901 SECTION 903 – AGGREGATES
903.01 Fine Aggregate for Concrete ................................ ........................ 901
903.02 Fine Aggregate for Mortar ................................ ........................... 903
903.03 Coarse Aggregate for Concrete ................................ .................... 904
903.04 Reserved ................................ ................................ ....................... 906
903.05 Aggregate for Mineral Aggregate Base and Surface Courses ...... 906
903.06 Aggregate for Plant Mix Base and Leveling Courses (Hot Mix) . 911
903.07 Reserved ................................ ................................ ....................... 915
903.08 Reserved ................................ ................................ ....................... 915
903.09 Reserved ................................ ................................ ....................... 915
903.10 Aggregate for Bituminous Plant Mix Surface Course (Cold
Mix) ................................ ................................ ............................. 915
903.11 Aggregate for Asphaltic Concrete Surface Courses (Hot Mix) .... 916
903.12 Aggregate for Slurry Seal and Micro -Surface .............................. 920
903.13 Aggregate for Bituminous Seal Coat ................................ ........... 922
903.14 Aggregate for Double Bituminous Surface Treatment ................. 922
903.15 Aggregate for Aggregate -Cement Base Course ........................... 923
903.16 Mineral Filler ................................ ................................ ............... 923
903.17 Aggregate for Underdrains ................................ ........................... 923
903.18 Reserved ................................ ................................ ....................... 924
903.19 Lightweight Aggregates for Structural Concrete ......................... 924
903.20 Stockpiling Aggregates ................................ ................................ 924
903.21 Test Methods ................................ ................................ ................ 925
903.22 Sizes of Coarse Aggregate ................................ ........................... 926
903.23 Reserved ................................ ................................ ....................... 927
903.24 Aggregates for Riding Surfaces (Polish -Resistant Aggregates) ... 927
903.25 Aggregate Quality Requirements ................................ ................. 928
903.01 Fine Aggregate for Concrete
For concrete provide aggregate conforming to AASHTO M 6, with the following exceptions and additions: 903.01 902 1. The option regarding alternate freeze -thaw tests for soundness is waived.
2.The fine aggregate shall be washed in the processing operations.
3.Provide fine aggregate meeting the quality requirements in 903.25.
4.The amount of deleterious substances shall not exceed the limits specified in Tabl e 903.01-1. Table 903.01-1: Limits of Deleterious Substances in Fine Aggregate for Concrete Substance Maximum Permissible Limits Percent by Weight Clay Lumps 0.5 Coal and Lignite 0.5 Material Passing the No. 200 Sieve (1) (3) 3.0 Other deleterious substances (such as shale, alkali, mica, coated/grains, soft and flaky particles) (1) (2) 3.0
1.If the fine aggregate is manufactured from crushed stone and if material finer than the No. 200 sieve consists of the dust of fracture, essentially free from clay or shale, this limit may be increased to 10%.
2.Determine other organic impurities according to AASHTO T 267.
3.If the fine aggregate is manufactured from crushed gravel and if material finer than the No. 200 sie ve consists of the dust of fracture, essentially free from clay or shale, this limit may be increased to 3.5%.
5.Provide fine aggregate that is well graded from coarse to fine within the limits specified in Table 903.01 -2. 903.02 903 Table 903.01-2: Gradation Requ irements for Fine Aggregate Sieve Size Total Percent Passing by Weight 3/8 inch 100 No. 4 95-100 No. 16 50-90 No. 50 5-35 No. 100 0-20 No. 200 (1) 0-3
1.If the fine aggregate is manufactured from crushed stone and if material finer than the No. 200 sieve consists of the dust of fracture, essentially free from clay or shale, this limit may be increased to 10%.
6.For use in flowable mortar, provide fine aggregate meeting the above requirements, except the gradation shall be as specified in Table 903.01-3. Table 903.01-3: Gradation Requirements for Fine Aggregate used in Flowable Mortar Sieve Size Total Percent Passing by Weight 1/2 inch 100 No. 200 0-20
903.02 Fine Aggregate for Mortar
Provide mortar sand that conforms to AASHTO M 45 , meets the quality requirements in 903.25, and that is uniformly graded from coarse to fine within the limits specified in Table 903.02 -1. 903.03 904 Table 903.02-1: Gradation Requirements for Mortar Sand Sieve Size Total Percent Passing by Weight No. 8 100 No. 50 15-40 No. 100 0-10 No. 200 0-5
903.03 Coarse Aggregate for Concrete
For any type or class of Portland cement concrete, provide coarse aggregate consisting of crushed stone, crushed slag, or crushed or uncrushed gravel, unless otherwise specified. For Portland cement concrete base and pavement, furnish coarse aggregate in two sizes: Size No. 4 and Size No. 67, graded as specified in 903.22. Manufacture the two sizes, within the specified limits, to produce Size No. 467, in accordance with 903.22, when combined in the proper proportions at the batching plant, or a size No. 467, manufactured within t he specified limits of 903.22 . Coarse aggregate in Portland cement concrete pavements for finished riding surfaces of travel lanes including mainline pavements and ramps shall consist of Size No. 467. Ensure that e ither the Size No. 4 or Size No. 67 fract ions meet 903.24. Ramps using Class A paving concrete or any riding surface travel lane consisting of Size No. 57 shall meet 903.24. Coarse aggregate in two -lift composite pavements shall consist of Size No. 467 in the lower lift, graded as specified in 903.22. Coarse aggregate in the upper lift shall be Size No. 57 or 67 graded as specified in 903.22 and shall meet 903.24 riding surfa ce requirements. Coarse aggregate in Portland cement concrete bridge decks and overlays on interstates and four or more lane highways consisting of Size No. 57 shall meet 903.24. The coarse aggregates for travel lanes and bridge decks shall be crushed and consist of stone, slag, gravel, quartzite, gneiss , or combination thereof with an absorption of plus 4 material not to exceed 5% . Do not use u ncrushed gravel, pea gravel, or any other uncrushed particles. Crushed gravel, if used, shall consist of siliceo us washed particles after processing, of which at least 903.03 905 70% by count of the material retained on the No. 4 sieve contains a minimum of two fractured faces. One face shall be fractured for the approximate average diameter or thickness of the particle. For other uses of concrete, provide coarse aggregate of the sizes specified in Table 903.03 -1, or as otherwise shown or directed. Table 903.03-1: Coarse Aggregate Sizes Application Coarse Aggregate Size (1) Structural concrete No. 57 Self-Consolidating concrete Maximum -No. 67 Prestressed concrete No. 57 or 67 Precast concrete Any size fraction Concrete for Bridge Repair (2) No. 57 or 67 Concrete curbing placed by machine - extrusion methods No. 7, 57, 67, or 78 Cement treated permeable base No. 57
1.Gradation shall conform to 903.22.
2.If proposing to use a coarse aggregate size not specified submit a written request to Regional Materials and Tests explaining the necessity for the change. The coarse aggregates shall otherwise conform to the requirements of AASHTO M 80, with the following exceptions and additions:
A.Deleterious Substances The amount of deleterious substances shall not exceed the limits specified in Table 903.03 -2. 903.04 906 Table 903.03-2: Limits of Deleterious Substances in Coarse Aggregate for Concrete Substance Maximum Percent by Weight Soft or non -durable fragments (fragments that are structurally weak such as shale, soft sandstone, limonite concretions, gypsum, weathered schist , or cemented grav el), and organic impurities as determined by AASHTO T 267 (1) 3 Coal and lignite (1) 1 Clay lumps (1) 0.25 Material passing the No. 200 sieve (1) (2) 1.5 Thin or elongated pieces (length greater than 5 times average thickness) 10 Other local deleterious substances (1) 1
1.The sum of the percentages of these materials (i.e., soft or non -durable fragments, coal and lignite, clay lumps, material passing the No. 200 sieve, and other local deleterious substances) shall not exceed 5.0.
2.For crushed aggregate, if all the material finer than the No. 200 sieve, as determined in accordance with AASHTO T 11, consists of the dust of fracture, essentially free of clay or shale, this limit may be increased to 2.0.
B.Quality Requirements The coarse aggregate shall meet the quality requirements in 903.25.
903.04 Reserved
903.05 Aggregate for Mineral Aggregate Base and Surface Courses
Provide crushed stone, crushed slag, crushed or uncrushed gravel, or crushed or uncrushed chert that may be blended with crushed recycled concrete aggregate or screened recycled asphalt pavement (RAP), together with material such as manufactured sand or other fine materials tha t are either naturally contained or added as needed to conform to these Specifications. Provide aggregate of Types A and B, as specified below. 903.05 907 A. Type A Aggregate Provide hard, durable particles or fragments of stone, slag, gravel, or chert, and other finely divided mineral matter. The Contractor may use recycled concrete aggregate at any percentage and up to full replacement by weight per 903.05.C or recycled asphalt pavement at a maximum rate of 25% by weight for Type A aggregate, provided the combined ag gregate blend meets all the requirements specified below. Crush and screen the recycled concrete and asphalt to produce a uniform stockpile before blending it with the virgin material. Keep the recycled stockpiles free of bricks, steel, wood, and all oth er deleterious materials. Provide individual or blended materials meeting the following requirements:
1.Crushed Stone. Provide stone free of silt and clay and having a coarse aggregate portion (retained on the No. 4 sieve) that conforms to the requirements specified in 903.25.
2.Crushed Slag. Provide material that:
a.Is free of silt and clay,
b.Meets the quality requirements in 903.25,
c.Is reasonably uniform in density, and
d.Has a dry -rodded weight of at least 70 pounds per cubic foot.
3.Gravel and Chert. Screen gravel and chert. All oversize material may be crushed and fed uniformly back over the screen. The coarse aggregate portion shall conform to the quality requirements specified in 903.25. The portion of the material passing the No. 40 sieve shall be non -plastic or shall have a liquid limit of not greater than 30 and a plasticity index of not more than 8. If fine aggregate, coarse aggregate, or binder, in addition to that present in the base material, is necessary to meet the gradation or de nsity requirements or to ensure satisfactory bonding of the material, blend such material uniformly with the base course material at the mixing plant by a mechanical feeder to maintain a uniform flow on the belt to the mixer. Do not blend materials on the stockpiles or in the pits using a bulldozer, clamshell, dragline, or similar equipment. 903.05 908 The composite gradation of Type A aggregate shall be the grading specified in the Contract or shown on the Plans and shall conform to the limits specified in Table 903 .05-2.
B.Type B Aggregate Provide crushed or uncrushed gravel, crushed or uncrushed chert, crushed stone or crushed slag, and other finely divided particles. The Contractor may use recycled concrete aggregate at any percentage and up to full replacement by weight per 903.05.C or recycled asphalt pavement at a maximum rate of 30% by weight for Type B aggregate, provided the combined aggregate blend meets all the requirements specified. Crush and screen recycled concrete and asphalt to produce a uniform stockpile before blendin g it with the virgin material. Keep the recycled stockpiles free of bricks, steel, wood, and all other deleterious materials. Provide Type B aggregate meeting the same requirements as specified in
903.05 A for Type A aggregate, with the following except ions:
1.The aggregate shall meet the quality requirements in 903.25.
2.Screen Type B aggregate. Oversize materials may be wasted or crushed and returned over the screen and uniformly blended with the other material.
3.Do not use material having a clay content greater than 12%, as determined by hydrometer analysis performed in accordance with AASHTO T 88. Material may be used having a clay content exceeding 12% if a plasticity index -fines product does not exceed 3 when calculated by the following formul a: % Passing No. 40 sieve × P.I. of Minus No. 40 Material If an excess of binder occurs, uniformly incorporate crushed stone, crushed slag, gravel, chert, sand, or other approved granular materials in such proportions, not to exceed 20% of the total mix , as directed by the Engineer. If the quantity of binder is insufficient to bond the base or surface course properly, uniformly incorporate additional binder of approved quality, in 903.05 909 an amount not to exceed 15% of the total mix, as directed by the Engineer. Do not use material requiring the addition of coarse aggregate or binder in excess of the above limits, unless otherwise shown on the Plans or specified in the Contract. The Contractor may blend additional material, if required, at the screening or mixing plant. When blending is done at the plant, use mechanical feeders that will maintain a uniform flow of the materials on the conveyor belt to the mixer or screening plant. Do not blend materials on the stockpile or in the pit using a bulldozer, clamshell , or similar equipment. The composite gradation of Type B aggregate shall be the grading shown on the Plans or specified in the Contract , and shall conform to the limits specified in Table 903.05 -2. Table 903.05-2: Grading Table for Type A and Type B Aggr egate for Mineral Aggregate Base and Surface Courses Sieve Size Total Percent by Weight, Passing Sieves Grading A Grading B Grading C Grading D Grading E 2-1/2 inch 100 -- -- -- -- 2 inch 95-100 100 -- -- -- 1-1/2 inch -- 95-100 100 100 -- 1 inch -- -- 90-100 85-100 100 3/4 inch -- 65-95 -- 60-95 90-100 3/8 inch 35-65 -- 45-74 50-80 65-100 No. 4 -- 35-55 30-55 40-65 -- No. 16 -- 15-45 -- 20-40 (1) -- No. 100 0-10 4-15 4-15 9-18 (2) 5-15
1.For gravel and chert bases containing clay, the range is 20 -43.
2.For gravel and chert bases containing clay, the range is 7 -18. 903.05 910 C. Recycled Concrete Aggregate Provide material comprised of concrete reclaimed from the demolition of a concrete structure or pavement. Recycled concrete aggregate may only be used as a mineral aggregate base course, subbase , or shoulder course. The material shall be free of any materials classified as Solid or Hazardous Waste, especially asbestos, lead and mercury, with test results submitted by the contractor to th e Project Supervisor . These test results shall be certified and notarized. The aggregate shall meet the quality requirements in 903.25. Deleterious substances shall be kept to a minimum and may not be higher than the amounts listed on Table
903.05 3.
Table 903.05 -3: Deleterious Materials Material Maximum Permissible Limits Percent by Weight Brick 5 Bituminous Concrete Materials 5 Weathered Rock 2 Wood 0.1 Metals 0.1 The gradations of the coarse and fine fractions of aggregate shall be such that, when combined in proper proportions, the resultant mixture will fall within the grading specified in Table 903.05 -4. Table 903.05 -4: RCA Grading Tolerances Sieve Size Total Percent Passing per Weight 1 ½ inch 100 1 inch 85-100 ¾ inch 60-95 3/8 inch 50-80 No. 4 40-65 No. 16 20-40 No. 100 5-18 903.06 911 903.06 Aggregate for Plant Mix Base and Leveling Courses (Hot Mix) For plant mix base and leveling courses, provide coarse aggregate, fine aggregate, and mineral filler when required. If at any time the sources of materials are changed, prepare and submit a new mix design as specified in 407.03.
A.Coarse Aggregate (retained on a No. 4 sieve) Provide crushed stone, crushed granite, crushed gravel, crushed slag, or a combination of these materials. This material shall conform to the physical properties of ASTM D692 and the quality requirements of
903.25 The agg regate shall contain no more than 5% soft or nondurable
particles. Crushed gravel shall consist of particles processed from washed material. At least 70% by count of the gravel retained on the No. 4 sieve shall have a minimum of two fractured faces, one o f which must be fractured for the approximate average diameter or thickness of the particle. Do not add pea gravel or uncrushed particles. For virgin coarse aggregate for Grading A, ACRL, and AS mixes, use crushed stone, crushed slag, or a combination of these materials.
B.Fine Aggregate (passing a No. 4 sieve) Provide limestone fines, natural sand, sand manufactured from stone, gravel, or slag, or combinations of these materials, consist ing of hard, tough grains free from injurious amounts of deleterious substances. The fine aggregate shall meet the quality requirements in 903.25. Fine aggregate containing gypsum (CaSO 4) shall not chemically contain more than 5% sulfur trioxide (SO 3) as determined by analysis of the material passing the No. 8 sieve. In natural sand or sand manufactured from gravel, the percentage of material finer than No. 200 sieve shall not exceed 5%. For use in Grading A and AS mixes, provide virgin fine aggregate consisting of crushed stone or crushed slag only, and store the material separately from the coarse aggregate. Ensure that the amount of deleterious substances in natural sand does not exceed the limits specified in Table 903.06 -1. 903.06 912 Table 903.06-1: Maximum L imits for Deleterious Substances in Natural Sand Substance Maximum Permissible Limits, Percent by Weight Clay Lumps 0.5 Coal and Lignite 0.5 Other deleterious substances (such as shale, alkali, mica, coated grains, soft and flaky particles) and organic impurities as determined by AASHTO T 267 3.0
C.Combined Aggregate Grading Provide the appropriate combination of coarse aggregate and fine aggregate to achieve the combined grading. Use a minimum of three sizes of v irgin aggregate for all mix designs except for C, CS, and CW mixes, which shall be designed from a minimum of two sizes of virgin aggregate. Establish a gradation for each aggregate used in the mix. Table 903.06 -2 specifies the stockpile gradation tolerance on each sieve for each virgin aggregate component used in the mix. Table 903.06 -2: Stockpile Gradation Tolerance Sieve Size Gradation Tolerance 3/8-inch sieve and larger ± 10% No. 4 sieve ± 7% No. 8 sieve ± 5% No. 30 sieve ± 4% No. 200 sieve (coarse aggregate) ± 2% No. 200 sieve (fine aggregate) ± 4% When the coarse aggregate portion of Grading CW mix is crushed limestone, use no less than 20% and no more than 50% by weight natural sand, or sand manufactured from slag or other approved polish -resistant aggregate. When the coarse aggregate portion is crushed gravel or 903.06 913 crushed slag, between 15% and 40% by weight of the mineral aggregate shall be agricultural limestone or Size No. 10 limestone screenings. The gradations of the coarse and fine fractions of aggregate shall be such that, when combined in proper proportions, the resultant mixture will meet one of the gradings specified in Tables 903.06 -3 and 903.06 -4. Table 903.0 6-3: Hot Plant Mix Base Course Mixture Design Range o f Gradations Sieve Size Total Per cent Passing, by Weight Grading A Grading AS Grading ACRL Grading B 2 inch 100 100 100 100 1-1/2 inches 81-100 75-100 80-93 95-100 3/4 inch 50-71 55-80 60-75 70-85 3/8 inch 35-50 -- -- 49-72 No. 4 24-36 7-11 12-16 34-51 No. 8 13-27 -- -- 23-42 No. 30 7-17 -- -- 11-22 No. 50 -- -- -- 9-14 No. 100 0-10 0-6 0-4 4-10 No. 200 0-4.5 0-4.5 0-3.5 2.5-6.5 903.06 914 Table 903.06 -4: Hot Plant Mix Leveling Course Mixture Design Range of Gradations Sieve Size Total Per Cent Passing, by Weight Grading BM Grading BM2 (1) Grading C Grading CW Grading CS 1-1/4 inch -- 100 -- -- -- 1 inch 100 -- -- -- -- 3/4 inch 85-100 81-93 100 100 -- 3/8 inch 59-79 57-73 70-90 75-100 100 No. 4 42-61 40-56 39-66 -- 89-94 No. 8 29-47 28-43 23-47 43-67 53-77 No. 30 13-27 13-25 10-27 23-47 23-42 No. 50 7-20 9-19 8-15 -- -- No. 100 4-10 6-10 4-8 4-10 9-18 No. 200 0-6.5 2.5-6.5 2.5-6.5 2.5-6.5 6-13.5
1.When using natural sand as the fine aggregate, limit it to a maximum amount of 20% by weight of the mineral aggregate. For asphalt treated permeable base as specified in 313, meet the gradation requirements specified in Table 903.06 -5. 903.07 915 Table 903.06 -5: Gradation Requirements for Asphalt Treated Permeable Base Sieve Size Total Percent Passing by Weight 2 inch 100 1-1/2 inch 70-100 3/4 inch 55-80 No. 4 0-11 No. 100 0-4 No. 200 0-3
903.07 Reserved
903.08 Reserved
903.09 Reserved
903.10 Aggregate for Bituminous Plant Mix Surface Course (Cold Mix)
For cold bituminous plant mix, provide mix aggregate, consisting of crushed stone or crushed slag, meeting the quality require ments of ASTM D692. Crushed slag aggregate retained on the No. 4 sieve shall contain no more than 20% by weight of glassy particles. The amount of material finer than the No. 200 sieve, as determined in accordance with AASHTO T 11, shall not exceed 1%. I f all material finer than the No. 200 sieve consists of the dust of fracture, essentially free from clay or shale, this percentage may be increased to 1.5. For leveling and surface course mixtures, provide mix aggregate meeting the gradation requirements specified in 903.22 for Size No. 68. For key or choker aggregate, provide crushed stone, crushed slag, or crushed gravel meeting the gradation requirements specified in 903.22 for Size No. 8 and the same quality requirements as the mix aggregate. 903.11 916 903.11 Aggregate for Asphaltic Concrete Surface Courses (Hot Mix) Provide aggregate, consisting of a combination of coarse and fine aggregate, and mineral filler when required or specified. Use a minimum of three sizes of virgin aggregates for all mix designs. If at any time the sources of materials are changed, provide a new mix design as specified in 407.03.C.2 .
A.Coarse Aggregate (retained on a No. 4 sieve) Provide aggregate, consisting of crushed stone, crushed slag, crushed gravel, crushed granite, crushed quartzite, crushed gneiss, or natural combinations of these materials. The coarse aggregate shall meet the physical requirements of ASTM D692, with the following exceptions and additions:
1.The aggregate shall meet the quality requirements in 903.25.
2.Material retained on the No. 4 sieve shall contain a maximum of 10% by weight elongated pieces (length greater than five times the average thickness).
3.Combined aggregate shall consist of siliceous particles processed from washed material, of which at least 70% by count of the material retained on the No. 4 sieve shall have a minimum of two fractured faces, one of which must be fractured for the approximate average diameter or thickness of the particle. Do not add pea gravel or uncrushed particles.
4.Crushed slag coarse aggregate shall contain no more than 20% by weight of glassy particles.
B.Fine Aggregate (passing a No. 4 sieve) Provide fine aggregate, co nsisting of natural sand, fines prepared from stone, slag, gravel, granite, quartzite, gneiss, or combinations of these materials. The fine aggregate shall meet the following requirements:
1.Fine aggregate shall consist of hard tough grains free from injurious amounts of clay, loam, or other deleterious substances. 903.11 917 2. Fine aggregate shall meet the quality requirements in 903.25.
3.Manufactured sand shall have no more than 5% passing the No. 200 sieve when tested in accordance with AASHTO T 11.
4.Fine aggregate containing gypsum (CaSO 4) shall not chemically contain more than 5% sulfur trioxide (SO 3) as determined by analysis of the material passing the No. 8 sieve.
5.Wash and grade natural sand so that not more than 5% will be retained on the No. 4 sieve.
6.For fine aggregate consisting of natural sand, the amount of material finer than a No. 200 sieve, as tested in accordance with AASHTO T 11, shall not exceed 4% by weight. The amount of deleterious substances in natural sand shall not exceed th e limits specified in Table 903.11 -1. Table 903.11-1: Limits of Deleterious Substances in Natural Sand used in Hot Mix Substance Maximum Permissible Limits Percent by Weight Clay Lumps 0.5 Coal and Lignite 0.5 Other deleterious substances (such as shale, alkali, mica, coated grains, soft and flaky particles) and organic impurities as determined by AASHTO T 267 3.0
7.When using agricultural limestone as a portion of the fine aggregate, manufacture it from sound, durable stone that is crushed so tha t at least 85% will pass the No. 8 sieve and at least 50% will pass the No. 30 sieve.
C.Combined Aggregate Grading Provide aggregate fractions sized, graded, and combined in proportions that will ensure t he resulting composite blend will meet one of the 903.11 918 gradation requirements specified in Table 903.11 -2, together with the additional requirements pertaining to the constituents of the blend specified thereafter. Establish a single value for each sieve size required in the mix for each virgin aggregate stockpile, with an allowable stockpile tolerance on each sieve as specified in Table 903.06-2. When using Gradings D or E for the surfacing of shoulders or for other non-traffic lane construction, the Contractor may modify the design with the Engineer’s approval. Table 903.11 -2: Asphalt Concrete Surface Course Mixture Designation Design Range of Gradations Sieve Size Total Percent Passing by Weight Grading D Grading E Grading TL Grading TLD/TLE Grading OGFC 3/4 inch -- -- -- -- 100 5/8 inch 100 100 -- -- -- 1/2 inch 95-100 95-100 100 100 85-100 3/8 inch 80-93 80-93 100 90-100 55-75 No. 4 54-76 54-76 89-94 54-76 10-25 No. 8 35-57 35-57 53-77 35-57 5-10 No. 30 17-29 17-29 23-42 17-33 -- No. 50 10-18 10-18 -- 10-18 -- No. 100 3-10 3-11 9-18 3-10 -- No. 200 0-6.5 0-8 6-14 3-7 2-4
1.Grading D and TLD. Use fine aggregate consisting of natural sand or sand manufactured from gravel, slag, or from crushed stone aggregate meeting the physical and chemical requirements specified in 903.24. The use of carbonate rocks such as limestone and dolomite or other aggregates that tend to polish under traffic will not be permitted in the coarse aggregate and will be permitted only to the extent specified herein in the fine aggregate. 903.11 919 When using limestone screenings or agricultural limestone, the maximum amount by wei ght of the mineral aggregate shall be 25% unless the material is shown to meet the same requirements for limestone as specified in Table 903.24-1 for Surface Mixtures . In no case shall the combined aggregate blend consist of less than 75% polish-resistant material. When using natural sand as fine aggregate, limit it to a maximum amount of 25% by weight of the mineral aggregate. The Contractor may substitute a maximum of 5% mineral filler meeting the requirements of 903.16 for an equal quantity of the lim estone fines. If the mixture does not comply with the design criteria, provide another source of aggregate. When using gravel as the coarse aggregate for a 411 Grading D mix, use a minimum of 20% by weight limestone screenings, agricultural limestone , or mineral filler. Recycled asphalt pavement (RAP) milled from Department or other State Highway Agency projects shall be assumed to contain 75% polish-resistant material.
2.Grading E and TLE . When using Grading E as a surface for traffic lanes, 50% to 80% of the mineral aggregate shall be composed of crushed limestone, and the remaining 50% to 20% shall be natural sand, slag sand, sand manufactured from gravel or other approved polish-resistant aggregates , or any combination of these materials, with the following exceptions:
a.The sand percentage on the Job Mix Formula (JMF) shall range from 20% to 50%. However, if needed to meet or improve the specified design criteria, the Contractor may alter the lime stone and sand percentage by 5% from the percentage shown on the original JMF. If altering the aggregate percentages shown on the original JMF, submit a revision of the original design showing the altered percentages of aggregate.
b.When using Grading E for surfacing of shoulders or other non-traffic lane construction, the mineral aggregate may be composed entirely of limestone, including Size No. 10 (screenings) and manufactured sand, but in no case shall the mineral aggregate for this construction consi st of less than 50% limestone. 903.12 920 c. Recycled asphalt pavement (RAP) milled from Department or other State Highway Agency projects shall be assumed to contain 75% polish -resistant material.
3.Grading OGFC. A minimum of 75% of the aggregate shall meet the requirements specified in 903.24 for Surface Mixtures (Polish - Resistant Aggregates). The coarse aggregate shall have at least 90% crushed aggregate with two fractured faces and 100% with one fractured face as determined in accordance with ASTM D 5821. The coarse aggregate shall have a LA Abrasion value of less than 40% and a maximum absorption of 3.0%. Recycled asphalt pavement (RAP) milled from Department or other State Highway Agency projects shall be assu med to contain 75% polish-resistant material.
4.Grading TL. A minimum of 75% of the aggregate shall meet the requirements specified in 903.24 for Surface Mixtures ( Polish- Resistant Aggregates) for the appropriate traffic level. The mixture shall contain a m aximum of 15% natural sands . Recycled asphalt pavement (RAP) milled from Department or other State Highway Agency projects shall be assumed to contain 75% polish-resistant material.
5.Grading C, CS, CW. The mixture shall meet all requirements of
903.06 When using Grading C, CS, or CW as a final riding surface
for traffic lanes and the design ADT is greater than 1 ,000, a minimum of 75% of the aggregate shall meet the requirements specified in 903.24 for Surface Mixtures (Polish -Resistant Aggregate) for the appropriate levels. Recycled asphalt pavement (RAP) milled from Department or other State Highway Agency projects shall be assumed to contain 75% polish-resistant material.
903.12 Aggregate for Slurry Seal and Micro -Surface
A.Aggregate for Slurry Seal The aggregate shall be crushed slag, crushed granite, or crushed stone (crushed stone as specified in 903.24), meeting the requirements of 903.12 921 ASTM D692, except the gradation shall be as specified in Table
903.12 1. The aggregate shall meet the quality requirements in 903.25.
The aggregate shall have a minimum sand equivalent, as determined in accordance with AASHTO T 176, of 45. Table 903.12 -1: Gradation Limi ts for Aggregate for Slurry Seal Based on Wash Gradation Sieve Design Master Range (Total Percent Passing) Mixture Control Tolerances 3/8 inch 100 No. 4 90-100 ±6.0 No. 8 65-90 ±5.0 No. 16 45-70 ±5.0 No. 30 30-50 ±4.0 No. 50 20-38 ±4.0 No. 100 12-28 ±3.0 No. 200 8-16 ±3.0
B.Aggregate for Micro -Surface The aggregate shall be crushed slag, crushed granite , or crushed stone (crushed stone as specified in 903.24) meeting the gradation limits specified in Table 903.12 -2 and the physical properties of ASTM D692 , except the percent of fractured pieces shall be 100. The aggregate shall meet the quality requirements in 903.25. The aggregate shall have a minimum sand equivalent , as determined in accordance with AASHTO T 176, of 65. Polish-resistant aggregates will not be required for leveling courses, provided they will be covered with riding surface mixtures. If blending aggregates from more than one source, use automated proportioning and blending equipment which has individual bins for each aggregate source used to produce a uniform stockpile meeting the job mix formula gradation. Proportion and blending equipment shall be calibrated at the beginning of production. All aggregate sources shall be polish-resistant as specified in 903.24. The contractor shall provide a Type A laboratory as defined by 106.06 capable of verifying gradation at the location where blending occurs. 903.13 922 Table 903.12 -2: Gradation Limits for Aggregate for Micro -Surfacing Based on Wash Gradation Sieve Design Master Rang e (Total Percent Passing) Mixture Control Tolerances 3/8 inch 100 No. 4 70-98 ±6.0 No. 8 45-70 ±5.0 No. 16 28-50 ±5.0 No. 30 19-34 ±4.0 No. 50 12-25 ±4.0 No. 100 7-18 ±2.0 No. 200 4-15 ±2.0
903.13 Aggregate for Bituminous Seal Coat
Provide aggregate consisting of crushed stone, crushed slag, or crushed gravel, meeting the physical requirements of ASTM D692, except that at least 50% by count of crushed gravel aggregates shall have at least o ne fractured face. The aggregate shall meet the quality requirements of 903.25. Crushed slag aggregate retained on the No. 4 sieve shall contain no more than 20% by weight of glassy particles. Provide aggregates meeting the requirements of
903.24 except, if ADT is less than 1000 .
The amount of material finer than the No. 200 sieve shall not exceed 1%. If all material finer than the No. 200 sieve consists of the dust of fracture, essentially free from clay or shale, the percentage may be increased to 1.5 . Use aggregate meeting the gradation requirements in 903.22 for the size identified on the Plans and in accordance with Table 405.06-1.
903.14 Aggregate for Double Bituminous Surface Treatment
Provide aggregate meeting 903.13. In the mat, use aggregate meeting the gradation requirements specified for Size No. 7 in 903.22. In the seal, use aggregate meeting the gradation requirements specified for Size No. 8 in
903.22 Ensure that at least 90% of t he aggregate particles retained on the
903.15 923 No. 4 sieve have one or more fractured faces fractured for the approximate average diameter or thickness of the particle.
903.15 Aggregate for Aggregate -Cement Base Course
Provide coarse aggregate, composed of sound, tough, durable fragments of crushed stone, crushed slag, crushed or uncrushed gravel, or crushed or uncrushed chert, which may be blended with crushed recycled concrete or screened recycled asphalt pavemen t (RAP), and fine aggregate composed of natural or manufactured sand, and silt -clay or other finely divided mineral matter. Provide gravel or chert aggregate that is screened and of such gradation that 100% will pass a 1 -1/2-inch sieve, not more than 75% w ill pass the No. 4 sieve, and not less than 5% nor more than 15% will pass the No. 200 sieve. The fraction passing the No. 40 sieve shall have liquid limit not greater than 35, and a plasticity index not greater than 10. Provide crushed stone or slag aggregate that is sized and proportioned to meet the gradation requirements specified in 903.05 for Grading D. Blend materials, if required, at the screening plant or at the stationary mixing plant. Recycled concrete aggregate per 903.05.C or recycled asphalt pavement (RAP) may be used at a maximum rate of 25% by weight, provided the combined aggregate blend meets all the requirements specified above. If blending, c rush and screen the recycled concrete and/or asphalt to produce a uniform s tockpile before blending it with the virgin material. Keep the recycled asphalt pavement stockpiles free of bricks, steel, wood, and all other deleterious materials. The virgin aggregate shall meet the quality requirements specified in 903.25. Ensure tha t the combined total of shale, organic material, and other unwanted substances does not exceed 5% by weight.
903.16 Mineral Filler
Provide mineral filler conforming to AASHTO M 17, except that the mineral filler shall be non -plastic.
903.17 Aggregate for Underdrains
Provide crushed stone, crushed slag, or washed gravel meeting the physical requirements of ASTM D692 , the quality requirements of 903.25, and the gradation requirements specified for Size 6, 7, 8, 57, or 78 in 903.22. 903.18 924 903.18 Reserved
903.19 Lightweight Aggregates for Structural Concrete
Provide lightweight aggregate conforming to AASHTO M 195, with the following additions:
1.Produce the lightweight aggregate by fusing raw shale, slate, or clay in a rotary kiln.
2.The lightweight coarse aggregate shall conform to the gradation requirements for size 3/4 inch to No. 4, as shown in Table 1 of AASHTO M 195.
3.The aggregate shall meet the quality requirements in 903.25.
4.Concrete with approximately 6% air content made from the aggregate shall have a minimum durability factor of 90% when tested in accordance with AASHTO T 161.
5.Use material liste d on the Department’s Producer List.
903.20 Stockpiling Aggregate s
Clean and grub sites for aggregate stockpiles before storing aggregates, and ensure the ground is firm, smooth, and well -drained. Maintain a cover of at least 3 inches of aggregate to prevent contamination by soil or foreign material. Build the stockpiles in layers not exceeding 4 feet in height and have each layer completely in place before starting the next layer to prevent segregation. Deposit the material to prevent coning, except in the case of aggregate composed essentially of material finer than the No. 4 sieve and base material. Do not dump, cast, or push material over the sides of stockpiles, except in the case of aggregate for base material and fine aggregate materials. Unless otherwise approved, store aggregates from different sources or of different gradings, or that differ in specific gravity by more than 0.03, in separate stockpiles. To prevent the aggregates from mixi ng, either locate stockpiles of different types or sizes of aggregates far enough apart or separate them with suitable walls or partitions. 903.21 925 When building stockpiles, only operate trucks or other equipment on a stockpile in a manner approved by the Engineer . Use stockpiling methods that will prevent both excessive degradation of the aggregate and contamination of the stockpile with foreign matter. The Engineer will determine excessive degradation by conducting sieve tests of samples taken from any portion of the stockpile over which equipment has operated; failure of such samples to meet all gradation requirements for the aggregate is cause for discontinuing such stockpiling procedure.
903.21 Test Methods
In stating requirement s for most materials in 903, reference has been made to AASHTO and ASTM Standard Specifications for materials. The current AASHTO or ASTM Standard Specification effective at the time of letting for a Contract shall be the governing specification. Those S pecifications, in turn, include reference to the respective AASHTO and ASTM methods of sampling and testing. In a few instances, however, properties of materials in 903 have been specified without reference to corresponding AASHTO and ASTM Standard Specif ications. In such instances, the methods of sampling and testing specified in Table 903.21 -1 will govern. Table 903.21-1: Aggregate Sampling and Testing Methods Test Test Method Unit Weight AASHTO T 19 Percentage of Wear AASHTO T 96 Soundness AASHTO T 104 Liquid Limit AASHTO T 89 Plastic Limit and Plasticity Index AASHTO T 90 Sieve Analysis AASHTO T 27 Hydrometer Analysis AASHTO T 88 Material Passing No. 200 Sieve in Aggregate AASHTO T 11 Ten Minute Boil Test 407.03.E.2 Resistance to Plastic Flow by Marshall Method AASHTO T 245 (1)
1.Use a mechanically operated hammer with a rotating base. The compaction hammer shall have a slanted, circular tamping face. The slant on the face shall be 1.6% + 0.0/ -0.1. 903.22 926 903.22 Sizes of Coarse Aggregate Provide coarse aggregate meeting the gradation requirements of AASHTO M 43. Table 903.22 -1: Standard Sizes of Processed Aggregate 903.23 927 903.23 Reserved
903.24 Aggregates for Riding Surfaces (Polish-Resistant Aggregates )
Provide coarse aggregate consisting of crushed gravel, crushed granite, crushed slag, crushed quartzite, crushed gneiss , or crushed sandstone . Other crushed aggregate may be used provided it has the chemical, physical, and performance characteristics specified in Table 903.24 -1. Table 903.24 -1: Quality Requirements for Type I, II, III, and IV Aggregate Aggregate Property Test Method Type I Type II Type III Type IV (all roads) (all roads) (15,000 ADT max, excluding Interstates) (5,000 ADT max) Silica Dioxide Content, % min ASTM C25 40% 30% 20% 10% Calcium Carbonate Content, % max 32% -- -- -- Acid Insoluble Residue, % min ASTM D3042 50% 35% 25% -- British Pendulum Number,(1) min AASHTO T 278 AASHTO T 279 30 30 25 22
1.After 9 hours of accelerated polishing using the British Wheel in accordance with AASHTO T 279 In addition to the requirements specified in Table 903.2 4-1, Type II, III, and IV aggregates shall have met the preapproval process of the Division of Materials and Tests. All aggregate types must also maintain a satisfactory level of field performance to remain an approved source. Process and stockpile the mat erial as an independent and separate operation. The Engineer will sample and test each stockpile for approval prior to use. 903.25 928 903.25 Aggregate Quality Requirements Table 903.25 -1: Fine Aggregate Quality Requirements Application Sodium Sulfate Soundness Lo ss AASHTO T 104, %max L A Abrasion AASHTO T 96, %max Absorption AASHTO T 84, %max Concrete ( 903.01) 10 40 (1) N/A Mortar (903.02) 10 N/A N/A Hot Mix Asphalt Mix Base and Leveling Courses ( 903.06) 12 40 (1) N/A Hot Mix Asphalt Surface Courses ( 903.11) 12 40 (1) N/A Slurry Seal ( 903.12) 12 40 (1) N/A Microsurface ( 903.12) 12 40 (1) N/A (1)Applicable for fine aggregate manufactured from limestone or dolomite. 903.25 929 Table 903.25 -2: Coarse Aggregate Quality Requirements Application Sodium Sulfate Soundness Loss AASHTO T 104, %max L A Abrasion AASHTO T 96, %max Absorption AASHTO T 8 5, %max Concrete ( 903.03) 9 40 5 Mineral Aggregate Base – Type A (903.05) 15 50 N/A Mineral Aggregate Base – Type B (903.05) 20 50 N/A Recycled Concrete Aggregate ( 903.05) N/A 50 N/A Hot Mix Asphalt Mix Base and Leveling Courses (903.06) 9 50 5 (1) (2) Hot Mix Asphalt Surface Courses ( 903.11) 9 40 5 (1) (3) Bituminous Seal Coat (903.13) 12 40 N/A Double Bituminous Surface Treatment ( 903.14) 12 40 N/A Aggregate Cement Base Course (903.15) 15 50 N/A Underdrains ( 903.17) 12 50 N/A Lightweight Concrete (903.19) 9 40 10 Machined Riprap ( 709.02) 12 N/A N/A Graded Solid Rock ( 203.02) 12 N/A N/A Solid Rock ( 203.02) 12 N/A N/A Masonry Stone ( 921.07) 12 N/A N/A
1.To be based on the properties of the combined coarse aggregate blend.
2.For Grading CW only.
3.Maximum absorption for OGFC is 3.0%. 904.01 930 SECTION 904 – BITUMINOUS MATERIALS
904.01 Asphalt Cements ................................ ................................ .......... 930
904.02 Reserved ................................ ................................ ....................... 931
904.03 Emulsifi ed Asphalts ................................ ................................ ..... 931
904.01 Asphalt Cements
Only obtain a sphalt cement for use on Department projects from Certified Asphalt Suppliers that are on the Department’s Producer List . Asphalt cement shall conform to AASHTO M 320 and Department procedures . Direct Tension testing is not required. Instead of PG 64 -22, the Contractor may use asphalt cement graded to PG 67-22. PG 67 -22 shall conform to the requirements of AASHTO M 320 when the applicable tests are conducted at 67 °C and -12 °C, and the dynamic shear of the rolling thin film, pressure aged vessel sample is tested at 26.5 °C. To modify the asphalt , properly b lend one or more modifier(s) consisting styrene butadiene (SB), styrene butadiene styrene (SBS), styrene butadiene rubber (SBR), or Ground Tire Rubber (GTR) to a PG 64 -22 or PG 67 -22 base asphalt. The use of Re -refined Engine Oil Bottoms (REOB) or Vacuum Tower Asphalt Extender (VTAE) is prohibited. GTR used to modify asphalt shall meet the requirements of 921.17. Blending of GTR into asphalt cement shall occur only at the asphalt terminal. Polyphosphoric acid may be used as a modifier but shall not exceed 0.5% by weight of asphalt binder and may only be used when the primary modifier is one of the styrene -based products listed above. In addition to the above, asphalt cement modified with GTR shall meet the following requirement. The temperature difference determined by the Separation Test shall not exceed 15 °F. The separation test shall consist of taking the difference in softening point, as determined by the Ring and Ball Test (AASHTO T 53), between the top and bottom thirds of a specimen prepared per A STM D7173.
Source: Tennessee Standard Specifications for Road and Bridge Construction, 2021 Edition. Pages 910–938 of 1,072.