305PORTLAND CEMENT CONCRETE BASE

304.08 Basis of Payment. The Department will pay for accepted quantities at

the contract price as follows: Item Unit Description 304 Cubic Yard Aggregate Base (Cubic Meter) ITEM 305 PORTLAND CE MENT C ONCRETE BASE

305.01 Description

305.02 Construction

305.03 Method of Measurement

305.04 Basis of Payment

305.01 Description. This work consists of constructing a portland cement

concrete base on a prepared surface.

305.02 Construction. The requirements of Item 451 apply, except as follows.

Do not comply with the requirements of 451.08. Provide dowels at transverse contraction joints in mainline pavement, ramps, acceleration/deceleration lanes, or collector/distributor lanes. Dowels for 305.03 168 contraction joints i n concrete shoulders on mainline pavement, ramps, acceleration/deceleration lanes, or collector/distributor lanes are not required unless the contraction joint is located within 500 feet (150 m) of a pressure relief joint. Do not place construction joints within 6 feet (1.8 m) of another parallel joint. Modify the curing membrane application rate specified in 451.11 to 200 square feet per gallon (5 m²/L) of treated pavement surface. Produce a final surface with a uniform, gritty, longitudinal, or transverse texture using a broom drag in either direction. Ensure that pavement surface variations do not exceed 1/4 inch in 10 feet (6 mm in 3 m). Impressing station numbers into the plastic concrete as specified in 451.10 is not required.

305.03 Method of Measurem ent. The Department will measure Concrete Base

by the number of square yards (square meters) completed and accepted in place. The width equals the base width shown on the typical cross -section of the plans plus additional widening as the Engineer directs i n writing. The Department will field measure the length along the centerline of each roadway or ramp.

305.04 Basis of Payment. For base found deficient in thickness, the Department

will pay a reduced price according to 451.18.A. The Department will not mak e additional payment over the Contract unit price for any base with an average thickness in excess of that shown on the plans. For base found deficient in strength, the Department will pay a reduced price according to 451.18.B and table 451.19 -2. Use the determination and pay procedures for non QC/QA items. The Department will pay for accepted quantities at the contract price as follows. Item Unit Description 305 Square Yard Concrete Base (Square Meter) ITEM 320 RUBBLIZE AN D ROLL

320.01 Description

320.02 Materials

320.03 Equipment

320.04 Construction Details

320.05 Method of Measurement

320.06 Basis of Payment

320.01 Description. This work consists of rubblizing and rolling reinforced

concrete pavement before placing an asphalt concrete pavement.

320.02 Materials. Furnish filler aggregate conforming to Item 304. 320.03

169 320.03 Equipment. Use a self -contained and self -propelled unit of either the resonant frequency type or the multiple head breaker type for rubblizing the concrete pavement. If using a reson ant frequency unit, ensure that it is capable of producing low amplitude, 2000 -pound -force (8900 N) blows at a rate of not less than 44 blows per second. If using a multiple head breaker unit, ensure that it has the capability of rubblizing the full 12 -foot (3.6 m) lane width in a single pass. Ensure the breaking head consists of 12 to 16 hammers, each weighing 1000 to 1500 pounds (450 to 680 kg). Attach each hammer to a hydraulic lift cylinder that operates as an independent unit, develops 2000 to 12,000 f oot-pounds (2700 to 16,000 J) of energy depending on lift height selected, cycles at a rate of 30 to 35 impacts per minute, and has a maximum lift height of 60 inches (1.5 m). Use a vibratory steel wheel roller having a total weight of not less than 10 ton s (9 metric tons).

320.04 Construction Details. Make a full depth saw cut or cut load transfer

devices at joints on ramps or mainline where the rubblizing abuts concrete pavement or approach slabs that are to remain in place permanently or temporarily for maintenance of traffic. Before the rubblizing operations begin, the Engineer will designate a test section. Rubblize the test section according to this specification. After rubblizing, excavate a test pit, where the Engineer designates, to check for proper particle size throughout the thickness of the concrete. Fill in the test pit using the excavated material and additional filler aggregate as necessary. Compact the test pit as part of the rolling operation. Excavate at least one test pit, at the location designated by the Engineer, for each production day or every 7040 square yards (5886 m2), whichever is greater. Adjust the rubblizing procedure to maintain the proper particle sizes. Control the operating speed of the rubblizing equipment such that: 75% of the rubblized particles above the reinforcing steel are reduced to 3 inches (75 mm) in their largest dimension, 90% of the rubblized particles below the reinforcing steel do not exceed 9 inches (230 mm) in their largest dimension, and no particles exceed 12 inches (300 mm) in their largest dimension. Before placing the initial asphalt concrete course, compact the rubblized pavement with two passes of the vibratory roller. Operate the roller in the vibratory mode and at a speed not to exceed 6 feet (1.8 m) per second. Leave steel reinforcement in place in the rubblized pavement. However, cut off any exposed steel reinforcement below the surface and remove it from the site. Fill depressions 1 inch (25 mm) or greater in depth compared to the immediate surround ing area resulting from the rubblizing, the compactive effort, or the steel reinforcement removal, with the filler aggregate. Strike off excess aggregate level with the surrounding area. Compact filled depressions with the same roller and compactive effort previously described. Do not allow traffic on the rubblized pavement before the asphalt concrete base and intermediate courses are in place. 320.05 170 Do not allow more than 48 hours to elapse between rubblizing the pavement and placing the initial asphalt concrete course. However, in the event of rain, the Engineer may waive this time limitation to allow sufficient time for the rubblized pavement to dry to the Engineer’s satisfaction. If the Engineer waives the time limitation, cease rubblizing the pavement until t he Engineer allows paving to resume.

320.05 Method of Measurement. The Department will measure Rubblize and

Roll by the number of square yards (square meters). The Engineer will use the width of the concrete pavement prior to rubblizing and will measure th e length along the centerline of each roadway or ramp. The Department will measure the Filler Aggregate by the number of cubic yards (cubic meters) furnished, placed, and compacted.

320.06 Basis of Payment. The Department will pay for accepted quantities a t the

contract prices as follows: Item Unit Description 320 Square Yard Rubblize and Roll (Square Meter) 320 Cubic Yard Filler Aggregate (Cubic Meter) ITEM 321 CRACKING AN D SEATING NON - REINFORCED CONCRETE PAVEMENT

321.01 Description

321.02 Equipment

321.03 Construction Details

321.04 Method of Measurement

321.05 Basis of Payment

321.01 Description. This work consists of cracking and seating non -reinforced

concrete pavement or concrete base before placing an asphalt concrete pavement.

321.02 Equipment . Use devices for cracking the concrete capable of producing

the desired crack pattern without extensive spalling or excessive shattering. Extensive spalling is spalling over 1 1/4 inches (30 mm) in depth. Do not use whiphammers. Use watering equipment cap able of wetting the cracked surface uniformly to reveal the crack pattern. Use a 50 -ton (45 metric tons) pneumatic tire roller conforming to the requirements of Item 204 for seating the cracked concrete slabs. Use pneumatic tire towing equipment capable of moving the roller forward and backward along predetermined lines.

321.03 Construction Details. Demonstrate, to the Engineer’s satisfaction, the

ability of the selected equipment and procedures to produce cracking of acceptable 321.04 171 quality by cracking at least three, but no more than five, concrete slabs. When cracking the test slabs, furnish and apply water to dampen the cracked concrete to enhance visual determination of the cracking pattern. In addition to 107.07, provide positive provision to contain any fl ying debris during cracking operations. Crack concrete into nominal 4  4-foot (1.2  1.2 m) segments. In the event panels are already cracked into segments, crack these segments further into nominally equal -sized square or rectangular pieces having longit udinal and transverse dimensions not more than 5 feet (1.5 m) and not less than 3 feet (0.9 m), wherever feasible. Do not allow the cracking equipment to impact the slabs within 1 foot (0.3

321.04 Method of Measurement. The Engineer will measure the area of non -

reinforced concrete pavement or concrete base satisfactorily cracked and seated in square yards (square meters). The Engineer will use the width of the concrete pavement prior to cracking and will measure the length along the centerline of each roadway or ramp.

321.05 Basis of Payment. Include the cost of all crack pattern test and check

sections including water; and for repairing of joint, cracks, spalls, and voids in the contract unit price for Cracking and Seating Non -Reinforced Concrete Pavement. The Department will pay for the accepted quantities at the contract price as follows. Item Unit Description 321 Square Yard Cracking and Seating Non - Reinforced (Square Meter) Concrete Pavement 401.01 172 400 FLEXIBLE PAVEMENT ITEM 401 ASPHALT CON CRETE PAVEMENTS —GENERAL

401.01 Description

401.02 Mix Design and Quality Control

401.03 Materials

401.04 Reclaimed Asphalt Concrete Pavement and Reclai med Asphalt

Shingles

401.05 Mixing Plants

401.06 Weather Limitations

401.07 Notification

401.08 Asphalt Binder

401.09 Aggregate Preparation

401.10 Mixing

401.11 Hauling

401.12 Spreading Equipment

401.13 Rollers

401.14 Conditioning Existing Surface

401.15 Spreading, Finishing and Night Work

401.16 Compaction

401.17 Joints

401.18 Asphalt Binder Compatibility

401.19 Spreading and Surface Tolerances

401.20 Asphalt Binder Price Adjustment

401.21 Method of Measurement

401.22 Basis of Payment

401.01 Description. This specification is applicable to all types of asphalt

concrete pavements irrespective of gradation of aggregate, kind, and amount of asphalt binder, or pavement use. Deviations from these general requirements are covered in the specific requirements fo r each type according to the appropriate contract item or items. Work consists of one or more courses of asphalt concrete constructed on a prepared foundation. The asphalt concrete consists of a mixture of graded aggregate and specified type and grade of a sphalt binder. Control all production processes to assure the Engineer that the mixture delivered to the paving site is uniform in composition, conforms to the specification requirements and that the placed mixture is free of any defect (ex. segregation, tenderness, lack of mixture and texture uniformity, raveling, flushing, rutting, holes, debris etc.) within the Contractor’s control at project completion. The asphalt concrete pavement thickness shown on the plans or stated in the Proposal is for exclusiv e use in calculating the weight required to be placed per unit of surface area. 401.02 173 401.02 Mix Design and Quality Control. Use an approved Job Mix Formula (JMF). The quality control and acceptance requirements of Item 403 apply unless otherwise specified. If required to perform the mix design or quality control, provide laboratory and personnel meeting the requirements of Supplement 1041 to perform mix design and quality control tests. Calibrate asphalt content nuclear gauges according to Supplement 1043 usin g personnel with a minimum Level 2 approval according to Supplement 1041. Mix and test the calibration verification sample with a Department employee present. Provide and dispose of the solvent used for cleaning the asphalt content nuclear gauge pans.

401.03 Materials. Furnish materials conforming to:

Asphalt binder (asphalt concrete, 401.14, 401.15) ..................... 702.01 Asphalt material (401.14, 401.18) ................................ ..... ............................ SS875.02, 702.01, 702.04, or 702.13 Aggregates (base courses) ................................ ....... 703.04 Aggregates (intermediate and surface courses ) ................................ .................. 703.05 Mineral filler ................................ .......................... 703.07 Sample aggregate, asphalt binder, asphalt material, and mineral filler according to 106.01. If 100 percent of coarse aggregate in an asphalt mix design is steel slag (703.01.E.), the Contractor may include steel slag as a m aximum of up to 50 percent of fine aggregate. If a steel slag source causes bulking (expansion resulting in flushing or material loss) in asphalt concrete courses, OMM will place limits on the amount of steel slag allowed in a mix design. Bulking may be sh own through testing, such as ASTM D 4792, or through field failure such as, but not limited to, flushing on newer pavement or apparent over -asphalting in production. The Department may require the steel slag processor at any time to perform additional test ing to verify steel slag properties. Potential pavement performance problems due to poor control of steel slag aggregate include bulking, poor gradation and specific gravity control resulting in highly variable void properties, excess soft pieces resulting in pock marks, flushing, etc. Take prompt corrective action if mixture delivered to the paving site is not uniform in composition, does not conform to the specification requirements or is not free of any defect (ex. segregation, tenderness, lack of mixtur e and texture uniformity, raveling, flushing, rutting, holes, debris etc.) within the Contractor’s control as determined by the Engineer. The Engineer will stop conditional acceptance of the asphalt concrete for failure to correct problems.

401.04 Reclaime d Asphalt Concrete Pavement and Reclaimed Asphalt

Shingles. Provide reclaimed asphalt concrete pavement (RAP) and/or reclaimed asphalt shingles (RAS) according to the following requirements when choosing to use them in a mix. Failure to follow these requir ements will result in a rejection of 401.04 174 the Contractor QCP (403.03); restriction of any RAP or RAS use at the facility; and/or a change to Unconditional Acceptance at the facility. Job Mix Formula . The Contractor may use a blend of new materials in combination with RAP obtained from verifiable Department or Ohio Turnpike Commission projects and/or RAS obtained from un -used manufactured shingle waste or used roofing tear -off shingles as listed in Tables 401.04 -1 and 401.04 -2 and as follows. If the RAP is not from the above sources or the source is unknown, process and blend the RAP into a single uniform stockpile, test according to Level 3 Asphalt Mix Design requirements and obtain District Testing approval for use. Obtain written approval from OMM for use of unusually large, old RAP stockpiles of unknown content and/or age. Include approved methods in the QCP for ongoing processing and testing of these piles. Ensure no foreign or deleterious material (703.04, 703.05) is present in RAP. All RAS supplier s must be approved and meet the requirements of Supplement 1116. Ensure that the JMF falls within the specified limits of the required mix item. Ensure the JMF submittal includes the percentages of RAP, RAS, virgin aggregates, and virgin asphalt binder required for the mix item. Report all RAP and RAS test results, including binder blend analysis, in the JMF submittal. Identify the RAP in the JMF submittal as to project origin and mix type(s). Identify the approved manufactured shi ngle waste manufacturer source or the approved tear -off RAS processor in the JMF submittal. Determine RAP properties and uniformity as follows. Determine the final RAP gradation and asphalt binder content on a minimum of four separate stockpile (or roadway for concurrent grinding) samples all agreeing within a range of 0.4 percent for asphalt binder content and 5 percent passing the No. 4 (4.75 mm) sieve. If fractionated RAP is used use a suitable sieve for determining gradation uniformity. Determine RAP bi nder content from a centrifuge extraction test. Do not use reflux extraction or oven burnoff. Determine RAS properties and usage as follows. Use no more than 5.0 percent RAS by dry weight of mix. When using RAP and RAS in combination use no more than 3.0 p ercent RAS. For design assume 18.0 percent available RAS binder. Determine gradation and specific gravity according to AASHTO PP 78 -14, Section 5 or subsequent AASHTO applicable standard. Provide the required certification forms in the JMF submittal docume nting that the RAS meets AASHTO MP 23 -14, section 4 and that RAS from roofing tearoffs conforms to the EPA’s NESHAP, 40 CFR 61 Subpart M, and other applicable agency requirements for asbestos. RAP and RAS Usage Limits and Requirements. Process and use RAP and RAS as follows. Process and use RAP by one of the following two methods. Note on the JMF submittal RAP page which of Method 1 or Method 2 methods described below apply to the RAP. When using RAS without RAP apply the virgin binder requirements of Table 401.04 -2 Method 2. Use PG64 -28 virgin binder in all 442 intermediate courses regardless of the percentage of RAP used. If greater than 25 percent RAP is used in a JMF submittal use PG58 -28 or PG64 -28 virgin binder. If 26 -30 percent RAP is used in the J MF submittal, the Contractor may submit a 3000 gram RAP 401.04 175 sample along with a blend chart, according to Level 3 Mix Design procedures, to determine the grade of virgin asphalt binder to use. When using both 15 percent or greater RAP and 3 percent RAS in an i ntermediate or base course use PG58 -28 or PG64 -28. ODOT may request RAP and/or RAS samples or binder properties at any time.

302.02 does not apply.

[1] No more than 5.0% RAS by dry weight of mix RAP Processing for Table 401.04 -2 Method 2 -Extended RAP. Process RAP by means of fractionation or by additional in line processing. Include in the QCP additional methods and procedures to dictate how this is to be accomplished at plants. Specify documentation method for RAP measurement. Fractionation is the process of creating separate piles of RAP from one pile when split over a specific sieve or sieves. Test fractionated piles to show uniformity. For additional in line processing only process RA P from a uniform, tested and approved stockpile by passing the RAP over a double deck screen placed in -line between the RAP cold feed bin and the mixer. Use a 9/16 inch (14.3 mm) screen for surface and intermediate mixes and a 1.5 inch (37.5 mm) screen for base mixes. Do not use concurrent project RAP in a stream process.

401.04 2 unless specified differently in the applicable mix specification. When

using RAS without RAP apply the virgin binder requirements of Table 401.04 -2 Method 2. Ensure RAS is processed to have 100 percent passing the 1/2 -inch (12.5 mm) sieve and at least 85 percent passing the No. 4 (4.7 5 mm) sieve. Ensure RAS has less than 1.0 percent deleterious materials and 0.1 percent metals by weight. Do not blend RAS from manufacturing waste and RAS from roofing tearoffs. Ensure the QCP includes RAS usage methods before using RAS. Include in the Contractor QCP what Contractor requirements apply to the RAS processor. Introduce and control RAS in asphalt plants in the same manner as RAP is introduced and controlled. RAS for base courses may be preblended with RAP if using rate control equipment to e nsure uniformity of blending and if satisfactory blend and production is achieved. RAS may be preblended with a small amount of virgin aggregate meeting 703.05 to minimize stockpile agglomeration. Include in the Contractor QCP blending equipment type and o peration and uniformity testing 401.04 177 requirements for preblended RAP and RAS or RAS and virgin aggregate. Other methods must be approved by OMM. RAP and RAS QC and Management Requirements. Maintain as part of the QC records the signed certification forms as req uired in Supplement 1116. Always note on the daily quality control report how much RAP and RAS is actually being used. Apply a tolerance of ± 5.0 percent on the amount of RAP used if needed for a quality control adjustment but do not exceed the limits of Table

401.04 1 or Table 401.04 -2, whichever applies. If this adjustment is not adequate

for maintaining control of the mix submit a new JMF for approval. Do not apply this tolerance to RAS. Include in the QCP methods to be used to meet Method 1 and Method 2 requirements above and the following requirements: Provide enough space for meeting all RAP and RAS handling requirements at a hot mix facility. Provide a clean, graded base for stockpiles that does not collect water. Test blend ed RAP and RAS stockpiles to assure uniform gradation and asphalt binder content. Ensure uniform stockpile properties match the JMF submitted RAP and RAS properties unless the uniform stockpile will be processed into the asphalt plant using plant cold feed in line processing. If the uniform stockpile will be processed into the asphalt plant using plant cold feed in line processing determine the processed RAP properties for use in the mix design. Record in the JMF submittal both the uniform stockpile and in line processed RAP properties. If desired, when applying Method 1 Standard RAP requirements, use concurrent Department project RAP in a stream process in place of stockpiling and testing for uniformity but do so in the following manner. Concurrent projec t RAP must be taken from one existing mix type on the concurrent project or two existing mix types if both mix types are taken at the same time in one pass of the milling machine. Submit a new JMF for each existing mix type on the project (or each milling pass of two types) desired for use as concurrent project RAP. Include in the QCP methods of validating RAP properties when using concurrent project RAP. If these requirements are not met blend and test for uniformity and apply the stockpile requirements of this specification. Maintain in the plant lab and control room an up to date and dated site map of all tested and untested RAP and RAS stockpiles. Give each stockpile a unique identification and identify if RAS piles are from un -used manufactured shingle waste or used roofing tear -off shingles. Provide in the plant lab RAP and RAS properties for each uniform, blended stockpile cross referenced with its identification. In addition, provide the date the stockpile processing was completed and the stockpile e stimated size in tons. Provide signage at all RAP and RAS piles. Do not add to a stockpile once it is tested for uniformity. Provide signage at all uniform stockpiles to inform haulers that uniform piles are not to be added to. Stockpiles and processing me thods are subject to inspection and approval by the Laboratory at any time. Rejection of stockpiles can occur for the presence of foreign or deleterious materials, lack of uniformity, incomplete mixing in the asphalt mixture, adding to piles, or moving RAP or RAS in a way not traceable through the 401.05 178 QCP records and methods. OMM will resolve disputes over acceptability of RAP or RAS.

401.05 Mixing Plants. The Department will approve mixing plants before

preparation of the mixtures. Schedule a date with the Dep artment for approval inspection to be at least 1 week before mix production. Do not produce mixtures for projects from un -approved plants. General requirements for asphalt concrete mixing plants are specified in Item 402. Set the asphalt binder controls fo r the computerized plant at the virgin asphalt binder content of the JMF at all times unless change is authorized by OMM. Asphalt mixtures may be produced using the warm mix asphalt method according to 402.04 except as restricted by specification.

401.06 Weather Limitations. Place asphalt concrete only if the surface is dry

and if weather conditions are such that proper handling, finishing, and compaction can be accomplished. Never place asphalt concrete if the surface temperature is below the minimum estab lished in Table 401.06 -1. TABLE 401.06 -1 Course Thickness Minimum Surface Temperature 3.0 inches (75 mm) and over 36 F [1] (2 C [1]) 1.5 to 2.9 inches (38 to 74 mm) 40 F (5 C) 1.0 to 1.4 inches (25 to 37 mm) 50 F (10 C) Less than 1.0 inch (25 mm) 60 F (16 C) Variable Intermediate, 0 to 3.0 inches (0 to 75 mm) 40 F (5 C) [1] Instead of 36 F (2 C), use a minimum air temperature of 40 F (5 C) if paving on an aggregate base or subgrade. In addition to the above surface temperature requirements, do not place surface courses if the air temperature is less than 40 F (5 C). For any surface course with a polymer modified asphalt binder, ensure that the paving surface is at least 50 F (10 C) and the air temperature is at least 50 F (10 C). Do not schedule the placement of any surface course with a polymer modified asphalt binder after November 1, regardless of pavement or air temperature.

401.07 Notification. Notify the Engineer at least 24 hours before starting paving

on a project. After starting, if paving operations are stopped for 1 week or more, notify the Engineer at least 24 hours before resuming paving on a project.

401.08 Asphalt Binder. Heat the asphalt binder and deliver it to t he mixer

within the temperature range specified in Table 702.00 -1. Do not use asphalt binder while it is foaming in a storage tank. Take samples using correct new containers from the binder line between the last piping ‘tee’ and inlet into the plant unless a different storage method requires a different sampling location.

401.09 Aggregate Preparation. Feed aggregates in their proper proportions and

at a rate to permit correct and uniform control of heating and drying. Remove all aggregates in the plant tha t will produce a mix outside the temperature limits or that 401.10 179 contain excessive moisture or expanding gases causing foaming in the mixture, and return them to the proper stockpiles.

401.10 Mixing. Maintain the temperature of the mix at the plant within the r ange

in JMF or according to the specification. Ensure the mixture is workable and temperature is sufficient for compaction at the point of placement. The Engineer will verify the required temperature of the mixture on arrival at the project site based on the temperature range in the JMF and heat losses in transit. For batch plants, after all of the aggregate is in the mixer, add the asphalt binder in an evenly spread sheet over the full length of the mixer. The mixing time is defined as the interval between the start of application of the asphalt binder and the opening of the mixer gate. Discharge all asphalt binder required for one batch in 30 seconds or less. After the asphalt binder is added, apply the mixing time determined by OMM but not less than 30 se conds.

401.11 Hauling. Use trucks for hauling asphalt concrete that have tight, clean,

smooth metal beds from which the entire quantity of mixture is discharged smoothly into the spreading equipment. Before loading, apply a thin coating of an approved rele ase agent to the inside surfaces of the truck bed to prevent adhesion of mixture to the bed surfaces. OMM maintains a list of approved release agents. Do not use fuel oil for this purpose. Drain truck beds after applying the release agent and before loadin g. Load trucks in manner to minimize segregation of the mixture according to the approved QCP. Do not clean out truck beds on the roadway ahead of the paver. Provide a location away from the roadway or off the project for cleaning trucks. If there is exces sive sticking of material in truck beds, the sticking is in areas of the truck that would indicate excessive cooling of the mix (front corners, bottom, etc.) due to a long haul, and it is not resolved in a reasonable time, the Engineer will require an insu lated bed. The Contractor may only make procedure changes for better mix handling at the discretion of OMM. Equip each truck with a securely fastened, waterproof cover of suitable material to protect the mixture from wind and weather. At the request of the Engineer, remove covers before dumping into the paver. If transporting hot asphalt concrete at prevailing air temperatures below 50 F (10 C) or if the length of haul exceeds 20 miles (32 km), insulate all truck beds to maintain workable mix temperature, and ensure that all covers are fastened to exclude the wind. Do not exceed a distance of 50 miles (80 km) from the asphalt concrete plant to the paving site except by specific permission of the Department. Completely discharge the mixture into the spreading equipment and within 90 minutes of loading .

401.12 Spreading Equipment. Use self -contained spreading equipment of

sufficient size, power, and stability to receive, distribute, and strike -off the asphalt concrete at rates and widths meeting the ty pical sections and other details shown on the plans. Use spreading equipment that has automatic control systems that maintain the screed in a constant position relative to profile and cross -slope references. Ensure control of the screed position is reasona bly independent of irregularities in the underlying surface and of the spreader operation. Equip asphalt spreading equipment 401.12 180 to prevent the segregation of coarse aggregate from the remainder of the asphalt concrete when the material moves from the hopper t o the screed. Use means and methods approved by the asphalt spreader manufacturer consisting of but not limited to any combination of chain curtains, deflector plates, or other such devices. When a safety edge is required, attach a device to the screed tha t confines the material at the end gate and extrudes it in such a way that results in a compacted wedge shape pavement edge of approximately 30 degrees and not steeper than 40 degrees. Ensure the device maintains contact with the prepared surface and allo ws for transition to crossroads, driveways, and obstructions. Do not use conventional single plate strikeoff. Short sections of handwork are allowed when necessary for transitions and turnouts or other areas approved by the Engineer. The Engineer will ba se final approval of spreading equipment on the demonstrated capability of the equipment to place the mixture to the required cross - section, profile and alignment in an acceptable, finished condition ready for compaction. Where the use of standard full -scale spreading equipment is impractical due to the size or irregularity of the area to be paved, use specialized equipment or hand methods approved by the Engineer to spread the asphalt concrete. Anti -Segregation Equipment. When specified, provide a Materia l Transfer Vehicle (MTV) with paver hopper insert; a Material Transfer Device (MTD) with paver hopper insert; or a remixing paver specifically manufactured to eliminate segregation. Use paver hopper inserts with a minimum capacity of 10 tons (9 metric tons). Remixing may be done by the MTV or MTD, in the paver hopper insert, or by the remixing paver. Provide and operate equipment in a manner that does not result in physical segregation, and limits temperature differentials to less than 35 °F (20 °C) through out the mixture. Use anti -segregation equipment when paving intermediate and surface courses on all mainline lanes of the traveled way including express lanes, collector - distributor lanes, continuous center turn lanes, acceleration/ deceleration lanes, an d ramp lanes. On the first day or night of paving any JMF, perform a test strip of a minimum of 1000 ft (300 m) in length. Notify the Engineer a minimum of 24 hours prior to performing the test strip. Demonstrate to the Engineer that the selected equipment is not physically segregating the mix and consistently limits the temperature differential of the mat surface, measured transversely, to 35 °F (20 °C) or less. Document results of each test strip on Department form CA -FP-5. Remove equipment or JMF that pr ovides a mat with physical segregation, does not meet the temperature differential requirement, or both. Perform a new test strip any time placement equipment or JMF is replaced. If the Contractor is unable to produce a satisfactory test strip in two attem pts per JMF, cease paving and provide a written plan to the DCA for approval prior to continuing the paving operation. Cease the paving operation in the events of; equipment breakdown, inability to consistently provide a mat free of physical segregation, inability to consistently meet 401.13 181 the temperature differential requirements, or any combination. Do not resume paving until equipment is replaced with suitable equipment. The Engineer may allow paving to continue if an isolated area of mat temperature differe ntial is in excess of 35 °F (20 °C). The Engineer may require additional evaluation of the area to determine the acceptability of the material.

401.13 Rollers. Use only steel wheel and pneumatic tire types of rollers meeting

the minimum requirements of the following tables. Conform to manufacturer’s specifications for all ballasting. TABLE 401.13 -1 ROLLER CAPACITY Roller Type Maximum Capacity square yards per hour (m²/hr) Tandem 700 (600) Three -Wheel 700 (600) Trench 15 per inch width (13 per 25 mm width) Pneumatic Tire, Type I 1000 (850) Pneumatic Tire, Type II 700 (600) Vibratory, Vibrating Roll 15 per inch width (13 per 25 mm width) Vibratory, Static Roll (not vibrating) 3 per inch width (3 per 25 mm width) TABLE 401.13 -2 STEEL WHEEL ROLLERS Roller Type Three - Wheel Tandem Vibratory Static Trench Total weight, tons (metric tons) 10

401.14 Conditioning Existing Surface. Clean the surface on which the asphalt

concrete is to be placed, and keep it free of accumulations of materials that would, in the judgment of the Engineer, contaminate t he mixture, prevent bonding, or interfere with spreading operations. Where approved subgrade or pavement courses previously constructed under the Contract become loosened, rutted, or otherwise defective, correct the deficiency according to the contract ite m or items involved before the spreading of a subsequent pavement course. If a quantity of asphalt concrete is specified for use in spot leveling or patching, spread and compact the material needed to make the corrections as directed by the Engineer. If placing asphalt concrete against a vertical pavement face, curb, gutter, manhole, or other structure, clean the surface of foreign material and apply a thick, uniform coating of 702.01 PG binder, Supplemental Specification 875.02 Hot Applied Asphaltic Joint Adhesive, or 702.13 SBR Asphalt Emulsion to provide 100 percent coverage.

401.15 Spreading, Finishing and Night Work

Spreading and Finishing. Do not co -mingle multiple JMFs in the same asphalt paver. Spread the mixture at a rate calculated using the specified thickness and the compacted width of the pavement course being placed, and the weight -to-volume conversion factors established in 401.21. Maintain the actual rate of spreading the mixture equal to the required calculated rate within the tolerance specified in 401.19. For pavement courses specified for leveling, the actual rate of spreading the mixture may vary from the required calculated rate as approved by the Engineer to accomplish the intended purpose. For intermediate courses, make the maximum compacted depth of any one layer 3 inches (75 mm). Spread and finish the mixture using approved equipment or methods such that compaction can follow immediately. Preheat screeds and extensions before placing any asphalt concrete. Use side plates su fficient to contain the mixture laterally during spreading. Use only screed extensions, rigid or extendable, having the same features as the main screed including, but not limited to, vibration, heating, pre - strikeoffs, and tamping bars. When using front -mounted hydraulically extendable screeds at a fixed paving width use full width auger extensions and full tunnel extensions. When using fixed screed extensions use full width auger extensions and full tunnel extensions. Do not allow a buildup of excess mate rial in front of the screed. Where excessive buildup of material is not controlled, the Engineer will require paver changes to correct the problem. Ensure the paver operation, screed, screed extension, and, or, mix design provide a mat, prior to compactio n, that is free of texture inconsistencies, shadowing, streaking, tearing, pulling, or other deficiencies. Take immediate action to correct the paver operation, screed, screed extensions, or, mix design. The Engineer may stop placement until corrections ar e completed. 401.15 183 Use strike -off plates/strike -off extensions only on irregular areas such as mailbox turnouts, driveway turnouts, and other irregular non -travelled roadway areas. The Engineer may approve the use of strike -off plates/extensions on variable width shoulders if the use of a standard extendable screed extension with the same features as the main screed is not practicable. Perform supplemental hand forming and tamping where irregularities develop and where placing the mixture by hand methods. Take prompt corrective action if placed mixture exhibits any defect (ex. segregation, tenderness, lack of mixture and texture uniformity, raveling, flushing, rutting, holes, debris etc.) within the Contractor’s control and as determined by the Engineer. Remov e and replace, or otherwise correct in a manner satisfactory to the Engineer, any portion of the pavement course found to be defective in surface texture or composition before or after compaction. Coordinate the spreading operation with the rate of product ion and delivery of the mixture to attain uniform, continuous progress. Avoid erratic spreader operation due to irregular contact with the hauling vehicle, surging in the feed and distribution of the mixture, or other cause. Maintain sufficient control of the spreading equipment with regard to line and grade references so that the pavement course, when compacted as specified, is in reasonable conformance with the Contract Documents. Do not displace or damage bridge deck waterproofing membranes during spread ing operations on the membranes. Do not allow traffic on the compacted mixture until it has cooled sufficiently to prevent glazing as determined by the Engineer. After completion of the surface course, seal gutters with asphalt binder as directed by the En gineer. Apply the material at a uniform width of approximately 4 inches (100 mm) and at a rate just sufficient to fill surface voids. Night Work . Do not start night work or carry on day work into night work without operating an adequate and approved lighti ng system. Night work is defined as work performed from 30 minutes after sunset to 30 minutes before sunrise. Operation of adequate lighting system consists of furnishing, installing, operating, maintaining, moving, and removing night time lighting to illu minate construction work areas for night work. Obtain the Engineer’s approval of the lighting at the beginning of the project and before starting the paving operation by measuring the luminance. Provide an illuminated zone around all operating machinery. Provide an illuminated zone of at least 5 Foot -candles (55 lux) of lighting luminance in the immediate vicinity of pavers, rollers, grinding equipment, material transfer vehicles, etc., and at least 1 Foot -candle (10 lux) at 25 feet (7.6 m) from this equipm ent. Provide an illuminated zone of at least 5 Foot -candles (55 lux) of lighting luminance in the immediate vicinity of coring equipment and at least 1 Foot -candle (10 lux) at 10 feet (3 m). Position the light sources so they don’t interfere with or impede traffic in any direction and do not cause glare for motorists or point onto adjacent properties. Provide a photometer capable of measuring the level of luminance on each night project. Take luminance measurements at a height of 20 inches (500 millimeters) above the roadway. 401.16 184 Obtain the luminance level any time requested by the Engineer. Test the illumination levels on the site each time a change in lighting configuration is made. Replace non -functioning lamps immediately. Check the luminaires aiming daily. Clean the luminaires regularly. Correct any deficient lighting within one hour or the Engineer will terminate construction activities. When the total project includes more than one continuous lane mile (including bridges) of surface course paving in combin ation with night paving, and no pay item for anti -segregation equipment, provide anti -segregation equipment according to

401.12 , for only the surface course. No additional payment will be made for this

anti-segregation equipment .

401.16 Compaction . Immedia tely after spreading the asphalt concrete and

adjusting any surface irregularities, compact the mixture uniformly using rollers conforming to 401.13. Do not use a spreading rate that exceeds the total of the specified capacities of the rollers in use. Howe ver, if compacting a mixture spread as an intermediate or pre -leveling course less than 1 inch (25 mm) thick do not use a spreading rate that exceeds twice the total capacity of the rollers in use. Coordinate the spreading of the mixture with the required roller coverage, considering the rate of cooling of the mixture as affected by lift thickness and environmental conditions. Complete the required roller coverage during the period of time in which the temperature of the mixture is sufficient for the rolle r coverage to be effective in compacting the mixture. Compact base mixtures using a combination of both steel wheel and Type I pneumatic tire rollers; however, in small areas, compact these mixtures as the Engineer approves using any of the rollers specifi ed in 401.13. Compact intermediate and surface mixtures using a three -wheel roller in the breakdown position (roller immediately behind the paver) of the roller train; however, in small areas, compact these mixtures as the Engineer approves using any of the roller types specified in 401.13. Compact variable depth courses using a combination of both steel wheel and pneumatic tire rollers; however, in small areas, compact these mixtures as the Engineer approves using any of the roller types specified in 401.1 3. For surface courses using a polymer modified asphalt binder give a copy of the JMF approval letter containing the design compaction temperature to the Engineer before any mix is placed. Unless otherwise specified ensure that the mix temperature immediat ely before rolling is not less than 290 °F (145 °C) if placing hot mix asphalt, and not less than 250 °F (121 °C) if placing warm mix asphalt according to

402.04 Do not compact polymer asphalt concrete surface courses with pneumatic

tire rollers. When usi ng pneumatic tire rollers, ensure for any mix that surface deviations and deformations caused by the tires are removed with steel wheel rollers. Do not use pneumatic tire rollers if any resultant surface deformations cannot be removed. Do not use vibratory rollers on courses with a thickness under 1 1/2 inches (38 mm). 401.17 185 If using vibratory rollers, supplement them with three -wheel or pneumatic tire rollers. Unless otherwise directed, begin rolling at the sides and proceed longitudinally parallel to the center line at a slow, uniform speed. After each coverage or complete round trip, move the roller towards the crown of the road to begin its next pass, overlapping the previous pass by at least one -half the width of the previous pass. On superelevated curves, beg in rolling at the low side and progress toward the high side. Where a longitudinal joint is being made, roll the joint then follow the applicable rolling procedure. When constructing a safety edge, operate the rollers in a manner that does not damage or obliterate the tapered edge. Do not roll the taper. Continue rolling until full coverage of the course is complete and all roller marks are eliminated. Take care to p revent displacement of the edge line and grade. Where displacement occurs, correct the area immediately in a manner satisfactory to the Engineer. Along curbs, headers, walls, and in other areas not accessible to rollers, thoroughly compact the mixture with hot, hand tampers or with mechanical tampers. On depressed areas, the Contractor may use trench rollers or rollers fitted with compression strips. Replace mixture that becomes loose, broken, contaminated, or otherwise defective with fresh, hot mixture. Compact it to match with the surrounding area.

401.17 Joints. Place the asphalt concrete mixture as continuous as possible. Set

up joints at the proper height above the adjacent construction to receive maximum compaction. Where the edge of the new pavement i s significantly rounded, trim it to a vertical face before placing the adjacent pavement. On projects where traffic is allowed to cross the edge of the new pavement lane, complete the longitudinal joint of the adjacent lane or shoulder within 24 hours. Construct longitudinal joints using string line or other controls as a point of reference to provide a straight longitudinal joint. Prior to placing adjacent pavement, trim any locations along the longitudinal joint that deviate horizontally from the point of reference. Maintain a consistent overlap of 1 to 1 1/2 inches (25 to 38 mm) on adjacent pavement when closing longitudinal joints. Where phasing for maintenance of traffic will not allow lapping cold longitudinal joints according to Standard Drawing BP -3.1, provide a minimum of 6 inches (150 mm) offset between cold joints for each course placed. Form hot longitudinal joints using pavers operating in contiguous lanes, one just ahead of the other. Maintain the distance between pavers in adjacent lanes such that it does not exceed the distance that a normal size load of mixture will cover. Alternate loads of mixture between the pavers. Do not allow rollers performing the initial rolling operation in one lane closer than 12 inches (0.3 m) to the longitudinal joint until the adjacent lane is placed. Instead of hot joint construction using multiple pavers, the Contractor may use full width construction with a single unit paver. Compact all cold longitudinal joints on intermediate and surface courses using a three -wheel roller. 401.18 186 For surface courses, form or cut all transverse construction joints to a vertical. Seal all cold longitudinal construction joints by coating the entire face of the cold joint with a certified 702.01 PG binder or Supplemental Specification 87 5.02 Hot Applied Asphaltic Joint Adhesive to provide 100 percent coverage of the joint. Overlap the joint edges by at least 1/2 inch (13 mm). Seal all cold transverse construction joints with a certified 702.01 PG binder, Supplemental Specification

875.02 Hot Applied Asphaltic Joint Adhesive or 702.13 SBR Asphalt Emulsion to

provide 100 percent coverage of the joint or with a certified 702.04 asphalt material applied at a rate of 0.25 gallon per square yard (1 L/m²).

401.18 Asphalt Binder Compatibility. If excess fat spots, regular random areas

of flushing, or excess drain down occur on a project that are not attributable to over rolling, plant operation, or mix quality compared to the JMF, the Department will consider the asphalt binder incompatible. The De partment will reject any on -hand asphalt binder because of incompatibility. The Department may use its discretion in determining if problem areas can be corrected, or if removal and replacement is required. Demonstrate to OMM through reporting actual testi ng analysis the compatibility of another asphalt binder and that proper equipment is in place in order to be allowed to resume.

401.19 Spreading and Surface Tolerances. If a uniform course is specified,

make checks and adjustments to maintain the rate of s preading within a tolerance of ±5 percent of the required calculated weight per unit of area. If a variable depth course is specified, place the mixture as shown on the plans. If a longitudinal profile is specified by elevations on the plans, do not allow the completed pavement surface to deviate more than 1/2 inch (13 mm) at any point from parallel with the specified profile. Before placing the surface course, check the profile of the preceding course at 50 -foot (15 m) intervals along the outside edge of each traffic lane and along any additional line described in superelevation tables, and submit a tabulation of all results that includes documentation of all deviations from the above tolerance to the Engineer. Perform corrective work necessary for complian ce with the profile tolerance before placing the surface course. The requirements of this paragraph do not apply to small incidental areas of pavement less than 500 feet (150 m) in length. Do not vary the transverse slope of the surface of the completed co urse from the specified slope by more than 3/8 inch in 10 feet (10 mm in 3 m). Do not vary the surface of each completed intermediate or surface course from the testing edge of a 10 foot (3 m) rolling straightedge by more than 1/4 inch (6 mm). Furnish str aightedges, straightedges equipped with levels, or other devices such as approved profilers conforming to Supplement 1058 and using ProVAL software. Equipment will be satisfactory to the Engineer. Check the surface course for variations in slope or s urface at locations where bumps are suspected when directed by the Engineer. Correct variations in excess of slope or surface tolerance by removing mixture to neat lines and replacing, or by surface grinding in a manner satisfactory to the Engineer. 401.20 187 401.20 Asphalt Binder Price Adjustment . A contract item is eligible for a price adjustment when the contract’s proposal specifically includes an Asphalt Binder Price Adjustment note and the contract item meets the quantity limitations of the proposal note.

401.21 Method of Measurement. The Contractor is responsible for recording

the net weight of each truckload of mixture to the nearest 100 pounds (50 kg) in triplicate on plant ticket forms approved by the Department. If the pay quantities are established by platform scales, provide a tare weight for each truck at the beginning of each day’s operation and a minimum of every 4 hours of operation each day. The Engineer may require additional tare weight measurements at any time. The Engineer will have the right to monitor all weighing operations and may require reweighing trucks at any time or location. Correct any discrepancies immediately. Continued non -compliance will result in the Department taking necessary and appropriate action, such as, but not limited t o, assigning a Department ticket writer to the plant. Send one copy of the plant ticket with each load delivered to the paver and present it to the Engineer. The Engineer will convert the total of the weights recorded on the plant tickets representing mixt ure finished according to contract requirements to cubic yards (cubic meters) using a conversion factor established by OMM. OMM will establish this conversion factor from the approved JMF. However, if a mix design is not available, OMM will use the convers ion factors in Table 401.21. If a uniform course is specified, the Department will not pay for a number of cubic yards (cubic meters) that exceeds the quantity calculated from plan lines and dimensions. TABLE 401.21 Aggregate lb/yd³ (kg/m³) Gravel and stone 4000 (2370) Slag less than 90 lb/yd³ (less than 1450 kg/m³) [1] 3600 (2135) Slag 90 to 100 lb/yd³ (1450 to 1600 kg/m³) [1] 4000 (2370) Slag more than 100 lb/yd³ (more than 1600 kg/m³) [1] 4300 (2550) [1] Based on average dry rodded weight at the Laboratory.

401.22 Basis of Payment. The Department will pay for all work performed and

measured as specified above according to the appropriate contract items for each type. The cost of sealing the joints is included in the unit price bid for the asphal t concrete. The Department will assess all costs against the Contractor that it incurs as a result of taking necessary and appropriate action due to the Contractor’s continued non-compliance. The Department will not pay for removing and replacing incompati ble asphalt binder areas. 402.01 ITEM 402 ASPHALT CON CRETE MIXING PLANTS

402.01 Description

402.02 Calibration

402.03 Polymer Binders

402.04 Water Injection System for Warm Mix Asphalt

402.01 Description . This specification consists of the minimum requirements

for an asphalt concrete mixing plant to produce asphalt concrete mixes according to Department specifications. Ensure asphalt concrete mixing plants conform to the requirements of Supplement 1101 in addition to the following.

402.02 Calibration . Ensure the plant is calibrated according to Supplement

1101 when producing any asphalt concrete for the Department. Ensure that the calibration is accurate within 1.0 percent. When performing a complete calibration for ODOT projects notify Dis trict Testing 24 hours in advance of the calibration.

402.03 Polymer Binders . If an asphalt binder is modified by SBR at an asphalt

concrete mixing plant, equip the plant with an automated SBR flow control and monitoring system. Obtain OMM’s approval of th e system before operating and demonstrate the system calibration to District Testing. If District Testing waives the demonstration, provide a letter documenting calibration data for the flow system to District Testing for each project. Obtain written appro val from OMM for the use of SBR and ensure the QCP contains methods for properly controlling and sampling SBR binder blends. For drum mix plants, introduce the SBR directly into the asphalt binder line through means of an in -line motionless blender or othe r device approved by OMM which is able to provide a homogeneous blend. Ensure the in -line motionless blender design provides aggressive interaction of asphalt binder and SBR emulsion to provide a homogenous blend at the sampling port. Some blenders such as ‘swirl’ type blenders do not accomplish proper blending. The Astec in line SBR blender or similar design accomplishes proper blending. Locate a sampling valve between the in-line blender and the plant drum, at least 12 ft (3 m) downstream of the in -line blender and at least 5 ft (1 m) downstream of a piping elbow. Ensure the sampling valve port is at least 1 in (25.4 mm) in diameter. Ensure the sampling valve can be opened quickly for maximizing sample flow for the purpose of obtaining a proper sample. In place of an in -line sampling valve, a sample may be taken from a 3 to 5 gal (11 to 19 L) surge tank as long as the tank is downstream of the required blender and the in -line flow can be quickly and directly diverted to the surge tank. Contents of the tank should be drained into a 5 gal (19 L) sampling bucket and stirred before filling the required sample container. Provide a sampling valve port that is in a position to safely obtain the required sample volume in the required 5 gal (19 L) sampling bucket. Provide a stable sampling rack to obtain a sample. 402.04 189 For batch plants, add the SBR after the aggregate has been completely coated with asphalt binder. Continue mixing for a minimum of 20 seconds after SBR is added and long enough to provide a uniform mixture. Ensure the SBR pumping and metering system is capable of adding the SBR within the limits of 702.01. For drum plants ensure the SBR pump is automatically controlled by an independent computer and interfaced with the asphalt binder flow to automatically mai ntain the SBR flow within specification limits. Produce asphalt mixtures for placement in automatic SBR control mode only. Ensure the SBR meter is accurate to ± 2.0 percent over a flow range typical of that used at the asphalt plant (typically 0.8 to 12 gp m (0.05 to 0.76 L/s) at drum plants and 10 to 25 gpm (0.63 to 1.58 L/s) at batch plants). Ensure the SBR meter is a magnetic flow meter consisting of a metering flow tube which utilizes Faraday’s Law of Induction to measure the flow and includes a transmit ter to transmit the flow signal to a totalizer located in the control room of the asphalt plant. Locate the SBR meter downstream of any recirculation lines. Provide a means for removing the SBR line at the in -line blender to be able to obtain a sample of t he SBR for calibration purposes. Obtain OMM approval for use of any other type of SBR meter. Ensure the totalizer displays total volume measured and flow rate in standard engineering units. Ensure the totalizer is interfaced with a data logger that produc es printouts of the logged data every five minutes for a drum plant or every batch for a batch plant. Ensure the logged data includes time, date, flow rate, and flow total except flow rate is not necessary for batch plant production. Balling or wadding of SBR or uncoated aggregate indicates improper mixing; cease production immediately and until corrected to District Testing satisfaction.

402.04 Water Injection System for Warm Mix Asphalt.

When allowed by specification use a water injection system approved by OMM for the purpose of foaming the asphalt binder and lowering the mixture temperature. Only use equipment that has been proven stable and effective through project use on non -ODOT projects. Ensure equipment for water injection meets the following requirements:

403.01 Description

403.02 General

403.03 Quality Control Program (QCP)

403.04 Plant Calibration

403.05 Quality Control Tests

403.06 Verification Acceptance (VA)

403.07 Unconditional Acceptance

403.08 Acceptance Tables for 448 Mixes

403.01 Description. This specification outlines the Contractor requirements for

controlling asphalt concrete, asphalt concrete base, or other asphalt mixtures as specified.

403.02 General. The Department will verify quality control by Department

Verification Acceptance (VA) tests and monitoring reviews as specified. If the Contractor fails to operate according to its Quality Control Program (QCP), the Department will accept asphalt mixtures by Unconditional Acceptance. Resto ration of VA procedures will be by the Department’s Quality Control Qualification Committee (QCQC) based on District recommendation and review of the Contractor problems, resolutions and QCP. Acceptance does not relieve the Contractor of responsibility for supplying and installing a finished product conforming to all requirements of the Contract.

403.03 Quality Control Program (QCP). Create and implement a Quality

Control Program (QCP) for each paving season. The QCP will cover processes conducted to provid e an asphalt mixture at the paving site that is uniform in composition, conforms to the specification requirements and that when placed is free of any defect (ex. segregation, lack of mixture and texture uniformity, raveling, rutting, holes, debris etc.) w ithin the Contractor’s control at project completion. A minimum of 3 weeks before mix production, but no later than February 28, submit a hard copy of the proposed QCP to OMM for review and acceptance. Send a hard copy and a digital copy (if available) of the acceptance letter and accepted QCP to District Testing in every District in which work is performed. Keep copies of the letter and the QCP in each Contractor plant laboratory and plant operation control room. Digital copies of the QCP and letter in pdf format are 403.03 191 allowed in each Contractor plant laboratory and plant operation control room with the following requirements: The file icon must be appropriately labeled and be on the computer desktop of a computer in each area, the QCP must contain page numbering and a Table Of Contents inside the front cover locating all sections by page number , and out of date QCPs must be removed from the computer desktop. Failure to comply with the approved QCP may result in remo val of personnel in accordance with Supplement 1041, removal from VA, and adversely affect the Contractor’s Prequalification rating. The QCP is a reflection of a Contractor’s sincerity and ability in producing a quality product. Development of this program beyond the minimum requirements specified below is encouraged and is taken into consideration by the QCQC when reviewing Contractor plant operation for qualification for VA. Include in the program:

441.10 1 specification requirements. 403.03

192 F. Methods to maintain all worksheets, including all handwritten records, and other test and sample recor ds from the plant or project for the duration of the contract or 5 years, whichever is longer. Define the test record process. Define company records retention requirements. Provide copies of all test reports and forms used in the quality control process.

403.04 Plant Calibration. Conform to the requirements of Item 402.

Before manufacturing asphalt concrete, demonstrate to the Monitoring Team that the Contractor’s facility adequately meets the specification requirements. Calibrate the plant using procedures approved by the Department. Perform initial calibrations in the presence of the Monitoring Team. District Testing may request a letter of certification and certified data documenting the calibration results, instead of having the Monitoring Team present. Verify the calibrations biweekly using a Quick Calibration. However, District Testing may request additional Quick Calibrations if there are mix production problems or plant operation concerns. The Quick Calibration is a quality control procedure developed by the Contractor that verifies the accuracy of a facility to 403.05 193 proportion materials to meet the current JMF. Include the Quick Calibration procedure and data forms in the QCP in accordance with 403.03.H. If the differenc e between current calibration and the Quick Calibration is within 2 percent, then the current calibration is acceptable. If the 2 percent variation is exceeded, perform a recalibration of the facility. Document the Quick Calibration procedure as specified in the QCP and post the procedure and results in plain view in the plant control room and plant laboratory for reference by the Monitoring Team. Document all data from calibrations in a format approved by OMM, and retain the data for review by the Monitor ing Team. If asphalt concrete is being produced from a batch type facility, verify the accuracy of the aggregate and asphalt binder weighing devices on a biweekly basis. Include the verification procedure in the QCP. Document the verification procedure as specified in the QCP and post the procedure and results in plain view in the plant control room and plant laboratory for reference by the Monitoring Team. Do not allow the deviation between the plant recorded weights and actual weights to exceed 1 percent. Record all data from verification of weighing devices in a format approved by OMM, and retain the data for review by the Monitoring Team.

403.05 Quality Control Tests. Perform quality control tests to control the

asphalt concrete mix within the appropriat e specifications. For items that use 446 , 447, and 448 acceptance, perform all mix testing and quality control according to 441.09. The Contractor may test a 448 Sublot sample instead of the required quality control test provided the sample is tested in the half day in which the Sublot sample mix was produced and is tested for all required quality control properties. For mixes that do not use 446 , 447, and 448 acceptance (Basic mixes, e.g. Items 301, 302, and Supplemental Specification 803), test the mix according to 441.09 for asphalt binder content and gradation. Other requirements of 441.09 and 441.10 do not apply. Control the Basic mixes as follows:

403.07 Unconditional Acceptance . If the Contractor is removed from

Department VA, the following will occur. The Contract or must bring its QCP and operation to a level acceptable to the District and QCQC before production continues. District Testing will ensure that the project C -95 (Contractor’s Prequalification Rating survey) reflects the change to Unconditional Acceptance in all of the appropriate C -95 categories. The Department will accept all material for Department projects from the facility under Unconditional Acceptance. While the facility is under Unconditional Acceptance, acceptance of small quantities under the sma ll quantities policy will not apply. Quality control testing requirements specified in 403.05 are modified as follows:

403.06 F) is not exceeded in a series of 30 comparison tests .

403.08 Acceptance Tables for 448 Mixes . A Lot is considered acceptable for

gradation and asphalt binder content if the deviation of the average from the JMF and the Range is no more than the tolerances shown in Table 403.08 -1. TABLE 403.08 -1 DEVIATION FROM THE J MF AND RANGE TOLERANCE S [1] Mix Property Deviation from JMF (Percent) Range (Percent) Asphalt Binder Content 0.3 1.0 1/2 inch (12.5 mm) sieve 6 15 No. 4 (4.75 mm) sieve 5 15 No. 8 (2.36 mm) sieve 4 15 [1] Based on average of four Lot Acceptance tests. If the average of the Lot acceptance tests for a particular sieve or sieves, or for asphalt binder content deviates from the JMF by more than the tolerances shown in Table 403.08 -1, but falls within the tolerances shown in Table 403.08 -2, then the Lot is considered reasonab ly acceptable and may remain in place with payment at a reduced pay factor as show in Table 403.08 -2. If the Range of the Lot acceptance tests for asphalt binder content or for any particular sieve, or sieves, exceeds the tolerance shown in Table 403.08 -1, the Department will apply a pay factor of 0.95. 403.08 201 TABLE 403.08 -2 448 ACCEPTANCE SCHED ULE [1] Mix Property Pay Factor 2 Tests 3 Tests 4 Tests Asphalt Binder Content 1.00 0 to 0.47 0 to 0.36 0 to 0.30 0.98 0.48 to 0.54 0.37 to 0.42 0.31 to 0.35 0.90 0.55 to 0.61 0.43 to 0.48 0.36 to 0.40 0.80 0.62 to 0.68 0.49 to 0.54 0.41 to 0.45 0.60 0.69 to 0.75 0.55 to 0.59 0.46 to 0.50 [2] > 0.75 > 0.59 > 0.50 1/2 inch (12.5 mm) sieve 1.00 0 to 8.5 0 to 6.9 0 to 6.0 0.99 8.6 to 9.9 7.0 to 8.1 6.1 to 7.0 0.97 10.0 to 11.3 8.2 to 9.2 7.1 to 8.0 0.94 11.4 to 12.7 9.3 to 10.4 8.1 to 9.0 0.90 12.8 to 14.1 10.5 to 11.5 9.1 to 10.0 [3] > 14.1 > 11.5 > 10.0 No. 4 (4.75 mm) sieve 1.00 0 to 7.1 0 to 5.8 0 to 5.0 0.99 7.2 to 8.5 5.9 to 6.9 5.1 to 6.0 0.97 8.6 to 9.9 7.0 to 8.1 6.1 to 7.0 0.94 10.0 to 11.3 8.2 to 9.2 7.1 to 8.0 0.90 11.4 to 12.7 9.3 to 10.4 8.1 to 9.0 [3] > 12.7 > 10.4 > 9.0 No. 8 (2.36 mm) sieve 1.00 0 to 5.7 0 to 4.6 0 to 4.0 0.99 5.8 to 7.1 4.7 to 5.8 4.1 to 5.0 0.97 7.2 to 8.5 5.9 to 6.9 5.1 to 6.0 0.94 8.6 to 9.9 7.0 to 8.1 6.1 to 7.0 0.90 10.0 to 11.3 8.2 to 9.2 7.1 to 8.0 [3] > 11.3 > 9.2 > 8.0 [1] Based on average of Lot Acceptance tests from the JMF. [2] Remove and replace material [3] Engineer will determine if the material may remain in place. Pay factor for material allowed to remain in place is 0.70. The Department will determine payment for the Lot by multiplying the contract unit price by the pay factor. When any pay factors for a specific Lot are less tha n 1.00, use the lowest pay factor to calculate the payment. The Department will base acceptance of partial Lots on the average and the Range of the results of tests on the number of samples obtained 407.01 202 ITEM 407 TACK COAT

407.01 Description

407.02 Materials

407.03 Equipment

407.04 Weather Limitations

407.05 Preparation of Surface

407.06 Application of Asphalt Material

407.07 Method of Measurement

407.08 Basis of Payment

407.01 Description. This work consists of preparing and treating a paved

surfac e with asphalt material, and cover aggregate if required.

407.02 Materials. Conform to the applicable requirements of 702 for the asphalt

material and use one of the following types: 702.04 RS -1, SS -1, SS -1h, CRS -1, CSS - 1, or CSS -1h; 702.12 Non -Tracking As phalt Emulsion or 702.13 SBR Asphalt Emulsion. Supply 702.12 Non -Tracking Asphalt Emulsion any time Item 407 Non -Tracking Tack Coat is specified. Conform to 703.06 for cover aggregate.

407.03 Equipment. Provide adequate cleaning equipment, spreader boxes, and

distributors. Use distributors designed, equipped, maintained, and operated to apply asphalt material at the specified rate per square yard (square meter) with uniform pressure over the required width of application. Ensure that the distributor include s a tachometer, pressure gauges, and an accurate volume measuring device or a calibrated tank. Mount an accurate thermometer with a range covering the specified application temperature for asphalt material at approximately center height of the tank with th e stem extending into the asphalt material. Ensure that the distributor has a full -circulating system with a spray bar that is adjustable laterally and vertically. Ensure that the spray bar will maintain a constant height above the pavement under variable load conditions. Supply each distributor with suitable charts showing truck and pump speeds and other pertinent application data necessary to obtain the required results. Do not use equipment that cannot obtain the correct tack application.

407.04 Weather Limitations. Do not apply the asphalt material if the surface

temperature is below the minimum placement temperature for the pavement course to be placed, as specified in 401.06.

407.05 Preparation of Surface. Ensure that the surface is thoroughly clean a nd

dry when the asphalt material is applied. Remove material cleaned from the surface and dispose of it as the Engineer directs.

407.06 Application of Asphalt Material. Uniformly apply the asphalt material

with a distributor having clean nozzles functionin g properly. 407.07 203 For irregular areas such as driveways and intersections, apply the asphalt material using a method the Engineer approves. If paving asphalt concrete directly onto Portland cement concrete or brick pavement, tack the pavement with SBR asphalt e mulsion conforming to 702.13. Apply the asphalt material in a manner that offers the least inconvenience to traffic . Only apply the asphalt material to areas that will be covered by a pavement course during the same day. Ensure the tack breaks before relea sing to construction traffic unless the paver is equipped with a spray bar system to apply tack just prior to mat placement. Apply asphalt material to obtain uniform coverage within the range specified in Table 407.06 -1, as directed by the Engineer. Obtain the Engineer's approval for the quantity, rate of application, temperature, and areas to be treated before application of the asphalt material. The Engineer will determine the actual application in gallons per square yard (liters per square meter) by a ch eck on the project. TABLE 407.06 -1, TYPICAL TACK COAT APPLICATION RATES Existing Pavement Application Rate gal/yd2 (L/m2) New Asphalt 0.05 to 0.06 (0.23 to 0.27) Oxidized Asphalt 0.08 to 0.09 (0.36 to 0.41) Milled Asphalt Surface 0.08 to 0.09 (0.36 to 0.41) Milled PCC Surface 0.06 to 0.08 (0.27 to 0.36) PCC Surface 0.06 to 0.08 (0.27 to 0.36) The application is considered satisfactory when the actual rate is within ±10 percent of the required rate and the material is applied uniformly with no visib le evidence of streaking, ridging or pickup by construction traffic. The Engineer will require proper correction when ridging, streaking, pickup or other non -uniform coverage is observed. Correct non -uniform tack only in areas of non -uniform coverage. Do n ot reapply tack in areas where the tack meets uniformity and application requirements. If the coverage is not uniform and not corrected the total square yardage of non - uniform application will be considered non -specification material. The Engineer will det ermine the number of gallons (liters) for non -payment by using the approved rate of application times the total square yards (square meters) of non -uniform application.

407.07 Method of Measurement. The Department will measure Tack Coat and

Non-Tracking Ta ck Coat by the number of gallons (liters) of undiluted asphalt material applied for each according to Item 109.