401PLANT PRODUCTION

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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 202 4 Volume 2 Section 400 ASPHALT MIXTURE AND PAVEMENT SECTION 401 - PLANT PRODUCTION (Last Revised January , 2023)

401-1 DESCRIPTION. The contractor is responsible for Quality Control (QC). QC is defined as all

activities required to produce asphalt mixture that meets all specification requirements. The contractor shall incorporate a Quality Control system for all plant production of asphalt mixture and assume responsibilities for all QC activities at the production facilities. The contractor shall produce the asphalt mixture according to the specifications herein and provide production documentation. Quality Adjustment Factors (QAFs) will be used to assess asphalt mixture production quality and these factors will be applied to calculate a quality payment adjustment. The Department is responsible for Quality Assurance (QA). QA is defined as all activities performed by the Department to assure that asphalt mixture production meets the specification requirements. The Department will determine quality payment adjustments for each day’s production using a daily QAF obtained from the calculations of the average absolute values for volumetric and non -volumetric mixes in accordance with Materials Procedure (MP) 401, Quality Control and Quality Assurance Procedures for Quality Control Asphalt Mixture Production. The daily QAFs measure production variation from the mean of the specification limits.

401-2 MATERIALS. The provisions of §40 4-4, Materials , apply and are as modified herein. Produce

asphalt mixture in accordance with the requirements outlined in this specification, including all applicable Test Methods and Materials Procedures. Asphalt mixture designs must be accepted by the Department prior to any asphalt production. The Department reserves the right to suspend any mixture design when the mixture produces unacceptable paving results or exhibits properties that will affect the anticipated pavement performance.

401-2.01 Asphalt Mixture Designs. Formulate and submit an asphalt mixture design to the Regional

Materials Engineer (RME) that satisfies all design criteria outlined in MM 5.16, Asphalt Mixture Design and Mixture Verification Procedures . When the submitted asphalt mixture design is assigned verification status, the design must be verified during production. Notify the RME at least 24 hours prior to the start of verification status production. When producing under verification status, make necessary adjustm ents to control the process. Apply daily QAFs to both verification and production status mix designs. Mixtures produced under verification status are allowed for use on State projects. For any asphalt permeable base and shim mixtures required by the contract documents, formulate and submit to the RME a job mix formula that satisfies the General Limits imposed by Table 401 -1, Composition of Asphalt Mixtures .

401-2.02 Aggregates. Aggregate must be from a source approved by the Department. Use fine aggregate

that consists of materials conforming to the requirements of §703 -01, Fine Aggregate . In addition, fine aggregate may consist of screenings, free from deleterious materials and manufactured from sources of stone, gravel, or slag meeting the requirements of §703 -02, Coarse Aggregate .

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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 202 4 Volume 2 Use coarse aggregate that consists either of crushed stone, crushed gravel, or crushed slag conforming to the requirements of §703 -02, Coarse Aggregate and MM 5.16. Use slag aggregate on State projects only when an alternate pay item which takes the mix yield differential into account is included on the plans or in the itemized proposal. When coarse aggregates for the mixture are from more than one source or of more than one type of material, proportion and blend them to provide a uniform mixture. TABLE 401 -1 COMPOSITION OF ASPHALT MIXTURES Mixture Requirements Permeable Base Shim Type 2 Type 5 Screen Sizes General Limits % Passing1 Job Mix Tolerance % General Limits % Passing1 Job Mix Tolerance % 2 in 100 --- --- --- 1½ in 75 – 100 ±7 --- --- 1 in 55 – 80 ±8 --- --- ½ in 23 – 42 ±7 --- --- ¼ in 5 – 20 ±6 100 --- 1/8 in 2 – 15 ±4 80 – 100 ±6 No. 20 --- --- 32 – 72 ±7 No. 40 --- --- 18 – 52 ±7 No. 80 --- --- 7 – 26 ±4 No. 200 --- --- 2 – 12 ±2 Asphalt Content, %2,3 2.5 – 4.5 NA 7.0 – 9.5 NA Mixing and Compaction Temperature Range ºF 225 – 300 250 – 325 NOTES: 1.All aggregate percentages are based on the total weight of the aggregates. 2.The asphalt content is based on the total weight of the mix. When using slag aggregates in the mix, the asphalt content shall be increased accordingly, a minimum of 25 percent for an all slag mix. 3.Use the PG binder listed in the proposal or as designated by the Regional Materials Engineer following the guidance specified in the Comprehensive Pavement Design Manual, Chapter 6, Section 6.2.5 – Performance Graded Binder Selection .

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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 202 4 Volume 2 a. 12.5 Nominal Maximum Size Aggregate Mixes. Noncarbonate plus 1/8 inch particles must comprise a minimum of 30.0% of the total aggregate (by weight with adjustments to equivalent volumes for materials of different specific gravities). A minimum of 90.0% of plus 3/8 inch particles must be non -carbonate.

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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 202 4 Volume 2 4. Gravel, or a natural or manufactured blend of the following types of materials: limestone, dolomite, gravel, sandstone, granite, chert, traprock, ore tailings, slag or other similar materials, meeting the following requirements:

401-2.03 Mineral Filler. Use m ineral filler conforming to the requirements of §703 -08, Mineral Filler .

401-2.04 Performance -Graded Binder. Use the Performance -Graded Binder (PG Binder) in the

production of these mixtures that meets Section 702 – Bituminous Materials . Initial acceptance of the PG Binder is based on the primary source appearing on the Department’s Approved List for Bituminous Material Primary Sources, A. Performance -Graded Binders for Paving. Acceptance of the PG Binder is contingent upon satisfactory t est results from samples taken, as required by the Department’s procedural directives, at the location where the material is incorporated into the work. A primary source is defined as a firm that samples, tests, and certifies by Production Lot that the PG Binder is in conformance with the specifications. The procedural directives for sampling, testing, and certifying the PG Binder, and for achieving and maintaining approved list status, are available from the Materials Bureau. The temperature of PG Binder delivered to the Asphalt Mixture Production Facility shall not exceed 350°F, unless the PG Binder supplier recommends it.

401-2.05 Reclaimed Asphalt Pavement. Reclaimed Asphalt P avement (RAP) shall meet the

requirements of MM 5.16.

401-3 Construction Details.

401-3.01 Quality Control. Perform all sampling and testing in accordance with Materials Procedure

401. Document all QC test results and records in a legible manner and provide them to the State at the end of each production season or when requested by the RME. Asphalt Mixture produced without the required sampling, testing and documentation may be rejected.

401-3.02 Production Facility Laboratory. Maintain an approved production facility site laboratory to

perform all required asphalt mixture sampling and testing according to MP 401.

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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 202 4 Volume 2 401-3.03 Plant Lots and Sublots. Determine plant lots and sublots on a daily basis in accordance with MP 401.

401-3.04 Quality Control Sampling and Testing. Obtain and test QC samples as outlined in MP 401.

401-3.05 Production Control. Produce asphalt mixture according to MP 401. Make necessary process

control adjustments during production according to MP 401.

401-3.06 Production Quantities. Whenever production is made for the Department, notify the Regional

Materials office by 3:00 p.m. the business day before the day of production. Maintain a record of each day’s production quantity for each mix design supplied to the project site daily. Retain these records at the production facility. These records must be available to the Department’s representative for review. Ship all production quantities as outlined in §401 -3.07 Documentation .

401-3.07 Documentation. Record all QC test data for each plant on the appropriate forms provided by

the Department according to MP 401. Also, keep a copy of the plant automation printout at the plant facility for each mix type produced and make them available for review at all times. Transmit a summary of all test data weekly to the RME. Provide a delivery ticket indicating the total quantity in tons being delivered with each delivery vehicle supplying asphalt mixture . The method of determining the delivered quantity is subject to the approval of the RME. Make one legible copy of the delivery ticket available to the Department’s paving inspector prior to the placement of the mixture showing the following minimum information:

401-3.08 Asphal t Mixing Plant. Asphalt mixing plants must meet the requirements in MP 401.

401-3.09 Asphalt Mixture Holding Bins. Asphalt mixtures may be held in holding bins which meet the

requirements in MP 401.

401-3.10 Evaluation of Lots Represented by 0.85 QAF. When any material results in a QAF of 0.85,

the Engineer will evaluate the subject material to determine if it will be left in place. The Engineer may require the Contractor to core the pavement to determine if the in -place density is acceptable at no additional cost to the State. When cores are required, the Engineer will divide the pavement area being

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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 202 4 Volume 2 evaluated into 4 sublots in accordance with the requirements of §40 4-3.08, Pavement Density Samples. The material will be left in -place when either of the following sets of conditions is met.

401-4 METHOD OF MEASUREMENT. The quantity will be the number of tons delivered as

determined from the automated proportioning system, the delivery vehicle weigh system, or the asphalt mixture holding bin weigh system. The measurement or calculation will be the quantity based on the measured amount and reported to the nearest 0.01 of a ton. SECTION 402 - VACANT SECTION 403 - VACANT SECTION 404 - ASPHALT PAVEMENTS

404-1 DESCRIPTION. These specifications apply to all plant mixed asphalt produced at a production

facility under Section 401 Plant Production This work will consist of providing, placing, and performing density monitoring of one or more courses of asphalt pavement constructed on the prepared foundation in accordance with the contract documents or as directed by the Engineer.