347Thin Overlay Mixtures

2.1 Aggregate . Furnish aggregates from sources that conform to the requirements shown in Table 1 and this

Section. Aggregate requirements in this Section, including those shown in Table 1, may be modified or eliminated when shown on the plans. Additional aggregate requirements may be specified when shown on the plans. Provide aggregate stockpiles that meet the definitions in this Section for coarse, intermediate, or fine aggregate. Do not use reclaimed asphalt pavement or recycled asphalt shingles . Supply aggregates that meet the definitions in Tex-100-E for crushed gravel or crushed stone. The Engineer will designate the plant or the quarry as the sampling location. Provide samples from materials produced for the project. The Engineer will establish the Surface Aggregate Classification (SAC) and perform Los Angeles abrasion, magnesium sulfate soundness, and Micro -Deval tests. Perform all other aggregate quality tests in accordance with Table 1. Document all test results in the mixture design report. The Engineer may perform tests on independent or split samples to verify Contractor test results. Stockpile aggregates for each source and type separately. Determine aggregate gradations for mixture design and production testing based on the washed sieve analysis in accordance with Tex-200-F , Part II.

2.1.1 Coarse Aggregate. Coarse aggregate stockpiles must have no more than 20% material passing the No. 8

sieve. Aggregates from sources listed in the Department’s Bituminous Rated Source Quality Catalog (BRSQC), are preapproved for use. Use only the rated values for hot mix listed in the BRSQC. Rated values for surface treatment do not apply to coarse aggregate sources used in hot -mix asphalt. For sources not listed in the Department’s BRSQC:  build an individual stockpile for each material;  request the Department test the stockpile for specification compliance;  allow 30 calendar days for the Engineer to sample, test, and report results;  use only when tested and approved; and  once approved, do not add additional material to the stockpile unless otherwise allowed by the Engineer. Provide coarse aggregate with at least the minimum SAC shown on the plans. SAC requirements apply only to aggregates used on the surface of travel lanes, unless otherwise shown on the plans. The SAC for sources in the Department’s Aggregate Quality Monitoring Program (AQMP) ( Tex-499-A ) is listed in the BRSQC . 388 2.1.1.1. Blending Class A and Class B Aggregates. Class B aggregate meeting all other requirements shown in Table 1 may be blended with a Class A aggregate to meet requirements for Class A materials, unless otherwise shown on the plans. When blending Class A and Class B aggregates to meet a Class A requirement, ensure that at least 50% by weight, or volume if required, of the material retained on the No. 8 sieve comes from the Class A aggregate source, unless otherwise shown on the plans. Blend by volume if the bulk specific gravities of the Class A and Class B aggregates differ by more than 0.300. Class B aggregate may be disallowed when shown on the plans. The Engineer may perform tests anytime during production, when the Contractor blends Class A and Class B aggregates to meet a Class A requirement. The Engineer will use the Department’s mix design template, when electing to verify conformance, to calculate the percent of Class A aggregate retained on the No. 4 sieve by inputting the bin percentages shown from readouts in the control room at the time of production and stockpile gradations measured at the time of production. The Engineer may determine the gradations based on either washed or dry sieve analysis from samples obtained from individual aggregate cold feed bins or aggregate stockpiles. The Engineer may perform spot checks to verify the percent of Class A aggregate retained on the No. 4 sieve. The Engineer will use the gradations supplied by the Contractor in the mixture design report as an input for the template. A failing spot check will require confirmation with a stockpile gradation determined by the Engineer . 2.1.1.2. Micro -Deval Abrasion . The Engineer will perform at least one Micro-Deval abrasion test in accordance with Tex-461-A for each coarse aggregate source used in the mixture design that has a Rated Source Soundness Magnesium (RSSM) loss value greater than 15 as listed in the BRSQC. The Engineer will perform testing before the start of production and may perform additional testing anytime during production. The Engineer may obtain the coarse aggregate samples from each coarse aggregate source or may require the Contractor to obtain the samples. The Engineer may waive all Micro- Deval testing based on a satisfactory test histor y of the same aggregate source. The Engineer will estimate the magnesium sulfate soundness loss for each coarse aggregate source, when tested, using the following formula: Mgest. = (RSSM)(MDact./RSMD) where: Mgest . = magnesium sulfate soundness loss RSSM = rated source soundness magnesium MDact = actual Micro- Deval percent loss RSMD = rated source Micro- Deval When the estimated magnesium sulfate soundness loss is greater than the maximum magnesium sulfate soundness loss specified, the coarse aggregate source will not be allowed for use unless otherwise approved. The Engineer will consult the Materials and Tests Division, and additional testing may be required before granting approval.

2.1.2 Intermediate Aggregate . Aggregates not meeting the definition of coarse or fine aggregate will be defined

as intermediate aggregate. Supply intermediate aggregates, when used, that are free of organic impurities. Supply intermediate aggregate from coarse aggregate sources, when used that meet the requirements shown in Table 1 unless otherwise approved. Test the stockpile if 10% or more of the stockpile is retained on the No. 4 sieve, and verify that it meets the requirements shown in Table 1 for crushed face count (in accordance with Tex -460-A ) and flat and elongated particles (in accordance with Tex-280-F ).

2.1.3 Fine Aggregate . Fine aggregates consist of manufactured sands and screenings. Natural sands are not

allowed in any mixture. Fine aggregate stockpiles must meet the fine aggregate properties shown in Table 1 and the gradation requirements shown in Table 2. Supply fine aggregates that are free of organic impurities. The Engineer may test the fine aggregate in accordance with Tex -408-A to verify the material is free of 389 organic impurities. Use fine aggregate from coarse aggregate sources that meet the requirements shown in Table 1 unless otherwise approved. Test the stockpile if 10% or more of the stockpile is retained on the No. 4 sieve, and verify that it meets the requirements shown in Table 1 for crushed face count (in accordance with Tex -460-A ) and flat and elongated particles (in accordance with Tex-280-F ). Table 1 Aggregate Quality Requirements Property Test Method Requirement Coarse Aggregate SAC Tex-499-A (AQMP) A1 Deleterious material, %, Max Tex-217-F, Part I 1.5 Decantation, %, Max Tex-217-F, Part II 1.5 Micro -Deval abrasion, % Tex-461-A Note2 Los Angeles abrasion, %, Max Tex-410-A 30 Magnesium sulfate soundness, 5 cycles, %, Max Tex-411-A 20 Crushed face count,3 %, Min Tex-460-A, Part I 95 Flat and elongated particles @ 5:1, %, Max Tex-280-F 10 Fine Aggregate Linear shrinkage, %, Max Tex-107-E 3 Sand equivalent, %, Min Tex-203-F 454 Organic impurities Tex-408-A Note5 1. Surface Aggregate Classification of “A” is required unless otherwise shown on the plans. 2. Used to estimate the magnesium sulfate soundness loss in accordance with 3. Only applies to crushed gravel. 4. The Department may perform Tex -252-F on fine aggregates not meeting this minimum requirement. Fine aggregates with a methylene blue value of 10.0 mg/g or less may be used. 5. Optional test. Table 2 Gradation Requirements for Fine Aggregate Sieve Size % Passing by Wt. or Volume 3/8″ 100 #8 70–100 #200 0–30

2.2 Mineral Filler . Mineral filler consists of finely divided mineral matter such as agricultural lime, crusher fines,

or hydrated lime. Mineral filler is allowed unless otherwise shown on the plans. Fly ash is not permitted unless otherwise shown on the plans. Use no more than 2% hydrated lime unless otherwise shown on the plans. Test all mineral fillers, except hydrated lime and fly ash, in accordance with Tex -107-E to ensure specification compliance. The plans may require or disallow specific mineral fillers. Provide mineral filler, when used, that :  is dry enough, free- flowing, and free of clumps and foreign matter, as determined by the Engineer;  does not exceed 3% linear shrinkage when tested in accordance with Tex -107-E ; and  meets the gradation requirements shown in Table 3, unless otherwise shown on the plans Table 3 Gradation Requirements for Mineral Filler Sieve Size % Passing by Wt. or Volume #8 100 #200 55–100

2.3 Baghouse Fines . Fines collected by the baghouse or other dust -collecting equipment may be reintroduced

into the mixing drum. 390 2.4. Asphalt Binder . Furnish performance- graded (PG) asphalt binder with a high-temperature grade of PG 76 and low -temperature grade as shown on the plans, in accordance with Section 300.2.11., “Performance- Graded Binders.”

2.5 Tack Coat . Furnish CSS -1H, SS- 1H, EBL, or a PG binder with a minimum high temperature grade of PG 58

for tack coat binder in accordance with Item 300, “Asphalts, Oils, and Emulsions.” Specialized tack coat materials listed on the MPL for Tracking Resistant Asphalt Interlayer (TRAIL) will be allowed or required when shown on the plans. The Engineer may suspend paving operations until there is adequate coverage. Do not dilute emulsified asphalts at the terminal, in the field, or at any other location before use, unless required in conformance with the manufacturer’s recommendation for approved TRAIL products on the MPL.

2.6 Additives . Use the type of additive specified when shown on the plans. Use the rate of additive specified in

conformance with the manufacturer’s recommendation. Additives that facilitate mixing and compaction or improve the quality of the mixture are allowed when approved. Provide the Engineer with documentation, such as the bill of lading showing the quantity of additives used in the project, unless otherwise directed.

2.6.1 Lime and Liquid Antistripping Agent . Lime or liquid antistripping agent is required when shown on the

plans. When lime or a liquid antistripping agent is used, add in accordance with Item 301, “Asphalt Antistripping Agents.” Use no more than 1% hydrated lime when using crushed gravel. Do not add lime directly into the mixing drum of any plant where lime is removed through the exhaust stream unless the plant has a baghouse or dust collection system that reintroduces the lime into the drum.

2.6.2 Compaction Aid. Compaction aid is defined as a Depart ment -approved chemical warm mix additive,

denoted as “chemical additive” on the MPL, that is used to facilitate mixing and compaction of hot -mix asphalt (HMA) at a discharge temperature greater than 275°F. Compaction aid is allowed for use on all projects. Compaction aid is required when shown on the plans or as required in Section 347.4.7.1., “Weather Conditions.” Warm -mix foaming processes, denoted as “foaming process” on the MPL, may be used to facilitate mixing and compaction of HMA at target discharge temperatures greater than 275°F; however, warm -mix foaming processes are not defined as a compaction aid.

2.7 Recycled Materials. Recycled materials are not allowed for use.

4.1 Certification . Personnel certified by the Department -approved HMA certification program must conduct all

mixture designs, sampling, and testing shown in Table 4. Supply the Engineer with a list of certified personnel and copies of their current certificates before beginning production and when personnel changes are made. Provide a mixture design developed and signed by a Level 2 certified specialist. Provide Level 1A certified specialists at the plant during production operations. Provide Level 1B certified specialists to conduct placement tests. Provide AGG101- certified specialists for aggregate testing. 391 Table 4 Test Methods, Test Responsibility, and Min Certification Levels Test Description Test Method Contractor Engineer Level1 Aggregate Testing Sampling Tex-221-F   1A/AGG101 Dry sieve Tex-200-F, Part I   1A/AGG101 Washed sieve Tex-200-F, Part II   1A/AGG101 Deleterious material Tex-217-F, Part I   AGG101 Decantation Tex-217-F, Part II   AGG101 Los Angeles abrasion Tex-410-A –  Department Magnesium sulfate soundness Tex-411-A –  Department Micro -Deval abrasion Tex-461-A –  AGG101 Crushed face count Tex-460-A   AGG101 Flat and elongated particles Tex-280-F   AGG101 Linear shrinkage Tex-107-E   AGG101 Sand equivalent Tex-203-F   AGG101 Methylene blue test Tex-252-F –  Department Bulk specific gravity Tex-201-F   AGG101 Organic impurities Tex-408-A   AGG101 Asphalt Binder and Tack Coat Sampling Asphalt binder sampling Tex-500-C, Part II   1A/1B Tack coat sampling Tex-500-C, Part III   1A/1B Mix Design and Verification Design and JMF changes Tex-204-F   2 Mixing Tex-205-F   2 Molding (SGC) Tex-241-F   1A Laboratory -molded density Tex-207-F, Part I and Part VI   1A Rice gravity Tex-227-F, Part II   1A Drain -down Tex-235-F   1A Ignition oven correction factors2 Tex-236-F, Part II   1A Overlay test Tex-248-F  Department Hamburg wheel test Tex-242-F   1A Witnessing mixing of correction factors Tex-236-F, Part III –  1A/Department Boil test Tex-530-C   1A Production Testing Selecting production random numbers Tex-225-F, Part I –  1A Mixture sampling Tex-222-F   1A/1B Molding (SGC) Tex-241-F   1A Laboratory -molded density Tex-207-F, Parts I and Part VI   1A Rice gravity Tex-227-F, Part II   1A Gradation and asphalt binder content2 Tex-236-F, Part I   1A Drain -down Tex-235-F   1A Control charts Tex-233-F   1A Moisture content Tex-212-F, Part II   1A/AGG101 Hamburg wheel test Tex-242-F   1A Overlay test Tex-248-F   Department Micro -Deval abrasion Tex-461-A  AGG101 Boil test Tex-530-C   1A Abson recovery Tex-211-F –  Department Placement Testing Establish rolling pattern Tex-207-F, Part IV  – 1B In-place density (nuclear method) Tex-207-F, Part III  – 1B Control charts Tex-233-F   1A Ride quality measurement Tex-1001 -S   Note3 Thermal profile Tex-244-F   1B Water flow test Tex-246-F   1B 1. Levels 1A, 1B, AGG101, and 2 are certification levels provided by the Hot Mix Asphalt Center certification program. 2. Refer to Section 347.4.9.2.3., “Production Testing,” for exceptions to using an ignition oven. 3. Profiler and operator are required to be certified at the Texas A&M Transportation Institute facility when surface test Type B is specified. 392 4.2. Reporting and Responsibilities . Use Department -provided templates to record and calculate all test data, including mixture design, production and placement QC and QA, control charts, and thermal profiles. Obtain the current version of the templates from the Department’s website or from the Engineer. The Engineer and the Contractor will provide any available test results to the other party when requested. The maximum allowable time for the Contractor and Engineer to exchange test data is as shown in Table 5, unless otherwise approved. The Engineer and the Contractor will immediately report to the other party any test result that requires suspension of production or placement or that fails to meet the specification requirements. Record and electronically submit all test results and pertinent information on Department provided templates. Subsequent sublots placed after test results are available to the Contractor, which require suspension of operations, may be considered unauthorized work. Unauthorized work will be accepted or rejected at the discretion of the Engineer in accordance with Article 5.3., “Conformity with Plans, Specifications, and Special Provisions.” Table 5 Reporting Schedule Description Reported By Reported To To Be Reported Within Production Quality Control Gradation1 Contractor Engineer 1 working day of completion of the sublot Asphalt binder content1 Laboratory -molded density2 Moisture content3 Boil test4 Production Quality Assurance Gradation3 Engineer Contractor 1 working day of completion of the sublot Asphalt binder content3 Laboratory -molded density1 Hamburg wheel test5 Overlay test5 Boil test4 Binder tests5 Placement Quality Control Thermal profile1 Contractor Engineer 1 working day of completion of the lot Water flow1 Placement Quality Assurance Thermal profile3 Engineer Contractor 1 working day of completion of the lot Aging ratio5 Water flow 1. These tests are required on every sublot. 2. Optional test. When performed on split samples, report the results as soon as they become available. 3. To be performed at the frequency shown in Table 12 or as shown on the plans. 4. When shown on the plans. 5. To be reported as soon as the results become available. Use the procedures described in Tex-233-F to plot the results of all QC and QA testing. Update the control charts as soon as test results for each sublot become available. Make the control charts readily accessible at the field laboratory. The Engineer may suspend production for failure to update control charts.

4.3 Quality Control Plan (QCP) . Develop and follow the QCP in detail. Obtain approval for changes to the Q CP

made during the project. The Engineer may suspend operations if the Contractor fails to comply with the QCP. Submit a written QCP before the mandatory pre- paving meeting. Receive approval of the QCP before beginning production. Include the following items in the QCP.

4.3.1 Project Personnel . For project personnel, include:

 a list of individuals responsible for QC with authority to take corrective action,  current contact information for each individual listed, and 393  current copies of certification documents for individuals performing specified QC functions.

4.3.2 Material Delivery and Storage. For material delivery and storage, include:

 the sequence of material processing, delivery, and minimum quantities to assure continuous plant operations;  aggregate stockpiling procedures to avoid contamination and segregation;  frequency, type, and timing of aggregate stockpile testing to assure conformance with material requirements before mixture production; and  procedure for monitoring the quality and variability of asphalt binder

4.3.3 Production. For production, include:

 loader operation procedures to avoid contamination in cold bins;  procedures for calibrating and controlling cold feeds;  procedures to eliminate debris or oversized material;  procedures for adding and verifying rates of each applicable mixture component (e.g., aggregate, asphalt binder, lime, liquid antistrip, compaction aid, and foaming process);  procedures for reporting job control test results; and  procedures to avoid segregation and drain-down in the silo.

4.3.4 Loading and Transporting. For loading and transporting, include:

 type and application method for release agents, and  truck- loading procedures to avoid segregation.

4.3.5 Placement and Compaction . For placement and compaction, include:

 proposed agenda for mandatory pre -paving meeting, including date and location;  proposed paving plan (e.g., production rate, paving widths, joint offsets, and lift thicknesses);  type and application method for release agents in the paver and on rollers, shovels, lutes, and other utensils;  procedures for the transfer of mixture into the paver, while avoiding physical and thermal segregation and preventing material spillage;  process to balance production, delivery, paving, and compaction to achieve continuous placement operations and good ride quality;  paver operations (e.g., speed, operation of wings, and height of mixture in auger chamber) to avoid physical and thermal segregation and other surface irregularities; and  procedures to construct quality longitudinal and transverse joints

4.4 Mixture Design .

4.4.1 Design Requirements. Use the Superpave mixture design procedure provided in accordance with

Tex-204-F , Part IV. Design the mixture to meet the requirements shown in Tables 1, 2, 3, 6, and 7. Design the mixture using a Superpave Gyratory Compactor (SGC), and 50 gyrations as the design number of gyrations (Ndesign). Use a target laboratory -molded density of 96.0% to design the mixture; however, adjustments may be made to the Ndesign value shown in Table 7. The Ndesign level may be reduced to at least 35 gyrations at the Contractor’s discretion. Use an approved laboratory from the MPL to perform the Hamburg Wheel test and provide results with the mixture design or provide the laboratory mixture and request that the Department perform the Hamburg wheel test. Use an approved laboratory from the MPL to perform the overlay test and provide results with the mixture design or provide the laboratory mixture and request that the Department perform the overlay test. Upon receiving the sample from the Contractor, the Engineer be allowed 10 working days to provide the Contractor with Hamburg wheel test and overlay test results on the laboratory mixture design. 394 The Engineer will provide the mixture design when shown on the plans. The Contr actor may submit a new mixture design at any time during the project. The Engineer will verify and approve all mixture designs (JMF1) before the Contractor can begin production. Provide the Engineer with a mixture design report using the Department -provided template. Include the following items in the report:  the combined aggregate gradation, source, specific gravity, and percent of each material used;  the binder source and optimum asphalt content;  Ndesign level used on the SGC;  results of all applicable te sts;  the mixing and molding temperatures;  the signature of the Level 2 person or persons that performed the design;  the date the mixture design was performed; and  a unique identification number for the mixture design. Table 6 Master Gradation Limits (% Passing by Wt. or Volume) and Volumetric Requirements Sieve Size Coarse (TOM -C) Fine (TOM -F) 1/2″ 100.01 100.01 3/8″ 95.0–100.0 98.0–100.0 #4 40.0–60.0 70.0–95.0 #8 17.0–27.0 40.0–65.0 #16 5.0–27.0 20.0–45.0 #30 5.0–27.0 10.0–35.0 #50 5.0–27.0 10.0–20.0 #200 5.0–9.0 2.0–12.0 Asphalt Binder Content, % Min – 6.0 6.5 Design VMA, % Min – 16.0 16.5 Production (Plant -Produced) VMA, % Min – 15.5 16.0 1. Defined as Max sieve size. No tolerance allowed. Table 7 Laboratory Mixture Design Properties Mixture Property Test Method Requirement Target laboratory -molded density, % (SGC) Tex-207 F 96.0 Design gyrations (Ndesign for SGC) Tex-241-F 501 Hamburg wheel test, passes at 12.5 -mm rut depth for PG 76 mixtures Tex-242-F 20,000 Min Overlay test, critical fracture energy, lb.-in./sq. in. Tex-248-F 1.5 Min Overlay test, crack progression rate Tex-248-F 0.40 Max Drain -down, % Tex-235-F 0.20 Max 1. Adjust within the range of 35–100 gyrations when shown on the plans or specification or when mutually agreed between the Engineer and Contractor.

4.4.2 Job-Mix Formula Approval . The JMF is the combined aggregate gradation, Ndesign level, and target

asphalt percentage used to establish target values for hot -mix production. The JMF1 is the original laboratory mixture design used to produce the trial batch. When a compaction aid or foaming process is used, JMF1 may be designed and submitted to the Engineer without including the compaction aid or foaming process. When a compaction aid or foaming process is used, document the compaction aid or foaming process used and recommended rate in the JMF1 submittal. The Engineer and the Contractor will verify JMF1 based on plant -produced mixture from the trial batch, unless otherwise approved. The Engineer may accept an existing mixture design previously used on a Department project and may wai ve the trial batch to verify JMF1. The Department may require the Contractor to reimburse the Department for verification tests if more than two trial batches per design are required. 395 4.4.2.1. Contractor’s Responsibilities. 4.4.2.1.1. Providing Superpave Gyratory Compactor (S GC). Provide an SGC in accordance with Item 504, “Field Office and Laboratory,” and make the SGC available to the Engineer for use in molding production samples . 4.4.2.1.2. Gyratory Compactor Correlation Factors. Use Tex -206-F , Part II, to perform a gyratory compactor correlation when the Engineer uses a different SGC. Apply the correlation factor to all subsequent production test results . 4.4.2.1.3. Submitting JMF1 . Furnish a mix design report (JMF1) with representative samples of all component materials and request approval to produce the trial batch. Provide approximately 25 lb. of the design mixture if opting to have the Department perform the Hamburg wheel test on the laboratory mixture, and request that the Department perform the test. Provide approximately 60 lb. of the design mixture to perform the overlay test. 4.4.2.1.4. Supplying Aggregates . Provide approximately 40 lb. of each aggregate stockpile unless otherwise directed. 4.4.2.1.5. Supplying Asphalt . Provide at least 1 gal. of the asphalt material and enough quantities of any additives proposed for use. 4.4.2.1.6. Ignition Oven Correction Factors . Notify the Engineer before performing Tex-236-F , Part II. Allow the Engineer to witness the mixing of ignition oven correction factor sample. Determine the aggregate and asphalt correction factors from the ignition oven in accordance with Tex-236-F , Part II. If the Engineer witnessed the mixing of ignition oven correction factor samples, provide the Engineer with identically prepared samples of the mixtures before the trial batch production, including all additives (except water), and blank samples used to determine the correction factors for the ignition oven used for QA testing during production. Correction factors established from a previously approved mixture design may be used for the current mixture design if the mixture design and ignition oven are the same as previously used, unless otherwise directed. Correction factors must be performed every 12 mo. 4.4.2.1.7. Boil Test . When shown on the plans, perform the test and retain the tested sample from Tex -530-C until completion of the project or as directed. Use this sample for comparison purposes during production. 4.4.2.1.8. Trial Batch Production. Provide a plant -produced trial batch upon receiving conditional approval of JMF1 and authorization to produce a trial batch. If applicable, include the compaction aid or foaming process for verification testing of JMF1 and development of JMF2. Produce a trial batch mixture that meets the requirements shown in Table 8. The Engineer may accept test results from recent production of the same mixture instead of a new trial batch. 4.4.2.1.9. Trial Batch Production Equipment . Use only equipment and materials proposed for use on the project to produce the trial batch. Provide documentation to verify the calibration or accuracy of the asphalt mass flow meter to measure the binder content. Verify that asphalt mass flow meter meets the 0.4% accuracy requirement, when applicable, in accordance with Item 520, “Weighing and Measuring Equipment.” The Engineer may require that the accuracy of the mass flow meter be verified based on quantities used. 4.4.2.1.10. Trial Batch Quantity. Produce enough quantity of the trial batch to ensure that the mixture meets the specification requirements. 4.4.2.1.11. Number of Trial Batches. Produce trial batches as necessary to obtain a mixture that meets the specification requirements. 396 4.4.2.1.12. Trial Batch Sampling . Obtain a representative sample of the trial batch and split it into three equal portions in accordance with Tex -222-F . Label these portions as “Contractor,” “Engineer,” and “Referee.” Deliver samples to the appropriate laboratory as directed. 4.4.2.1.13. Trial Batch Testing . Test the trial batch to ensure the mixture produced using the proposed JMF1 meets the mixture requirements shown in Table 8. Ensure the trial batch mixture is also in compliance with Table 6 and Table 7. Use a Department -approved laboratory listed on the MPL to perform the Hamburg wheel test on the trial batch mixture, or request that the Department perform the Hamburg wheel test. Provide approximately 25 lb. of the trial batch mixture if opting to have the Department perform the Hamburg wheel test, and request that the Department perform the test. Obtain and provide approximately 60 lb. of trial batch mixture in sealed containers, boxes, or bags labeled with the control -section- job (CSJ) number, mixture type, lot, and sublot number in accordance with Tex 222-F for the overlay test. Upon receiving the sample from the Contractor, the Engineer will be allowed 10 working days to provide the Contractor with Hamburg wheel test and overlay test results on the trial batch. Provide the Engineer with a copy of the trial batch test results. 4.4.2.1.14. Development of JMF2. After the Engineer grants full approval of JMF1, evaluate the trial batch test r esults, determine the optimum mixture proportions, and submit as JMF2. Adjust the asphalt binder content or gradation to achieve the specified target laboratory -molded density. The mixture produced using JMF2 must meet the requirements shown in Table 6 and Table 7. Verify that JMF2 meets the operation tolerances of JMF1 shown in Table 8. 4.4.2.1.15. Mixture Production. Use JMF2 to produce Lot 1 after receiving approval for JMF2 and passing test results on the trial batch from laboratories listed on the Hamburg wheel MPL and overlay MPL. Once JMF2 is approved, and without receiving the results from the Department’s Hamburg wheel test or overlay test on the trial batch, the Contractor may proceed to Lot 1 production at their own risk. Notify the Engineer if electing to proceed without Hamburg wheel test and overlay test results from the trial batch. Note that the Engineer may require up to the entire sublot of any mixture failing the Hamburg wheel test or overlay test to be removed and replaced at the Contractor’s expense. 4.4.2.1.16. Development of JMF3. Evaluate the test results from Lot 1, determine the optimum mixture proportions, and submit as JMF3 for use in Lot 2. 4.4.2.1.17. JMF Adjustments . If JMF adjustments are necessary to achieve the specified requirements, make the adjustments before beginning a new lot. The adjusted JMF must:  be provided to the Engineer in writing before the start of a new lot,  be numbered in sequence to the previous JMF,  meet the master gradation limits shown in Table 6, and  be within the operational tolerances of JMF2 shown in Table 8. 4.4.2.1.18. Requesting Referee Testing . Use referee testing, if needed, in accordance with Section 347.4.9.1., “Referee Testing,” to resolve testing differences with the Engineer. 397 Table 8 Operational Tolerances Description Test Method Allowable Difference Between JMF2 and JMF1 Target1 Allowable Difference Between Current JMF and JMF22 Allowable Difference Between Contractor and Engineer3 Individual % retained on #8 sieve and larger Tex-200-F or Tex-236-F Must be within master gradation limits in Table 6 ±3.04 ±5.0 Individual % retained on sieves smaller than #8 and larger than #200 ±3.04 ±3.0 % passing the #200 sieve ±2.04 ±1.6 Asphalt binder content,5 % Tex-236-F ±0.36 ±0.36 ±0.3 Laboratory -molded density, % Tex-207-F ±1.0 ±1.0 ±1.0 Laboratory -molded bulk specific gravity – – ±0.020 VMA, % Min Tex-204-F Note 7 Note 7 – Theoretical maximum specific (Rice) gravity Tex-227-F – – ±0.020 Drain -down, % Tex-235-F Note 8 Note 8 – 1. JMF1 is the approved laboratory mixture design used for producing the trial batch. JMF2 is the approved mixture design developed from the trial batch used to produce Lot 1. 2. Current JMF is JMF3 or higher. JMF3 is the approved mix design used to produce Lot 2. 3. Contractor may request referee testing when values exceed these tolerances. 4. When within these tolerances, mixture production gradations may fall outside the master grading limits; however, the % passing the #200 will be considered out of tolerance when outside the master grading limits. 5. May be obtained from asphalt meter readouts as determined by the Engineer. 6. Binder content is not allowed to be outside the limits shown in Table 6. 7. Verify that Table 6 requirements are met. 8. Verify that Table 7 requirements are met. 4.4.2.2. Engineer’s Responsibilities. 4.4.2.2.1. Superpave Gyratory Compactor . The Engineer will use a Department SGC, calibrated in accordance with Tex-241-F , to mold samples for laboratory mixture design verification. For molding trial batch and production specimens, the Engineer will use the Contractor -provided SGC at the field laboratory or provide and use a Department SGC at an alternate location. 4.4.2.2.2. Conditional Approval of JMF1 and Authorizing Trial Batc h. The Engineer will review and verify conformance of the following information within 2 working days of receipt.  the Contractor’s mix design report (JMF1);  the Department -provided overlay test results;  the Contractor -provided Hamburg wheel test results;  all required materials including aggregates, asphalt, and additives; and  the mixture specifications. The Engineer will grant the Contractor conditional approval of JMF1 if the information provided on the paper copy of JMF1 indicates that the Contractor’s mixture design meets the specifications. When the Contractor does not provide Hamburg wheel test results with laboratory mixture design, 10 working days are allowed for conditional approval of JMF1. The Engineer will base full approval of JMF1 on test results on mixture from the trial batch. Unless waived, the Engineer will determine the Micro-Deval abrasion loss in accordance with Section 347.2.1.1.2., “Micro- Deval Abrasion.” If the Engineer’s test results are pending after 2 working days, conditional approval of JMF1 will still be granted within 2 working days of receiving JMF1. When the Engineer’s test results become available, they will be used for specification compliance. The Contractor is authorized to produce a trial batch after the Engineer grants conditional approval of JMF1. 398 4.4.2.2.3. Hamburg Wheel and Overlay Testing of JMF1. If the Contractor requests the option to have the Department perform the Hamburg Wheel test on the laboratory mixture, the Engineer will mold samples in accordance with Tex -242-F to verify compliance with the Hamburg Wheel test requirement shown in Table 7. The Engineer will perform the overlay test and mold samples in accordance with Tex-248-F to verify compliance with the overlay test requirements shown in Table 7. Upon receiving the sample from the Contractor, the Engineer will be allowed 10 working days to provide the Contractor with Hamburg wheel and overlay test results on the laboratory mixture design. 4.4.2.2.4. Ignition Oven Correction Factors . The Engineer will determine ignition oven correction factors by one of the following options.  Witness the mixing of ignition oven correction factor samples by the Contractor in accordance with Tex-236-F , Part. II. The Engineer will use the identically prepared samples provided by the Contractor to determine the aggregate and asphalt correction factors for the ignition oven in accordance with Tex-236-F , Part II I.  If the Engineer does not witness the mixing of ignition oven correction factor samples, the Engineer will prepare the samples to determine the aggregate and asphalt correction factors for the ignition oven in accordance with Tex -236-F , Part II. Notify the Contractor before performing Tex -236-F , Part II. Allow the Contractor to witness the Engineer performing Tex-236-F , Part II. Correction factors must be performed every 12 mo. to be used for QA testing during production. 4.4.2.2.5. Testing the Trial Batch . Within 1 full working day, the Engineer will sample and test the trial batch to ensure that the mixture meets the requirements shown in Table 8. If the Contractor requests the option to have the Department perform the Hamburg wheel test on the trial batch mixture, the Engineer will mold samples in accordance with Tex -242-F to verify compliance with Hamburg wheel test requirements shown in Table 7. The Engineer will mold samples for the overlay test in accordance with Tex-248-F to verify compliance with the overlay test requirement shown in Table 7. The Engineer will have the option to perform Tex -530-C on the trial batch when shown on the plans. These results may be retained and used for comparison purposes during production. 4.4.2.2.6. Full Approval of JMF1 . The Engineer will grant full approval of JMF1 and authorize the Contractor to proceed with developing JMF2 if the Engineer’s results for the trial batch meet the requirements shown in Table 6 and Table 7. The Engineer will notify the Contractor that an additional trial batch is required if the trial batch does not meet these requirements. 4.4.2.2.7. Approval of JMF2 . The Engineer will approve JMF2 within 1 working day if the mixture meets the requirements shown in Tables 6, 7, and 8. 4.4.2.2.8. Approval of Lot 1 Production. The Engineer will authorize the Contractor to proceed with JMF2 for Lot 1 production after passing test results on the trial batch are achieved from laboratories listed on the Hamburg wheel MPL and overlay MPL. The Contractor may proceed at their own risk with Lot 1 production without the results from the Hamburg wheel test or overlay test on the trial batch. If the Department -approved laboratory’s sample from the trial batch fails the Hamburg wheel test or overlay test, the Engineer will suspend production until further Hamburg wheel tests or overlay tests meet the specified values. The Engineer may require up to the entire sublot of any mixture failing the Hamburg wheel test or overlay test to be removed and replaced at the Contractor’s expense. 4.4.2.2.9. Approval of JMF3 and Subsequent JMF Changes . JMF3 and subsequent JMF changes are approved if they meet the master gradation limits and asphalt binder content in accordance with Table 6 and are within the operational tolerances of JMF2 shown in Table 8. The addition of a warm -mix asph alt (WMA) additive to facilitate mixing or as a compaction aid does not require a new laboratory mixture design or trial batch. Current JMF changes that exceed the operational tolerances of JMF2 in accordance with Table 8 may require a new laboratory mixture design, trial batch, or both. 399 4.5. Production Operations . Perform a new trial batch when the plant or plant location is changed. All asphalt source changes will require a passing Hamburg wheel result from a laboratory listed on the MPL. The Contractor may proceed at their own risk with Lot 1 production without the results from the Hamburg wheel test on the trial batch. All aggregate source changes will require a new laboratory mixture design and trial batch. Take corrective action and receive approval to proceed after any production suspension for noncompliance with the specification.

4.5.1 Storage and Heating of Materials . Do not heat the asphalt binder above the temperatures specified in

accordance with Item 300, or outside the manufacturer’s recommended values. Provide the Engineer with daily records of asphalt binder and HMA discharge temperatures (in legible and discernible increments) in accordance with Item 320, unless otherwise directed. Do not store mixture for a period long enough to affect the quality of the mixture, nor in any case longer than 12 hr., unless otherwise approved.

4.5.2 Mixing and Discharge of Materials. Notify the Engineer of the target discharge temperature and produce

the mixture within 25°F of the target. Monitor the temperature of the material in the truck before shipping to ensure that it does not exceed the maximum production temperatures shown in Table 9. The Department will not pay for or allow placement of any mixture produced above the maximum production temperatures shown in Table 9. Table 9 Max Production Temperature High -Temperature Binder Grade1 Max Production Temperature (°F) PG 76 345 1. The high -temperature binder grade refers to the high -temperature grade of the virgin asphalt binder used to produce the mixture. Control the mixing time and temperature so that substantially all moisture is removed from the mixture before discharging from the plant. Determine the moisture content, if requested, by oven- drying in accordance with Tex-212-F , Part II, and verify that the mixture contains no more than 0.2% of moisture by weight. Obtain the sample immediately after discharging the mixture into the truck and perform the test promptly.

4.6 Hauling Operations . Clean all truck beds before use to ensure that mixture is not contaminated. Use a

release agent listed on the MPL to coat the inside bed of the truck when necessary. Do not use diesel or any release agent not listed on the MPL. Use equipment for hauling as defined in Section 347.4.7.3.3., “Hauling Equipment.” Use other hauling equipment only when allowed.

4.7 Placement Operations. Collect haul tickets from each load of mixture delivered to the project and provide

the Department’s copy to the Engineer approximately every hour, or as directed. Use a hand- held thermal camera or infrared thermometer, when a thermal imaging system is not used, to measure and record the internal temperature of the mixture as discharged from the truck or material transfer device (MTD) before or as the mix enters the paver. Measure the mixture temperature at a minimum frequency of one per ten trucks, or as approved. Include an approximate station number or Global Positioning System coordinates of the location where the temperature was taken on each ticket. Ensure the mixtures meets the temperature requirements shown in Table 9. Calculate the daily yield and cumulative yield for the specified lift and provide to the Engineer at the end of paving operations for each day unless otherwise directed. The Engineer may suspend production if the Contractor fails to produce and provide haul tickets and yield calculations by the end of paving operations for each day. Prepare the surface by removing raised pavement markers and objectionable material, such as moisture, dirt, sand, leaves, and other loose impediments, from the surface before placing mixture. Remove vegetation from pavement edges. Place the mixture to meet the typical section requirements and produce a smooth, finished surface with a uniform appearance and texture. Offset longitudinal joints of successive courses of hot mix by at least 6 in. Place mixture so that longitudinal joints on the surface course coincide within 6 in. of lane lines, are not placed in the wheel path, or will not be covered with pavement markings, or as directed. 400 Ensure that all finished surfaces will drain properly. Place the mixture at the rate or thickness shown on the plans. The Engineer will use the guidelines shown in Table 10 to determine the compacted lift thickness. The thickness determined is based on the rate of 110– 115 lb. per square yard for each inch of pavement unless otherwise shown on the plans. Table 10 Compacted Lift Thickness Mixture Type Min (in.) Max (in.) TOM -C 0.75 1.25 TOM -F 0.5 1.00

4.7.1 Weather Conditions .

4.7.1.1. When Using a Thermal Imaging System . Place mixture when the roadway is dry and the roadway surface temperature is at or above 60°F, unless otherwise approved or as shown on the plans. Place mixtures only when weather conditions and moisture conditions of the roadway surface are suitable as determined by the Engineer. Provide output data from the thermal imaging system to demonstrate to the Engineer that no recurring severe thermal segregation exists in accordance with Section 347.4.7.3.1.2., “Thermal Imaging System.” Produce mixture with a target discharge temperature higher than 300°F and with a compaction aid to facilitate compaction when the air temperature is 70°F and falling. 4.7.1.2. When Not Using a Thermal Imaging System . When using a thermal camera instead of the thermal imaging system, place mixture when the roadway surface temperature is at or above 70°F, unless otherwise approved or as shown on the plans. Measure the roadway surface temperature using a handheld thermal camera or infrared thermometer. Place mixtures only when weather conditions and moisture conditions of the roadway surface are suitable as determined by the Engineer. The Engineer may restrict the Cont ractor from paving if the air temperature is 70°F and falling. Produce mixture with a target discharge temperature higher than 300°F and with a compaction aid to facilitate compaction when the air temperature is 70°F and falling.

4.7.2 Tack Coat .

4.7.2.1. Application . Clean the surface before placing the tack coat. The Engineer will set the rate between 0.04 gal. and 0.10 gal. of residual asphalt per square yard of surface area. Apply a uniform tack coat at the specified rate unless otherwise directed. Apply the tack coat in a uniform manner to avoid streaks and other irregular patterns. Apply the tack coat to all surfaces that will come in contact with the subsequent HMA placement, unless otherwise directed. Apply adequate overlap of the tack coat in the longitudinal direction during placement of the mat to ensure bond of adjacent mats, unless otherwise directed. Allow adequate time for emulsion to break completely before placing any material. Prevent splattering of tack coat when placed adjacent to curb, gutter, and structures. The Engineer may suspend paving operations until there is adequate coverage. Do not dilute emulsified asphalts at the terminal, in the field, or at any other location before use unless required in conformance with the manufacturer’s recommendation for approved TRAIL products on the MPL. 4.7.2.2. Sampling . The Engineer will obtain at least one sample of the tack coat binder per project per source in accordance with Te x-500-C , Part III, and test it in accordance with Item 300. The Engineer will notify the Contractor when the sampling will occur and will witness the collection of the sample from the asphalt distributor immediately before use. Label the can with the corresponding lot and sublot numbers; producer; producer facility location; grade; District; date sampled; all applicable bills of lading (if available); and project information, including highway and CSJ number. For emulsions, the Engineer may test as often as necessary to ensure the residual of the emulsion is greater than or equal to the specification requirement in Item 300. 401 4.7.3. Lay-Down Operations . Use the placement temperatures shown in Table 11 to establish the minimum placement temperature of mixture delivered to the paving operation. Table 11 Min Mixture Placement Temperature High -Temperature Binder Grade1 Min Placement Temperature2,3 (F°) PG 76 280 1. The high -temperature binder grade refers to the high -temperature grade of the virgin asphalt binder used to produce the mixture. 2. The mixture temperature must be measured using a handheld thermal camera or infrared thermometer immediately before entering MTD or paver. 3. Min placement temperatures may be reduced 20°F if using a chemical WMA additive as a compaction aid, MTD with re- mixing capabilities, or paver hopper insert with re -mixing capabilities. 4.7.3.1. Thermal Profile. Use a handheld thermal camera or a thermal imaging system to obtain a continuous thermal profile in accordance with Tex -244-F . Thermal profiles are not applicable in areas described in 4.7.3.1.1. Thermal Segregation. 4.7.3.1.1.1. Moderate. Any areas that have a temperature differential greater than 25°F, but not exceeding 50°F. 4.7.3.1.1.2. Severe. Any areas that have a temperature differential greater than 50°F. 4.7.3.1.2. Thermal Imaging System . Review the output results when a thermal imaging system is used, and provide the automated report described in Tex -244-F to the Engineer daily, unless otherwise directed. Modify the paving process as necessary to eliminate any recurring (moderate or severe) thermal segregation identified by the thermal imaging s ystem. The Engineer may suspend paving operations if the Contractor cannot successfully modify the paving process to eliminate recurring severe thermal segregation. Density profiles are not required and not applicable when using a ther mal imaging system. Provide the Engineer with electronic copies of all daily data files that can be used with the thermal imaging system software to generate temperature profile plots daily or as requested. 4.7.3.1.3. Thermal Camera. Provide the Engineer with the thermal profile of every sublot within 1 working day of the completion of each lot. When requested by the Engineer, provide the thermal images generated using the thermal camera. Report the results of each thermal profile in accordance with Section 347.4.2., “Reporting and Responsibilities.” The Engineer will use a handheld thermal camera to obtain a thermal profile at least once per project. Take immediate corrective action to eliminate recurring moderate thermal segregation when a handheld thermal camera is used. Evaluate areas with moderate thermal segregation by performing water flow testing in accordance with Tex -246-F , and verify the water flow is greater than 120 sec. Suspend operations and take immediate corrective action to eliminate severe thermal segregation unless otherwise directed. Resume operations when the Engineer determines that subsequent production will meet the requirements of this Section. Evaluate areas with severe thermal segregation by performing water flow testing in accordance with Tex -246-F , and verify the water flow is greater than 120 sec. Remove and replace the material in any areas that have severe thermal segregation and a failing result for water flow test unless otherwise directed. 4.7.3.2. Windrow Operations . Operate windrow pickup equipment so that when hot mix is placed in windrows, substantially all the mixture deposited on the roadbed is picked up and loaded into the paver. 402 4.7.3.3. Hauling Equipment . Use belly dump, live- bottom, or end dump trucks to haul and transfer mixture. Except for paving miscellaneous areas, end dump trucks are allowed only when used in conjunction with an MTD with remixing capability, unless otherwise approved. 4.7.3.4. Screed Heaters. Turn off screed heaters to prevent overheating of the mat if the paver stops for more than 5 min. The Engineer may evaluate the suspect area in accordance with Section 347.4.9.3.3., “Recovered Asphalt Dynamic Shear Rheometer (DSR),” if the screed heater remains on for more than 5 min. while the paver is stopped.

4.8 Compaction. Roll the freshly placed mixture using as many steel -wheeled rollers as necessary to ensure

desired compaction without excessive breakage of the aggregate, and to provide a smooth surface and uniform texture. Operate each roller in static mode for TOM -F mixtures only. Do not use pneumatic rollers. Use the control strip method in accordance with Tex -207-F , Part IV, to establish the rolling pattern. Thoroughly moisten the roller drums with a soap and water solution to prevent adhesion. Use only water or an approved release agent on rollers, tamps, and other compaction equipment unless otherwise directed. Use tamps to thoroughly compact the edges of the pavement along curbs, headers, and similar structures, and in locations that will not allow thorough compaction using rollers. The Engineer may require rolling using a trench roller on widened areas, in trenches, and in other limited areas. Test and verify that the compacted mixture meets the water flow requirements in accordance with Tex -246-F . Measure the water flow once per sublot at locations as directed by the Engineer. The water flow rate must be greater than 120 sec. Investigate the cause of the water flow rate test failures and take corrective actions during production and placement to ensure the water flow rate is greater than 120 sec. Suspend production if two consecutive water flow rate tests fail, unless otherwise approved. Resume production after the Engineer approves changes to production or placement methods. Measure water flow to verify the mixture is adequately compacted at confined longitudinal joints in accordance with Tex -246-F as directed by the Engineer. Complet e all compaction operations before the pavement temperature drops below 180°F, unless otherwise allowed. The Engineer may allow compaction using a light finish roller operated in static mode for pavement temperatures below 180°F. Allow the compacted pavement to cool to 160°F or lower before opening to traffic, unless otherwise directed. Sprinkle the finished mat with water or limewater, when directed, to expedite opening the roadway to traffic.

4.9 Acceptance Plan . Sample and test the HMA on a l ot-and-sublot basis.

4.9.1 Referee Testing . The Materials and Tests Division is the referee laboratory. The Contractor may request

referee testing if a “remove and replace” condition is determined based on the Engineer’s test results, or if the differences between Contractor and Engineer test results exceed the maximum allowable difference shown in Table 8 and the differences cannot be resolved. The Contractor may also request referee testing if the Engineer’s test results require suspension of production and the Contractor’s test results are within specification limits. Make the request within 5 working days after receiving test results from the Engineer. Referee tests will be performed only on the sublot in question and only for the particular tests in question. Allow 10 working days from the time the referee laboratory receives the samples for test results to be reported. The Department may require the Contractor to reimburse the Department for referee tests if more than three referee tests per project are required and the Engineer’s test results are closer to the referee test results than the Contractor’s test results. The Materials and Tests Division will determine the laboratory -molded density based on the molded specific gravity and the maximum theoretical specific gravity of the referee sample. 403 4.9.2. Production Acceptance . 4.9.2.1. Production Lot . A production lot consists of four equal sublots. The default quantity for Lot 1 is 500 ton; however, when requested by the Contractor, the Engineer may increase the quantity for Lot 1 to no more than 2,000 ton. The Engineer will select subsequent lot sizes based on the anticipated daily production such that approximately three or four sublots are produced each day. The lot size will be between 500 ton and 2,000 ton. The Engineer may change the lot size before the Contractor begins any lot. 4.9.2.1.1. Incomplete Production Lots . If a lot is begun but cannot be completed, such as on the last day of production or in other circumstances deemed appropriate, the Engineer may close the lot. Close al l lots within 5 working days unless otherwise allowed. 4.9.2.2. Production Sampling. 4.9.2.2.1. Mixture Sampling. The Engineer will perform or witness the sampling of production sublots from trucks at the plant in accordance with Tex -222-F . The sampler will split each sample into three equal portions in accordance with Tex-200-F and label these portions as “Contractor,” “Engineer,” and “Referee.” The Engineer will perform or witness the sample splitting and take immediate possession of the samples labeled “Engineer” and “Referee.” The Engineer will maintain the custody of the samples labeled “Engineer” and “Referee” until the Department’s testing is completed. 4.9.2.2.1.1. Random Sample . At the beginning of the project, the Engineer will select random numbers for all production sublots. Determine sample locations in accordance with Tex -225-F . Take one sample for each sublot at the randomly selected location. The Engineer will perform or witness the sampling of production sublots. 4.9.2.2.1.2. Blind Sample . For one sublot per lot, the Engineer will sample, split, and test a “blind” production sample instead of the random sample collected by the Contractor. The location of the Engineer’s blind sample will not be disclosed to the Contractor before sampling. The Engineer’s “blind” sample may be randomly selected in accordance with Tex -225-F for any sublot or selected at the discretion of the Engineer. The Engineer may sample and test an additional blind sample when the random sampling process does not result in obtaining a sample. For one sublot per lot, the Contractor must obtain from the Engineer a “blind” production sample collected by the Engineer. If desired, the Contractor may witness the collection of blind samples. Test either the “blind” or the random sample; however, referee testing for the sublot (if applicable) will be based on a comparison of results from the “blind” sample. 4.9.2.2.2. Informational Methylene Blue Testing . During the project and at random, obtain and provide the Engineer with approximately 50 lb. of each fine aggregate and approximately 20 lb. of all mineral fillers used to produce the mixture. Label the samples with the CSJ number, mixture type, and approximate lot and sublot number corresponding to when the sample was taken. The Engineer will ship the samples to the Materials and Tests Division for methylene blue testing in accordance with Tex -252-F . Results from these tests will not be used for specification compliance. 4.9.2.2.3. Asphalt Binder Sampling. The Engineer will witness the Contractor obtain a 1-qt. sample of the asphalt binder for each lot of mixture produced. The Contractor must notify the Engineer when the sampling will occur. Obtain the sample at approximately the same time the mixture random sample is obtained. Sample from a port located immediately upstream from the mixing drum or pug mill and upstream from the introduction of any additives in accordance with Tex -500-C , Part II. Label the can with the corresponding lot and sublot numbers, producer, producer facility location, grade District date sampled, all applicable bills of lading (if available), and project information, including highway and CSJ number. The Engineer will retain these samples for 1 yr. The Engineer may also obtain independent samples. If obtaining an independent asphalt binder sample and upon request of the Contractor, the Engineer will split a sample of the asphalt binder with the Contractor. 404 At least once per project, the Engineer will collect split samples of each binder grade and source used. The Engineer will submit one split sample to the Materials and Tests Division to verify compliance with Item 300, and will retain the other split sample for 1 yr. 4.9.2.3. Production Testing. Th e Contractor and Engineer must perform production tests shown in Table 12. The Contractor has the option to verify the Engineer’s test results on split samples provided by the Engineer. Determine compliance with operational tolerances shown in Table 8 for all sublots. Take immediate corrective action if the Engineer’s laboratory -molded density on any sublot is less than 95.0% or greater than 98.0% to bring the mixture within these tolerances. The Engineer may suspend operations if the Contractor’s corrective actions do not produce acceptable results. The Engineer will allow production to resume when the proposed corrective action is likely to yield acceptable results. The Engineer may allow alternate methods for determining the asphalt binder content and aggregate gradation if the aggregate mineralogy is such that Tex -236-F , Part I does not yield reliable results. Provide evidence that results from Tex-236-F , Part I are not reliable before requesting permission to use an alternate method unless otherwise directed. Use the applicable test procedure as directed if an alternate test method is allowed. Table 12 Production and Placement Testing Frequency Description Test Method Min Contractor Testing Frequency Min Engineer Testing Frequency Individual % retained on #8 sieve and larger Tex-200-F or Tex-236-F 1 per sublot 1 per 12 sublots Individual % retained on sieves smaller than #8 and larger than #200 % passing the #200 sieve Laboratory -molded density Tex-207-F – 1 per sublot Laboratory -molded bulk -specific gravity VMA Tex-204-F Moisture content Tex-212-F, Part II When directed Theoretical maximum specific (Rice) gravity Tex-227-F, Part II – 1 per sublot Asphalt binder content1 Tex-236-F, Part I 1 per sublot 1 per lot Overlay test2 Tex-248-F – 1 per project Hamburg wheel test Tex-242-F – 1 per project Thermal profile Tex-244-F 1 per sublot3 1 per project Asphalt binder sampling and testing4,5 Tex-500-C, Part II – 1 per project Tack coat sampling and testing Tex-500-C, Part III – Boil test6 Tex-530-C 1 per sublot Water flow test7 Tex-246-F 1 per sublot Methylene blue test8 Tex-252-F – 1. May be obtained from asphalt mass flow meter readouts as determined by the Engineer. 2. Use a laboratory listed on the Overlay MPL to test a sample obtained from Lot 2 or higher . 3. To be performed in the presence of the Engineer when not using the thermal imaging system, unless otherwise approved. 4. Sampling witnessed by the Engineer. The Engineer will retain these samples for 1 yr. 5. Testing performed by the Materials and Tests Division or designated laboratory. 6. When shown on the plans. 7. To be performed in the presence of the Engineer, unless otherwise directed. 8. Testing performed by the Materials and Tests Division for informational purposes only. 4.9.2.4. Operational Tolerances. Control the production process within the operational tolerances in accordance with Table 8. When production is suspended, the Engineer will allow production to resume when test results or other information indicates the next mixture produced will be within the operational tolerances. 4.9.2.4.1. Gradation . Suspend operation and take corrective action if any aggregate is retained on the maximum sieve size shown in Table 6. A sublot is defined as out of tolerance if either the Engineer’s or the Contractor’s test results are out of operational tolerance. Suspend production when test results for gradation exceed the operational tolerances shown in Table 8 for three consecutive sublots on the same sieve or four consecutive sublots on any sieve, unless otherwise directed. The consecutive sublots may be from more than one lot. 405 4.9.2.4.2. Asphalt Binder Content . A sublot is defined as out of operational tolerance if either the Engineer’s or the Contractor’s test results exceed the values in accordance with Table 8. Suspend production when two or more sublots within a lot are out of operational tolerance or below the minimum asphalt binder content shown in Table 6 unless otherwise directed. Suspend production and shipment of mixture if the Engineer’s or Contractor’s asphalt binder content deviates from the current JMF by more than 0.5% for any sublot or is less than the minimum asphalt content allowed shown in Table 6. 4.9.2.4.3. VMA . The Engineer will determine the VMA for every sublot. For sublots when the Engineer does not determine asphalt binder content, the Engineer will use the asphalt binder content results from QC testing performed by the Contractor to determine VMA. Take immediate corrective action if the VMA value for any sublot is less than the minimum VMA requirement for production shown in Table 6. Suspend production and shipment of the mixture if the Engineer’s VMA results on two consecutive sublots are below the minimum VMA requirement for production shown in Table 6. Suspend production and shipment of the mixture if the Engineer’s VMA result is more than 0.5% below the minimum VMA requirement for production shown in Table 6. In addition to suspending production, the Engineer may require removal and replacement or may allow the sublot to be left in place without payment. 4.9.2.4.4. Hamburg Wheel Test . The Engineer may perform a Hamburg wheel test on plant -produced mixture at any time during production. Suspend production until further Hamburg wheel tests meet the specified values when the production samples fail the Hamburg wheel test criteria shown in Table 7. The Engineer may require up to the entire sublot of any mixture failing the Hamburg wheel test to be removed and replaced at the Contractor’s expense. If the Department -approved laboratory’s Hamburg wheel test on plant -produced mixture results in a “rem ove and replace” condition, the Contractor may request that the Materials and Tests Division determine the final disposition of the material in question by re- testing the failing material. 4.9.2.5. Individual Loads of Hot Mix . The Engineer may reject individual truckloads of hot mix. When a load of hot mix is rejected for reasons other than temperature, contamination, or excessive uncoated particles, the Contractor may request that the rejected load be tested. Make this request within 4 hr. of rejection. The Engineer will sample and test the mixture. If test results are within the operational tolerances shown in Table 8, payment will be made for the load. If test results are not within operational tolerances, no payment will be made for the load.

4.9.3 Placement Acceptance.

4.9.3.1. Placement Lot . A placement lot consists of four placement sublots. A placement sublot consists of the area placed during a production sublot. 4.9.3.2. Miscellaneous Areas. Miscellaneous areas include areas that typically involve significant handwork or discontinuous paving operations, such as driveways, mailbox turnouts, crossovers, gores, pavement repair sections less than 300 ft. The specified layer thickness is based on the rate of 110–115 lb. per square yard for each inch of pavement, unless another rate is shown on the plans. Miscellaneous areas are not subject to thermal profiles or water flow testing. 4.9.3.3. Recovered Asphalt Dynamic Shear Rheometer (DSR). The Engineer may take production samples or cores from suspect areas of the project to determine recovered asphalt properties. Asphalt binders with an aging ratio greater than 3.5 do not meet the requirements for recovered asphalt properties and may be deemed defective when tested and evaluated by the Materials and Tests Division. The aging ratio is the DSR value of the extracted binder divided by the DSR value of the original unaged binder. Obtain DSR values in accordance with AASHTO T 315 at the specified high-temperature performance grade of the asphalt. The Engineer may require removal and replacement of the defective material at the Contractor’s expense. The asphalt binder will be recovered for testing from production samples or cores in accordance with Tex -211-F . 406 4.9.3.4. Irregularities. Identify and correct irregularities, including segregation, rutting, raveling, flushing, fat spots, mat slippage, irregular color, irregular texture, roller marks, tears, gouges, streaks, uncoated aggregate particles, or broken aggregate particles. The Engineer may also identify irregularities, and in such cases, the Engineer will promptly notify the Contractor. The Engineer may require the Contractor to remove and replace (at the Contractor’s expense) areas of the pavement that contain irregularities if the Engineer determines that the irregularity will adversely affect pavement performance. The Engineer may also require the Contractor to remove and replace (at the Contractor’s expense) areas where the mixture does not bond to the existing pavement. The Engineer may require the Contractor to immediately suspend operations if irregularities are detected or may allow the Contractor to continue operations for no more than 1 day while the Contractor is taking appropriate corrective action.

4.9.4 Ride Quality. Measure ride quality in accordance with Item 585, “Ride Quality for Pavement Surfaces,” unless otherwise shown on the plans.

5.1 TOM HMA . TOM hot mix will be measured by the ton of composite mixture, which includes asphalt,

aggregate, and additives. Measure the weight on scales in accordance with Item 520.

5.2 Tack Coat . Tack coat will be measured at the applied temperature by strapping the tank before and after

road application and determining the net volume in gallons from the calibrated distributor. The Engineer will witness all strapping operations for volume determination. All tack, including emulsions, will be measured by the gallon applied. The Engineer may allow the use of a metering device to determine asphalt volume used and application rate if the device is accurate within 1.5% of the strapped volume.