322ASPHALT CONCRETE – CLASS Q

322 Page 171322 ASPHALT CONCRETE – CLASS Q

322.1DESCRIPTION

The work consists of constructing one or more courses of gyratory controlled QC/QA hot mixed asphalt concrete pavement on a prepared foundation.

322.2MATERIALS

Mineral aggregate will conform to the requirements of Section 322.3 . All other materials and their use will conform to Section 320.2 .

322.3CONSTRUCTION REQUIREMENTS

The construction requirements will be as prescribed in Section 320.3 with the following additional requirements: A.Laboratories: 1.Quality Control Laboratory: The Contractor will furnish and maintain a Quality Control (QC) laboratory at the plant site. The laboratory will be furnished with the necessary space, equipment, and supplies to properly perform all specified testing. The laboratory will be equipped with a gyratory compactor meeting the requirements of AASHTO T 312. The laboratory equipment will meet the requirements of the test methods contained in the Department’s Materials Manual and Materials Testing & Inspection Certification Program Manual. A copy of the equipment calibration records will be kept in the QC laboratory. The Contractor's QC laboratory will be equipped with a mechanical convection oven meeting the requirements of Section 600. The Contractor will furnish a cut off saw equipped with a diamond tipped blade. The saw is to separate the core samples to the actual lift thickness. The cores will be sawed by the Contractor to the correct lift line prior to testing the cores for density. 2.Quality Assurance Laboratory: The Contractor will also provide a separate Quality Assurance

requirements of Section 600. B.Quality Control: 1.Contractor Furnished Quality Control Program: QC for the asphalt concrete pavement is the responsibility of the Contractor. The Contractor will provide and maintain a QC program. The program will assure that all asphalt concrete materials and constructed pavement submitted for acceptance conforms to the contract requirements. The Contractor will be responsible for all asphalt concrete materials and constructed pavement, including aggregate process control and handling. The Contractor will provide at least one technician certified in Asphalt Concrete Aggregate Testing and Asphalt Concrete Hot Mix Testing for conducting the QC testing and at least one technician certified in Asphalt Concrete Roadway Inspection for roadway inspection. 322 Page 172All of the Contractors QC testing and inspection technicians will meet the Department’s certification requirements or be under the direct supervision of a certified technician for the type of work they are actually performing. The certified testing and inspection technicians must be present at the plant and roadway whenever the plant is supplying asphalt concrete to the roadway. At or prior to the preconstruction meeting the Contractor will submit a QC plan to the Engineer for approval. The plan will contain the following minimum requirements: a.The names and phone numbers of the individual(s) responsible for the Contractor’s QC program. b.A listing of the certified technician(s) responsible for the QC inspection, material sampling, and testing. c.A copy of the completed performance checklist and training and evaluation records for all temporary or seasonal personnel who will be performing QC inspection or sampling and testing. d.An organizational chart indicating lines of authority. e.The Contractor will notify the Engineer if a control test strip will be used. The Contractor may produce approximately 500 tons of material to establish a roller pattern and verify the field produced mix properties match those of the lab mix design. After test strip placement, further mixing and laydown operations will be suspended until the laboratory test results of the asphalt mixture and core densities are available. The material used in the test strip will not be included in the mix pay factor analysis. The material used in the test strip will be tested for all the properties listed in the Department’s Materials Manual. The Engineer will approve the location of the test strip. If a control test strip is not constructed, the QC plan will specify how the Contractor will establish a roller pattern to achieve the specified density and volumetric requirements. The Engineer will provide the following to the Contractor at the preconstruction meeting: •Names of the certified individuals in charge of Quality Assurance (QA) testing and roadway inspection. •An organizational chart including the names and phone numbers of those in the direct line of authority. 2.Mineral Aggregate Testing Prior to Production: The aggregate producer will provide test results to the Contractor and Engineer for each stockpile of virgin mineral aggregate that will be incorporated into the asphalt concrete mixture a minimum of 3 weeks prior to asphalt concrete production. The aggregate producer will use an individual certified in Asphalt Concrete Aggregate Testing. The required tests will include gradation, crushed particles, fine aggregate angularity, flat and elongated particles, sand equivalent, and lightweight particles at the following minimum frequencies: 322 Page 173One test per 1500 tons for each virgin mineral aggregate ingredient produced. A minimum of three tests for each virgin mineral aggregate stockpile. The Contractor may vary the frequency of the crushed particles, fine aggregate angularity, flat and elongated particles, sand equivalent, and lightweight particles tests on ledge rock sources depending on the quality and uniformity of the materials. 3.Contractor Furnished Mix Designs: Asphalt concrete mix designs will be performed by the Contractor and verified by the Department’s Bituminous Mix Design Lab. A certified Asphalt Concrete Mix Design and Production Control technician will perform the asphalt concrete mix design. All Contractors submitting mix designs to the Department are required to participate in the Proficiency Sample Program. Prior to submitting samples to the Department’s Bituminous Mix Design Lab, 50% of the plans quantity or 15,000 tons, whichever is less, of the virgin mineral aggregate will be produced. When RAP is required, the Contractor will sample the RAP from the roadway by an approved method. The sampling method will ensure a representative sample of material is obtained from approximately the same depth as the plans shown milling depth. The RAP sample will be obtained from a minimum of three locations throughout the project length. The Contractor will daylight all edges of the sampling area leaving no vertical faces or will fill the sample area with an approved product leaving no vertical faces. The equipment used will generate a representative sample of RAP similar to what will be produced from the cold milling operation. The Contractor will notify the Area office a minimum of 5 calendar days prior to sampling the RAP from the roadway. A representative from the Area office will witness all sampling of RAP to be submitted for mix design. This material will be used to perform the mix design. A portion of this sample will be submitted to the Department’s Bituminous Mix Design Lab. The Contractor will notify the Area office a minimum of 5 calendar days prior to sampling and submitting the mix design aggregates. A representative from the Area office will witness all sampling of aggregates to be submitted for mix design. A representative from the Area office will complete the Form DOT-1 for the composite aggregate sample and RAP sample required for submittal to the Department’s Bituminous Mix Design Lab. The Area office representative will take possession of the aggregate and RAP samples for mix design and aggregate quality testing. Samples will be obtained a minimum of 21 calendar days prior to hot mix production. The Area office will deliver the samples to the Department’s Bituminous Mix Design Lab in Pierre, SD. The Area office may allow the Contractor to transport and deliver the RAP and aggregate samples for mix design and aggregate quality testing only when the Area office representative has sealed the samples with a tamper evident tag, with the DOT-1 attached. Mix designs will only be performed on samples when accompanied by the following information: 322 Page 174a.A completed data sheet (form DOT-1), including the legal description of virgin mineral aggregate source(s). b.Representative virgin mineral aggregate samples and RAP samples will be proportionate to the bin splits proposed for use during construction. c.A summary sheet showing all test results from the gradations completed and the average gradation of each mineral aggregate stockpile produced along with the proposed bin splits to be used in the production of asphalt concrete pavement. d.A 2 gallon sample of asphalt binder intended for use will be obtained from the designated supplier for the project. e.A mix design report and moisture sensitivity test results, if required, that includes the lab data and test results required in SD 318, SD 319, and Section 322.3 B.4. The Contractor’s mix design will meet all of the mix design specifications. When the mix design verification is completed by the Department’s Bituminous Mix Design Lab, an approved mix design report (DOT 64) will be provided to the Area Engineer and the Contractor prior to production. The mix design report will include the single percentage of aggregate passing each required sieve size, a single percentage of asphalt binder to be added to the mixture, a single percentage of hydrated lime to be added to the mixture, a single asphalt binder application temperature, a single temperature at which the mix is to be discharged from the mixer, and a single temperature at which the mix is to be delivered on the road. 4.Gyratory Controlled QC/QA Mix Design Requirements and Specifications : Unless otherwise specified in the plans, the mix design criteria will conform to the following requirements. a.Consensus Virgin Mineral Aggregate Requirements: 1)Crushed Particles (SD 211) The crushed particles will be tested on the composite virgin mineral aggregate sample. Table A Crushed Particles Minimum two or more crushed faces (%) Class Q1 50 Class Q2 65 Class Q3 75 Class Q4 90 Class Q5 100 322 Page 1752)Fine Aggregate Angularity (SD 217) Table B - Fine Aggregate Angularity Minimum Uncompacted Void Content (%) Class Q1 40.0 Class Q2 41.5 Class Q3 43.0 Class Q4 44.0 Class Q5 45.0 3)Flat and Elongated Particles (SD 212) The maximum amount of flat and elongated particles for the coarse aggregate will not exceed the limits shown in Table C. Flat and elongated particles are defined where the ratio of maximum to minimum dimension is greater than 5:1. The aggregate tested will be the composite virgin aggregate material that is retained on a #4 sieve. Table C – Flat and Elongated Particles Maximum Flat and Elongated Particles (%)*1 Class Q1 No Limit Class Q2 10 Class Q3 10 Class Q4 10 Class Q5 10 *1evaluated for specification at mix design only 4)Sand Equivalent (SD 221) Table D - Sand Equivalent Sand Equivalent Minimum (%) Class Q1 40 Class Q2 42 Class Q3 45 Class Q4 50 Class Q5 60 322 Page 176b.Source Virgin Mineral Aggregate Requirements: 1)Source Virgin Mineral Aggregate Requirements: Table E - Source Mineral Aggregate Requirements Light Weight Particles (SD 208 & SD 214)Sodium Sulfate Soundness (SD 220; 5 cycles) +#4 -#4 +#4 -#4Los Angeles Abrasion Loss (SD 204) Class Q14.5% maximum4.5% maximum15% maximum15% maximum45% maximum Class Q23.0% maximum3.0% maximum15% maximum15% maximum45% maximum Class Q33.0% maximum3.0% maximum15% maximum15% maximum40% maximum Class Q41.0% maximum1.0% maximum12% maximum12% maximum35% maximum Class Q50.5% maximum0.5% maximum12% maximum12% maximum35% maximum 2)Gyratory Controlled QC/QA Gradation (Sieve Analysis; SD 202): Virgin mineral aggregate gradations, at mix design, must be within the control points for the designated aggregate size of the table below. Table F - Gyratory Controlled QC/QA Gradation*1 Control Points (percent passing) Sieve Size Min. Max. 3/4 inch 100 1/2 inch 90 100 3/8 inch 85 #8 30 55 #200 2.0 7.0 *1the gradation sample will not include hydrated lime. c.Mixture Requirements: 1)Gyratory Compactive Effort: The mixture will be compacted in accordance with SD 318. The number of gyrations and densification criteria are in listed in Tables G and H. Table G - Gyratory Compactive Effort Ninitial Ndesign Nmaximum Class Q1 6 40 65 Class Q2 6 50 75 Class Q3 6 60 85 Class Q4 7 70 95 Class Q5 7 80 110 322 Page 1772)Mixture Densification Criteria: Table H – Target Mixture Densification Criteria Percent of Mixture Maximum Specific Gravity (Gmm) Ndesign Nmaximum *1 Class Q1 96.0 98.0 Class Q2 96.0 98.0 Class Q3 96.0 98.0 Class Q4 96.0 98.0 Class Q5 96.0 98.0 *1Nmaximum evaluated for specification at mix design only 3)Voids in Mineral Aggregate Criteria (VMA): VMA is calculated from the mixture bulk specific gravity at Ndesign gyrations. Table I - Voids in Mineral Aggregate Criteria Nominal Maximum Aggregate SizeMinimum VMA, %*1 Class Q1 14.5 Class Q2 14.5 Class Q3 14.5 Class Q4 14.5 Class Q5 14.5 *1the minimum VMA% required for hot mix during production will be 13.5% 4)Voids Filled with Asphalt (VFA): VFA is calculated from the mixture bulk specific gravity at Ndesign gyrations. Table J - Voids Filled with Asphalt Criteria VFA*1, % Class Q1 70-80 Class Q2 65-80 Class Q3 65-78 Class Q4 65-78 Class Q5 65-75 *1evaluated for specification at mix design only 5)Dust to Binder Ratio: The dust to binder ratio will be 0.6 to 1.4 The dust to binder ratio is calculated as the percent by mass of the total material passing the #200 sieve (including hydrated lime) divided by the effective asphalt binder content (expressed as percent by mass of mix). If the aggregate gradation percent passing the #8 sieve is less than 39% at mix design, the dust to binder ratio will be increased to 0.8 to 1.6. 6)Moisture Sensitivity (SD 309): The minimum retained tensile strength ratio for the mixture is 80%. The moisture sensitivity requirement will be waived if 1.00% hydrated lime is added to the mix. Hydrated lime will not be required or can be added at a rate lower than 1.00% if 322 Page 178the moisture sensitivity requirement is met. If lime is used, a minimum of 0.50% hydrated lime will be added to the mix. Liquid anti-stripping additives will not be allowed in lieu of hydrated lime. An item will be included in the contract for hydrated lime. Payment for hydrated lime will only be made when hydrated lime is used. Moisture sensitivity will only be evaluated during the mix design process. 7)Asphalt Pavement Analyzer (AASHTO T 340): Samples will be compacted at the Ndesign gyratory level at the Contractor selected binder content and tested at the PG binder high temperature. Field samples will be tested at the binder and air void content of the selected field gyratory samples or as made at the Ndesign gyratory level from a sample of field produced mix. Table K - Asphalt Pavement Analyzer Criteria APA, Maximum Rutting (mm) Class Q1 8 Class Q2 7 Class Q3 6 Class Q4 5 Class Q5 5 8)Moisture Content of Mix: The maximum moisture in the field produced mix will be 0.3%. The mix will be sampled from the windrow in front of the laydown machine and placed in an airtight tared container. The mix will be dried to a constant mass as described in SD 305. 5.Quality Control Testing: a.Calibration Testing: 1)Cold Feed: Prior to production of asphalt concrete, the QC and QA certified technicians will conduct comparison tests at the plant with a split companion cold feed calibration sample of virgin aggregate to assure that all associated equipment and procedures provide comparable results. Comparison test results will meet the requirements of the mix design report and will conform to the tolerances shown in the Department’s Materials Manual. The split companion calibration testing will continue until the results meet the requirements of the mix design report and are within the listed tolerances. The split companion calibration testing will be performed on each mix type produced prior to production of that mix type. 2)Mixture Testing: The QC and the QA technicians will perform correlation testing on a reheated prebuilt split companion sample (from the mix design process) supplied by the Contractor. The correlation testing will be for the theoretical maximum specific gravity (Rice Method) and gyratory bulk specific gravities. Two gyratory compaction samples will be made using a compactive effort of Ndesign. The bulk specific gravity will then be measured on specimens compacted to Ndesign gyrations. Air voids will be calculated using the theoretical maximum specific gravity and bulk specific gravity at Ndesign gyrations. The percent of theoretical 322 Page 179maximum specific gravity densification will be determined at Ndesign. The results will be within the tolerances shown in the Department’s Materials Manual. 3)Bulk Specific Gravity Reheat Correlation: The QC and the QA technicians will perform a reheat correlation test for the bulk specific gravity. The reheat correlation test will be performed on a split sample of a sublot from within the first lot of production for the mix design. An additional reheat correlation test will be performed on a split sample of a sublot from within the first lot of production for any new mix designs. Cool a split portion of the sample down to room temperature. After the split sample has cooled, reheat and compact according to SD 318. Calculate the difference in the bulk specific gravities of the non-reheated and reheated tests. The average difference using the QC and QA technician's test results will be the correction factor for a reheated bulk specific gravity. This test may be repeated at the discretion of the Contractor or the Engineer. b.Asphalt Concrete Quality Control (Production) Testing: After the calibration cold feed and mixture testing is completed and the results are within the specified tolerances, the Contractor will be allowed to begin production of asphalt concrete. The Engineer will randomly determine all sample locations. Sampling and splitting not performed by the Engineer will be witnessed by the Engineer. To ensure that a representative random sample is obtained, the QC sample locations will only be given to the Contractor immediately prior to sampling. The hot mix sample will be obtained before the cold feed gradation sample. If hydrated lime is used in the mix, the hydrated lime will be momentarily shut off while obtaining the cold feed gradation sample. If hydrated lime is to be included in the mix, care will be taken to ensure that the hot mix sample is obtained with hydrated lime included in the sample. There will be a 200 ton buffer between the random sample locations. The intent of the buffer is to prevent back-to-back sampling and to more evenly distribute the sampling and testing workload. A lot will consist of five sublots. Sublots will not represent more than 1000 tons of asphalt concrete unless the current sublot is terminated. The Contractor will obtain QC samples at the specified locations for four of the five sublots. The Engineer will sample and split a minimum of one of the five sublots and witness all QC sampling. The Contractor will test all five sublot samples (a split of the one sublot sampled by the Engineer and four sublot samples taken by the Contractor). The material will be sampled, split, and tested by the methods and procedures described in the Department’s Materials Manual. The aggregate and hot mix samples will be large enough to obtain 4 splits of the minimum sample size needed for testing. If the sample is to be used for IA testing, the samples will be large enough to obtain 6 splits of the minimum size needed for testing. Immediately after splitting, the QA technician will take possession of half of the sample for all of the QC samples. The QA technician will ensure the Department’s portion of the backup samples for all QC and QA tests are properly labeled, stored, and retained until the Department’s Bituminous Engineer has completed the F-test and t-test 322 Page 180statistical evaluation. The QC technician will retain their backup split until the QC, QA, and IA technicians have obtained their test results for the individual lot and have found the results to be within the allowable tolerances in the Department’s Materials Manual, SD 317, and the Engineer has approved the disposal of the backup samples. The Engineer will determine and mark the core locations after the mix is placed and compacted. The cores will be taken the next working day after the asphalt pavement is placed. The Contractor will perform the coring under observation by the Engineer. The Engineer will take immediate possession of the core samples for density testing. The Contractor will fill all core holes before the end of the next working day with hot asphalt concrete and compact the mix to a density close to that of the surrounding pavement. Core samples for density will be tested by the Engineer. The QC technician will complete all of the required tests on the samples selected for QA or IA testing. c.Specification Control Limits: The control limits of materials being produced will be evaluated under two different categories, pay factor attributes and non-pay factor attributes. 1)Pay Factor Attributes: Air voids and in place density (compaction) are the two pay factor attributes. These attributes will be statistically analyzed for contract unit price adjustment. The percent air voids will meet the requirement in Table L and the in place density of the asphalt concrete when expressed as a percent of the lot average maximum specific gravity (Rice Method) will meet the requirements in Table L. TABLE L - PAY FACTOR ATTRIBUTES

Class Q1 92.0% to 97.0% Class Q2 92.0% to 97.0% Class Q3 92.0% to 97.0% Class Q4 92.0% to 97.0%b.In Place Density (% Compaction) Class Q5 92.0% to 97.0% When field test results for air voids or in place density deviate from the job mix formula values, the Contractor may adjust the gradation, asphalt binder content, or both within the allowable tolerances shown for items a, b, c, and d shown in Table N. Bin splits may be adjusted up to ± 5% from the job mix formula bin splits. Adjustments will be made as a result of an interactive process between the Contractor and the Engineer. The Contractor's recommendations will prevail, provided all specifications and established mix design criteria are being met. If new materials are to be incorporated into the asphalt concrete or if any cold feed bin split percentage is adjusted by more than ±5 from the job mix formula, a new mix design will be required by the Contractor (unless waived by the Bituminous Engineer) with verification by the Department’s Bituminous Mix Design Lab. The 322 Page 181Contractor will be responsible to verify all mix design criteria are being met prior to written job mix formula approval. When a new mix design and job mix formula is required, the current sublot will be terminated and incorporated into the previous sublot for pay factor analysis. A new lot will be started when production is changed to the new job mix formula. At the end of production, the current sublot will be terminated and incorporated into the previous sublot unless the hot mix sample and both core sample locations have been obtained and tested for the current sublot. 2)Non-Pay Factor Attributes: There are several requirements not used in the determination of the pay factor that are very important to the performance of the asphalt concrete. The below listed attributes are tested at the frequency listed in the Department’s Materials Manual. The attributes will be maintained within the requirements in Section 322.3 B.4 or as otherwise specified. Table M – Non-Pay Factor Attributes Virgin Mineral Aggregate Gradation Asphalt Binder Content Hydrated Lime Content Moisture Content of Mix Sand Equivalent Lightweight Particles Crushed Particles Fine Aggregate Angularity Voids in Mineral Aggregate (VMA) Dust to Binder Ratio RAP Content (if used) The asphalt binder and hydrated lime content are not statistically evaluated as pay factor attributes but may be price adjusted (DOT-18) for failure to conform to specification requirements. The VMA and dust to binder ratio is calculated using the asphalt binder percentage determined from the daily cutoff from that day’s production. The bulk specific gravity of the mineral aggregate will be determined by the Department’s Materials & Surfacing Central Laboratory during the mix design verification. When RAP is required, the VMA will be calculated using the bulk specific gravity of the mixture, the percent stone of the mixture, and the bulk specific gravity of the aggregate as determined by the Department’s Materials & Surfacing Central Laboratory during the mix design verification, all including RAP. When RAP is required, the Dust to Binder Ratio will be calculated using the percent -#200 material from the virgin aggregate, the percent hydrated lime, and the effective binder content of the total mixture including RAP. The bulk specific gravity of the mineral aggregate may be tested during production at the discretion of the Contractor or the Engineer. A split portion of material will be given to the other entity for verification. 322 Page 182If the VMA or dust to binder ratio value does not meet the requirements in Section 322.3 B.4, the Contractor will make corrective actions before production continues and document the corrective actions taken. If three out of any five consecutive tests for VMA or dust to binder ratio exceed the criteria in Section 322.3 B.4, the Contractor will immediately cease operations. A new mix design will be required by the Contractor (unless otherwise approved by the Department’s Bituminous Engineer) with verification by the Department’s Bituminous Mix Design Lab prior to resuming production. The Contractor will be responsible to verify that all mix design criteria are being met. TABLE N – JOB MIX FORMULA TOLERANCES AttributeTolerance from Target Value

*1These properties are not listed on the job mix formula but will be tested for compliance with the mix design specifications listed in Tables A-E. If two out of any five consecutive tests for the gradation requirements (Items a, b, or c) fail to meet the tolerances contained in Table N, the Contractor will immediately cease operations. The Contractor will investigate the cause of the variation in production. Production will not be allowed to resume until a passing cold feed sample is obtained and the Engineer has approved the corrective action. If the asphalt binder content, hydrated lime content, or RAP content falls outside the tolerance in Table N; the Contractor will make corrective actions before production continues and document the corrective actions taken. If two out of any five consecutive tests for the asphalt binder content, hydrated lime content, or RAP content fail to meet the tolerances contained in Table N; the corrective action will include recalibration of the binder meter, the lime weigh and feed system, or the RAP feed system, respectively. The maximum moisture content in the field-produced mix will be 0.3%. If the moisture content in the mix exceeds the maximum allowed the Contractor will make corrective actions before production continues and document the corrective actions taken. Burner adjustments, increase mix temperature, slower plant production rates, use of drier aggregates, and adjustment to the amount of time material is in drum for mixing and heating are possible corrective actions. 322 Page 183Additional moisture content in the field-produced mix tests will be conducted to verify that the corrective action has worked to produce specification mix. If the sand equivalent, percent lightweight particles, fine aggregate angularity, or crushed particles (Items e, f, g, or h) for a single test fall outside the tolerances shown in Table N, the Contractor will immediately cease operations. The Contractor will investigate the cause of the variation in production. The Contractor will not be allowed to continue operations until a passing cold feed sample is obtained, and the Engineer has approved the corrective action. 3)Test Identification: Number the production control sublot tests consecutively in accordance with the Department’s Materials Manual starting with number “QC01” or “QC001” based on the total number of samples needed. The two density cores in a sublot will have the same number along with an “A” or “B” designation and will match the sublot number. The two gyratory specimens will be numbered with the sublot number and an “A” and a “B” for the two specimens. Use “N” before the sublot number for non-pay factor material. Use “Info” before the number for information samples. Use “TS” before the sublot number for test strip samples. Use “R” after the number for remedial samples. Use “Cal” before the number for calibration samples. 4)Control Charts: The Contractor will provide QC charts that include the control limits and each individual test result for the following parameters: a)Gradation of the control sieves in the Job Mix Formula b)Asphalt Binder Content c)Hydrated Lime Content d)Maximum Specific Gravity (Rice) e)Bulk Specific Gravity (Gyratory) f)Air voids g)In place density h)VMA i)Dust to Binder Ratio QC test results will be recorded on the control charts immediately after completion of the test. The control charts will also include the QA and Independent Assurance test results. The control charts will be prominently displayed and accessible to the Engineer. The control charts will be given to the Engineer upon completion of the project. 5)Documentation: The Contractor is responsible for documenting all observations, inspection records, mixture adjustments, test results, and corrective actions on a daily basis. The Contractor will also record and maintain a plant record of plant starts and stops, mix temperatures leaving the plant, bin split of aggregates, and the temperature of the asphalt binder going into the mix. Field observations and inspections will be noted as they occur in a permanent duplicating field book or diary, provided by the Engineer. The roadway diaries will include hours paved, equipment in use, stations paved, course depth, width, crown, spread checks, tonnage, weather, and temperature of mixture delivered to 322 Page 184the road. Plant diaries will include plant start and shutdown times, mix temperature of material produced, binder spot checks, aggregate bin splits being used, actual calculated asphalt binder percentage for the day, tons of mix produced, mixture or aggregate adjustments, weather conditions, and any other pertinent information. The Engineer will collect copies of documentation records and recorded mix temperature charts daily. All records will be always made available upon request by the Engineer. The test results and original work sheets, including all gyratory specimen compaction sheets, for the production control testing listed in Table M will be given to the Engineer upon completion of the test. C.Quality Assurance: The Engineer will randomly sample and test a minimum of one sublot for each lot. The Engineer may test any or all splits of the QC sublot samples as part of the QA program. The Engineer will provide at least one individual certified in Asphalt Concrete Aggregate Testing and Asphalt Concrete Hot Mix Testing for conducting the QA testing and at least one individual certified in Asphalt Concrete Roadway Inspection for roadway inspection. The QA technician will complete all the required tests on the samples that are selected for QA testing. The services of Contractor’s personnel to assist in obtaining the QA samples should be limited only to instances when hazardous conditions or liability issues exists that dictate their involvement, and the following requirements are met: 1.The QA sample location or time is only given to the contractor immediately prior to sampling. 2.The contractor’s personnel are used only to provide labor to assist in physically obtaining the QA sample. 3.The Engineer is present to witness the taking of the QA sample. 4.The Engineer witnessing the sampling and the contractor labor performing the sampling are certified in accordance with the Department’s Certification program. 5.The Engineer immediately takes possession of the QA sample. QA test results will be made available to the Contractor within 24 hours, or the next working day. The split sample test results (QA) of the sample taken by the Engineer will be compared to the Contractor test results (QC) for conformance with the Department’s Materials Manual. Populations of the QC sample test results will be compared to the QA sample test results utilizing the procedures shown in SD 317. If the test results are within the allowable tolerances, found to be similar, and found to represent the same population, as determined by F-test and t-test statistical evaluation procedures conducted by the Bituminous Engineer, the Contract unit price adjustments will be based on the Contractor QC test results. Sampling and splitting not required to be performed by the Engineer will be witnessed by the Engineer. The Engineer will test the core samples for density. 322 Page 185The Engineer will perform or witness the measurement of the depth of the asphalt binder in the storage tanks as described in SD 314. The Engineer will determine the temperature of the asphalt binder in the tank and will perform the daily calculation of the asphalt binder content. The Engineer will perform the daily calculation of the hydrated lime content. The Engineer will test the moisture content of the hot mix. The mix for the moisture test will be sampled from the windrow in front of the laydown machine and placed in an airtight, tared container. The mix will be dried to a constant mass as described in SD 305. D.Independent Assurance Procedures: The Department will perform Independent Assurance (IA) testing on project produced materials. Random samples of mineral aggregate and hot mix asphalt concrete used for QC testing will be selected by the Region Materials Engineer for IA testing. The Region Materials Engineer will perform IA testing for the attributes listed in the Department’s Materials Manual. The tolerances from the Department’s Materials Manual will be used to independently evaluate the QC and QA testing procedures and equipment. The Region Materials Engineer will witness the sampling and splitting of the designated IA sample (an actual sublot sample). The Region Materials Engineer may select either Engineer or Contractor sampled sublot for the IA testing. The Region Materials Engineer will also perform IA testing for the bulk specific gravity on in place density cores. A separate IA core will be obtained by the Contractor while obtaining the in-place density core used to determine the pay factor. The IA core will be taken at the same offset and within one foot of the core used in determining the pay factor. E.Dispute Resolution System: Process verification procedures using F-test and t-test statistical evaluation procedures to determine if both QC and QA test results represent the same sample population may result in the need for testing backup sublot samples and substituting the new test result for pay factor calculations. If the QC and QA test results do represent the same population, as determined by F-test and t-test statistical evaluation procedures, the Contractor’s test results may be used for quality acceptance.

322.4METHOD OF MEASUREMENT AND ACCEPTANCE

The method of measurement will be as prescribed in Section 320.4 except the method of measurement for QA and QC field laboratories and the method of measurement and acceptance for asphalt concrete will be made according to the following: A.Asphalt Concrete: The asphalt concrete will be statistically accepted by lots. A lot will consist of five sublots. Sublots will not represent more than 1000 tons unless the current sublot is terminated. The first lot will start at the beginning of production or following the Control Test Strip. A lot will be terminated when a new mix design is completed, and a new job mix formula is issued. If less than five sublots have been completed when a lot is terminated, the sublots will be included in the previous lot, and the pay factor computed for the revised lot. If there is no previous lot, the lot will not be terminated until five sublots are obtained. 322 Page 1861.Determination of Contract Unit Price Adjustment: Asphalt concrete that is not compacted according to the Specified Density Method will not be included in the pay factor calculations but may be price adjusted (DOT-18) for failure to conform to specification requirements. The material specified to be sampled and tested on a QC/QA basis will be evaluated for payment under this subsection. All QC test results for a lot will be analyzed collectively and statistically by the Quality Level Analysis-Standard Deviation Method using the procedures herein defined. The lots will be analyzed to determine the total estimated percent of the lot that is within the specification limits. Quality Level Analysis (specification conformance analysis) is a statistical procedure for estimating the percent of material that is within the specification limits (PWL). The PWL is determined by using the lot mean, (𝑋) and the lot standard deviation(s). Two measures of quality are required to establish the contract unit price adjustment. The first measure is the Acceptable Quality Level (AQL) which is the PWL at which the lot will receive 100% pay or a composite pay factor of 1.00. The second measure of quality is the Rejectable Quality Level (RQL) at which the Engineer has determined the material may not perform as desired and may be rejected. The AQL has been selected at 90 PWL and the RQL at 60 PWL. The RQL using the pay factor equation will result in 85% pay or a pay factor of 0.85. An individual pay factor for any attribute resulting in less than 85% pay may result in the lot being rejected. When the Acceptable Quality Level of any individual pay factor attribute has a QL of 90 or less the composite pay factor will not exceed 1.00.

A lot may be accepted provided the composite pay factor is at least 0.85 and there are no isolated defects identified by the Engineer. A lot containing material with less than a 0.85 composite pay factor may be rejected. All of the rejected material will be removed from the work. The Engineer will determine if the material may remain in place at a reduced price. A lot containing material with less than a 0.85 composite pay factor may not be overlaid prior to the Engineer determining the acceptability of the lot. The Engineer may reject any quantity of material that appears to be defective based on visual inspection or test results. The visual rejection may include segregation, low temperature material, very high or low asphalt content, etc. Such rejected material will not be used in the work or included with the lot acceptance tests. Rejected material will not be measured for payment. The Contractor may elect to remove any defective material and replace it with new material to avoid a pay factor less than 1.00. Any such new material will be sampled, tested, and evaluated for acceptance according to this specification. 322 Page 1872.Quality Level Analysis: The standard deviation method procedures are as follows: a.Only test results on material incorporated in the work will be included in the quality level analysis. b.Calculate the arithmetic mean (𝑋) of the test values: 𝑋=∑𝑥 𝑛 Where:  = summation of x = individual test value to 𝑥𝑛 n = total number of test values c.Calculate the sample standard deviation( s): S =𝑛∑(𝑥2)―(∑𝑥)2 𝑛(𝑛―1) Where: ∑(𝑥2) = summation of the squares of individual test values. (∑𝑥)2 = summation of the individual test values squared. d.Calculate the upper quality index (𝑄𝑈): 𝑄𝑈=𝑈𝑆𝐿 ― 𝑋 𝑆 Where: USL = upper specification limit or target value (TV) plus allowable deviation. Target Value =the single specification value which would result in an ideal product. e.Calculate the lower quality index (𝑄𝐿): 𝑄𝐿=𝑋―𝐿𝑆𝐿 𝑆 Where: LSL = lower specification limit or target value minus allowable deviation. f.Determine 𝑃𝑈 (percent within the upper specification limit which corresponds to a given 𝑄𝑈) from table P. Note: If a USL is not specified 𝑃𝑈, will be 100. 322 Page 188g.Determine 𝑃𝐿 (percent within the lower specification limit which corresponds to a given 𝑄𝐿) from table P. Note: If an LSL is not specified 𝑃𝐿, will be 100. h.Determine the Quality Level (the total percent within specification limits). 𝑄𝑢𝑎𝑙𝑖𝑡𝑦 𝐿𝑒𝑣𝑒𝑙 (𝑄𝐿)=(𝑃𝑈+𝑃𝐿)―100 i.To determine the pay factor for each individual attribute

j.Determine the Composite Pay Factor (CPF) for each lot. The third decimal place of the CPF will be rounded to the nearest hundredth by the computer program. 𝐶𝑃𝐹 =[𝑓1(𝑃𝐹1)+𝑓2(𝑃𝐹2)] (100)∑𝑓 f = 1 to 2 Where: 𝑓1 1 1 2 = Price adjustment factor listed in Table O for each measured attribute. 𝑃𝐹1 1 1 2 = Pay Factor for each measured attribute. ∑𝑓 = Sum of the "f" (price adjustment) factors. The asphalt concrete pavement contract unit price will be adjusted according to Section 322.4 . Payment for the asphalt concrete will be made at a price determined by multiplying the contract unit price by the composite pay factor. The following table will be used to calculate the composite pay factor: Table O - Pay Attributes & Price Adjustment Factors Measured Attribute Factor "f" Design Air Voids 50 In Place Density (% Compaction) 50 All mineral aggregate testing prior to production and QC/QA testing will be incidental to the contract unit price per ton for asphalt concrete. Asphalt concrete will be measured to the nearest 0.1 ton. The mixture of mineral aggregate and asphalt will be weighed after mixing. No deduction will be made for the weight of the asphalt included in the mixture. Deduction will not be made for material removed from temporary approaches. Deductions will be made for all rejected and wasted asphalt concrete pavement. B.QA and QC Field Laboratories: There will be no measurement or payment for the QC laboratory furnished and used by the Contractor to perform the QC testing. The Contractor furnished QA laboratory will be measured in accordance with Section 600.4 . 322 Page 189322.5 BASIS OF PAYMENT The basis of payment will be as prescribed in Section 320.5 except the basis of payment for asphalt binder, asphalt concrete, and QA and QC field laboratories will be made according to the following: A.Asphalt Binder: The accepted quantities of asphalt binder will be paid for at the contract unit price per ton. Payment for the asphalt binder is not subject to the statistical pay factor adjustment. B.Asphalt Concrete: The accepted quantities of asphalt concrete will be paid for at the contract unit price as adjusted by the pay factor calculations in Section 322.4 of this specification per ton complete and accepted in place. Asphalt concrete that is not compacted according to the Specified Density Method will not be included in the pay factor calculations. Asphalt concrete that is not included in the pay factor calculations will be paid for at the contract unit price per ton. The contract unit price of asphalt concrete will include all cost for labor, equipment, materials, testing, and all incidentals required to furnish and place the asphalt concrete mix according to these specifications. C.Laboratories: 1.QC Laboratory: The laboratory used by the Contractor for QC testing will be incidental to the asphalt concrete pavement item(s). 2.QA Laboratory: Payment for the QA laboratory will be according to Section 600.5 of the Standard Specifications. 322 Page 190TABLE P - QUALITY LEVELS QUALITY LEVEL ANALYSIS BY STANDARD DEVIATION METHOD Pu or Pl Percent Within Limits forUPPER QUALITY INDEX QU OR LOWER QUALITY INDEX QL Positive Values Of Qu or Qln=3 n=4 n=5 n=6 n=7 n=8 n=9n=10 to n=11n=12 to n=14n=15 to n=18n=19 to n=25n=26 to n=37n=38 to n=69n=70 to n=20 0n=20 to n= 100 1.16 1.50 1.79 2.03 2.23 2.39 2.53 2.65 2.83 3.03 3.20 3.38 3.54 3.70 3.83 99 1.47 1.67 1.80 1.89 1.95 2.00 2.04 2.09 2.14 2.18 2.22 2.26 2.29 2.31 98 1.15 1.44 1.60 1.70 1.76 1.81 1.84 1.86 1.91 1.93 1.96 1.99 2.01 2.03 2.05 97 1.41 1.54 1.62 1.67 1.70 1.72 1.74 1.77 1.79 1.81 1.83 1.85 1.86 1.87 96 1.14 1.38 1.49 1.55 1.59 1.61 1.63 1.65 1.67 1.68 1.70 1.71 1.73 1.74 1.75 95 1.35 1.44 1.49 1.52 1.54 1.55 1.56 1.58 1.59 1.61 1.62 1.63 1.63 1.64 94 1.13 1.32 1.39 1.43 1.46 1.47 1.48 1.49 1.50 1.51 1.52 1.53 1.54 1.55 1.55 93 1.29 1.35 1.38 1.40 1.41 1.42 1.43 1.44 1.44 1.45 1.46 1.46 1.47 1.47 92 1.12 1.26 1.31 1.33 1.35 1.36 1.36 1.37 1.37 1.38 1.39 1.39 1.40 1.40 1.40 91 1.11 1.23 1.27 1.29 1.30 1.30 1.31 1.31 1.32 1.32 1.33 1.33 1.33 1.34 1.34 90 1.10 1.20 1.23 1.24 1.25 1.25 1.26 1.26 1.26 1.27 1.27 1.27 1.28 1.28 1.28 89 1.09 1.17 1.19 1.20 1.20 1.21 1.21 1.21 1.21 1.22 1.22 1.22 1.22 1.22 1.23 88 1.07 1.14 1.15 1.16 1.16 1.16 1.16 1.17 1.17 1.17 1.17 1.17 1.17 1.17 1.17 87 1.06 1.11 1.12 1.12 1.12 1.12 1.12 1.12 1.12 1.12 1.12 1.12 1.12 1.13 1.13 86 1.04 1.08 1.08 1.08 1.08 1.08 1.08 1.08 1.08 1.08 1.08 1.08 1.08 1.08 1.08 85 1.03 1.05 1.05 1.04 1.04 1.04 1.04 1.04 1.04 1.04 1.04 1.04 1.04 1.04 1.04 84 1.01 1.02 1.01 1.01 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.99 0.99 0.99 83 1.00 0.99 0.98 0.97 0.97 0.96 0.96 0.96 0.96 0.96 0.96 0.96 0.95 0.95 0.95 82 0.97 0.96 0.95 0.94 0.93 0.93 0.93 0.92 0.92 0.92 0.92 0.92 0.92 0.92 0.92 81 0.96 0.93 0.91 0.90 0.90 0.89 0.89 0.89 0.89 0.88 0.88 0.88 0.88 0.88 0.88 80 0.93 0.90 0.88 0.87 0.86 0.86 0.86 0.85 0.85 0.85 0.85 0.84 0.84 0.84 0.84 79 0.91 0.87 0.85 0.84 0.83 0.82 0.82 0.82 0.82 0.81 0.81 0.81 0.81 0.81 0.81 78 0.89 0.84 0.82 0.80 0.80 0.79 0.79 0.79 0.78 0.78 0.78 0.78 0.77 0.77 0.77 77 0.87 0.81 0.78 0.77 0.76 0.76 0.76 0.75 0.75 0.75 0.75 0.74 0.74 0.74 0.74 76 0.84 0.78 0.75 0.74 0.73 0.73 0.72 0.72 0.72 0.71 0.71 0.71 0.71 0.71 0.71 75 0.82 0.75 0.72 0.71 0.70 0.70 0.69 0.69 0.69 0.68 0.68 0.68 0.68 0.68 0.67 74 0.79 0.72 0.69 0.68 0.67 0.66 0.66 0.66 0.66 0.65 0.65 0.65 0.65 0.64 0.64 73 0.76 0.69 0.66 0.65 0.64 0.63 0.63 0.63 0.62 0.62 0.62 0.62 0.62 0.61 0.61 72 0.74 0.66 0.63 0.62 0.61 0.60 0.60 0.60 0.59 0.59 0.59 0.59 0.59 0.58 0.58 71 0.71 0.63 0.60 0.59 0.58 0.57 0.57 0.57 0.57 0.56 0.56 0.56 0.56 0.55 0.55 70 0.68 0.60 0.57 0.56 0.55 0.55 0.54 0.54 0.54 0.53 0.53 0.53 0.53 0.53 0.52 69 0.65 0.57 0.54 0.53 0.52 0.52 0.51 0.51 0.51 0.50 0.50 0.50 0.50 0.50 0.50 68 0.62 0.54 0.51 0.50 0.49 0.49 0.48 0.48 0.48 0.48 0.47 0.47 0.47 0.47 0.47 67 0.59 0.51 0.47 0.47 0.46 0.46 0.46 0.45 0.45 0.45 0.45 0.44 0.44 0.44 0.44 66 0.56 0.48 0.45 0.44 0.44 0.43 0.43 0.43 0.42 0.42 0.42 0.42 0.41 0.41 0.41 65 0.52 0.45 0.43 0.41 0.41 0.40 0.40 0.40 0.40 0.39 0.39 0.39 0.39 0.39 0.39 64 0.49 0.42 0.40 0.39 0.38 0.38 0.37 0.37 0.37 0.37 0.36 0.36 0.36 0.36 0.36 63 0.46 0.39 0.37 0.36 0.35 0.35 0.35 0.34 0.34 0.34 0.34 0.34 0.33 0.33 0.33 62 0.43 0.36 0.34 0.33 0.32 0.32 0.32 0.32 0.31 0.31 0.31 0.31 0.31 0.31 0.31 61 0.39 0.33 0.31 0.30 0.30 0.29 0.29 0.29 0.29 0.29 0.28 0.28 0.28 0.28 0.28 60 0.36 0.30 0.28 0.27 0.27 0.27 0.26 0.26 0.26 0.26 0.26 0.26 0.26 0.25 0.25 59 0.32 0.27 0.25 0.25 0.24 0.24 0.24 0.24 0.23 0.23 0.23 0.23 0.23 0.23 0.23 58 0.29 0.24 0.23 0.22 0.21 0.21 0.21 0.21 0.21 0.21 0.20 0.20 0.20 0.20 0.20 57 0.25 0.21 0.20 0.19 0.19 0.19 0.18 0.18 0.18 0.18 0.18 0.18 0.18 0.18 0.18 56 0.22 0.18 0.17 0.16 0.16 0.16 0.16 0.16 0.16 0.15 0.15 0.15 0.15 0.15 0.15 55 0.18 0.15 0.14 0.14 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 54 0.14 0.12 0.11 0.11 0.11 0.11 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 53 0.11 0.09 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 52 0.07 0.06 0.06 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 51 0.04 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.02 50 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 NOTE: For negative values of QU or QL, PU or PL is equal to 100 minus the table PU or PL. If the value of QU or QL does not correspond exactly to a figure in the table, use the next higher value. 324 Page 191324 ASPHALT CONCRETE COMPOSITE

324.1DESCRIPTION

This work consists of constructing one or more courses of asphalt concrete and treating a prepared surface with asphalt material and sand as required.

324.2MATERIALS

The materials for treating a prepared surface will conform to Section 330.2 . The materials for asphalt concrete composite and their use will conform to Section 320.2 except as modified by the following: The mineral aggregate for asphalt concrete composite will conform to Section 321 - Class E, Type 1, with the following modifications: The asphalt binder used in the mixture will be PG 64-28, PG 58-34, or PG 64-34 unless otherwise specified in the plans. In addition, PG 58-28 may be used on projects with a future truck AADT less than 250 trucks per day or projects with no mainline or turning lane paving areas. The Department will use the design designation information in the plans and the following formula to calculate the future truck AADT: Future AADT (future year) x AADT T% = Future Truck AADT The Contractor will provide a job mix formula to the Department’s Bituminous Engineer with supporting mix design data prior to production. The asphalt binder content may be adjusted by the Engineer. The Engineer may accept the mixture on the basis of the Certificates of Compliance and visual inspection or may test the mixture for specification compliance.

324.3CONSTRUCTION REQUIREMENTS

The construction requirements will be as prescribed in Section 320.3 and Section 330.3 with the following modifications: A.Density: Compaction of the asphalt concrete composite will be by methods and to a density satisfactory to the Engineer. B.Thickness: The compacted thickness of each lift will not exceed 3 inches. C.Asphalt: Asphalt for tack SS-1h or CSS-1h will be applied prior to each lift of asphalt concrete. Asphalt for tack will be applied at a rate of 0.10 gallons per square yard on existing pavement or milled asphalt concrete surface and at a rate of 0.05 gallons per square yard on new asphalt concrete pavement. Asphalt for flush seal SS-1h or CSS-1h and sand for flush seal will be applied to the final lift of asphalt concrete in accordance with Section 330. Asphalt for flush seal will be applied at