422Chip Seal

422.01 Description. This work consists of preparing and applying a single or double chip seal.

Warrant exposed chip seals for two years.

422.02 Materials. Use polymer emulsified binder conforming to 702.16 Type A.

Provide aggregate consisting of washed limestone or washed dolomite conforming to 703.05. Do not use an aggregate source designated with “SR” on the Aggregate Source Group list in accordance with

703.01 F. Additionally the following requirements apply:

Stockpile the material to be used for the chip seal at the aggregate source. Obtain five (5) samples from the stockpile and perform gradation testing on each sample and determine the percent passing for each sieve size listed in Table 422.02-1

422.02 1.

Evaluate the staging location aggregate samples the same as the aggregate source samples except allow an average for the No. 200 (75 µm) sieve not greater than 1.7 percent. Submit the JMF gradations from the staged stockpile and the calculations to show the cover aggregate meets requirements in letter form to the Engineer and District Testing. If the chip seal aggregates fail to meet requirements, either at the aggregate source or the staging location, re-wash and/or rework the aggregate materials and retest the new stockpiles. TABLE 422.02-1 Sieve Size Total Percent Passing Type A Type B 1/2 inch (12.5 mm) 100 3/8 inch (9.5 mm) 85 to 100 100 No. 4 (4.75 mm) 5 to 25 85 to 100 No. 8 (2.36 mm) 0 to 10 5 to 30 No. 16 (1.18 mm) 0 to 5 0 to 10 No. 200 (75 µm) 0 to 1.5 [1] 0 to 1.5 [1] [1] Washed gradation value The District may obtain and test verification samples of the JMF aggregates at any time. If a single verification sample is either outside the values in Table 422.02-1 with the exception that the No. 200 (75 µm) value is not greater than 2.0 percent, the district will obtain five (5) samples and retest to determine if the aggregate JMF falls within the limits of Table 422.02-1. If the JMF verification test doesn’t meet the source or staging location limits the stockpile is not acceptable.

422.03 Equipment. Provide equipment conforming to the requirements of this section. Obtain

approval of equipment before starting the job. Use equipment for binder distribution conforming to 407.03, except ensure that it has a computerized rate control that automatically adjusts the binder pump to the unit ground speed and has a gauge or meter in plain view for reading gallons (liters). Use appropriate spray nozzles for the material and rate specified. Adjust spray bar and nozzles to provide triple lap coverage. Use Type II pneumatic tire rollers conforming to 449.02 with the exception of the requirements of Table 449.02-1 Roller Capacity. Use a minimum of 3 Type II pneumatic tire rollers capable of ballast loading. The roller weight must be between 6 to 8 Tons (5 to 7 metric tons) each to achieve a minimum contact pressure of 80 psi (550 kPa). Tires must be inflated to the proper pressure as specified by the roller manufacturer. Use self -propelled aggregate spreaders with a variable width aggregate hopper capable of placing from 8 to 16 feet (2.4 to 4.8 m) in any increment and a computerized rate control that automatically adjusts the aggregate output to the unit ground speed. Equip spreaders with pneumatic tires, a screen to remove oversized material, revolving cylinders, and adjustments necessary to produce a uniform distribution of particles at the specified rate. Furnish power sweepers, pickup sweepers, or rotary brooms as required for the initial surface preparation and for removing loose aggregate particles. Furnish accurate thermometers for determining any of the applicable temperature requirements of this specification.

422.04 Weather Limitations. Place the chip seal when the pavement temperature is between 60

F (16 C) and 140 F (60 C). Do not schedule the performance of this work for the time period before May 1 or after September 15. Do not place chip seal if any of the following conditions exist:

422.05 Test Strip. Construct a continuous 1000 foot (300 m) long by lane width test strip in the

presence of the Engineer. Do not waive test strips regardless if the same materials have been used on another project. Determine the initial binder application rates and aggregate application rates for the test strip to achieve 2/3 aggregate embedment. For a single chip seal, Type A, an initial target rate of 0.37 ±0.03 gallon per square yard (1.68 L/m²) is recommended for the test strip. For a single chip seal, Type B, an initial target rate of 0.35 ±0.03 gallon per square yard (1.58 L/m²) is recommended for the test strip. For double chip seal, a target rate of 0.36 ±0.03 gallon per square yard (1.63 L/m²) for the first course and 0.33 ±0.05 gallon per square yard (1.49 L/m²) for the second course is recommended for the test strip. Notify the Engineer of the initial target rates. Calibrate the aggregate spreader to ensure a uniform application rate in both the transverse and longitudinal directions. Verify the application rates with a one square yard (one square meter) piece of cardboard or other material to collect and weigh the a ggregate. Adjust spreader rates to maintain application rate within 10% of the target rate. Do not over apply cover aggregate relying on vacuum and broom sweeping to pick up all excess. Amounts of loose aggregate that create a nuisance to the public will result in work stoppage. If work is stopped by the Engineer recalibrate the aggregate spreader determining a new application rate and apply cover aggregate at the new rate. Verify the aggregate gradation meets 422.10.C. during the test strip and provide the results to the Engineer. The Engineer and Contractor will review the test strip the next workday for streaking, ridging, bleeding, aggregate loss or other problems. If the review shows the test strip meets the requirements of

422.11 and the application rate and quality control tests show all is in control compared to the JMF,

then progress with the work. Should problems be noted, the Engineer may require another test strip. JMF gradation targets may be adjusted once within the limits of Table 422.02-1 based on results of the approved test strip. Provide adjusted gradation targets to the Engineer and the DET prior to progressing with the work.

422.06 Surface Preparation. Clean the pavement according to 407.05. If necessary, clean areas

of the pavement with a hand broom. Remove all existing pavement markings so that less than 5% of the line remains visible. Repair damage to the pavement that results in the removal of more than 1/8 inch of pavement thickness. When a grinder drum is mounted to a skid steer loader, the drum m ust be able to accommodate a minimum of 150 teeth. Remove the raised pavement markers according to 621.08. Do not place material until the Engineer approves the existing surface.

422.07 Binder Application. Before applying binder, ensure that sufficient cover aggregate is

available for immediate application. Apply the binder at the target rate(s) established from a successful test strip. Ensure distributor spray bar and nozzles are set to provide triple over lap coverage with no streak or drill patterns on the road surface. Maintain the binder temperature from 150 to 185 F (65 to 85 C) during construction, including the start of each day. Reheat the binder at a rate of no more than 25 F (14 C) per hour, when the binder is allowed to cool below 150 F (65 C). If the target application rates are not the optimum application rates to achieve proper stone embedment during the actual application, immediately notify the Engineer . Proper stone embedment is 2/3 of the stone chip height and can be checked by pulling out several chips by hand. Adjust and document the new application rate by stationing. Recheck stone embedment after adjustment and obtain the Engineer’s approval of the new rate. Do not allow the binder to streak on the road surface. If the Engineer determines that streaking is occurring, cease operations until the Engineer is satisfied that streaking has been eliminated. At the beginning and at the end of a contract section, start and stop the application on a removable protective cover (paper, metal sheets, or other suitable material) sufficiently wide enough to allow full application on the surface being treated. Make transverse and longitudinal laps in such manner to ensure that the texture of the finished surface is uniform and continuous. To prevent lapping at transverse junctions, promptly shut off the binder spray at the end of the application. Before continuing the application, place a removable protective cover a sufficient distance back from the joint on the cover aggregate so the sprayers are operating at full force when the distributor has attained the predetermined speed upon reaching the uncovered surface. Upon completion, remove all removable protective covers.

422.08 Cover Aggregate Application. Verify the application rate with a one square yard (one

square meter) piece of cardboard or other material to collect and weigh the aggregate before placing binder. Adjust if necessary and re -verify. Record final results and inform the Engineer . Immediately after applying the binder, apply cover aggregate uniformly without ridges or laps at the specified rate adjusted as directed by the Engineer to produce a minimum of excess loose particles. Spread the material in such manner that the tires of the truck or aggregate spreader at no time contact the uncovered and newly applied binder. Before rolling, correct deficiencies in the application of cover aggregate in a manner satisfactory to the Engineer. After rolling, protect the surface from traffic damage during the period required for the binder to cure sufficiently and prevent dislodging of the aggregate particles by normal traffic. During this period and as directed by the Engineer, correct deficiencies in cover aggregate by spreading additional aggregate or by light brooming. Apply cover aggregate at a rate necessary to provide full coverage of the binder and to avoid tracking. Do not over apply cover aggregate relying on vacuum and broom sweeping to pick up all excess. Nuisance to the public amounts of aggregate will result in work stoppage. If work is stopped by the Engineer recalibrate the aggregate spreader determining a new application rate and apply cover aggregate at the new rate. If the target rate needs adjustment due to the gradation of the aggregate or due to existing surface conditions of the pavement, immediately notify the Engineer and document the new rate by stationing.

422.09 Construction Operation. Establish stations at 1000 foot (300 m) intervals on the entire

project before placing materials. Clearly identify and maintain the stations until project completion. Keep the binder distributor, aggregate spreader, and rollers as close to each other as possible. Do not allow the binder distributor to be more than 150 feet (45 m) ahead of the aggregate spreader. Perform rolling immediately after placing the aggregate, but before the binder sets up. Do not leave aggregate unrolled for more than 5 minutes. Perform a minimum of two complete roller passes over the aggregate. A single complete pass is forward and backward over the same path. For each new pass, overlap the previous pass by about one-half the width of the roller. Use a minimum of three rollers, and roll in a longitudinal direction at a speed not greater than 5 miles per hour (8 km/h). Do not operate rollers at speeds that cause pick-up or dislodging of aggregate particles. Within 4 hours of placement but after the binder sets, sweep the pavement as needed to remove all loose aggregate. Use pickup sweepers in curbed areas and where aggregate shoulders do not exist. Do not sweep loose aggregate onto lawns, curbed areas, or intersections. If the pavement cannot be swept within the 4-hour period due to problems associated with the stone moisture, binder, breaking, humidity, or other unknown, the Engineer may suspend the operation until the problem is resolved or more suitable conditions are obtained to maintain the 4-hour time frame for sweeping. Extend sweeping 1 foot (0.3 m) beyond the edge of the chip seal to help prevent migration of loose aggregate back onto the pavement. Do not re-use aggregate from a chip seal that is swept from the pavement or that is already loose off the pavement edge. Perform a final sweeping immediately before application of permanent pavement markings or a fog seal, if a fog seal is required. Use pickup sweepers in curbed areas and where aggregate shoulders do not exist. Do not sweep loose aggregate onto lawns, curbed areas, or intersections. The Contractor is responsible for claims of damage to vehicles prior to the final sweeping. Wait at least 24 hours before placing the second course of a double chip seal. Ensure the first course of a double chip seal meets the gradation of Table 422.02-1 Type A and the second course meets the gradation of Table 422.02-1 Type B. Ensure that the first course meets requirements of this specification and is cured and capable of withstanding construction traffic without damage. If loose aggregate is evident, sweep the first course again just prior to placing the second course. Correct damage to the underlying chip seal before placing the second course. Place the longitudinal construction joint on a lane line or as directed by the Engineer . For double chip seal, place the longitudinal construction joint for the first course 6 inches (150 mm) off the centerline and place the second course so the longitudinal joint is at the centerline. Before opening to traffic, post the roadway with “Loose Gravel /Fresh Tar” signs and a “35 mph” speed plaque mounted below the sign. Ensure that signs conform to Item 614. Place these signs in the advance warning area and just beyond each intersecting road throughout the length of the activity area. Remove the signs as directed by the Engineer. On two-lane roads or pavements where traffic is maintained on a chip seal constructed that workday, provide a traffic control pilot vehicle operated at no more than 25 miles per hour (40 km/h) in the immediate work area. Protect all utility castings, monument boxes, and other similar items using tarpaper or other approved material. Remove protection before sweeping and opening to traffic.

422.10 Quality Control

422.11 Acceptance. Inspect the chip seal daily for deficiencies resulting from poor

workmanship, flushing, tracking from equipment, surface patterns, loss of stone, and sweeping. Inspect workmanship for untreated areas, minimum overlap on longitudinal joints, and minimum o verlap on construction joints. Verify the following for daily acceptance:

422.12 Performance Review. Perform remedial actions for any defect exceeding the threshold

levels in Table 422.12-1 for a period of two years from the date of substantial work complete as documented on the Department’s Form C-85. Contact the Department to schedule a final performance review at least 60 days prior to the end performance review period. The Department wil l review the pavement before the end of the two year performance review period to determine if remedial action is required. The Department will issue the results in writing to the Contractor upon completion of the performance review. Remedial Actions. Perform Remedial Actions between May 1 and September 1. If the Department determines that immediate repairs are necessary, due to a potential hazard to the traveling public, the Department will notify the Contractor and establish a date that all repairs are to be finished. Provide construction traffic control when performing any work required or allowed by this specification during the warranty period in accordance with current Department policy and the Ohio Manual of Uniform Traffic Control Devices . The Department will approve when the work is performed. Provide approved materials, equipment, and labor to perform Remedial Actions at no additional cost to the Department. Prior to performing a Remedial Action, submit a Remedial Action plan to the DCA for approval. State in the plan when and how the Remedial Action will be performed; what material will be used; and how traffic will be controlled. Warrant Remedial Action work for the remainder of the warranty period. Replace pavement markings or raised pavement markers (RPM) removed, obliterated, or damaged while performing a Remedial Action with pavement markings or RPMs equal approved products at no cost to the Department. The Contractor is not responsible for pavement damage beyond the Contractor’s control (i.e., car fire, oil spill, structural issues, etc.). TABLE 422.12-1 Each segment will be 300 ft (91 m) in length and the width of the lane. The beginning point of a 300 ft (91 m) segment starts at the beginning of any individual defect type. For loss of aggregate, the beginning point of a 300 ft (91 m) lane segment will exclude locations where vehicles turn from or onto other state highways. Defect Severity Threshold Levels Surface Patterns Severe - light and heavy lines over the pavement surface 40% of segment length affected, continuous or localized Bleeding/ Flushing Moderate - excess binder on surface (loss of stone/tire contact) not subject to wearing off quickly 5% of segment length affected continuously or total of 20% localized problems Loss of Aggregate Moderate- patches of aggregate loss 10% of segment length affected continuously or total of 20% localized problems

422.13 Method of Measurement. The Department will measure Single Chip Seal or Double

Chip Seal by the number of square yards (square meters) of aggregate, and the gallons (liters) of polymer emulsified binder, completed and accepted in place. The Department will determine the width by measuring the actual width of the chip seal. The Department will determine the length along the centerline of each roadway or ramp. The Department will determine the gallons (liters) of polymer emulsified binder applied according to Item 109. The Department will measure the number of raised pavement markers removed.

422.14 Basis of Payment. The Department will not pay for materials, equipment, or labor to

make corrections. The Department will pay for removal of existing pavement markings according to Items 642, 643, 644, 645, 646, 647, and 648 as specified. The Department will pay for removal of existing raised pavement markers according to Item 621 Raised Pavement Markers Removed. The Department will pay for accepted quantities at the contract prices as follows: Item Unit Description 422 Square Yard Aggregate, Single Chip Seal, Type __ (Square Meter) 422 Gallons Emulsion, Single Chip Seal, Type ___ (Liters) 422 Square Yard Aggregate, Double Chip Seal, Type ___ (Square Meter) 422 Gallons Emulsion, Double Chip Seal, Type ___ (Liters)

Chip Seal in other states

• Colorado 409 · CHIP SEAL
• New York 410 · Chip Seal
• Oklahoma 403 · Chip Seal