieve is non-plastic when tested according to AASHTO T 90. Table 902.02.02-2 Additional Fine Aggregate Requirements for HMA Tests Test Method Minimum Percent Uncompacted Void Content of Fine Aggregate AASHTO T 304, Method A 45 Sand Equivalent AASHTO T 176 45

902.02.03 Mix Design

Submit a mix design including a job mix formula (JMF) for each mixture on forms supplied by the ME. Include a statement naming the source of each component and a report showing that the results conform to the criteria specified in Table 902.02.03-1, Table 902.02.03-2, and Table 902.02.03-3. If a change in sources or properties of materials occur, the ME may require the HMA producer to establish a new mix design and to obtain approval before production can continue. To establish the JMF for each mix design, determine the percentage of dry weight of aggregate passing each required sieve size and an optimum percentage of asphalt binder based upon the weight of the total mix. Determine the optimum percentage of asphalt binder according to AASHTO M 323 and R 35. Combine the aggregates to ensure that the resulting mixture conforms to the grading requirements specified in Table 902.02.03-1. In determining the percentage of aggregates of the various sizes necessary to conform to gradation requirements, exclude the asphalt binder. Table 902.02.03-1 HMA Mixtures Nominal Maximum Size of Aggregate – Grading of Total Aggregate Sieve Size Nominal Maximum Aggregate Size – Control Point (Percent Passing) 37.5 mm 25 mm 19 mm 12.5 mm 9.5 mm 4.75 mm Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. 2" 100 – – – – – – – – – – – 1 1/2" 90 100 100 – – – – – – – – – 1" – 90 90 100 100 – – – – – – – 3/4" – – – 90 90 100 100 – – – – – 1/2" – – – – – 90 90 100 100 – 100 – 3/8" – – – – – – – 90 90 100 95 100 No. 4 – – – – – – – – – 90 90 100 No. 8 15 41 19 45 23 49 28 58 32 67 – – No. 16 – – – – – – – – – – 30 60 No. 200 0 6 1 7 2 8 2 10 2 10 6 12 Table 902.02.03-2 Gyratory Compaction Effort for HMA Mixtures Compaction Level ESALs1 (millions) Ndes Nmax L  0.3 50 75 M ≥ 0.3 75 115

1.Design ESALs (Equivalent (80kN) Single-Axle Loads) refer to the anticipated traffic level expected on the design lane over a 20 year period. Table 902.02.03-3 HMA Requirements for Design Compaction Levels Required Density (% of Theoretical Max. Specific Gravity) Voids in Mineral Aggregate (VMA), % (minimum) Voids Filled With Asphalt (VFA)1 % Dust-to-Binder Ratio Nominal Max. Aggregate Size, mm @Ndes2 @Nmax 37.5 25.0 19.0 12.5 9.5 4.75 L 96.0 ≤ 98.0 11.0 12.0 13.0 14.0 15.0 16.0 70 – 80 0.6 – 1.2 M 96.0 ≤ 98.0 11.0 12.0 13.0 14.0 15.0 16.0 65 – 78 0.6 – 1.2

1.For 37.5 mm nominal maximum size mixtures, the specified lower limit of the VFA is 64 percent for all design traffic levels.

2.As determined from the values for the maximum specific gravity of the mix and the bulk specific gravity of the compacted mixture. Maximum specific gravity of the mix is determined according to AASHTO T 209. Bulk specific gravity of the compacted mixture is determined according to AASHTO T 166. For verification, specimens must be between 95.0 and 97.0 percent of maximum specific gravity at Ndes. For mix designs that include RAP or GBSM, also include the following based on the weight of the total mixture:

1.Percentage of RAP or GBSM.

2.Percentage of asphalt binder in the RAP or GBSM.

3.Percentage of new asphalt binder.

4.Total percentage of asphalt binder.

5.Percentage of each type of virgin aggregate. At the ME’s request, test the mix design to ensure that it meets a minimum tensile strength ratio of 80 percent, when tested according to AASHTO T 283. The ME will require tensile strength ratio testing for new aggregate sources and for aggregates or mixes suspected of stripping susceptibility. For each mix design, su bmit with the mix design forms 2 gyratory specimens and 1 loose sample corresponding to the composition of the JMF. The ME will use these to verify the properties of the JMF. Compact the specimens to the design number of gyrations (Ndes). For the mix design to be acceptable, all gyratory specimens must comply with the requirements specified in Table 902.02.03-1 and Table 902.02.03-3. The ME reserves the right to be present at the time the gyratory specimens are molded. The ME’s may verify a mix on an annual basis rather than on a project-to-project basis if the properties and proportions of the materials do not change. If written verification is submitted by the HMA supplier that the same source and character of materials are to be used, the ME may waive the requirement for the design and verification of pr eviously approved mixes.

902.02.04 Sampling and Testing

A.General Acceptance Requirements. The RE or ME may reject and require disposal of any batch or shipment that is rendered unfit for its intended use due to contamination, segregation, improper temperature, lumps of cold material, or incomplete coating of the aggregate. For other than improper temperature, visual inspection of the material by the RE or ME is considered sufficient grounds for such rejection. For PG 64S-22, ensure that the temperature of the mixture at discharge from the plant or surge and storage bins is at least 290 °F when the ambient temperature is less than 50 °F or is at least 275 °F when the ambient temperature is greater than or equal to 50 °F. For PG 64E-22, ensure that the temperature of the mixture at discharge from the plant or surge and storage bins is at least 10 °F above the manufacturer’s recommended laydown temperature. For mixes produced using a WMA additive or process, ensure that the temperature of the mixture at discharge from the plant or surge and storage bins is at least 10 °F above the WMA manufacturer’s recommended laydown temperature. Do not allow the mixture temperature to exceed 330 °F at discharge from the plant. Combine and mix the aggregates and asphalt binder to ensure that at least 95 percent of the coarse aggregate particles are entirely coated with asphalt binder as determined according to AASHTO T 195. If the ME determines that there is an ongoing problem with coating, the ME may obtain random sampl es from 5 trucks and will determine the adequacy of the mixing on the average of particle counts made on these 5 test portions. If the requirement for 95 percent coating is not met on each sample, modify plant operations, as necessary, to obtain the required degree of coating. If used, ensure that the equipment for controlled asphalt foaming system is running according to the manufacturer’s recommendations. Ensure that the metering of water to foam the asphalt is controlled to produce a uniform mixture.

B.Sampling. The ME will take a random sample from each 700 tons of production for volumetric acceptance testing and to verify composition. The ME will perform sampling according to AASHTO T 168 , NJDOT B -2, or ASTM D 3665. During production at the plant, a sample of asphalt binder will be taken once every 3,500 tons or as directed by the ME.

C.Quality Control Testing. The HMA producer shall provide a quality control (QC) technician who is certified by the Society of Asphalt Technologists of New Jersey as an Asphalt Technologist, Level 2. The QC technician may substitute equivalent technician certification by the Mid -Atlantic Region Technician Certification Program (MARTCP). Ensure that the QC technician is present during periods of mix production for the sole purpose of quality control testing and to assist the ME. The ME will not perform the quality control testing or other routine test functions in the absence of, or instead of, the QC technician. The QC technician shall perform sampling and testing according to the approved quality control plan, to keep the mix within the limits specified for the mix being produced. The QC technician may use acceptance test results or perform additional testing as necessary to control the mix. To determine the composition, perform ignition oven testing according to AASHTO T 308 and aggregate gradation according to AASHTO T 30. For each acceptance test, perform maximum specific gravity testing according to AASHTO T 209 on a test portion of the sample taken by the ME. Sample and test coarse aggregate, fine aggregate, mineral filler, and RAP according to the approved quality control plan for the plant. When using RAP, ensure that the supplier has in operation an ongoing daily quality control program to evaluate the RAP. As a minimum, this program shall consist of the following:

1.An evaluation performed to ensure that the material conforms to 901.05.04 and compares favorably with the design submittal.

2.An evaluation of the RAP material performed using a solvent or an ignition oven to qualitatively evaluate the aggregate components to determine conformance to 901.05.

3.Quality control reports as directed by the ME.

D.Acceptance Testing and Requirements. The ME will determine volumetric properties at Ndes for acceptance from samples taken, compacted, and tested at the HMA plant. The ME will compact HMA to the number of design gyrations (N des) specified in Table 902.02.03-2, using equipment according to AASHTO T 312. The ME will determine bulk specific gravity of the compacted sample according to AASHTO T 166. The ME will use the most current QC maximum specific gravity test result in calculating the volumetric properties of the HMA. The ME will determine the dust-to-binder ratio from the composition results as tested by the QC technician. Ensure that the HMA mixture conforms to the requirements specified in Table 902.02.04-1, and to the gradation requirements in Table 902.02.03-1. If 2 samples in 5 consecutive samples fail to conform to the gradation or volumetric requirements, immediately initiate corrective action. The ME will test a minimum of 1 sample per 3,500 tons for moisture, basing moisture determinations on the weight loss of an approximately 1,600 gram sample of mixture heated for 1 hour in an oven at 280 ± 5 °F. Ensure that the moisture content of the mixture at discharge from the plant does not exceed 1.0 percent. Table 902.02.04-1 Hot Mix Asphalt Requirements for Control Compaction Levels Required Density (% of Theoretical Max. Specific Gravity) Voids in Mineral Aggregate (VMA), % (minimum) Dust-to-Binder Ratio Nominal Max. Aggregate Size, mm @Ndes1 37.5 25.0 19.0 12.5 9.5 4.75 L, M 95.0 – 97.0 11.0 12.0 13.0 14.0 15.0 16.0 0.6 – 1.3

1.As determined from the values for the maximum specific gravity of the mix and the bulk specific gravity of the compacted mixture. Maximum specific gravity of the mix is determined according to AASHTO T 209. Bulk specific gravity of the compacted mixture is determined according to AASHTO T 166.

902.03 Open-Graded Friction Course (Ogfc) and Modified Open-Graded Friction

COURSE (MOGFC)

902.03.01 Composition of Mixtures

Mix OGFC and MOGFC in a plant that is listed on the QPL and conforms to the requirements for HMA plants as specified in 1009.01. Composition of mixture for OGFC and MOGFC is coarse aggregate, fine aggregate, and asphalt binder, and may include a WMA additive. Ensure that the mixture conforms to the following requirements:

1.Use aggregate for OGFC and MOGFC that conforms to 901.05, except, for coarse aggregate, use broken stone of gneiss, granite, quartzite, or trap rock. Do not use RAP, CRCG, GBSM, or RPCSA.

2.Use asphalt binder for OGFC and MOGFC that is PG 64E-22 as specified in 902.01.01.

3.If used, ensure that WMA additives or processes conform to 902.01.04. If a WMA additive is pre -blended in the asphalt binder, ensure that the asphalt binder meets the requirements of the specified grade after the addition of the WMA additive. If a WMA additive is added at the HMA plant, ensure that the addition of the additive will not negatively impact the grade of asphalt binder. Follow the manufacturer’s recommendations for percentage of WMA additive needed. For controlled asphalt foaming system WMA, the Department may require an anti-stripping additive.

4.For MOGFC, add a stabilizing additive consisting of mineral fiber or cellulose fiber to the mix. Use a stabilizing additive that conforms to the requirements for stabilizing additives in AASHTO M 325. Use only one type per mix design. If using mineral fibers, use a dosage rate of 0.4 percent by weight of total mix. If using cellulose fibers, use a dosage rate of 0.3 percent by weight of total mix. The dosage rate may be increased, as necessary, to prevent draindown as measured by the visual draindown determination of asphalt content in NJDOT B-8. Accurately control proportioning the fibers into the mixture within ±10 percent of the required weight, and use equipment that ensures uniform dispersion of the fibers. Store fibers in a dry location with a storage temperature not to exceed 120 °F. The supplier of the cellulose or mineral fibers shall provide a certification of compliance, as specified in 106.07, that the material supplied conforms to AASHTO M 325. Ensure that a technical representative from the additive supplier is at the work site for the first full day of construction for technical assistance.

902.03.02 Mix Design

Submit a mix design including JMF for each mixture on forms supplied by the Department. Include a statement naming the source of each component and a report with the results for the criteria specified in Table 902.03.03-1. Design the mix to meet the criteria in Table 902.03.03-1. In the JMF for each mixture, establish the percentage of dry weight of aggregate passing each required sieve size and an optimum percentage of asphalt binder based upon the weight of the total mix. Determine the optimum asphalt binder content for OGFC as specified in NJDOT B-7. Determine the optimum asphalt binder content for MOGFC as specified in NJDOT B-8. Ensure that the JMF is within the master range specified in Table 902.03.03-1. Prepare compacted test specimens for submittal to the ME at least 30 days before the initial production date. Prepare these specimens from m aterial mixed according to the final JMF, using 50 gyrations of the Superpave gyratory compa ctor according to AASHTO T 312. The ME will test 2 specimens to verify that the final JMF produces a mixture that has a minimum void content as specified in Table 902.03.03-1. The ME will determine percent air voids according to AASHTO T 209, and either NJDOT B-6 or AASHTO T 331. The ME will test 6 specimens according to AASHTO T 283, except for the following:

1.No specific air void level is required.

2.Compact specimens with 50 gyrations using the Superpave gyratory compactor.

3.Apply a vacuum of 26 inches of mercury for 10 minutes to saturate the compacted specimen. No specific saturation level is required.

4.Submerge the specimen in water during 1 freeze/thaw cycle. If the tensile strength ratio falls below 80 percent, adjust the mixture to satisfy the minimum req uirement. Adjustments may include the use of anti-stripping agents. For MOGFC only, the ME will test 2 test specimens for abrasion and impact resistance using a modified L.A. Abrasion Test according to NJDOT B-8. The maximum allowable loss as calculated by this method is 30 percent. Do not modify the JMF unless the ME approves the modification.

902.03.03 Sampling and Testing

Perform and meet require ments for quality control testing as specified in 902.02.04.C. Ensure that the mix meets the requirements as specified in 902.02.04.A, otherwise the RE or ME will reject the material. During production, the ME will take 1 random acceptance sample from each 700 tons of production to verify composition. Conduct air voids and draindown tests as directed by the ME. If the composition testing results are outside of the production control tolerances specified in Table 902.03.03-2 for an acceptance sample, immediately run a quality control sample. If the quality control sample is also outside of the control tolerances in Table 902.03.03-2, determine if a plant adjustment is needed and take corrective action to bring the mix into compliance. Take additional quality control samples after the corrective action to ensure that the mix is within the production control tolerances. If 2 conse cutive acceptance samples are outside the tolerances specified in Table 902.03.03-2, immediately stop production. Obtain ME approval of a plant correction plan before resuming production. Upon restarting production, do not transport mixture to the Project Limits before the results of a QC sample from the mixture indicate that the mixture meets JMF tolerances. The ME will reject mixture produced at initial restarting that does not meet tolerances. The ME will perform sampling according to NJDOT B-2 or ASTM D 3665, and will perform testing for composition according to AASHTO T 308 or NJDOT B-5. Perform testing for air voids according to AASHTO T 209 and either NJDOT B -6 or AASHTO T 331. Perform testing for draindown according to NJDOT B-7 or NJDOT B-8. During production at the plant, a sample of asphalt binder will be taken once every 3,500 tons or as directed by the ME. Table 902.03.03-1 JMF Master Ranges and Mixture Requirements Open-graded Friction Course Mixture Designations (% Passing1) Sieve Sizes OGFC – 9.5 mm MOGFC – 12.5 mm MOGFC – 9.5 mm 3/4" – 100 – 1/2" 100 85 – 100 100 3/8" 80 – 100 35 – 60 85 – 100 No. 4 30 – 50 10 – 25 20 – 40 No. 8 5 – 15 5 – 10 5 – 10 No. 200 2.0 – 5.0 2.0 – 5.0 2.0 – 4.0 Minimum asphalt binder, %1 5.5 5.7 6.0 Minimum % Air Voids, design 15% 20% 18% Minimum lift thickness, design 3/4" 1 1/4" 3/4"

1.Aggregate percent passing to be determined based on dry aggregate weight. Asphalt binder content to be determined based on total weight of mix. Table 902.03.03-2 Production Control Tolerances for OGFC and MOGFC Mixtures Sieve Sizes Production Control Tolerances from JMF1 1/2" 3.0 3/8" 4.0 No. 4 3.0 No. 8 1.0 No. 200 1.0 Asphalt Binder Content, % (AASHTO T 308)2 0.40 Asphalt Binder Content, % (NJDOT B-5)2 0.15 Minimum % Air Voids 1.0% less than design requirement

1.Production tolerances may not fall outside of the wide band gradation limits in Table 902.03.03-1.

2.The asphalt binder content may not be lower than the minimum after the production tolerance is applied.

902.04 Ultra-Thin Hma

902.04.01 Composition of Mixture

Mix ultra-thin HMA in a plant listed on the QPL conforming to the requirements for HMA plants specified in 1009.01. Use ultra-thin HMA that consists of coarse aggregate, fine aggregate, and polymer modified asphalt binder and that may contain mineral filler or a WMA additive. Do not add RAP, CRCG, GBSM, or RPCSA. Combine the material in such proportions that the total aggregate and asphalt binder conform to the composition percentages specified in Table 902.04.02-1. To produce the ultra-thin HMA, use aggregates and asphalt binder that conforms to the following:

1.For asphalt binder, use PG 64E-22 conforming to the requirements of 902.01.01.

2.If used, ensure that WMA additives or processes conform to 902.01.04. If a WMA additive is pre -blended in the asphalt binder, ensure that the asphalt binder meets the requirements of the specified grade after the addition of the WMA additive. If a WMA additive is added at the HMA plant, ensure that the addition of the additive will not negatively impact the grade of asphalt binder. Follow the manufacturer’s recommendations for percentage of WMA additive needed. For controlled asphalt foaming system WMA, the Department may require an anti-stripping additive.

3.For fine aggregate, use 100 percent stone sand conforming to 901.05.02. Ensure that the gradation conforms to Table 902.04.01 -1 and that the sand equivalent is more than 45 percent when tested according to AASHTO T 176. Table 902.04.01-1 Fine Aggregate Gradation Sieve Size Total % Passing By Mass 3/8″ 100 No. 4 95 – 100 No. 8 70 – 90 No. 16 50 – 70 No. 30 45 – 55 No. 50 25 – 40 No. 100 15 – 28 No. 200 10.0 – 17.0

4.Use coarse aggregate that conforms to 901.05.01 and Table 902.04.01-2. Permissible geologic classifications for coarse aggregate are gneiss, granite, quartzite, or trap rock. Ensure that the gradation con forms to Table 902.04.01-3. Table 902.04.01-2 Coarse Aggregate Properties Tests Test Method Minimum Percent Maximum Percent Percentage of wear, Los Angeles Abrasion Test AASHTO T 96 – 25 Flakiness Index NJDOT A-7 – 20 Clay Lumps and Friable Particles ASTM C 142 – 2 Asphalt Affinity1 ASTM D 3625 95 –

1.Anti-stripping agents may be required to provide resistance to stripping. Table 902.04.01-3 Coarse Aggregate Gradation Sieve Size Total % Passing By Mass 1/2″ 100 3/8″ 85 – 100 1/4″ 0 – 15 No. 4 0 – 5 No. 200 0.0 – 3.0

5.Use mineral filler, if necessary, that conforms to 901.05.03.

902.04.02 Mix Design

Design the ultra -thin HMA a s specified in NJDOT B-13 and ensure the JMF meets the requirements in Table 902.04.02-1. Size, uniformly grade, and combine aggregate fractions in proportions so that the grading of total aggregate and asphalt binder in the JMF conform to the composition by mass percentages specified in Table 902.04.02-1. Table 902.04.02-1 JMF Requirements for Ultra-Thin Friction Course Sieve Size Percent Passing1 Production Control Tolerances2 1/2″ 100 0.0 3/8″ 85 – 100 ±3.0 1/4″ 30 – 50 ±4.0 No. 4 24 – 40 ±3.0 No. 8 21 – 32 ±3.0 No. 16 16 – 26 ±3.0 No. 30 12 – 20 ±2.0 No. 50 8 – 16 ±2.0 No. 100 5 – 10 ±1.0 No. 200 4.0 – 7.0 ±1.0 Asphalt Binder Content (Ignition Oven)3 4.9 – 6.0 ±0.30

1.Aggregate percent passing to be determined based on dry aggregate weight.

2.Production tolerances are for the approved JMF and may not fall outside of the wide band gradation limits.

3.The asphalt binder content may not be lower than the minimum after the production tolerance is applied. Design the ultra-thin HMA to meet the requirements in Table 902.04.02-2. Table 902.04.02-2 UTFC Mix Properties Tests Test Method Minimum Maximum Draindown AASHTO T 305 – 0.3 % Film Thickness NJDOT B-13 10 micron – Cantabro Loss NJDOT B-8 – 30 % Air Voids (@ 75 gyrations) NJDOT B-13 – 8.0 % When tested for moisture sensitivity according to AASHTO T 283, ensure that the ultra-thin HMA has a tensile strength ratio of at least 80 percent. Prepare specimens according to AASHTO T 312, and test according to AASHTO T 283 except for the following:

1.Before compaction, condition the mixture for 2 hours according to AASHTO R 30, Section 7.1.

2.Compact specimens with 75 gyrations.

3.Extrude specimens as soon as possible without damaging.

4.Use NJDOT B-13 to determine void content.

5.Record the void content of the specimens.

6.If less than 55 percent saturation is achieved, repeat the procedure, unless the difference in tensile strength between duplicate specimens is greater than 25 pounds per square inch.

7.If visual stripping is detected, modify or readjust the mix. At least 30 days before the initial production date, submit the mix design to the ME for approval on forms supplied by the Department, including JMF for the ultra -thin HMA. Include a statement naming the source of each component and a report with the results for the criteria specified in Table 902.04.01-1, Table 902.04.01-2, and Table 902.04.02-1. If the source of any component material changes, submit a new JMF and obtain ME approval before using the new material. When unsatisfactory results or other conditions make it necessary, the ME may require a new JMF. During the construction of the test strip, take samples to confirm that the plant mixed material meets the requirements of the mix design. The ME will not grant final approval of the mix design until a successful verification of the plant produced mix and construction test strip.

902.04.03 Sampling and Testing

Ensure that the mix meets the requirements as specified in 902.02.04.A, otherwise the RE or ME will reject the material. Maintain the temperature of the mix between 300 °F and 330 °F. Perform and meet requirements for quality control testing as specified in 902.02.04.C. Ensure that a technical representative from the lab which designed the mix is present during the first night of production to make adjustments as needed for mix compliance. During production, the ME will take one random acceptance sample from each 700 tons of production to verify composition. Conduct draindown tests as directed by the ME. If the composition testing results are outside of the production control tolerances specified in Table 902.04.02-1 for an acceptance sample, immediately run a quality control sample. If the quality control sample is also outside of the control tolerances in Table 902.04.02-1, determine if a plant adjustment is needed and take corrective action to bring the mix into compliance. Take additional quality control samples after the corrective action to ensure that the mix is within the production control tolerances. If 2 consecutive acceptance samples are outside the tolerances specified in Table 902.04.02-1, immediately stop production. Obtain ME approval of a plant correction plan before resuming production. Upon restarting production, do not transport mixture to the Project Limits before the results of a QC sample from the mixture indicate that the mixture meets JMF tolerances. The ME will reject mixture produced at initial restarting that does not meet tolerances. The ME will perform sampling according to NJDOT B-2 or ASTM D 3665, and will perform testing for composition according to AASHTO T 308. Perform testing for draindown according to AASHTO T 305 for every 3 ,500 tons or as directed by the RE. The ME may require testing and calculations of film thickness according to NJDOT B-13. The ME may require adjustment or redesign of the UTFC for failure of draindown or film thickness based on the requirements in Table 902.04.02-2. During production at the plant, the ME will take a sample of the asphalt binder once every 3,500 tons or as directed by the ME.

902.05 Stone Matrix Asphalt (Sma)

902.05.01 Composition of Mixture

Mix SMA in a plant that is listed on the QPL and conforms to the requirements for HMA plants as specified in 1009.01. The composition of the SMA mixture is coarse aggregate, fine aggregate, mineral filler, mineral fibers or cellulose fibers, and polymer modified asphalt binder and may include a WMA additive. Use asphalt binder for SMA that is PG 64E-22 as specified in 902.01.01. For coarse aggregate in SMA, use crushed stone conforming to 901.05.01 and Table 902.05.01-1. Use at least 2 stockpiles of crushed stone with differing gradations to allow adjustments to meet the JMF. Table 902.05.01-1 Coarse Aggregate Properties for SMA Tests Test Method Maximum Percent Percentage of wear, Los Angeles Abrasion Test AASHTO T 96 30 Flat and Elongated, 5 to 1 (Material Retained on the No. 4 Sieve) ASTM D 4791 5 Flat and Elongated, 3 to 1 (Material Retained on the No. 4 Sieve) ASTM D 4791 20 For fine aggregate, use 100 percent manufactured stone sand conforming to 901.05.02. Ensure that the combined fine aggregate of 100 percent manufactured stone sand in the mixture conforms to the requirements in Table 902.02.02-2. For mineral filler, use rock dust or crushed limestone conforming to AASHTO M 17. Ensure that the mineral filler has a plasticity index of less than 4 percent when tested according to AASHTO T 90. Do not add RAP, CRCG, GBSM, or RPCSA to the mixture. Add stabilizing fibers consisting of mineral fiber or cellulose fiber conforming to AASHTO M 325. Use only one type per mix design. If using mineral fibers, use between 0.4 and 0.6 percent by weight of total mix. If using cellulose fibers, use between 0.3 and 0.4 percent by weight of total mix. Provide control to accurately proportion the fibers into the mixture within ±10 percent of the required weight, and us e equipment that ensures uniform dispersion of the fibers. If using pre-packaged bags of fibers added to the pugmill during the dry mix cycle, follow the manufacturer’s recommendations for the dry and wet mixing time. Store fibers in a dry location with a storage temperature not to exceed 120 °F. The supplier of the cellulose or mineral fibers shall provide a certification of compliance, as specified in 106.07, for the fibers. Ensure that a technical representative from the fiber supplier is at the HMA plant for the first full day of produ ction for technical assistance. If used, ensure that WMA additives or processes conform to 902.01.04. If a WMA additive is pre-blended in the asphalt binder, ensure that the asphalt binder meets the requirements of the specified grade after the addition of the WMA additive. If a WMA additive is added at the HMA plant, ensure that the addition of the additive will not negatively impact the grade of asphalt binder. Follow the manufacturer’s recommendations for percentage of WMA additive needed. For controlled asphalt foaming system WMA, the Department may require an anti-stripping additive.

902.05.02 Mix Design

Design the SMA to meet the requirements in Table 902.05.02-1 and Table 902.05.02-2. Prepare the JMF according to AASHTO R 46. Determine the JMF at 3.5 percent air voids and 75 gyrations of the Superpave gyratory compactor. Table 902.05.02-1 SMA Specification Band (% Passing) Nominal-Maximum Aggregate Size Production Control Tolerances from JMF1 Sieve Size 19 mm % Passing 12.5 mm % Passing 9.5 mm % Passing 0% 1" 100 100 100 3% 3/4" 90 – 100 100 100 5% 1/2" 50 – 88 90 – 100 100 5% 3/8" 25 – 60 50 – 80 70 – 95 6% No. 4 20 – 28 20 – 35 30 – 50 3% No. 8 16 – 24 16 – 24 20 – 30 4% No. 16 – – 0 – 21 3% No. 30 – – 0 – 18 3% No. 50 – – 0 – 15 2% No. 200 7.0 – 11.0 7.0 – 11.0 7.0 – 12.0 – Coarse Aggregate Fraction Portion Retained on No. 4 Sieve Portion retained on No. 4 Sieve Portion retained on No. 8 Sieve

1.Production tolerances are for the approved JMF and may not fall outside of the wide band gradation limits. Table 902.05.02-2 SMA Mixtures Volumetrics for Design and Plant Production Property Production Control Tolerances Requirement Air Voids 1% 3.5% Voids in Mineral Aggregate (VMA) – 17.0% minimum VCAmix – Less than VCADRC Draindown @ production temperature1 – 0.30% maximum Asphalt Binder Content (AASHTO T 308)2 0.40% 6% minimum3 Tensile Strength Ratio (AASHTO T 283) – 80% minimum

1.For design, conduct draindown test at anticipated mixing temperature and 15°F higher. Ensure draindown test meets requirement at both temperatures. For production, conduct draindown test at 15°F higher than anticipated mixing temperature.

2.Asphalt binder content may not be lower than the minimum after the production tolerance is applied.

3.Aggregate blends with a Gsb value of 2.90 and higher may produce the mix with a minimum asphalt content of 5.8% with ME approval.

902.05.03 Sampling and Testing

A.General Acceptance Requirements. Ensure that the mix meets the requirements as specified in 902.02.04.A.

B.Sampling. The ME will take a random sample from each 700 tons of production for volumetric acceptance testing and to verify composition. The ME will perform sampling according to AASHTO T 168, NJDOT B-2, or ASTM D 3665. During production at the plant, a sample of asphalt binder will be taken once every 3,500 tons or as directed by the ME.

C.Quality Control Testing. Perform quality control testing as specified in 902.02.04.C. For each acceptance test, perform testing for draindown according to AASHTO T 305 at 15°F above the mixing temperature. Perform bulk specific gravity of coarse aggregates (GCA) and dry-rodded voids in coarse aggregate VCADRC testing according to AASHTO R 46 by sampling and drying aggregates according to AASHTO R 90 and AASHTO T 255, respectively. The ME shall ensure that the G CA and VCADRC of the aggregate blend has been determined within 7 days of the start of production. Stop production and conduct VCADRC test immediately when there are major changes to aggregate blend percentages. When performing the VCA DRC test during production, use the GCA value that was determined prior to production. The ME may request additional VCA DRC tests to be conducted with or without requiring a new GCA test to be performed at any time.

D.Acceptance Testing and Requirements. The ME will determine volu metric properties at 75 gyrations for acceptance from samples taken, compacted, and tested at the HMA plant according to AASHTO T 312. The ME will determine bulk specific gravity of the compacted sample according to AASHTO T 166. The ME will use the QC maximum specific gravity test result in calculating the volumetric properties of the SMA. The ME will determine VCAmix according to AASHTO R 46. If the acceptance sample is outside of the control tolerances for the No. 4 sieve in Table 902.05.02-1 or VCAmix is greater than VCADRC, immediately take a quality control sample for testing. If the quality control sample is outside of the control tolerances for the No. 4 sieve in Table 902.05.02-1 or VCAmix is greater than VCADRC, immediately stop production and shipping. If the test results other than the No. 4 sieve or VCA DRC are outside of the production control tolerances specified in Table 902.05.02-1 or Table 902.05.02-2 for an acceptance sample, immediately run a quality control sample. If the quality control sample is also outside of the control tolerances in Table 902.05.02-1 or Table 902.05.02-2, determine if a plant adjustment is needed and take corrective action to bring the mix into compliance. Take an additional quality control sample immediately after completing the corrective action to ensure that the mix is within tolerances. If the mix is within tolerance based on the quality control sample results, then the ME will immediately take an acceptance sample to test and verify that the composition, air voids, draindown, VCAmix, and VMA meet the production control tolerances specified in Table 902.05.02-1 and Table 902.05.02-2. If 2 consecutive acceptance or quality control samples are outside the tolerances specified in Table 902.05.02-1 or Table 902.05.02-2, immediately stop production and shipping. After a production stop, obtain ME approval o f a plant correction plan before resuming production. Upon restarting production, do not transport mixture to the Project Limits before the results of a quality control sample from the mixture indicate that the mixture meets JMF tolerances and ME approval.

902.06 Asphalt-Stabilized Drainage Course (Asdc)

902.06.01 Composition

Mix ASDC in a plant that is listed on the QPL and conforms to the requirements specified in 1009.01. The mixture shall consist of asphalt binder and aggregate and may contain a WMA additive. Use asphalt binder that is PG 64S-22 as specified in 902.01.01. Use aggregate that conforms to 901.05.01 or 901.05.02 and the gradation requirements specified in Table 902.06.01-1. If used, ensure that WMA additives or processes conform to 902.01.04. If a WMA additive is pre-blended in the asphalt binder, ensure that the asphalt binder meets the requirements of the specified grade after the addition of the WMA additive. If a WMA additive is added at the HMA plant, ensure that the addition of the additive will not negatively impact the grade of asphalt binder. Follow the manufacturer’s recommendations for percentage of WMA additive needed. For controlled asphalt foaming system WMA, the Department may require an anti-stripping additive. Table 902.06.01-1 Gradation Requirements and Tolerances for ASDC Production Tolerance (Variation From JMF) Sieve Size JMF (Percent Passing) – 1" 100 ±1.0 3/4" 95 – 100 ±3.0 1/2" 85 – 100 ±6.0 3/8" 60 – 90 ±2.0 No. 4 15 – 25 ±2.0 No. 8 2 – 10 ±1.0 No. 200 2 – 5 Design the mixture to have an asphalt binder content of 3 ± 1/2 percent by weight of dry aggregate.

902.06.02 Mix Design

Submit to the ME for approval, a JMF for the material that includes the source of each component. Establish with the JMF the percentage of dry weight of aggregate passing each required sieve size and the optimum percentage of asphalt binder based upon the weight of the total mix. Ensure that the design values of percent passing each sieve size are wit hin the gradation band specified in Table 902.06.01-1. Design the mix to have a permeability of 2,000 ± 500 feet per day. At least 45 days befor e the production of the asphalt -stabilized drainage course, submit a mix design for approval. In addition, submit samples of the component materials to the ME for verification. Submit the following quantities: Table 902.06.02-1 Verification Samples for Asphalt-Stabilized Drainage Course Component Quantity Each Aggregate Component 35 pound Asphalt Binder 1 gallon Anti-Stripping Agent, if needed 0.264 gallon The ME will perform gradation testing according to AASHTO T 27 on the submitted aggregate sample. The ME will prepare the specimens for permeability testing according to AASHTO T 167. The ME will compact specimens at 260 F. The ME will determine permeability according to NJDOT B-1. At the ME’s option, verification may be done on an annual basis for a mix rather than on a project-to-project basis, provided the properties and proportions of the m aterials do not change. If written verification is submitted by the HMA supplier that the same source and character of materials are to be used, the ME may waive the requirement for the design and verification of previously approved mixes.

902.06.03 Sampling and Testing

Perform quality control testing as specified in 902.02.04.C. Ensure that the mix meets the requirements as specified in

902.02.04 A, except that the temperature of the mix at discharge is required to be between 230 °F and 275 °F, otherwise

the RE or ME will reject the material. For mixes produced using a WMA additive or process, ensure that the temperature of the mixture at discharge from the plant or surge and storage bins is at least 10 °F above the WMA manufacturer’s recommended laydown temperature. During production, the ME will take 1 random acceptance sample from each 700 tons of production to verify composition. Conduct draindown tests as directed by the ME. If the composition testing results are outside of the production control tolerances spec ified in Table 902.06.01-1 for an acceptance sample, immediately run a quality control sample. If the quality control sample is also outside of the control tolerances specified in Table 902.06.01-1, determine if a plant adjustment is needed and take corrective action to bring the mix into compliance. Take additional quality control samples after the corrective action to ensure that the mix is within tolerances. If 2 consecutive acceptance samples are outside the tolerances specified in Table 902.06.01-1, immediately stop production. Obtain ME approval of a plant correction plan before resuming production. Upon restarting production, do not transport mixture to the Project before the results of a QC sample from the mixture indicate that the mixture meets JMF tolerances. The ME will reject mixture produced at initial restarting that does not meet tolerances. The ME will perform sampling according to NJDOT B-2 or ASTM D 3665 and will perform testing for composition according to AASHTO T 308. If directed by the ME, perform testing for draindown according to AASHTO T 305. During production at the plant, a sample of asphalt binder will be taken once every 3,500 tons or as directed by the ME.

902.07 Asphalt-Rubber Open-Graded Friction Course (Ar-Ogfc)

902.07.01 Composition of Mixture

Mix AR-OGFC in a plant listed on the QPL and conforming to the requirements for HMA plants specified in 1009.01. Ensure the HMA plant is equipped with asphalt-rubber binder blending equipment as specified in 1009.03. Composition of mixture for AR -OGFC is coarse aggregate, fine aggregate , and asphalt-rubber binder. Ensure that the mixture conforms to the following requirements:

1.Use aggregates that conform to 901.05. Use fine aggregate that is 100 percent stone sand and conforms to Table 902.02.02-2.

2.Do not use RAP, CRCG, GBSM, or RPCSA.

3.Use asphalt-rubber binder that conforms to 902.07.02.

902.07.02 Asphalt-Rubber Binder

A.Materials. Use the following materials:

1.Ground Crumb Rubber. Ensure that the ground crumb rubber has a specific gravity of 1.15 ± 0.05, is free of wire or other contaminating materials, and contains not more than 0.5 percent fabric. Use crumb rubber that is ambient ground and conforms to the gradation requirements specified in Table 902.07.02-1. Ens ure that the moisture content is less than 0.75 percent. The Contractor may add up to four p ercent calcium carbonate by weight of the granulated rubber, to prevent the particles from sticking together. Table 902.07.02-1 Ground Crumb Rubber Gradation Sieve Size Percent Passing1, 2 No. 8 100 No. 16 65 – 100 No. 30 20 – 100 No. 50 0 – 45 No. 200 0 – 5

1.Perform gradation according to AASHTO T 27 using a minimum 50 gram sample.

2.Ensure that the gradation is performed as specified in NJDOT B-11. Submit to the ME a certification of compliance, as specified in 106.07, for the ground crumb rubber. In addition, ensure that the certificates confirm that the rubber is a crumb rubber, derived from processing whole scrap tires or shredded tire materials; and the tires from which the crumb rubber is produced are taken from automobiles, trucks, or other equipment owned and operated in the United States. Include with the certifications verifications that the processing did not produce, as a waste product, casings, or other round tire material that can hold water when stored or disposed of above ground.

2.Asphalt Binder.

a.Use asphalt binder that conforms to AAS HTO M 3 32, Table 1; PG 64 S-22, PG 58 -28 or an approved blend of both grades. The asphalt binder producer is required to provide the asphalt binder quality control plan annually to the ME for approval. Ensure that the quality control plan conforms to AASH TO R 26. Submit to the ME a certification of compliance, as specified in 106.07, for the asphalt binder. The ME will perform quality assurance sampling and testing of each asphalt binder lot as defined in the approved quality control plan.

b.Use one or more of the following types of warm mix asphalt (WMA) additives or processes:

1.Organic additives such as a paraffin wax or a low molecular weight esterified wax.

2.Chemical additive that acts as a surfactant or dispersing agent. Do not use controlled asphalt foaming systems or any other steam injection processes or steam introducing additives. WMA is a method of producing asphalt pavement at a mixing and compaction temperatures at least 30 ºF lower than Hot Mix Asphalt (HMA) by using one or more of the types of WMA additives listed above. Submit information on the WMA additive or process with the Paving Plan required in 402.03.02.A. Include in the submission, the name and description of the additive or process, the manufacturer’s recommendations for usage of the additive or process, recommendations for mixing and compaction temperatures, and details on at least one project on which the additive was successfully used in the United States on a crumb rubber modified asphalt mixture. In th e details of a project, include tonnage, type of mix, dosage, mixing and compaction temperatures, available test results, and contact information for project. If a WMA additive is pre-blended in the asphalt binder, ensure that the asphalt binder meets the requirements of the specified grade after the addition of the WMA additive. If a WMA additive is added at the HMA plant, ensure that the addition of the additive will not negatively impact the grade of asphalt binder. The ME will evaluate the impacts to performance grade of the asphalt binder based upon certification from manufacturer in conjunction with laboratory data indicating the effects of the additive on the asphalt binder properties. Follow the manufacturer’s recommendations for the dosage of WM A additive needed and approved blending method(s). Ensure that a technical representative of the WMA additive manufacturer is on -site or available for consultation during the production and placement of the AR-OGFC with the warm mix additive.

B.Mixing. Using the asphalt -rubber binder blending equipment in 1009.03, produce the asphalt -rubber binder to contain at least 17 percent ground rubber by the weight of total asphalt binder (asphalt + crumb rubber). Ensure that the temperature of the asphalt cement is between 350 and 400 °F at the time of addition of the ground rubber. Ensure that there are no agglomerations of rubber particles in excess of two inches in the least d imension in the mixing chamber. Document that the proportions are accurate and that the rubber has been uniformly incorporated into the mixture. Report as directed by the ME. Ensure that the crumb rubber and asphalt -cement are thoroughly mixed before beginning the one -hour reaction period. Rubber floating on the surface or agglomerations of rubber particles is evidence of insufficient mixing. Maintain the temperature of the asphalt -rubber binder immediately after mixing between 325 and 375 °F. Maintain the temperature of the asphalt-rubber binder for at least 1 hour before using.

C.Properties. Prepare asphalt-rubber binder using the “wet process.” Physical properties are required to comply with the requirements of ASTM D 6114, Type II, except for the properties specified in Table 902.07.02-2. Table 902.07.02-2 Asphalt-Rubber Binder Properties Property Test Procedure Requirement Resilience: 77 °F; %, minimum 500 ASTM D 5329 25 Rotational Viscosity1 350 °F; cP NJDOT B-12 2000 – 4000

1.The viscotester used must be correlated to a Rion (formerly Haake) Model VT-04 viscotester using the No. 1 Rotor. The Rion viscotester rotor, while in the off position, is required to be completely immersed in the binder at a temperature from 350 ± 3 °F for a minimum heat equilibrium period of 60 seconds, and the average viscosity determined from 3 separate constant readings ( 500 cP) taken within a 30 second time frame with the viscotester level during testing and turned off between readings. Continuous rotation of the rotor may cause thinning of the material immediately in contact with the rotor, resulting in erroneous results.

D.Handling and Testing. Once the asphalt-rubber binder has been mixed, thoroughly agitate during periods of use to prevent settling of the rubber particles. During production, maintain asphalt-rubber binder between 325 and 375 °F. Ensure that asphalt-rubber binder is not held at 325 °F or higher for more than 16 hours. Allow asphalt-rubber binder held for more than 16 hours to cool. To reuse, gradually reheat to between 325 and 375 °F. Do not cool and reheat more than one time. Do not store asphalt-rubber binder above 250 °F for more than 4 days. For each load or batch of asphalt-rubber binder, provide the RE with the following:

1.The source, grade, amount, and temperature of the asphalt cement before the addition of rubber.

2.The source and a mount of rubber and the rubber content expressed as percent by th e weight of the asphalt cement.

3.Times and dates of the rubber additions and resultant viscosity test.

4.A record of the temperature, with time and date reference for each load or batch. The record begins at the time of the addition of rubber and continue until the load or batch is completely used. Take readings and record every temperature change in excess of 20 °F, and as needed to document other events that are signif icant to batch use and quality.

902.07.03 Mix Design

Submit binder and mix designs including JMF for each mixture performed by an AASHTO accredited lab with at least five successfully completed asphalt-rubber open-graded friction course projects greater than 5,000 tons each. Include a statement naming the source of each component and a report with the results for the criteria specified in Table 902.07.03-1. Include a report detailing the rotational viscosity of the asphalt-rubber binder at 60, 90, 135, 240, and 1,440 minutes. Submit lab qualifications and references to the ME for approval prior to beginning work. Design the mix to meet the criteria in Table 902.07.03-1. Table 902.07.03-1 JMF Master Ranges and Mixture Requirements AR-OGFC Sieve Sizes Mixture Designations (% Passing1) AR-OGFC 1/2" 100 3/8" 90 – 100 No. 4 20 – 40 No. 8 5 – 10 No. 200 0 – 3.0 Minimum asphalt-rubber binder, %2 8.4 Minimum % Air Voids, design 15

1.Aggregate percent passing to be determined based on dry aggregate weight.

2.Asphalt-rubber binder content to be determined based on total weight of mix. Determine and verify the JMF according to NJDOT B-8. Ensure that the JMF is within the master range specified in Table 902.07.03-1. Prepare compacted test specimens for submittal to the ME at least 30 days before the initial production date. Prepare these specimens from material mixed according to the final JMF, using 50 gyrations of the Superpave gyratory compactor according to AASHTO T 312. The ME will test 2 specimens to verify stone-on-stone contact according to NJDOT B-8 and that the final JMF produces a mixture that has a minimum void content as specified in Table 902.07.03-1. The ME will determine percent air voids according to AASHTO T 209 and AASHTO T 331. The ME will test 2 test specimens for abrasion and impact resistance using a modified L.A. Abrasion Test according to NJDOT B-8. The maximum allowable loss as calculated by this method is 30 percent. Do not modify, which includes changing the asphalt cement supplier, the JMF unless the ME approves the modification.

902.07.04 Sampling and Testing

A.General Acceptance Requirements. The RE or ME may reject and require disposal of any batch or shipment that is rendered unfit for its intended use due to contamination, segregation, improper temperature, lumps of cold material, or incomplete coating of the aggregate. For other than improper temperature, visual inspection of the material by the RE or ME is considered sufficient grounds for such rejection. For AR-OGFC with WMA additive, ensure that the temperature of the mixture at discharge from the plant or surge and storage bins meets the WMA additive manufacturer’s recommendations. Do not allow the mixture temperature to exceed 300 °F at discharge from the plant. For mixes produced using a WMA additive or process, ensure that the temperature of the mixture at discharge from the plant or surge and storage bins is at least 10 °F above the WMA manufacturer’s recommended laydown temperature. Combine and mix the aggregates and asphalt-rubber binder to ensure that at least 95 percent of the coarse aggregate particles are entirely coated with asphalt -rubber binder as determined according to AASHTO T 195. If the ME determines that there is an ongoing problem with coating, the ME may obtain random samples from 5 trucks and will determine the adequacy of the mixing on the average of particle counts made on these 5 test portions. If the requirement for 95 percent coating is not met on each sample, modify plant operations, as necessary , to obtain the required degree of coating.

B.Quality Control Testing. The HMA producer is required to provide a quality control (QC) technician who is certified by the Society of Asphalt Technologists of New Jersey as an Asphalt Technologist, Level 2. The QC technician may substitute equivalent technician certification by the Mid -Atlantic Region Technician Certification Program (MARTCP). Ensure that the QC technician is present during periods of mix production for the sole purpose of quality control testing and to assist the ME. The ME will not perform the quality control testing or other routine test functions in the absence of, or instead of, the QC technician. The QC technician is required to perform sampling and testing according to the approved qu ality control plan, to keep the mix within the limits specified for the mix being produced. The QC technician may use acceptance test results or perform additional testing as necessary to control the mix. For each acceptance test, perform maximum specific gravity testing according to AASHTO T 209 on a test portion of the sample taken by the ME. Sample and test coarse aggregate, fine aggregate and mineral filler according to the approved quality control plan for the plant.

C.Acceptance Testing. During production, the ME will take one random acceptance sample from each 700 tons of production to verify composition. The ME will perform sampling according to NJDOT B-2 or ASTM D 3665, and will perform testing for composition according to AASHTO T 308. Perform testing for air voids according to T 209 and either B-6 or T 331. Perform testing for draindown according to NJDOT B-8. During production at the plant, a sample of asphalt binder will be taken once every 3,500 tons or as directed by the ME. Conduct air voids and draindown tests as directed by the ME. If the composition testing results are outside of the production control tolerances specified in Table 902.07.04-1 for an acceptance sample, immediately run a quality control sample. If the quality control sample is also outside of the control tolerances in Table 902.07.04-1, determine if a plant adjustment is needed and take corrective action to bring the mix into compliance. Take additional quality control samples after the corrective action to ensure that the mix is within the production control tolerances. If 2 consecutive acceptance samples are outside the tolerances specified in Table 902.07.04-1, immediately stop production. Obtain ME approval of a plant correction plan before resuming production. Upon restarting production, do not transport mixture to the Project Limits before the results of a QC sample from the mixture indicate that the mixture meets JMF tolerances. The ME will reject mixture produced at initial restarting that does not meet tolerances. Table 902.07.04-1 Production Control Tolerances for AR-OGFC Mixtures Sieve Sizes Production Control Tolerances from JMF1 1/2" 6.0 3/8" 2.0 No. 4 4.0 No. 8 1.0 No. 200 1.0 Asphalt-rubber binder, % (AASHTO T 308)2 0.40 902.08 HIGH PERFORMANCE THIN OVERLAY (HPTO)

902.08.01 Composition of Mixture

Mix HPTO in a plant that is listed on the QPL and conforms to the requirements for HMA Plants as specified in 1009.01. The composition of the mixture for HPTO is coarse aggregate, fine aggregate, and asphalt binder, and may also include mineral filler and a WMA additive. Do not use Reclaimed Asphalt Pavement (RAP), Ground Bituminous Shingle Material, Remediated Petroleum Contaminated Soil Aggregate, or Crushed Recycled Container Glass (CRCG). Use asphalt binder and aggregates that meet the following requirements:

1.Use polymer modified asphalt binder that is specially formulated for meeting the mix performance criteria as specified in 902.08.02. Consult with the asphalt binder supplier to obtain the appropriate material for the specific mix design. Submit a certificate of analysis (COA) showing th e PG continuous grading (AASHTO R 29) for the asphalt binder used in the mix design. For quality assurance testing of the asphalt binder, the ME may sample the asphalt binder during production of the mix and compare the results with the COA submitted at the time of test strip. To analyze the binder the ME will test the binder at the nearest standard PG temperature then compare the results with the COA. If the high (G*/ sin δ) and low (stiffness and m value) temperature passing test results are within 5 percent of the results from the passing temperature on the COA, then the ME will consider the asphalt binder comparable to the binder used during test strip.

2.WMA additives may be used in the mix and must conform to 902.01.04. If a WMA additive is pre-blended in the asphalt binder or added at the HMA plant, ensure that the mix meets the mix performance criteria in this specification and will not be negatively impacted by the WMA additive. Follow the manufacturer’s recommendations for percentage of WMA additive needed. Controlled as phalt foaming system WMA is prohibited for use in this mixture.

3.Use coarse aggregate that is gneiss, granite, quartzite, or trap rock and conforms to 901.05.01.

4.For fine aggregate, use 100 percent stone sand conforming to 901.05.02 and having an uncompacted void content of at least 45 percent when tested according to AASHTO T 304, Method A. In addition, the minimum sand equivalent is 45 percent when tested according to AASHTO T 176.

5.If necessary, use mineral filler as specified in 901.05.03.

902.08.02 Mix Design

At least 45 days before initial production, submit a job mix formula for the HPTO on forms supplied by the Department. Include a statement naming the source of each component and a report showing the results meet the criteria specified in Table 902.08.02-1 and Table 902.08.02-2. For the job mix formula for the HPTO mixture, establish the percentage of dry weight of aggregate passing each required sieve size and an optimum percentage of asphalt binder based upon the weight of the total mix. Determine the optimum percentage of asphalt binder according to AASHTO R 35 and M 323 with an N des of 50 gyrations. Before maximum specific gravity testing or compaction of specimens, condition the mix for 2 hours according to the requirements for conditioning for volumetric mix design in AASHTO R 30, Section 7.1. If the absorption of the combined aggregate is more than 1.5 percent according to AASHTO T 84 and T 85, condition the mix for 4 hours according to AASHTO R 30, Section 7.2 prior to compaction of specimens (AASHTO T 312) and determination of maximum specific gravity (AASHTO T 209). Ensure that the job mix formula is within the master range specified in Table 902.08.02-1. Minimum % Air Voids 1.0% less than design requirement

1.Production tolerances may fall outside of the wide band gradation limits in Table 902.07.03-1.

2.Asphalt-rubber binder content may not be lower than the minimum in Table 902.07.03-1 after the production tolerance is applied. Table 902.08.02-1 JMF Requirements for HPTO Sieve Sizes Percent Passing1 Production Control Tolerances2 3/8" 100 ±0.0% No. 4 65 – 85 ±4.0% No. 8 33 – 55 ±4.0% No. 16 20 – 35 ±3.0% No. 30 15 – 30 ±3.0% No. 50 10 – 20 ±2.0% No. 100 5 – 15 ±2.0% No. 200 5.0 – 8.0 ±1.0% Asphalt Binder Content (Ignition Oven)3 7.0 % minimum ±0.40%

1.Aggregate percent passing to be determined based on dry aggregate weight.

2.Production tolerances are for the approved JMF and may not fall outside of the wide band gradation limits.

3.The asphalt binder content may not be lower than the minimum after the production tolerance is applied. Design the HPTO to meet the requirements in Table 902.08.02-2. Table 902.08.02-2 Volumetric Requirements for Design and Control of HPTO Required Density (% of Max Sp. Gr.) Voids in Mineral Aggregate Dust-to-Binder Ratio Draindown AASHTO T 305 @ Ndes (50 gyrations) @ Nmax (100 gyrations) (VMA) Design Requirements 96.5 ≤ 99.0 ≥ 18.0 % 0.6 – 1.2 ≤ 0.1 % Control Requirements 95.5 - 97.5 ≤ 99.0 ≥ 18.0 % 0.6 – 1.3 ≤ 0.1 % Ensure that the job mix formula provides a mixture that meets a minimum tensile strength ratio (TSR) of 85 percent when prepared according to AASHTO T 312 and tested according to AASHTO T 283 with the following exceptions:

1.Before compaction, condition the mixture for 2 hours according to AASHTO R 30 Section 7.1.

2.Compact specimens with 40 gyrations.

3.Extrude specimens as soon as possible without damaging.

4.Use AASHTO T 269 to determine void content.

5.Record the void content of the specimens.

6.If less than 55 percent saturation is achieved, the procedure does not need to be repeated, unless the difference in tensile strength between duplicate specimens is greater than 25 pounds per square inch.

7.If visual stripping is detected, modify or readjust the mix. For each mix design, submit 3 gyratory specimens and 1 loose sample correspon ding to the composition of the job mix formula, including the design asphalt content. The ME will use these samples for verification of the properties of the job mix formula. Compact the specimens to the design number of gyrations (Ndes). To be acceptable all 3 gyratory specimens must comply with the gradation and asphalt content requirements in Table 902.08.02-1 and with the control requirements in Table 902.08.02-2. The ME reserves the right to be present at the time of molding the gyratory specimens. In addition, submit 11 gyratory specimens and two 5 gallon buckets of loose mix to the ME. The ME will use these additional gyratory samples for performance testing of the HPTO mix. The ME reserves the right to be present at the time of molding the gyratory specimens. Ensure that the additional gyratory specimens ar e compacted according to AASHTO T 312. Compact 6 of the specimens to 77 millimeters in height and an air void content of 5.0 ± 0.5 percent. The ME will test the six 77 millimeter specimens using an Asphalt Pavement Analyzer (APA) according to AASHTO T 340 at 64 °C, 100 poun d per square inch hose pressur e, and 100 pound wheel load. Compact the other 5 specimens to 115 millimeter in height. These 5 specimens will be cut, from the middle of each 115 millimeter in height specimen, to 38 millimeter in height test specimens. The air void content of the 5 cu t specimen will be determined to ensure compliance with the target air void content of 5.0 ± 0.5 percent. The ME will use the five 38 millimeter in height specimens to test using an Overlay Tester (NJDOT B-10) at 25 °C and a joint opening of 0.025 inch. The ME will eliminate the high and low Overlay test results then average and report the middle 3 test results. The ME will ensure that all submitted specimens are within the target air void content as tested at the Materials’ Central Lab. The ME will not accept specimens lower than the target air void content, but may accept and test specimens higher than the target air void content. The ME will approve the JMF if the average rut depth for the 6 specimens in the Asphalt Pavement Analyzer testing is not more than 4 millimeter in 8,000 loading cycles and the average number of cycles to failure in the Overlay Tester is not less than 600. If the JMF does not meet the APA and Overlay Tester criteria, redesign the HPTO mix and submit for retesting. The JMF for the HPTO mixture is in effect until modification is approved by the ME. If required, the ME may use the 5 gallon buckets of the loose HPTO mix to compact additional gyratory specimens for perf ormance testing and the performance test results may be used for approval of the JMF. When unsatisfactory results for any specified characteristic of the work make it necessary, the Contractor may establish a new JMF for approval. In such instances, if corrective action is not taken, the ME may require an appropriate adjustment to the JMF. Should a change in sources or changes in the properties of materials occur, the ME will require that a new JMF be established and approved before production can continue. The ME may verify a mix on an annual basis rather than on a project-to-project basis if the properties and proportions of the materials do not change. If written verification is submitted by the HMA supplier that the same source and character of materials are to be used, the ME may waive the requirement for the design and verification of previously approved mixes.

902.08.03 Sampling and Testing

B.Sampling. The ME will take a sample of HPTO for volumetric acceptance testing from each 700 tons of a mix. The ME will perform sampling according to AASHTO T 168, NJDOT B-2, or ASTM D 3665. During production at the plant, a sample of asphalt binder will be taken once every 3,500 tons or as directed by the ME.

C.Quality Control Testing. The HMA producer is required to provide a quality control (QC) technician who is certified by the Society of Asph alt Technologists of New Jersey as an Asphalt Technologist, Level 2. The QC technician may substitute equivalent technician certification by the Mid -Atlantic Region Technician Certification Program (MARTCP). Ensure that the QC technician is present during periods of mix production for the sole purpose of quality control testing and to assist the ME. The ME will not perform the quality control testing or other routine test functions in the absence of, or instead of, the QC technician. The QC technician is required to perform sampling and testing according to the approved quality control plan, to keep the mix within the limits specified for the HPTO mix being produced. The QC technician may use acceptance test results or perform additional testing as necessary to control the mix. To determine the composition, perform ignition oven testing according to AASHTO T 308. For each acceptance test, perform maximum specific gravity testing according to AASHTO T 209 on a test portion of the sample taken by the ME. Sample and test coarse aggregate, fine aggregate, mineral filler, and asphalt binder according to the approved quality control plan for the plant.

D.Acceptance Testing and Requirements. The ME will determine volumetric properties at Ndes for acceptance from samples taken, compacted, and tested at the HMA plant. The ME will compact HPTO to 50 gyrations, using equipment according to AASHTO T 312. The ME will determine bulk specific gravity of the compacted sample according to AASHTO T 166. The ME will us e the most current QC maximum specific gravity test result in calculating the volumetric properties of the HPTO. The ME will determine the dust-to-binder ratio from the composition results as tested by the QC technician. Ensure that the HMA mixture conform s to the requirements specified in Table 902.08.02-2, and to the gradation requirements in Table 902.08.02-1. If 2 samples in 5 co nsecutive samples fail to conform to the gradation or volumetric requirements, immediately initiate corrective action. The ME will test a minimum of 1 sample per 3,500 tons for moisture, basing moisture determinations on the weight loss of an approximately 1,600 gram sample of mixture heated for 1 hour in an oven at 280 ± 5 °F. Ensure that the moisture content of the mixture at discharge from the plant does not exceed 1.0 percent.

E.Performance Testing. Provide 11 gyratory specimens that are compacted according to AASHTO T 312 and 2 boxes of loose mix. Compact 6 of the specimens to 77 millimeter in height and an air void content of 5.0 ± 0.5 percent. Compact the other 5 specimens to 115 millimeter in height. These 5 specimens will be cut, from the middle of each 115 millimeter in height specimen, to 38 millimeter in height test specimens. The air void content of the 5 cut test specimens will be determined to ensure compliance with the target air void content of 5.0 ± 0.5 percent. The ME will use the b oxes of loose mix to determine the maximum specific gravity of the mix according to AASHTO T 209. The ME will use the gyratory samples for performance testing of the HPTO mix. The ME will test six 77 millimeter in height specimens using an Asphalt Pavement Analyzer (APA) according to AASHTO T 340 at 64 °C, 100 pound per square inch hose pressure, and 100 pound wheel load. The ME will use the five 38 millimeter in height specimens to test using an Overlay Tester (NJDOT B-10) at 25 °C and a joint opening of 0.025 inch. The ME will eliminate the high and low Overlay test result then average and report the middle 3 test results. The ME will ensure that all submitted specimens are within the target air void content as tested at the Materials’ Central Lab. The ME will not accept specimens lower than the target air void content, but may accept and test specimens higher than the target air void content. Ensure that the first sample is taken during the construction of the test strip as specified in 406.03.01.C. Thereafter, sample every lot or as directed by the ME. If t he test strip is done within the Project Limits and the performance testing results are acceptable to the ME, the results will be included into the first lot. A lot is defined as material placed on the traveled way within the Project Limits. If a sample does not meet the criteria for performance testing as specified in Table 902.08.03-1, the Department will assess a pay adjustment as specified. The Department will calculate the pay adjustment by multiplying the percent pay adjustment (PPA) by the quantity in the lot and the bid price for the HPTO item. If APA rutting is greater than 12 millimeters or Overlay cycles is less than 400 or both, the Department will assess the maximum pay adjustmen t of PPA = -100 percent or may require removal and replacement. PPA for both APA and Overlay are cumulative and may not exceed -100 percent in total. If samples received are lower than the target air void range, 5.0 ± 0.5 percent, the Department will consider the samples untestable and assess a PPA of -100 percent or may require removal and replacement of the lot. If the Department requires removal and replacement, then the replacement work is subject to the same requirements as the initial work. Table 902.08.03-1 Performance Testing Pay Adjustments for HPTO Test Requirement Test Result PPA APA @ 8,000 loading cycles, mm (AASHTO T 340) 5.0 maximum t ≤ 5.0 5.0 < t ≤ 12.0 t > 12.0 -50(t-5)/7 -100 or Remove & Replace Overlay Tester, cycles (NJDOT B-10) 600 minimum t ≥ 600 600 > t ≥ 400 t < 400 -(600-t)/4 -100 or Remove & Replace

902.09 Micro Surfacing

902.09.01 Composition of the Mixture

Ensure that the micro surfacing mixture components conform to the following:

1.Micro Surfacing Emulsion. Use polymer modified emulsified asphalt. Ensure that the emulsified asphalt and emulsified asphalt residue is a quick set polymer modified asphalt emulsion conforming to the requirements of AASHTO M 316 for a CQS-1hP emulsion and the following:

a.Use a minimum of 3 percent polymer material, by weight of asphalt.

b.Ensure that the polymer material is milled or blended into t he asphalt prior to the emulsification process by an emulsion manufacturer approved by the ME.

c.Ensure that the polymer modifier and any additives enable the micro surfacing material to receive normal traffic within 1 hour without causing damage to the s urface. The cement mixing test is waived for this emulsion.

d.Ensure that the emulsified asphalt and the emulsified asphalt residue meet all of the quality test criteria in Section 4.1.2 of the International Slurry Surfacing Association (ISSA) “Recommend ed Performance Guideline for Micro Surfacing”, A 143.

2.Aggregate. Use only manufactured stone sand and crushed stone that conform to 901.05. Ensure that the fine aggregate has a Sand Equivalent value of 65 percent minimum when tested according to AASHTO T 176.

3.Mineral Filler. Use mineral filler that conforms to ASTM D 242 and is free of lumps.

4.Water. Use water that conforms to 919.08.

5.Other Additives. The Contractor may use other additives to provide control of the break/set time in the field. Ensure that the type of additive is specified in the mix design.

902.09.02 Mix Design of Micro Surfacing Mixture

A.Mix Design Requirements. Ensure that an AASHTO accredited lab, with at least 5 successfully completed micro surfacing projects greater than 5,000 square yards each, performs the mix design. Submit the mix design and certified test results of the micro surfacing mixture for approval in accordance with the provisions of ASTM D 6372, Standard Practice for Design, Testing, and Construction of Micro Surfacing and the following:

1.Ensure that the aggregate used in the job mix formula is from the same source and representative of the material proposed for use on the project.

2.Ensure that the compatibility of the aggregate, micro surfacing emulsion, water, mineral filler, and other additives is evaluated in the mix design. Perform the mix design using materials consistent with those supplied by the contractor for the project. Ensure the micro surfacing mix conforms to the requirements as specified in Table 902.09.02-1. Table 902.09.02-1 Micro Surfacing Mixture Requirements Tests ISSA Test Method Specification Mix Time @ 77 °F Mix Time @ 100 °F TB 113 Controllable to 120 seconds minimum Controllable to 35 seconds minimum Wet Cohesion @ 30 minutes minimum (set) @ 60 minutes minimum (traffic) TB 139 12 kg-cm minimum 20 kg-cm or near spin minimum Wet Stripping TB 114 90 % minimum Wet-Track Abrasion Loss One-hour soak Six-day soak TB 100 50 g/ft2 (538 g/m2) maximum 75 g/ft2 (807 g/m2) maximum Lateral Displacement TB 147 5% maximum Specific Gravity after 1,000 cycles of 125 pounds (56.71 kg) TB 147 2.10 maximum Excess Asphalt by LWT Sand Adhesion TB 109 50 g/ft2 (538 g/m2) maximum Classification Compatibility TB 144 11 grade points minimum (AAA, BAA)

3.Ensure proportioning of the mix design is within the limits in Table 902.09.02-2. Table 902.09.02-2 Mix Design Proportion Requirements Component Materials Limits Residual Asphalt 5.5 to 11.5% by dry weight of aggregates Mineral Filler 0.0 to 3% by dry weight of aggregates Polymer-Based Modifier min. of 3% polymer solids based on bitumen weight content Additives as needed Water as required to ensure proper mix consistency

4.Ensure that the proportions of aggregate and mineral filler are provided and within the limits of Table 902.09.03-1.

B.Mix Design Report. Submit the final mix design in the following format:

1.Source of each individual material.

2.Aggregate:

a.Gradation.

b.Sand Equivalent.

c.Abrasion Resistance.

d.Soundness.

3.Field Simulation Tests:

a.Wet Stripping Test.

b.Wet Track Abrasion Loss.

c.Classification Compatibility.

d.Trial Mix Time @ 77 °F and 100 °F.

4.Interpretation of Results and the Determination of a Job Mix Formula (JMF):

a.Percentage of Mineral Filler (minimum and maximum).

b.Percentage of Water, including aggregate moisture (minimum and maximum).

c.Percentage of Mix Set Additive (if required).

d.Percentage of Modified Emulsion.

e.Residual Content of Modified Emulsion.

f.Percentage of Residual Asphalt.

g.Combined Aggregate Gradation (JMF).

5.Signature and date.

902.09.03 Sampling and Testing

The ME will perform sampling and testing of the aggregate at least 10 days prior to the start of work. The ME will sample aggregate from s tockpiles designated and constructed for each mixture type on the project. The ME will sample the aggregate according to AASHTO T 2 and test according to AASHTO T 11 and T 27 using the following sampling frequency:

1.When the project quantity for the specified mixture type is less than 500 tons, designate the entire quantity as 1 lot and divide into 3 equal sublots for sampling. Obtain 1 sample from each sublot and submit to the ME for testing. The ME will randomly select only 1 of the 3 samples and tes t for compliance with Table 902.09.03-1. If the sample tested meets the specification, the entire lot is acceptable for use on the project. If the sample fails, the ME will test the remaining 2 samples. If the 2 samples both meet specification, the entire lot is acceptable for use on the project. If either of the 2 additional samples fails to meet the specification, the entire lot is rejected.

2.When the project quantity for the specified mixture type is 500 tons or greater, divide the aggregate into equal lots at the discretion of the ME, but in no case is the lot size to exceed 1,000 tons. Divide each lot into 3 equal sublots and obtain 1 sample for each sublot. The ME will randomly select only 1 of the 3 samples and test for compliance with Table 902.09.03-1. If the sample tested meets the specification, the entire lot is acceptable for use on the project. If the sample fails, the ME will test the remaining 2 samples. If the 2 samples both meet specification, the entire lot is acceptable for use on the project. If either of the 2 additional samples fails to meet the specification, the entire lot is rejected. Take precautions to ensure that approved stockpiles of aggregate do n ot become contaminated at the jobsite. Screen oversize aggregate or foreign materials from the aggregate prior to delivery to the mixer. During the micro surfacing application, in the presence of the inspector, sample the mixture twice daily or as directed from the pug mill discharge chute. Use a rectangular non-absorptive container, such as a loaf pan, of sufficient size to obtain a sample from the entire cross section of the mixture being discharged. Ensure that an AASHTO accredited lab, with at least 5 successfully completed micro surfacing projects greater than 5,000 square yards each, analyzes the mix for binder content and compliance with specifications. Submit certified results to the ME. The ME may perform independent testing. Ensure that the asphalt content is within ± 0.40 of the JMF. If the asphalt content is outside of the allowable tolerance, recalibrate or adjust the mixing machine. The RE may stop the micro surfacing operation if 2 or more samples fail to conform to the tolerance. Take corrective action or redesign the micro surfacing mixture. Resume operations only after RE has approved the corrective action. Use aggregate, including mineral filler, which conforms to the gradation in Table 902.09.03-1. Table 902.09.03-1 Gradation Requirements for Aggregate and Mineral Filler Sieve Size Type II Percent Passing Type III Percent Passing Stockpile Tolerances from JMF 3/8″ 100 100 – No. 4 90 – 100 70 – 90 ±4% No. 8 65 – 90 45 – 70 ±5% No. 16 45 – 70 28 – 50 ±4% No. 30 30 – 50 19 – 34 ±3% No. 50 18 – 30 12 – 25 ±3% No. 100 10 – 21 7 – 18 ±2% No. 200 5 – 15 5 – 15 ±2%

902.10 Slurry Seal

902.10.01 Composition of the Mixture

Ensure that the slurry seal mixture components conform to the following:

1.Slurry Seal Emulsion. Use polymer modified emulsified asphalt. Ensure that the emulsified asphalt and emulsified asphalt residue is a quick set polymer modified asphalt emulsion conforming to the requirements of AASHTO M 316 for a CQS-1hP emulsion and the following:

a.Use a minimum of 3 percent polymer material, by weight of asphalt.

b.Ensure that the polymer material is milled or blended into the asphalt prior to the emulsification process by an emulsion manufacturer approved by the ME.

c.Ensure that the polymer modifier and any additives enable the slurry seal material to receive normal traffic within 1 hour without causing damage to the surface.

d.Ensure that the emulsified asphalt and the emulsified asphalt residue material conform to the requirements in Table 902.10.01-1.

902.10.01 1 Emulsified Asphalt and Residue Requirements

Tests Test Method Specification Tests on Emulsified Asphalt Storage Stability, 24 hours, percent AASHTO T 59 1 % maximum Residue by Distillation1, percent AASHTO T 59 62 % minimum Tests on Asphalt Residue Softening Point by Ring and Ball AASHTO T 53 135 °F minimum

1.Test temperature held at 350 °F for 20 minutes.

2.Aggregate. Use only manufactured stone sand and crushed stone that conform to 901.05. Ensure that the fine aggregate has a Sand Equivalent value of 45 percent minimum when tested according to AASHTO T 176.

3.Mineral Filler. Use mineral filler that conforms to ASTM D 242 and is free of lumps.

4.Water. Use water that conforms to 919.08.

5.Other Additives. The Contractor may use other additives to provide control of the break/set time in the field. Ensure that the type of additive is specified in the mix design.

902.10.02 Mix Design of Slurry Seal Mixture

A Mix Design Requirements. Ensure that an AASHTO accredited lab, with at least 5 successfully completed slurry seal projects greater than 5,000 square yards each, performs the mix design. Submit the mix design and certified test results of the slurry seal mixture for approval in accordance with the provisions of ASTM D 3910, Standard Practice for Design, Testing, and Construction of Slurry Seal and the following:

1.Ensure that the aggregate used in the job mix formula is from the same source and representative of the material proposed for use on the project.

2.Ensure that the compatibility of the aggregate, slurry seal emulsion, water, mineral filler, and other additives is evaluated in the mix design. Perform the mix design using materials consistent with those supplied by the contractor for the project. Ensure the slurry seal mix conforms to the requirements as specified in Table 902.10.02-1. Table 902.10.02-1 Slurry Seal Mixture Requirements Tests ISSA Test Method Specification Mix Time @ 77 °F Mix Time @ 100 °F TB 113 Controllable to 120 seconds minimum Controllable to 35 seconds minimum Slurry Seal Consistency TB 106 0.79 to 1.18 inches Wet Cohesion @ 30 minutes minimum (set) @ 60 minutes minimum (traffic) TB 139 12 kg-cm minimum 20 kg-cm or near spin minimum Wet Stripping TB 114 90 % minimum Wet-Track Abrasion Loss One-hour soak Six-day soak TB 100 50 g/ft2 (538 g/m2) maximum 75 g/ft2 (807 g/m2) maximum Lateral Displacement TB 147 5 % maximum Specific Gravity after 1,000 cycles of 125 pounds (56.71 kg) TB 147 2.10 maximum Excess Asphalt by LWT Sand Adhesion TB 109 50 g/ft2 (538 g/m2) maximum Classification Compatibility TB 144 11 grade points minimum (AAA, BAA)

3.Ensure proportioning of the mix design is within the limits in Table 902.10.02-2: Table 902.10.02-2 Mix Design Proportion Requirements Component Materials Limits Residual Asphalt 7.5 to 13.5% by dry weight of aggregates Mineral Filler 0.0 to 3% by dry weight of aggregates Polymer-Based Modifier min. of 3% polymer solids based on bitumen weight content Additives as needed Water as required to ensure proper mix consistency

4.Ensure that the proportions of aggregate and mineral filler are provided and within the limits of Table 902.10.03-1. B Mix Design Report. Submit the final mix design in the following format:

1.Source of each individual material.

2.Aggregate:

a.Gradation.

b.Sand Equivalent.

c.Abrasion Resistance.

d.Soundness.

3.Field Simulation Tests:

a.Wet Stripping Test.

b.Wet Track Abrasion Loss.

c.Classification Compatibility.

d.Trial Mix Time @ 77 °F and 100 °F.

4.Interpretation of Results and the Determination of a Job Mix Formula (JMF):

a.Percentage of Mineral Filler (minimum and maximum).

b.Percentage of Water, including aggregate moisture (minimum and maximum).

c.Percentage of Mix Set Additive (if required).

d.Percentage of Modified Emulsion.

e.Residual Content of Modified Emulsion.

f.Percentage of Residual Asphalt.

g.Combined Aggregate Gradation (JMF).

5.Signature and date.

902.10.03 Sampling and Testing

The ME will perform sampling and testing of the aggregate at least 10 days prior to the start of work. The ME will sample aggregate from stockpiles designated and constructed for each mixture type on the project. The ME will sample the aggregate according to AASHTO T 2 and test according to AASHTO T 11 and T 27 using the following sampling frequency:

1.When the project quantity for the specified mixture type is less than 500 tons, desi gnate the entire quantity as 1 lot and divide into 3 equal sublots for sampling. Obtain 1 sample from each sublot and submit to the ME for testing. The ME will randomly select only 1 of the 3 samples and test for compliance with Table 902.10.03-1. If the sample tested meets the specification, the entire lot is acceptable for use on the project. If the sample fails, the ME will test the remaining 2 samples. If the 2 samples both meet specification, the entire lot is acceptable for use on the project. If either of the 2 additional samples fails to meet the specification, the entire lot is rejected.

2.When the project quantity for the specified mixture type is 500 tons or greater, divide the aggregate into equal lots at the discretion of the ME, but in no case is the lot size to exceed 1,000 tons. Divide each lot into 3 equal sublots and obtain 1 sample for each sublot. The ME will randomly select only 1 of the 3 samples and test for compliance with Table 902.10.03-1. If the sample tested meets the specification, the entire lot is acceptable for use on the project. If the sample fails, th e ME will test the remaining 2 samples. If the 2 samples both meet specification, the entire lot is acceptable for use on the project. If either of the 2 additional samples fails to meet the specification, the entire lot is rejected. Take precautions to ensure that approved stockpiles of aggregate do not become contaminated at the jobsite. Screen oversize aggregate or foreign materials from the aggregate prior to delivery to the mixer. During the slurry seal application, in the presence of the inspector, sample the mixture twice daily or as directed from the pug mill discharge chute. Use a rectangular non -absorptive container, such as a loaf pan, of sufficient size to obtain a sample from the entire cross section of the mixture being discharged. Ensure that an AASHTO accredited lab, with at least 5 successfully completed slurry seal projects greater than 5,000 square yards each, analyzes the mix for binder content and compliance with specifications. Submit certified results to the ME. To ensure mix compliance, the ME may perform independent testing. Ensure that the a sphalt content is within ± 0.40 percent of the JMF. If the asphalt content is outside of the allowable tolerance, recalibrate or adjust the mixing machine. The RE may stop the slurry seal operation if 2 or more samples fail to conform to the tolerance. Take corrective action or redesign the slurry seal mixture. Resume operations only after RE has approved the corrective action. Use aggregate, including mineral filler, which conforms to the gradation in Table 902.10.03-1. Table 902.10.03-1 Gradation Requirements for Aggregate and Mineral Filler Sieve Size Type I Percent Passing Type II Percent Passing Type III Percent Passing Stockpile Tolerances from JMF 3/8″ 100 100 100 – No. 4 100 90 – 100 70 – 90 ±5% No. 8 90 – 100 65 – 90 45 – 70 ±5% No. 16 65 – 90 45 – 70 28 – 50 ±5% No. 30 40 – 65 30 – 50 19 – 34 ±5% No. 50 25 – 42 18 – 30 12 – 25 ±3% No. 100 15 – 30 10 – 21 7 – 18 ±3% No. 200 10 – 20 5 – 15 5 – 15 ±2%

902.11 Binder Rich Intermediate Course (Bric)

902.11.01 Composition of Mixture

Mix BRIC in a plant that is listed on the QPL and conforms to the requirements for HMA plants as specified in 1009.01. The composition of the BRIC mixture is coarse aggregate, fine aggregate, polymer modified asphalt binder, and may also include mineral filler, and crumb rubber. Do not add Reclaimed Asphalt Pavement (RAP), Crushed Recycled Container Glass (CRCG), Ground Bituminous Shingle Material (GBSM), or Remediated Petroleum Contaminated Soil Aggregate (RPCSA). Use asphalt binder and aggregates that meet the following requirements:

1.Use polymer modified asphalt binder that is specially formulated for meeting the mix performance criteria as specified in 902.11.02. Consult with the asphalt binder supplier to obtain the appropriate material for the specific mix design. Submit a certificate of analysis (COA) showing th e PG continuous grading (AASHTO R29) for the asphalt binder used in the mix design. For quality assurance testing of the asphalt binder, the ME may sample the asphalt binder during production of the mix and compare the results with the COA submitted at the time of test strip. To analyze the binder the ME will test the binder at the nearest standard PG temperature then compare the results with the COA. If the high (G*/ sin δ) and low (stiffness and m value) temperature passing test results are within 5 percent of the results from the passing temperature on the COA, then the ME will consider the asphalt binder comparable to the binder used during test strip.

2.For coarse aggregate in BRIC, use crushed stone conforming to 901.05.01.

3.For fine aggregate, use stone sand conforming to 901.05.02. Ensure that the combined fine aggregate in the mixture conforms to the requirements for compaction level M as specified in Table 902.02.02-2.

4.Use mineral filler, if necessary, that conforms to 901.05.03.

902.11.02 Mix Design

At least 45 days before initial production, submit a job mix formula for the BRIC on forms supplied by the Department, to include a statement naming the source of each component and a report showing that the results meet the criteria specified in Table 902.11.03-1 and Table 902.11.03-2. The job mix formula for the BRIC mixture establishes the percentage of dry weight of aggregate pass ing each required sieve size and an optimum percentage of asphalt binder based upon the weight of the total mix. Determine the optimum percentage of asphalt binder according to AASHTO R 35 and M 323 with an N des of 50 gyrations. Before maximum specific gravity testing or compaction of specimens, condition the mix for 2 hours according to the requirements for conditioning for volumetric mix design in AASHTO R 30, Section 7.1. If the absorption of the combined aggregate is more than 1.5 percent according t o AASHTO T 84 and T 85, ensure that the mix is short term conditioned for 4 hours according to AASHTO R 30, Section 7.2 prior to compaction of specimens (AASHTO T 312) and determination of maximum specific gravity (AASHTO T 209). Ensure that the job mix f ormula is within the master range specified in Table 902.11.03-1. Ensure that the job mix formula provides a mixture that meets a minimum tensile strength ratio (TSR) of 85 percent when prepared according to AASTHO T 312 and tested according to AASHTO T 283 with the following exceptions:

1.Before compaction, condition the mixture for 2 hours according to AASHTO R 30 Section 7.1.

2.Compact specimens with 40 gyrations.

3.Extrude specimens as soon as possible without damaging.

4.Use AASHTO T 269 to determine void content.

5.Record the void content of the specimens.

7.Report any visual stripping in accordance with AASHTO T 283 Section 11, modify or readjust the mix if stripping is evident. For each mix design, submit with the mix desi gn forms 3 gyratory specimens and 1 loose sample corresponding to the composition of the JMF. The ME will use these to verify the properties of the JMF. Compact the specimens to the design number of gyrations (Ndes). For the mix design to be acceptable, all gyratory specimens must comply with the requirements specified in Table 902.11.03-1 and Table 902.11.03-2. The ME reserves th e right to be present at the time the gyratory specimens are molded. In addition, submit 11 gyratory specimens and two 5 gallon buckets of loose mix to the ME. The ME will use these additional gyratory samples for performance testing of the BRIC mix. The ME reserves the right to be present at the time of molding the gyratory specimens. Ensure that the 6 gyratory specimens are compacted according to AASHTO T 312, are 77 millimeters high, and have an air void content of 3.5 ± 0.5 percent. The ME will test 6 specimens using an Asphalt Pavement Analyzer (APA) according to AASHTO T 340 at 64 °C, 100 pound per square inch hose pressure, and 100 pound wheel load. Compact the other 5 specimens to 115 millimeters in height. These 5 specimens will be cut, from the middle of each 115 millimeters in height specimen, to 38 millimeters in height test specimens. The air void content of the 5 cut specimen will be determined to ensure compliance with the target air void content of 3.5 ± 0.5 percent. The ME will use the five 38 millimeters in height specimens to test using an Overlay Tester (NJDOT B-10) at 25 °C and a joint opening of 0.025 inch. The ME will eliminate the high and low Overlay test results then average and report the middle 3 test results. The ME will ensure that all submitted specimens are within the target air void co ntent as tested at the Materials’ Central Lab. The ME will approve the JMF if the average rut depth for the 6 specimens in the asphalt pavement analyzer testing is not more than 6 millimeter in 8,000 loading cycles and the number of cycles to failure in the Overlay Tester is not less than 700. If the JMF does not meet the APA and Overlay Tester criteria, redesign the BRIC mix and submit for retesting. The JMF for the BRIC mixture is in effect until modification is approved by the ME. When unsatisfactory results for any specified characteristic of the work make it necessary, the Contractor may establish a new JMF for approval. In such instances, if corrective action is not taken, the ME may require an appropriate adjustment to the JMF. Should a change in sources be made or any changes in the properties of materials occur, the ME will require that a new JMF be established and approved before production can continue. The ME may verify a mix on an annual basis rather than on a project-to-project basis if the properties and proportions of the materials do not change. If written verification is submitted by the HMA supplier that the same source and character of materials are to be used, the ME may waive the requirement for the design and verification of previously approved mixes.

902.11.03 Sampling and Testing

B.Sampling. The ME will take a sample of BRIC for volumetric acceptance testing from each 700 tons. The ME will perform sampling according to AASHTO T 168, NJDOT B-2, or ASTM D 3665. During production at the plant, a sample of asphalt binder will be taken once every 3,500 tons or as directed by the ME.

C.Quality Control Testing. The HMA producer shall provide a quality control (QC ) technician who is certified by the Society of Asphalt Technologists of New Jersey as an Asphalt Technologist, Level 2. The QC technician may substitute equivalent technician certification by the Mid -Atlantic Region Technician Certification Program (MARTCP). Ensure that the QC technician is present during periods of mix production for the sole purpose of quality control testing and to assist the ME. The ME will not perform the quality control testing or other routine test functions in the absence of, or instead of, the QC technician. The QC technician shall perform sampling and testing according to the approved quality control plan, to keep the mix within the limits specified in Table 902.11.03-1, Table 902.11.03-2, and Table 902.11.03-4. The QC technician may use acceptance test results or perform additional testing as necessary to control the mix. To determine the composition, perform ignition oven testing according to AASHTO T 308. For fully automated plants, the QC technician may determine composition using hot bin analysis according to NJDOT B-5. Use only one method for determining composition within a lot.

D.Acceptance Testing and Requirements. The ME will determine volumetric properties at Ndes for acceptance from samples taken, compacted, and tested at the HMA plant. The ME will compact HMA to the number of design gyrations (Ndes) of 50 gyrations, using equipment according to AASHTO T 312. The ME will determine bulk specific gravity of the co mpacted sample according to AASHTO T 166. The ME will use the most current QC maximum specific gravity test result in calculating the volumetric properties of the HMA. The ME will determine the dust-to-binder ratio from the composition results as tested by the QC technician. Ensure that the HMA mixture conforms to the requirements specified in Table 902.11.03-2 and to the gradation requirements in Table 902.11.03-1. If 2 samples in a lot fail to conform to the gradation or volumetric requirements, immediately initiate corrective action. The ME will test a minimum of 1 sample per lot for moisture, basing moisture determinations on the weight loss of an approximately 1,600 gram sample of mixture heated for 1 hour in an oven at 280 ± 5 °F. Ensure that the moisture content of the mixture at discharge from the plant does not exceed 1.0 percent.

E.Performance Testing. Provide 11 gyratory specimens and 2 box samples of loose mix to the ME. The ME will use these additional gyratory samples for performance testing of the BRIC mix. The ME reserves the right to be present at the time of molding th e gyratory specimens. Ensure that the 6 gyratory specimens are compacted according to AASHTO T 312, are 77 millimeters high, and have an air void content of 3.5 ± 0.5 percent. The ME will test 6 specimens using an Asphalt Pavement Analyzer (APA) accordin g to AASHTO T 340 at 64 oC, 100 pound per square inch hose pressure, and 100 pound wheel load. Compact the other 5 specimens to 115 millimeters in height. These 5 specimens will be cut, from the middle of each 115 millimeters height specimen, to 38 millimeters in height test specimens. The air void content of the 5 cut specimen will be determined to ensure compliance with the target air void content of 3.5 ± 0.5 percent. The ME will use the five 38 millimeters in height specimens to test using an Overlay Tester (NJDOT B-10) at 25 °C and a joint opening of 0.025 inch. The ME will eliminate the high and low Overlay test results then average and report the middle 3 test results. The ME will use the boxes of loose mix to determine the maximum specific gravity of the mix according to AASHTO T 209. The ME will ensure that all submitted specimens are within the target air void content as tested at the Materials’ Central Lab. Ensure that the first sample is taken during the construction of the test strip as specified in 407.03.01.C. Thereafter, sample every second lot or as directed by the ME. If a sample does not meet the design criteria for performance testing as specified in Table 902.11.03-4, the ME may stop production of BRIC until corrective action is taken. If the BRIC mix exceeds the APA criteria of 12 millimeters in 8,000 loading cycles, the RE may require removal and replacement of the lot of BRIC. Table 902.11.03-1 JMF Requirements for BRIC Sieve Sizes Percent Passing1 Production Control Tolerances2 3/8" 100 ±0% No. 4 90 – 100 ±2% No. 8 55 – 90 ±4% No. 30 20 – 55 ±4% No. 200 4 – 10 ±2% Asphalt Binder Content (Ignition Oven)3 7.4 % minimum ±0.40% Maximum Lift Thickness 1.5 inch –

1.Aggregate percent passing to be determined based on dry aggregate weight.

2.Production tolerances are for the approved JMF and may fall outside of the wide band gradation limits.

3.The asphalt binder content may not be lower than the minimum after the production tolerance is applied. Table 902.11.03-2 Volumetric Requirements for Design and Control of BRIC Required Density (% of Max Sp. Gr.) Voids in Mineral Aggregate (VMA) Dust-to-Binder Ratio Draindown AASHTO T 305 @ Ndes (50 gyrations) @ Nmax (100 gyrations) Design Requirements 97.5 ≤ 99.0 ≥ 18.0 % 0.6 – 1.2 ≤ 0.1 % Control Requirements 96.5 – 98.5 ≤ 99.0 ≥ 18.0 % 0.6 – 1.3 ≤ 0.1 % Table 902.11.03-3 Mix Design Performance Testing Requirements for BRIC Test Requirement Asphalt Pavement Analyzer (AASHTO T 340) ≤ 6 mm @ 8,000 loading cycles Overlay Tester (NJDOT B-10) ≥700 cycles Table 902.11.03-4 Production Performance Testing Requirements for BRIC Test Requirement Asphalt Pavement Analyzer (AASHTO T 340) ≤ 7 mm @ 8,000 loading cycles Overlay Tester (NJDOT B-10) ≥ 650 cycles

902.12 Asphalt Rubber Gap Graded Course

902.12.01 Composition of Mixture

Mix ARGG course in a plant listed on the QPL and conforming to the requirements for HMA plants specified in 1009.01. Ensure the HMA plant is equipped with asphalt-rubber binder blending equipment as specified in 1009.03. Composition of mixture for ARGG surface course is coarse aggregate, fine aggregate and asphalt-rubber binder. Do not use RAP, CRCG, GBSM, or RPCSA in ARGG surface course. Composition of mixture for ARGG intermediate course is coarse aggregate, fine aggregate and asphalt -rubber binder. ARGG intermediate course may contain up to 10 percent RAP. Use aggregates that conform to 901.05. Use coarse aggregate that is crushed stone conforming to 901.05.01 and Table 902.12.01-1. Table 902.12.01-1 Coarse Aggregate Properties for ARGG Tests Test Method Maximum Percent Percentage of wear, Los Angeles Abrasion Test AASHTO T 96 30 Flat and Elongated, 5 to 1 (Material Retained on the No. 4 Sieve) ASTM D 4791 5 Flat and Elongated, 3 to 1 (Material Retained on the No. 4 Sieve) ASTM D 4791 20 Use fine aggregate that is manufactured stone sand and conforms to Table 902.02.02-2. Use asphalt-rubber binder that conforms to 902.07.02.

902.12.02 Mix Design

At least 45 days before initial production, submit job mix formula(s) for each ARGG mixture performed by an AASHTO accredited lab with at least 5 successfully completed ARGG course projects grea ter than 5,000 tons each. Include a statement naming the source of each component and a report with the results for the criteria specified in Table 902.12.02-1 and Table 902.12.02-2. Include a report detailing the rotational viscosity of the asphalt-rubber binder at 60, 90, 135, 240, and 1,440 minutes. Submit lab qualifications and references to the ME for approval prior to beginning work. Design the mix to meet the criteria in Table 902.12.02 -1 and Table 902.12.02 -2. Prepare the JMF according to AASHTO R 46. Determine the JMF at 4 percent air voids and 75 gyrations of the Superpave gyratory compactor. Table 902.12.02-1 JMF Master Ranges and Mixture Requirements ARGG Course Mixture Designations (% Passing1) Sieve Sizes ARGG Course Production Control Tolerances2 3/4" 100 ±0% 1/2" 90 – 100 ±2% 3/8" 83 – 87 ±1% No. 4 28 – 42 ±3% No. 8 14 – 22 ±2% No. 200 0 – 6 ±2% Coarse Aggregate Fraction Portion retained on No. 4 Sieve – Minimum Lift Thickness 1.5 inch –

1.Aggregate percent passing to be determined based on dry aggregate weight.

2.Production tolerances are for the approved JMF and may fall outside of the wide band gradation limits. Table 902.12.02-2 ARGG Course Mixtures Volumetrics for Design and Plant Production Property Production Control Tolerances Design Requirement Air Voids 1% 4% Voids in Mineral Aggregate (VMA) – 18.0% minimum Voids in Coarse Aggregate of Mix(VCAmix) – Less than VCAdry Draindown @ production temperature – 0.30% maximum Asphalt Binder Content (Ignition Oven)1, 2 0.40% 7.6% minimum Tensile Strength Ratio – 80% minimum

1.Asphalt-rubber binder content to be determined based on total weight of mix.

2.The asphalt binder content may not be lower than the minimum after the production tolerance is applied.

902.12.03 Sampling and Testing

Perform quality control testing as specified in 902.02.04.C. Ensure that the mix meets the requirements as specified in

902.02.04 A, otherwise the RE or ME will reject the material. Ensure that the temperature of th e mixture at discharge

from the plant or surge and storage bins meets the WMA additive manufacturer’s recommendations. Do not allow the mixture temperature to exceed 300 °F at discharge from the plant. During production at the plant, the ME will take a sample from each 700 tons of production to verify composition and air voids. Conduct draindown, VCAmix, VCAdry, and VMA testing every 3,500 tons or as directed by the ME. Perform tests according to AASHTO R 46. If the testing results are outside of the p roduction control tolerances specified in Table 902.12.02 -1 and Table 902.12.02-2 for an acceptance sample, immediately run a quality control sample. If the quality control sample is also outside of the control tolerances in Table 902.12.02-1, determine if a plant adjustment is needed and take corrective action to bring the mix into compliance. Take additional quality control samples after completing the corrective action to ensure that the mix is within tolerances. If 2 consecutive acceptance samples are outside the tolerances specified in Table 902.12.02-1 and Table 902.12.02-2, immediately stop production. Obtain ME approval of a plant correction plan before resuming production. Upon restarting production, do not transport mixture to the Project Limits before the results of a QC sample from the mixture indicate that the mixture meets JMF tolerances. The ME will reject mixture produced at initial restarting that does not meet tolerances. The ME will perform sampling according to NJDOT B-2 or ASTM D 3665, and will perform testing for composition according to AASHTO T 308 or NJDOT B-5. The ME will determine bulk specific gravity of the compacted s ample according to AASHTO T 166. The ME will use the most current QC maximum specific gravity test result, obtained according to AASHTO T 209, in calculating the volumetric properties of the ARGG. Perform testing for draindown according to AASHTO T 305. During production at the plant, the ME will take a sample of the asphalt binder once every 3,500 tons or as directed by the ME.

902.13 Hot Mix Asphalt High Rap

902.13.01 Mix Designations

The requirements for specific HMA mixtures with required minimum am ounts of RAP are identified by the abbreviated fields in the Item description as defined as follows: HOT MIX ASPHALT 12.5ME SURFACE COURSE HIGH RAP

1.“HOT MIX ASPHALT” “Hot Mix Asphalt” is located in the first field in the Item description for the purpose of identifying the mixture requirements.

2.“12.5” The second field in the Item description designates the nominal maximum size aggregate (in millimeters) for the job mix formula (sizes are 4.75, 9.5, 12.5, 19, 25, and 37.5 mm).

3.“M” The third field in the Item description designates the design compaction level for the job mix formula based on traffic forecasts as listed in Table 902.02.03-2 (levels are L=low and M=medium).

4.“E” The fourth field in the Item description designates the high temperature designation of the performance- graded binder. Options are “64” for PG 64S-22 and “E” for PG 64E-22.

5.“SURFACE COURSE” The last field in the Item description designates the intended use and location within the pavement structure (options are surface, intermediate, or base course).

6.“HIGH RAP” This additional field designates that there will be a minimum percentage of RAP required for the mixture in 902.13.02.

902.13.02 Composition of Mixture

Provide materials as specified: Aggregates for Hot Mix Asphalt ................................ ................................ ................................ .................... 901.05 Use a virgin asphalt binder that will result in a mix that meets the performance requirements specified in Table 902.13.03-2. Ensure that the virgin asphalt binder meets the requirements of 902.01.01 except the performance grade. Use a performance grade of asphalt binder as determined by the mix design and mix performance testing. Submit a certificate of analysis (COA) showing the PG continuous grading (AASHTO R 29) for the asphalt binder used in the mix design. For quality assurance testing of the asphalt binder, the ME may sample the asphalt binder during produc tion of the mix and compare the results with the COA submitted during test strip approval. To analyze the binder the ME will test the binder at the nearest standard PG temperature then compare the results with the COA. If the high (G*/ sin δ) and low (stiffness and m value) temperature passing test results are within 5 percent of the results from the passing temperature on the COA, then the ME will consider the asphalt binder comparable to the binder used during the test strip. Mix HMA HIGH RAP in a plan t that is listed on the QPL for HMA Plants and conforms to the requirements for HMA Plants as specified in 1009.01. Composition of the mixture for HMA HIGH RAP surface course is coarse aggregate, fine aggregate, asphalt binder, and a minimum of 20 percent Reclaimed Asphalt Pavement (RAP), and may also include mineral filler, asphalt rejuvenator , and Warm Mix Asphalt (WMA) additives or processes as specified in 902.01.04. When WMA is used it must meet the requirements as specified in 902.10. Ensure that the finished mix does not contain more than a total of 1 percent by weight contamination from Crushed Recycled Container Glass (CRCG). The composition of the mixture for HMA HIGH RAP base or intermediate course is coarse aggregate, fine aggregate, asphalt binder, and a minimum of 30 percent Reclaimed Asphalt Pavement (RAP), and m ay also include mineral filler, up to 10 percent of additional recycled materials, asphalt rejuvenator, and Warm Mix Asphalt (WMA) additives or processes as specified in 902.01.04. When WMA is used it must meet the requirements as specified in 902.10. The recycled materials may consist of a combination of RAP, CRCG, Ground Bituminous Shingle Material (GBSM), and RPCSA, with the following individual limits: Table 902.13.02-1 Use of Recycled Materials in Base or Intermediate Course Recycled Material Minimum Percentage Maximum Percentage RAP 30 – CRCG – 10 GBSM – 5 RPCSA – 20 Combine the aggregates to ensure that the resulting mixture meets the grading requirements specified in Table 902.02.03-1. In determining the percentage of aggregates of the various sizes nec essary to meet gradation requirements, exclude the asphalt binder. Ensure that the combined coarse aggregate, when tested according to ASTM D 4791, has less than 10 percent flat and elongated pieces retained on the No. 4 sieve and larger. Measure aggregat e using the ratio of 5:1, comparing the length (longest dimension) to the thickness (smallest dimension) of the aggregate particles. Ensure that the combined fine aggregate in the mixture conforms to the requirements specified in Table 902.02.02-2. Ensure that the material passing the No. 40 sieve is non-plastic when tested according to AASHTO T 90.

902.13.03 Mix Design

At least 45 days before initial production, submit a job mix formula for the HMA HIGH RAP on forms supplied by the Department, to include a statement naming the source of each component and a report showing that the results meet the criteria specified in Table 902.02.03-1 and Table 902.13.03-1. Include in the mix design the following based on the weight of the total mixture:

1.Percentage of RAP or GBSM.

2.Percentage of asphalt binder in the RAP or GBSM.

3.Percentage of new asphalt binder.

4.Total percentage of asphalt binder.

5.Percentage of each type of virgin aggregate. Table 902.13.03-1 HMA HIGH RAP Requirements for Design Compaction Levels Required Density (% of Theoretical Max. Specific Gravity) Voids in Mineral Aggregate (VMA)2, % (minimum) Voids Filled With Asphalt (VFA) % Dust-to-Binder Ratio Nominal Max. Aggregate Size, mm @Ndes1 @Nmax 25.0 19.0 12.5 9.5 4.75 L 96.0 ≤ 98.0 13.0 14.0 15.0 16.0 17.0 70 – 85 0.6 – 1.2 M 96.0 ≤ 98.0 13.0 14.0 15.0 16.0 17.0 65 – 85 0.6 – 1.2

2.For calculation of VMA, use bulk specific gravity of the combined aggregate include aggregate extracted from the RAP. The job mix formula for the HMA HIGH RAP mixture establishes the percentage of dry weight of aggregate, including the aggregate from the RAP, passing each required sieve size and an optimum percentage of asphalt binder based upon the weight of the total mix. Determine the optimum percentage of asphalt binder according to AASHTO R 35 and M 323 with an Ndes as required in Table 902.02.03-2. Before maximum specific gravity testing or compaction of specimens, condition the mix for 2 hours according to the requirements for conditioning for volumetric mix design in AASHTO R 30, Section 7.1. If the absorption of the combined aggregate is more than 1.5 percent according to AASHTO T 84 and T 85, ensure that the mix is short term conditioned for 4 hours according to AASHTO R 30, Section 7.2 prior to compaction of specimens (AASHTO T 312) and determination of maximum specific gravity (AASHTO T 209). Ensure that the job mix formula is within the master range specified in Table 902.02.03-1. Ensure that the job mix formula provides a mixture that meets a minimum tensile strength ratio (TSR) of 80 percent when prepared according to AASHTO T 312 and tested according to AASHTO T 283. Submit the TSR results with the mix design. Determine the correction factor of the mix including the RAP by using extracted aggregate from the RAP in the proposed proportions when testing is done to determine the correction factor as specified in AASHTO T 308. Use extracted aggregate from the RAP in determining the bulk specific gravity of the aggregate blend for the mix design. For each mix design, submit with the mix design forms 3 gyratory specimens and 1 loose sample corresponding to the composition of the JMF. Ensure that the samples include the percentage of RAP that is being proposed for the mix. The ME will use these to verify the properties of the JMF. Compact the specimens to the design number of gyrations (N des). For the mix design to be acceptable, all gyratory specimens must comply with the requirements specified in Table 902.02.03-1 and Table 902.13.03-1. The ME reserves the right to be present at the time the gyratory specimens are molded. In addition, subm it 11 gyratory specimens and two 5 gallon buckets of loose mix to the ME. The ME will use these additional gyratory samples for performance testing of the HMA HIGH RAP mix. The ME reserves the right to be present at the time of molding the gyratory specimens. Ensure that the additional gyratory specimens are compacted according to AASHTO T 312. Compact 6 of the specimens to 77 millimeter height, and have an air void content of 6.5 ± 0.5 percent. The ME will test 6 specimens using an Asphalt Pavement An alyzer (APA) according to AASHTO T 340 at 64 °C, 100 pound per square inch hose pressure, and 100 pound wheel load. Compact the other 5 specimens to 115 m illimeter height. These 5 specimens will be cut, from the middle of each 115 millimeter height speci men, to 38 millimeter height test specimens. The air void content of the 5 cut specimen will be determined to ensure compliance with the target air void content of 6.5 ± 0.5 percent. The ME will use the five 38 millimeter height specimens to test using a n Overlay Tester (NJDOT B-10) at 25 °C and a joint opening of 0.025 inch. The ME will eliminate the high and low Overlay test results then average and report the middle 3 test results. The ME w ill ensure that all submitted specimens are within the target air void content as tested at the Materials’ Central Lab. The ME will approve the JMF if the results meet the criteria in Table 902.13.03-2. Table 902.13.03-2 Performance Testing Requirements for HMA HIGH RAP Design Test Requirement Surface Course Intermediate and Base Course PG 64S-22 PG 64E-22 PG 64S-22 PG 64E-22 APA @ 8,000 loading cycles (AASHTO T 340) ≤ 7 mm ≤ 4 mm ≤ 7 mm ≤ 4 mm Overlay Tester (NJDOT B-10) ≥ 200 cycles ≥ 275 cycles ≥ 100 cycles ≥ 150 cycles If the JMF does not meet the APA and Overlay Tester criteria, redesign the HMA HIGH RAP mix and submit for retesting. The JMF for the HMA HIGH RAP mixture is in effect until modification is approved by the ME. When unsatisfactory results for any specified characteristic of the work make it necessary, the Contractor may establish a new JMF for approval. In such instances, if corrective action is not taken, the ME may require an appropriate adjustment to the JMF. Should a change in sources be made or any changes in the properties of materials occur, the ME will require that a new JMF be established and approved before production can continue.

902.13.04 Sampling and Testing

B.Sampling. The ME will take 5 stratified random samples of HMA HIGH RAP for volumetric acceptance test ing from each lot of approximately 3,500 tons of a mix. When a lot of HMA HIGH RAP is less than 3,500 tons, the ME will take samples at random for each mix at the rate of one sample for each 700 tons. The ME will perform sampling according to AASHTO T 168, NJDOT B-2, or ASTM D 3665. During production at the plant, a sample of asphalt binder will be taken once every 3,500 tons or as directed by the ME. Use a portion of the samples taken for volumetric acceptance testing for composition testing.

C.Quality Control Testing. The HMA HIGH RAP producer shall provide a quality control (QC) technician who is certified by the Society of Asphalt Technologists of New Jersey as an Asphalt Technologist, Lev el 2. The QC technician may substitute equivalent technician certification by the Mid -Atlantic Region Technician Certification Program (MARTCP). Ensure that the QC technician is present during periods of mix production for the sole purpose of quality control testing and to assist the ME. The ME will not perform the quality control testing or other routine test functions in the absence of, or instead of, the QC technician. The QC technician shall perform sampling and testing according to the approved quality control plan, to keep the mix within the limits specified for the mix being produced. The QC technician may use acceptance test results or perform additional testing as necessary to control the mix. To determine the composition, perform ignition oven testing according to AASHTO T 308. For each acceptance test, perform maximum specific gravity testing according to AASHTO T 209 on a test portion of the sample taken by the ME. Sample and test coarse aggregate, fine aggregate, mineral filler, and RAP according to the approved quality control plan for the plant. Ensure that the supplier has in operation an ongoing daily quality control program to evaluate the RAP. As a minimum, this program shall consist of the following:

1.An evaluation performed to ensure that the material conforms to 901.05.04 and compares favorably with the design submittal.

2.An evaluation of the RAP material performed using a solvent or an ignition oven to qu alitatively evaluate the aggregate components to determine conformance to 901.05.

3.Quality control reports as directed by the ME.

D.Acceptance Testing and Requirements. The ME will determine volumetric properties at Ndes for acceptance from samples taken, compacted, and tested at the HMA plant. The ME will compact HMA HIGH RAP to the number of design gyrations (Ndes) specified in Table 902.02.03-2, using equipment according to AASHTO T 312. The ME will determine bulk specific gravity of the compacted sample according to AASHTO T 166. The ME will use the most current QC maximum specific gravity test result in calculating the volumetric properties of the HMA HIGH RAP. The ME will determine the dust-to-binder ratio from the composition results as tested by the QC technician. Ensure that the HMA HIGH RAP mixture conforms to the requirements specified in Table 902.13.04-1, and to the gradation requirements in Table 902.02.03-1. If 2 samples in a lot fail to conform to the gradation or vo lumetric requirements, immediately initiate corrective action. The ME will test a minimum of 1 sample per lot for moisture, basing moisture determinations on the weight loss of an approximately 1,600 gram sample of mixture heated for 1 hour in an oven at 280 ± 5 °F. Ensure that the moisture content of the mixture at discharge from the plant does not exceed 1.0 percent. Table 902.13.04-1 HMA HIGH RAP Requirements for Control Compaction Levels Required Density (% of Theoretical Max. Specific Gravity) Voids in Mineral Aggregate (VMA), % (minimum) Dust-to-Binder Ratio Nominal Max. Aggregate Size, mm @Ndes1 25.0 19.0 12.5 9.5 4.75 L, M 95.0 – 98.5 13.0 14.0 15.0 16.0 17.0 0.6 – 1.3

E.Performance Testing for HMA HIGH RAP. Provide 11 gyratory specimens that are compacted according to AASHTO T 312 and 2 boxes of loose mix. Compact 6 of the specimens to 77 millimeter height and an air void content of 6.5 ± 0.5 percent. Compact the other 5 specimens to 115 millimeter height. These 5 specimens will be cut, from the middle of each 115 millimeter height specimen, to 38 millimeter height test specimens. The air void content of the 5 cut test specimens will be determined to ensure compliance with the target air void content of 6.5 ± 0.5 percent. The ME will use the boxes of loose mix to determine the maximum specific gravity of the mix according to AASHTO T 209. The ME will use the gyratory samples for performance testing of the HMA HIGH RAP mix. The ME will test six 77 millimeter height specimens using an Asphalt Pavement Analyzer (APA) according to AASHTO T 340 at 64 °C, 100 pound per square inch hose pressure, and 100 pound wheel load. The ME will use the five 38 millimeter height specimens to test using an Overlay Tester (NJDOT B-10) at 25 °C and a joint opening of 0.025 inch. The ME will eliminate the high and low Overlay test result then average and report the middle 3 test results. The ME will ensure that all submitted specimens are within the target air void content as tested at the Materials’ Central Lab. Ensure that the first sample is taken during the construction of the test strip as specified in 406.03.01.C. Thereafter, sample every lot or as directed by the ME. If the test strip is done within the P roject Limits and the performance testing results are acceptable to the ME, the results will be included into the first lot. A lot is defined as material placed on the traveled way within the Project Limits. If a sample does not meet the criteria for performance testing as specified in Table 902.13.03-2, the Department will assess a pay adjustment as specified in Table 902.13.04-2 and Table 902.13.04-3. If a lot fails to meet requirements for both APA and Overlay Tester, the Department will assess pay adjustments for both parameters or may require removal and replacement of the lot. The Department will calculate the pay adjustment by multiplying the percent pay adjustment (PPA) by the quantity in the lot and the bid price for the HMA HIGH RAP item. If samples received are not within the target air void range, 6.5 ± 0.5 percent, the Department will consider the sample s untestable and assess a PPA of -100 percent for APA specimens and/or Overlay specimens or may require removal and replacement of the lot. PPA for both APA and Overlay are cumulative and may not exceed -100 percent in total. If the Department requires removal and replacement, then the replacement work is subject to the same requirements as the initial work. Table 902.13.04-2 Surface Course Performance Testing Pay Adjustments for HMA HIGH RAP Surface Course PPA PG 64S-22 PG 64E-22 APA @ 8,000 loading cycles, mm (AASHTO T 340) t ≥ 7 t ≤ 4 0 7 < t ≤ 10 4 < t ≤ 7 PG 64S-22: -50(t-7)/3 PG 64E-22: -50(t-4)/3 t > 10 t > 7 -100 or Remove & Replace Overlay Tester, cycles (NJDOT B-10) t ≥ 200 t ≥ 275 0 200 > t ≥ 150 275 > t ≥ 200 Surface PG 64S-22: -(200-t) Surface PG 64E-22: -(275-t)/1.5 t < 150 t < 200 -100 or Remove & Replace Table 902.13.04-3 Intermediate and Base Course Performance Testing Pay Adjustments for HMA HIGH RAP Intermediate and Base Course PPA PG 64S-22 PG 64E-22 APA @ 8,000 loading cycles, mm (AASHTO T 340) t ≤ 7 t ≤ 4 0 7 < t ≤ 10 4 < t ≤ 7 PG 64S-22: -50(t-7)/3 PG 64E-22: -50(t-4)/3 t > 10 t > 7 -100 or Remove & Replace Overlay Tester, cycles (NJDOT B-10) t ≥ 100 t ≥ 150 0 100 > t ≥ 75 150 > t ≥ 110 Intermediate PG 64S-22: -(2t-200) Intermediate PG 64E-22: -1.25(150-t) t < 75 t < 110 -100 or Remove & Replace

902.14 Bridge Deck Waterproof Surface Course (Bdwsc)

902.14.01 Composition of the Mixture

Provide BDWSC mixture that is produced at an HMA plant that is listed on the QPL and meets the requirements specified in 1009.01. Composition of the mixture for BDWSC is coarse aggregate, fine aggregate, and asphalt binder, and may also include mineral filler and crumb rubber. Do not use Reclaimed Asphalt Pavement (RAP), Ground Bituminous Shingle Material, Remediat ed Petroleum Contaminated Soil Aggregate, or Crushed Recycled Container Glass (CRCG) in BDWSC.

1.Use polymer modified asphalt binder that is specially formulated for meeting the mix performance criteria as specified in 902.14.02. Consult with the asphalt binder supplier to obtain the appropriate material for the specific mix design. Submit a certificate of analysis (COA) showing the PG continuous grading (AASHTO R 29) for the asphalt binder used in the mix design. For quality assurance testing of the asphalt binder, the ME may sample the asphalt binder during production of the mix and compare the results with the COA submitted during test strip approval. To analyze the binder the ME will test the binder at the nearest standard PG temperature then compare the results with the COA. If the high (G*/ sin δ) and low (stiffness and m value) temperature passing test results are within 5 percent of the results from the passing temperature on the COA, then the ME will consider the asphalt binder comparable to the binder used during the test strip.

2.Use coarse aggregate that conforms to 901.05.01 and is classified as argillite, gneiss, granite, quartzite, or trap rock as defined in 901.03.01.

3.Use fine aggregate that is stone sand as specified in 901.05.02 and has an uncompac ted void content of at least 45 percent when tested according to AASHTO T 304, Method A. Ensure that the minimum sand equivalent of the fine aggregate is 45 percent when tested according to AASHTO T 176.

4.Ensure that mineral filler, if used, conforms to 901.05.03.

902.14.02 Mix Design

At least 45 days before initial production, submit a JMF for the BDWSC on forms supplied by the Department. Include a statement naming the source of each component and a report confirming the results meet the criteria specified in Table 902.14.02-1 and Table 902.14.02-2. Table 902.14.02-1 Job Mix Formula Requirements for BDWSC Sieve Size Percent Passing1 Production Control Tolerances2 1/2˝ 100 ± 0.0% 3/8˝ 80 – 100 ± 4.0% #4 55 – 85 ± 6.0% #8 32 – 42 ± 2.0% #16 20 – 30 ± 2.0% #30 12 – 22 ± 2.0% #50 7 – 16 ± 2.0% #100 3 – 12 ± 2.0% #200 2.0 – 6.0 ± 1.0% Asphalt Binder Content (Ignition Oven)3 7.0 % minimum ± 0.30% Lift Thickness 1.5 – 3.0 inch –

1.Aggregate percent passing to be determined based on dry aggregate weight.

2.Production tolerances are for the approved JMF and may not fall outside of the wide band gradation limits.

3.The asphalt binder content may not be lower than the minimum after the production tolerance is applied. Table 902.14.02-2 Volumetric Requirements for Design and Control of BDWSC Required Density (% of Max Sp. Gr.) Voids Filled with Asphalt (VFA) Voids in Mineral Aggregate (VMA) Dust-to-Binder Ratio Draindown AASHTO T 305 Ndes (50 gyrations) Design Requirements 99 90 – 100 ≥ 18.0 % 0.3 – 0.9 ≤ 0.1 % Control Requirements 98 – 100 90 – 100 ≥ 18.0 % 0.3 – 0.9 ≤ 0.1 % Establish the percentage of dry weight of aggregate passing each required sieve size and an optimum percentage of asphalt binder based upon the weight of the total mix. Determine the optimum percentage of asp halt binder according to AASHTO R 35 and M 32 3 with an N des of 50 gyrations. Before maximum specific gravity testing or compaction of specimens, condition the mix for 2 hours according to the requirements for conditioning for volumetric mix design in AASHTO R 30, Section 7.1. If the absorption of t he combined aggregate is more than 1.5 percent according to AASHTO T 84 and T 85, short term condition the mix for 4 hours according to AASHTO R 30, Section 7.2 prior to compaction of specimens (AASHTO T 312) and determination of maximum specific gravity (AASHTO T 209). Ensure that the JMF is within the master range specified in Table 902.14.02-1. Ensure that the mixture meets a minimum tensile strength ratio (TSR) of 90 percent when tested acco rding to AASHTO T 283 with the following exceptions:

1.Before compaction, condition the mixture for 2 hours according to AASHTO R 30 Section 7.1.

2.Compact specimens with 40 gyrations according to AASHTO T 312.

3.Extrude specimens as soon as possible without damaging.

4.Use AASHTO T 269 to determine void content.

5.Record the void content of the specimens.

7.If visual stripping is detected, modify or readjust the mix. For each mix design, submit 3 gyratory specimens and 1 loose sample corresponding to the composition of the JMF, including the design asphalt content, with the mix design forms. The ME will use these samples for verification of the properties of the job mix formula. Compact the specimens to the design number of gyrations (Ndes). To be acceptable, all 3 gyratory specimens must comply with the gradation and asphalt content requirements in Table 902.14.02-1 and with the control requirements in Table 902.14.02-2. The ME reserves the right to be present at the time of molding the gyratory specimens. In addition, submit 6 gyratory specimens and 12 boxes of loose mix to the ME. The ME will use these additional samples for performance testing of the BDWSC mix. Ensure that the additional gyratory specimens are compacted according to AASHTO T 312, are 77 millimeters high, and have a maximum air void content of 3.0 percent. The ME will test the specimens using an Asphalt Pavement Analyzer according to AASHTO T 340 at 64 C, 100 pounds per square inch hose pressure, and 100 pound wheel load. The ME will use the supplied loose mix to compact 2 samples to a maximum air void content of 3.0 percent for Flexural Beam Fatigue testing. The ME will test the fatigue specimens according to AASHTO T 321 at 15 C, 10 Hertz loading frequency, and 1,500 micro -strains. The ME will approve the JMF if the average rut depth for the 6 specimens in the Asphalt Pavement Analyzer testing is not m ore than 3 millimeters in 8,000 loading cycles and the fatigue life, as determined by AASHTO T 321, is not less than 100,000 cycles. If the JMF does not meet the APA and Flexural Beam Fatigue criteria, redesign the BDWSC mix and submit for retesting. The ME will ensure that all submitted specimens are within the target air void content as tested at the Materials’ Central Lab. The JMF for the BDWSC mixture is in effect until modification is approved by the ME. If required, the ME may use the 12 boxes of loose BDWSC mix to compact additional gyratory specimens for performance testing and the performance test results may be used for approval of the JMF. When unsatisfactory results for any specified characteristic of the work make it necessary, the Contractor may establish a new JMF for approval. In such instances, if corrective action is not taken, the ME may require an appropriate adjustment to the JMF. Should a change in sources be made or a change in the properties of materials occurs, the ME will require that a new JMF be established and approved before production can continue.

902.14.03 Sampling and Testing

B.Sampling. Perform sampling as specified in 902.02.04.B.

C.Quality Control Testing. Perform quality control testing as specified in 902.02.04.C.

D.Acceptance Testing and Requirements. The ME will determine volumetric properties at Ndes for acceptance from samples taken, compacted, and tested at the HMA plant. The ME will compact HMA to the 50 design gyrations (Ndes), using equipment according to AASHTO T 312. The ME will determine bulk specific gravity of the compacted sample according to AASHTO T 166. The ME will use the most current QC maximum specific gravity test result in calculating the volumetric properties of the BDWSC. The ME will determine the dust-to-binder ratio from the composition results as tested by the QC technician. Ensure that the HMA mixture conforms to the requirements specified in Table 902.14.02-1 and Table 902.14.02-2. If 2 samples in a lot fail to conform to the gradation or volumetric requirements, immediately initiate corrective action. The ME will test a minimum of 1 sample per lot for moisture, basing moisture determinations on the weight loss of an approximately 1,600 gram sample of mixture heated for 1 hour in an oven at 280 ± 5 °F. Ensure that the moisture content of the mixture at discharge from the plant does not exceed 1.0 percent.

E.Performance Testing. Provide 6 gyratory specimens that are compacted according to AASHTO T 312 and 12 boxes of loose mix. Compact the 6 gyratory specimens to 77 millimeters high and maximum air void content of 3.0 percent. The ME will test the specimens using an Asphalt Pavement Analyzer a ccording to AASHTO T 340 at 64 °C, 100 pound per square inch hose pressure, and 100 pound wheel load. The ME will use the supplied loose mix to determine the maximum specific gravity of the mix according to AASHTO T 209 and to compact 2 samples to a maximum air void content of 3.0 percent for Flexural Beam Fatigue testing. The ME will test the fatigue specimens according to AASHTO T 321 at 15 °C, 10 Hertz loading frequency, and 1,500 micro -strains. The ME will ensure that all submitted specimens are within the target air void content as tested at the Materials’ Central Lab. Ensure that the first sample is taken in the first lot of production. Thereafter, sample every second lot. The ME may stop production of BDWSC if a sample does not meet the design cr iteria for performance testing as detailed in Table 902.14.03-1. Table 902.14.03-1 Performance Testing Requirements for BDWSC Test Requirement APA @ 8,000 loading cycles (AASHTO T 340) ≤ 3 mm Flexural Fatigue Life (AASHTO T 321) ≥ 100,000 cycles

902.15 Retrofit Strip Seal Joint System

Use a strip seal joint system that builds up the joint using elastomeric or polymer concrete and seals the joint using a strip seal expansion joint. Ensure that the joint system includes a method for securing the strip seal with the elastomeric or polymer concrete. Ensure that the strip seal joint system is capable of being constructed within the allowable lane closure hours for the project and compatible with installation in an asphalt overlay. Use strip seal gland that is a neoprene strip seal gland according to 914.04.02.B or a preformed silicon strip seal meeting the criteria in Table 902.15-1.

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Source: Standard Specifications for Road and Bridge Construction, 2019 (rev. 2022-12-21) Edition. Pages 425–467 of 651. View official source ↗

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901 Aggregates

903 Concrete

902Asphalt

Ask about Section 902

902.01 Bituminous Materials

902.01.01 Asphalt Binder

902.01.02 Emulsified Asphalts

902.01.03 Polymer Modified Emulsified Asphalt

902.01.04 Warm Mix Asphalt (WMA) Additives and Processes

902.02 Hot Mix Asphalt (Hma)

902.02.01 Mix Designations

902.02.02 Composition of Mixtures

902.02.03 Mix Design

902.02.04 Sampling and Testing

902.03 Open-Graded Friction Course (Ogfc) and Modified Open-Graded Friction

902.03.01 Composition of Mixtures

902.03.02 Mix Design

902.03.03 Sampling and Testing

902.04 Ultra-Thin Hma

902.04.01 Composition of Mixture

902.04.02 Mix Design

902.04.03 Sampling and Testing

902.05 Stone Matrix Asphalt (Sma)

902.05.01 Composition of Mixture

902.05.02 Mix Design

902.05.03 Sampling and Testing

902.06 Asphalt-Stabilized Drainage Course (Asdc)

902.06.01 Composition

902.06.02 Mix Design

902.06.03 Sampling and Testing

902.02.04 A, except that the temperature of the mix at discharge is required to be between 230 °F and 275 °F, otherwise

902.07 Asphalt-Rubber Open-Graded Friction Course (Ar-Ogfc)

902.07.01 Composition of Mixture

902.07.02 Asphalt-Rubber Binder

902.07.03 Mix Design

902.07.04 Sampling and Testing

902.08.01 Composition of Mixture

902.08.02 Mix Design

902.08.03 Sampling and Testing

902.09 Micro Surfacing

902.09.01 Composition of the Mixture

902.09.02 Mix Design of Micro Surfacing Mixture

902.09.03 Sampling and Testing

902.10 Slurry Seal

902.10.01 Composition of the Mixture

902.10.01 1 Emulsified Asphalt and Residue Requirements

902.10.02 Mix Design of Slurry Seal Mixture

902.10.03 Sampling and Testing

902.11 Binder Rich Intermediate Course (Bric)

902.11.01 Composition of Mixture

902.11.02 Mix Design

902.11.03 Sampling and Testing

902.12 Asphalt Rubber Gap Graded Course

902.12.01 Composition of Mixture

902.12.02 Mix Design

902.12.03 Sampling and Testing

902.02.04 A, otherwise the RE or ME will reject the material. Ensure that the temperature of th e mixture at discharge

902.13 Hot Mix Asphalt High Rap

902.13.01 Mix Designations

902.13.02 Composition of Mixture

902.13.03 Mix Design

902.13.04 Sampling and Testing

902.14 Bridge Deck Waterproof Surface Course (Bdwsc)

902.14.01 Composition of the Mixture

902.14.02 Mix Design

902.14.03 Sampling and Testing

902.15 Retrofit Strip Seal Joint System

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