VTrans Section 406: Bituminous Concrete Pavement

406

4-11SECTIO N 406 – BITUMINOUS CONCRET E PAVEMENT

406.0 1 DESCRIPTION . This work shall consist of constructing one or more courses of Superpave bituminous concrete pavement on a prepared foundation in accordance with these specifications and in conformance with the lines, grades, thicknesses, and typical cross -sections shown on the Plans or established by the Engineer. The Agency will accept this work under quality assurance provisions, in accordance with these specifications and the provisions of AASHTO M 323 except where otherwise noted in Section 702 , Section 704, Section 716 , and the Agency’s Bitumi nous Concrete Policy Manual . 406.0 2 MATERIALS . Materials shall meet the requirements of the following subsections: Performance -Graded Asphalt Binder ................................ ................................ ......... 702.01 Emulsified Asphalt ................................ ................................ ................................ .....702.02 Warm -Mix Asphalt Technologies ................................ ................................ .............. 702.03 Anti-Strip Additives ................................ ................................ ................................ ...702.04 Aggregate for Bituminous Concrete Mixtures ................................ ........................... 704.10 Recycled Asphalt Materials ................................ ................................ ....................... 704.2 2 General Bituminous Concrete Mixture Design Requirements ................................ ..716.02(a) Superpave Mixtures ................................ ................................ ................................ ...716.02(b) Bituminous Mixing Plant and Laboratory ................................ ................................ .716.03 Preparing and Mixing Bituminous Concrete Mixtures ................................ .............. 716.04 406.0 3 AGENC Y MATERIA L EVALUATION . Material evaluation and acceptance by the Agency will follow the procedures outlined in this subsection for the applicable quality assurance tier and Contract item. Acceptance sampling of bituminous materials by the Agency will be on a statistically random basis in accordance with the specified requirements, and the material will be evaluated for acceptance based on the results of these tests. Contractor quality control samples will not be used to evaluate, accept, reject, or determine pay factors for any material. Material may be sampled at either the production facility or on the project site and may be tested at either the production facility ’s qualified laboratory or at the Agency’s Mate rials Testing and Certification Section Central Laboratory .

(a)General Requirements .

(1)Control of the Mixture . The actual mixture produced shall not vary from the job mix

formula target values by more than production tolerances specified in Table 406.03A . For the purposes of verification sampling, the tolerances in Table 406.03A will be considered the specificati on limits for an individual sample. Continued production outside these ranges will be grounds to halt production and revoke the mix design.

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4-12TABLE 406.03A – MIXTURE PRODUCTION TOLERANCES FOR ALL QA TIERS

Material Property Lower Mixture Tolerance Upper Mix ture Tolerance Coarse aggregate, percent passing the No. 4 (4.75 mm) or larger sieves (dry sieve) JMF – 6% JMF + 6% Fine aggregate, percent passing the No. 8 (2.36 mm) sieve through the No. 100 (0.150 mm) sieve (dry sieve) JMF – 4% JMF + 4% Fines , percent passing the No. 200 (0.075 mm) sieve (dry sieve) JMF – 1% JMF + 1% Mixture temperature 1 JMF – 20°F JMF + 20°F Air voids JMF – 1.0% JMF + 1.0% Dust proportion ( Type IS and Type IIS ) 0.50 1.20 Dust proportion ( Type IIIS , Type IVS , and Type IVSB ) 0.50 1.00 Voids in mineral aggregate JMF – 1.0% JMF + 1.0% Asphalt binder content JMF – 0.4% JMF + 0.4% 1 The m ixture temperatures shall not exceed 355°F.

(2)Quality Assurance Tiers . The Agency will use a tiered approach to evaluate bituminous

concrete material . The applicable QA tier for each mix type will be as specified on the Plans. If not specified on the Plans, the QA tier shall be based on the quantity of each mix type as specified in Table 406.03B . The Contract ma y specify mix produced under more than one QA tier, based on quantity. Sampling, testing, and evaluation by the Agency for the Contract will be in accordance with the criteria specified for each QA tier. Bituminous concrete pavement surface preparation an d non -paver placed bituminous concrete pavement paid separately are not subject to the requirements of any QA tier. TABLE 406.03B – QUALITY ASSURANCE TIER BY QUANTITY OF MIX Quality Assurance Tier Contract Quantity (Q) of Mix Type (tons) QA Tier I Q ≥ 3,000 QA Tier II 3,000 > Q ≥ 1,500 QA Tier III Q < 1,500

406 4-13 (3) Lots and Sublots . Sampling will be conducted using stratified random sampling on a lot and sublot basis for the applicable QA tiers. Standard lot and sublot sizes are specified for each QA tier and criteria. Adjustments to the lot and sublot size may be made by the Engineer. If the number of sublots in the final resultant partial lot is greater than or equal to the minimum number specified in the applicable table, then the final resultant partial lot will be processed as a full lot. If the number of sublots is less than the specified minimum, then the final resultant partial lot will be combined with the previous lot. The final sublot of a partial lot will consist of the quantity of material required to complete the partial lot.

(4)Evaluation Methods . Material produced u nder this specification will be sampled and tested

in accordance with the requirements of the applicable QA tier. The Agency will evaluate compliance based on the methods below.

a.Percent Within Limits Method . Detailed documentation on the PWL method is

available in the Agency’s Bituminous Concrete Policy Manual . Properties which are to be evaluated using the PWL method will be sampled once per sublot. The PWL for the lot will then be calculated from those sublot test results to determine if the lot of material is in compliance with the specification requirements.

b.Single Test Departure Method . The single test departure (STD) method is a

procedure that uses individual test results to determine the magnitude of departure from the specification limits. Properties which are to be evaluated using the STD method will be sampled once per lot. The test result from that one sample will be evaluated independentl y of all other samples to determine if the lot of material is in compliance with the specification requirements. The departure will be calculated using the equation below . 𝐷=1−|𝑇𝑅−𝐽𝑀𝐹 | where: D = Single test departure of the sample TR = Sample test result JMF = Job mix formula target value

406 4-14 c. Average Method . The average method is a procedure for estimating the overall compliance with a specification based on the average value of a property. The average value of the property for the entire lot will be used to evaluate the quality of the material.

(5)Types of Criteria . Every material property identified for each QA tier has been designated

as being an acceptance or quality criteria. These criteria will be used by the Agency as descri bed below.

a.Acceptance Criteria . Acceptance criteria will be used to determine the acceptability

of an entire lot of material. The material will be evaluated following the completion of the lot. No consideration will be given to results from adjacent lots, and sublots will not be conside red independently. The Engineer will evaluate all designated acceptance criteria separately and determine whether the material is compliant or non -compliant with each criterion. If the PWL or STD, as applicable, equals or exceeds the rejectable quality level (RQL), the material will be deemed compliant. If the PWL or STD is less than the RQL, the material will be deemed non -compliant. If the material is compliant with each and every designated acceptance criteria, then the lot will be deemed acc eptable material as described in Subsection 406.03(a)( 6)a. If the material is non -compliant with one or more designated acceptance criteria, then the lot will be deemed rejectable material as described in Subsection

406.03(a)( 6)b

b.Quality Criteria . Quality criteria will be used to determine closeness to the desired

target of an entire lot of material. This is only applicable to material which has already been accepted based on the designated acceptance criteria. Material will not be accepted or rejected based on quality criteria. The material will be evaluated following the completion of the lot. The Engineer will calculate pay factors for the material, as described under the appropriate QA tier. These pay factors may be positive, negative, or zero, depe nding on the quality of the material.

406 4-15 (6) Materials Acceptance . As described in Subsection 406.03(a)( 5)a., every lot will be evaluated and deemed to be either acceptable or rejectable material. Acceptable and rejectable material will be dealt with as specified below.

a.Acceptable Material . If a lot of material is deemed compliant with every acceptance

criteria , then the entire lot will be accepted by the Agency and paid for at the Contract unit price, unless otherwise directed by the Engineer. Following acceptance, the Engineer will calculate pay factors for the material, as described under the appropriate QA tier. These pay factors may be positive, negative, or zero, depending on the quality of the material.

b.Rejectable Material . If a lot of material is deemed non -compliant with one or more

acceptance criteria , then the entire lot will be rejected by the Agency and shall be removed and replaced with new material at no expense to the Agency, unless otherwise directed by the Engineer. No pay factors w ill be applied to rejected material. Any such new material will be sampled, tested, and evaluated for acceptance. Should the Engineer allow rejectable material to remain in place, it shall receive no positive pay adjustments.

c.Dispute Resolution . For ma terial deemed rejectable, the Agency’s Quality

Assurance Program will outline the applicable dispute resolution practices. At the time of collecting an acceptance sample, the Contractor may take loose mix replicate samples for the purposes of dispute resolution. Replicate sampling of cores will not be permitted.

(7)Removal of Defective Material by the Contractor . With the approval of the Engineer, the

Contractor may elect to remove any defective material and replace it with new material at no expense to the Agency. Any such new material will be sampled, tested, and evaluated for acceptance.

(8)Pay Factors . The pay factors which apply to material produced under each QA tier will be

as specified in this section. The se pay factors will only be applied to material which has been accepted by the Agency.

(9)Rounding and Reporting of Values . Results from all calculations shall be rounded and

reported as specified below:

a.All pay factors will be reported to 0.0001 and all pay adjustments to 0.01. For

intermediate calculations used to obtain pay factors and pay adjustments values shall retain the maximum available precision.

406 4-16 b. The use of ASTM E29 rounding will not be per mitted. Instead, when rounding, if the first digit to the right of the number to be rounded is greater than or equal to 5, then the number will be rounded away from zero to the next number with larger magnitude. If the digit to the right of the number to b e rounded is less than 5, then the number will remain the same.

For example, for rounding to the nearest one decimal (0.1):

5.35 rounds to 5.4 -5.35 rounds to -5.4

5.34 rounds to 5.3 -5.34 rounds to -5.3

(b)Quality Assurance Tier I. For evaluating mixtures produced under QA Tier I, the criteria specified

in Table 406.03D will apply. Lots and sublots will be established as specified in Subsection

(a)(3) and Table 406.03C

(1)Material Evaluation. Evaluation of the material will follow the procedures described in

Subsection 406.03(a)(4), and acceptance will follow the procedures described in

Subsection 406.03(a)(5) and Subsection 406.03(a)(6).

At the Engineer’s discretion, low production activities, defined as a daily production of

300 tons or less, that would otherwise be evaluated for air voids using the PWL method

will be excluded from the PWL lot, and instead evaluated using the STD method with an

RQL of -1 and an AQL of 0.

(2)Pay Factors. When they are included in the Contract, the following pay factors will apply

to all accepted material in this tier, except as noted below:

a.Mixture Properties Pay Factor (PFMP). This pay factor will be calculated based on

air voids.

b.Mat Density Pay Factor (PFMD). This pay factor will not apply to material used for

shoulders paved separately, leveling courses, side roads, or drives.

c.Longitudinal Joint Density Pay Factor (PFJD). This pay factor will not apply to

material used for leveling courses, side roads, or drives.

d.Pavement Roughness Pay Factor (PFPR). This pay factor only applies to the wearing

course.

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TABLE 406.03C – QUALITY ASSURANCE TIER I LOT AND SUBLOT SIZES

Property Lot Size Max.

Sublot Size

Min. No.

of Sublots

Air voids 3,000 tons 500 tons 4

Mat density Daily production

for each course 0.5 miles 6

Longitudinal joint density Entire project for

each course 0.5 miles 4

Pavement roughness on

limited access highways

Entire project

wearing course N/A N/A

Pavement roughness on non-

limited access highways

Entire project

wearing course N/A N/A

TABLE 406.03D – QUALITY ASSURANCE TIER I CRITERIA

Property Evaluation

Method

Type of

Criteria LSL USL RQL AQL

Air voids PWL Acceptance JMF – 1.0% JMF + 1.0% 50% 90%

Mat density PWL Acceptance 92% 97% 50% 90%

Longitudinal joint density PWL Quality 90% N/A N/A 75%

Pavement roughness on

limited access highways Average Quality N/A N/A N/A 48 in./mile

Pavement roughness on non-

limited access highways Average Quality N/A N/A N/A 58 in./mile

(c)Quality Assurance Tier II. For evaluating mixtures produced under QA Tier II, the criteria

specified in Table 406.03F will apply. Lots and sublots will be established as specified in

Subsection 406.03(a)(3) and Table 406.03E.

(1)Material Evaluation. Evaluation of the material will follow the procedures described in

Subsection 406.03(a)(4), and acceptance will follow the procedures described in

Subsection 406.03(a)(5) and Subsection 406.03(a)(6).

At the Engineer’s discretion, low production activities, defined as a daily production of

300 tons or less, that would otherwise be evaluated for air voids using the PWL method

will be excluded from the PWL lot, and instead evaluated using the STD method with an

RQL of -1 and an AQL of 0.

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(2)Pay Factors. When they are included in the Contract, the following pay factors will apply

to all accepted material in this tier, except as noted below:

a.Mixture Properties Pay Factor (PFMP). This pay factor will be calculated based on

air voids.

b.Mat Density Pay Factor (PFMD). This pay factor will not apply to material used for

shoulders paved separately, leveling courses, side roads, or drives.

c.Pavement Roughness Pay Factor (PFPR). This pay factor only applies to the wearing

course.

TABLE 406.03E – QUALITY ASSURANCE TIER II LOT AND SUBLOT SIZES

Property Lot Size Max.

Sublot Size

Min. No.

of Sublots

Air voids Entire project 500 tons 3

Mat density Entire project

for each course 0.1 miles 3

Pavement roughness on

limited access highways

Entire project

wearing course N/A N/A

Pavement roughness on non-

limited access highways

Entire project

wearing course N/A N/A

TABLE 406.03F – QUALITY ASSURANCE TIER II CRITERIA

Property Evaluation

Method

Type of

Criteria LSL USL RQL AQL

Air voids PWL Acceptance JMF – 1.0% JMF + 1.0% 50% 80%

Mat density PWL Acceptance 91% N/A 50% 80%

Pavement roughness on

limited access highways Average Quality N/A N/A N/A 48 in./mile

Pavement roughness on non-

limited access highways Average Quality N/A N/A N/A 58 in./mile

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(d)Quality Assurance Tier III. For evaluating mixtures produced under QA Tier III, the criteria

specified in Table 406.05H will apply. Lots and sublots will be established as specified in

Subsection 406.03(a)(3) and Table 406.03G.

(1)Material Evaluation. Evaluation of the material will follow the procedures described in

Subsection 406.03(a)(4), and acceptance will follow the procedures described in

Subsection 406.03(a)(5) and Subsection 406.03(a)(6).

(2)Pay Factors. When they are included in the Contract, the following pay factors will apply

to all accepted material in this tier, except as noted below:

a.Mixture Properties Pay Factor (PFMP). This pay factor will be calculated based on

air voids.

b.Mat Density Pay Factor (PFMD). This pay factor will not apply to material used for

leveling courses, side roads, or drives. The Engineer may elect to waive this pay

factor for other material at their discretion.

TABLE 406.03G – QUALITY ASSURANCE TIER III LOT AND SUBLOT SIZES

Property Lot Size Min. No.

of Sublots

Air voids 500 tons N/A

Mat density Entire project

for each course

TABLE 406.03H – QUALITY ASSURANCE TIER III CRITERIA

Property Evaluation

Method

Type of

Criteria LSL USL RQL AQL

Air voids STD Acceptance N/A N/A -1 0

Mat density PWL Acceptance 91% N/A 50% 80%

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406.04CONTRACTOR QUALITY CONTROL. The Contractor shall be responsible for maintaining

control of the mix production process. The mix production methods and technologies shall generally be

at the Contractor’s discretion, but will be limited to proven, Agency and industry accepted practice. Upon

approval of the Engineer and at no additional cost to the Agency, the Contractor may use innovative

equipment or techniques not included in the Specifications to produce or monitor the production or

placement of the mixture.

(a)Control of Mixtures. For all mixtures and all QA tiers, the plant shall be operated so that no

intentional deviations are made from the job mix formula. The Contractor shall provide quality

control adequate to produce work of acceptable quality. Continual production of non-conforming

work at a reduced price, in lieu of making adjustments to bring work into conformance, will not

be allowed.

The Contractor shall provide process control adequate to produce work of acceptable quality. At a

minimum, the Contractor shall perform sampling and testing at the frequencies specified in Table

A, as applicable for the mixture type. The Engineer will not sample or test for process

control or assist in controlling the Contractor’s production operations.

Control over production shall follow the control limits established for the mix design for quality

control samples. A single result outside the control limit will necessitate the Contractor take action

to control the process. Two out of three values in row that exceed the control limits will necessitate

the Contractor suspend production, as it is not in control. After suspension, a passing quality

control test from a trial drop shall be used to show the mix has been returned to in control, and

production may resume. Failure or inaction by the Contractor to maintain control over the mix

production will result in mix design suspension.

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TABLE 406.04A – QUALITY CONTROL SAMPLING AND TESTING CRITERIA

Parameter Test Method Minimum Frequency (Select

the Least Frequent)

Mixture gradation AASHTO T 30, AASHTO T 308 1 per 500 tons

Mixture temperature Verified thermometer 1 per 250 tons at plant (truck)

Mixture volumetrics (air voids, VMA, and

dust proportion)

AASHTO T 269, AASHTO T 166,

AASHTO T 209 1 per 500 tons

Asphalt binder content AASHTO T 308 1 per 500 tons

Cold feed gradation AASHTO T 27 1 per day

Cold feed percentage fractured face AASHTO T 335 st day of paving, 1 per week

or 5,000 tons

Cold feed flat and elongated particles ASTM D4791 1 per month

Fine and coarse aggregate moisture content AASHTO T 255 2 per day

Ram moisture content AASHTO T 255 2 per day

Fine aggregate, coarse aggregate, and RAM

specific gravities AASHTO T 84, AASHTO T 85 st day of paving, 1 per two

weeks or 5,000 tons

Stripping ASTM D3625 1 per week

Fractured face for crushed gravel sources only.

Flat and elongated percentage for all material retained on or above the No. 4 (4.75 mm) sieve.

For drum-mix and continuous mixing plants only.

New values will be required when the absorbed asphalt value is either zero or negative, or when requested by the

Engineer.

Stripping testing for stripping prone aggregates only. Testing will be witnessed by Agency staff.

In addition to the control limits referenced above, the Contractor shall cease production operations

whenever one or more of the following occurs:

(1)The Contractor fails to follow the approved QC plan.

(2)If the flat and elongated particles value exceeds 10% when measured by ASTM D4791.

(3)If there is any visible damage to the aggregate due to over-densification, except on variable

depth shim courses.

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The Contractor shall immediately notify the Agency in writing as to the reason for a shutdown, as

well as the proposed corrective action. The Agency will consider the corrective action successful

if the result of the trial drop quality control test for the failing property is in conformance with the

applicable requirements defined above. The Agency will consider the corrective action

unsuccessful if the result of the trial drop quality control test is not in conformance with the

applicable requirements specified above. If the corrective action is unsuccessful, the Contractor

shall cease production and submit a new corrective action plan.

(b)Contractor Quality Control Plan. For material produced and paved under all QA tiers, the

Contractor shall provide, maintain, and operate in accordance with a quality control plan for the

plant and the field, hereafter referred to as the plant QC plan and field QC plan, to ensure the

production of material that meets the Contract requirements. The Contractor shall develop and

submit program-wide QC plans annually in advance of the paving season, to document the QC

practices, personnel, facilities, and equipment to be used by the Contractor. Additionally, the

Contractor shall submit project-specific supplements to both the plant and field QC plans to

provide specific details applicable to each project. No paving shall occur until both QC plans and

their supplements have been approved for the project. Project supplements to the QC plans shall

be submitted at least 10 working days before the start of paving on the project.

(1)Plant QC Plan. Bituminous concrete mixture plants shall submit a program-wide plant QC

plan to cover all mix production, as detailed in the Agency’s Bituminous Concrete Policy

Manual. A project-specific supplement shall be submitted to apply the plant QC plan to

the project and provide specific details, including, but not limited to, the mix designs to be

used, the use of silos, changes in personnel, and other project-specific requirements.

(2)Field QC Plan. The Contractor shall submit a comprehensive program-wide field QC plan

to cover paving practices in the field, as detailed in the Agency’s Bituminous Concrete

Policy Manual. A project-specific supplement shall be submitted to apply the field QC plan

to the project and provide specific details, including, but not limited to, paving personnel

and equipment identification, QC personnel, mixing, loading, transportation, intended

paving sequence, and other project-specific requirements.

(3)Non-Compliance with the QC Plans. The Contractor shall comply with the approved QC

plans and shall take all other steps necessary to ensure a high-quality product. Failure of

the Contractor to comply with the approved QC plans may result in the Agency ordering

the Contractor to cease production or paving, revoking approval of the QC plan, or taking

other actions as necessary.

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406.05EQUIPMENT

(a)Hauling Equipment. To prevent the mixture from adhering to the beds, trucks used for hauling

bituminous mixture shall have tight, clean, and smooth metal beds which have been thinly coated

with a bond release agent. Petroleum-based products will not be permitted. Each truck shall have

a cover of canvas or other suitable material of sufficient size to extend over all sides of the haul

vehicle to properly protect the mix from the weather. When necessary, to ensure placement of

material at the specified temperature, truck beds shall be insulated and covers shall be securely

fastened.

The trucks used for hauling bituminous mixture shall be compatible with the equipment used for

placing the bituminous mixture.

Trucks shall not be cleaned or emptied on surfaces to be paved.

(b)Placing Equipment. The bituminous concrete paver shall be a self-propelled unit with an activated

screed or strike-off assembly capable of being heated if necessary and capable of spreading the

mixture without segregation for the widths and thicknesses required. The screed shall be adjustable

to provide the desired cross-sectional shape.

Pavers shall be in good mechanical condition, equipped with all necessary attachments, and

designed to operate electronically for controlling the grade of the finished surface. Additionally,

pavers shall be equipped such that, upon extension of the screed by 24 inches or more, auger

extensions shall be used, as directed by the Engineer. The adjustments and attachments of the paver

shall be checked and approved by the Engineer before placement of bituminous material.

Bituminous concrete pavers shall be equipped with a sloped plate to produce a tapered or notched

tapered edge at longitudinal joints. The sloped plate shall produce a tapered or notched tapered

edge having a face slope of 1:3 (V:H) or flatter. The plate shall be able to accommodate compacted

mat thicknesses from 1-1/4 inches to 4 inches. The bottom of the sloped plate shall be mounted

3/8 inch to 1/2 inch above the existing pavement.

Joint heaters, if used, shall be equipped with automated controls which will shut off the burners

when the paving machine stops and reignite them when the paver begins moving forward. The

joint heater shall heat the entire area of the previously placed wedge to the required temperature.

Heating to the point of 200°F or higher shall immediately precede placement of the bituminous

material.

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(c)Compaction Equipment. Rollers shall be in good mechanical condition, capable of reversing

without backlash, and operated at speeds slow enough to avoid displacement of the bituminous

mixture. The weight of the rollers shall be sufficient to compact the mixture to the required density

without crushing the aggregate. Rollers shall be equipped with tanks and sprinkling bars for

wetting the rollers or tires.

Pneumatic-tired rollers shall be equipped with appropriate skirts and shall be preheated prior to

use in order to avoid picking. The Contractor shall repair and remove all picked material from the

surface.

Vibratory rollers shall have separate controls for energy and propulsion. They shall be equipped

with automatic cutoffs that stop the vibration prior to the roller stopping or reversing its direction

of travel. The Contractor assumes full responsibility for, and shall repair at their expense, all

damage which may occur to highway components or adjacent property if vibratory compaction

equipment is used.

406.06TRAFFIC CONTROL. Traffic shall be maintained in accordance with Subsection 104.04 and

flaggers in accordance with Section 630 shall be stationed at each end of the section being paved and at

such other locations as may be required by the Engineer.

406.07WEATHER AND SEASONAL LIMITATIONS. Bituminous material shall not be placed on a

wet or frozen surface, or when weather or other conditions would prevent the proper handling, finishing,

or compacting of the material, unless otherwise approved by the Engineer.

(a)Temperature Limitations. Bituminous material shall not be placed unless both the ambient air

temperature, and the temperature of the existing surface at the paving site in the shade and away

from artificial heat, are greater than that specified in Table 406.07A.

TABLE 406.07A – MINIMUM TEMPERATURES REQUIRED FOR PAVING

Compacted Lift

Thickness (T)

Min. Temp. for

Mixes without

WMA Technologies

Min. Temp. for

Mixes with WMA

Technologies

T ≥ 1.25 inches 40°F 35°F

T < 1.25 inches 50°F 35°F

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(b)Seasonal Limitations. For the purpose of paving operations, including placement of temporary

pavements, the year shall be divided into in-season and extended season paving. The dates of these

seasons shall be as defined in Table 406.07B.

TABLE 406.07B – IN-SEASON AND EXTENDED-SEASON PAVING DATES

Type of Pavement Course In-Season Paving Dates

(Inclusive of End Dates)

Extended Season Paving Dates

(Inclusive of End Dates)

Temporary, leveling,

bottom, or intermediate May 1 st to October 31 st November 1 st to April 30 th

Wearing May 16 th to October 15 th October 16 th to May 15 th

(c)Extended-Season Paving Plan. Should paving operations be scheduled during the extended season,

the Contractor shall submit an extended season paving plan 14 calendar days prior to paving within

the extended season. Paving within the extended season shall not commence until the Engineer

has approved the plan. The Contractor shall operate in accordance with the plan in order to ensure

that the product meets the Contract requirements.

If the Contractor fails to follow the extended season paving plan, paving operations shall cease,

and the Contractor shall modify operations to comply with the extended season paving plan. All

process modifications shall be communicated to the Engineer. Paving operations shall only resume

once the Engineer has approved all modifications.

An extended season pre-paving meeting shall be conducted at least 5 calendar days prior to paving

within the extended season, and shall include the Agency, Contractor, producer, and other

stakeholders as necessary. The extended season paving plan shall include, but not be limited to,

the following:

(1)General Requirements.

a.Minimum mixing and delivery mixture temperatures. Details on the use of WMA

technologies or other additives to enhance workability shall be provided.

b.Calculations providing a balanced paving operation. The anticipated paver speed

shall be specified.

c.A plan for an enhanced rolling pattern. The enhanced rolling pattern shall be

established by a QC technician during the first shift of paving within the extended

season.

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d.Methods for determining the time available for compaction. The time available

shall be determined and reported to the Engineer on a daily basis to confirm that

compaction has been completed within the time available.

e.The sequence of paving for remaining placement.

f.A description of the level of staffing and additional equipment necessary to ensure

paving and rolling operations can proceed without delay and achieve the desired

compaction in a shorter timeframe.

(2)Schedule of Extended-Season Items.

a.The scope of remaining paving, including number of shifts and project limits to be

completed.

b.Information about the application of retroreflective pavement markings.

Retroreflective pavement markings shall be monitored and maintained throughout

the extended season.

c.A schedule of adjacent work items to be completed.

406.08CONDITIONING OF EXISTING SURFACE. All surfaces shall be cleaned and sprayed with an

emulsified asphalt tack coat in accordance with Subsection 404.06(b) before placing of any bituminous

mixture, unless otherwise ordered by the Engineer.

Prior to paving any mainline or drive surfaces, the existing bituminous concrete pavement surface shall

be prepared as shown on the Plans and as directed by the Engineer. Bituminous concrete pavement surface

preparation shall consist of performing all necessary surface preparation, including pothole repairs,

raveling repairs, and other repairs directed by the Engineer prior to placing the final surface treatment.

Grass growing adjacent to pavement or through cracks in the pavement which may hinder the placement

of new bituminous concrete shall be removed by the Contractor as directed by the Engineer.

Where deficiencies in any full depth reclamation, recycled bituminous pavement, or subbase exist,

bituminous concrete mixtures approved by the Engineer shall be used to correct them.

Where bituminous concrete pavement is used to resurface existing pavements and the existing pavement

contains irregularities, depressions, or waves, such deficiencies shall be eliminated using extra bituminous

material for spot leveling to bring the existing pavement to uniform section and grade before placing of

the required courses of bituminous concrete.

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406.09PLACING AND FINISHING

(a)General Requirements. The bituminous mixture shall be placed and finished with the specified

equipment, shall be struck off in a uniform layer to the full width required and of such depth that

each course, when compacted, shall have the required thickness, and shall conform to the grade

and elevation specified. The finished surface shall be of uniform texture and evenness and shall

not show tearing, shoving, or pulling of the mixture.

In areas where irregularities or unavoidable obstacles make the use of mechanical placing and

finishing equipment impracticable, the mixture shall be spread, raked, luted, and compacted by

hand methods.

At the time of placement, the bituminous mixture shall be within 10°F of the compaction

temperature for the approved mix design. No traffic will be permitted on placed material until the

material has been thoroughly compacted and has cooled to 140°F unless otherwise authorized by

the Engineer. The use of water to cool the pavement will not be permitted.

The Contractor shall protect all exposed surfaces and objects which are not to be treated from

damage during all phases of the paving operation.

All material shall be produced early enough in the work day such that the completion of placing

and compaction of the mixture will occur during daylight hours, unless night work is allowed for

the project.

Mainline temporary transverse tapers shall have a minimum slope rate of 1 inch per 5 feet for

speeds of 40 mph and lower, and a minimum slope rate of 1 inch per 10 feet for speeds greater

than 40 mph.

A load ticket shall accompany each vehicle supplying bituminous concrete and shall be made

available to the Engineer prior to placement of the mixture.

(b)Driveways and Side Road Intersections. Suitable temporary aprons or fillets shall be constructed

at side road intersections and driveways as directed by the Engineer within 24 hours of adjacent

mainline paving. Reasonable access to and from the mainline mat shall be maintained at all times.

Permanent drive construction shall consist of placing one or more courses of bituminous concrete

material on a prepared foundation in conformance with the Plans, or as directed by the Engineer.

Placement of bituminous concrete material for driveways and side roads may be done with

mechanical or hand methods as specified on the Plans and as directed by the Engineer.

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All vegetation and soft, yielding, or unsuitable material shall be excavated and replaced with

properly compacted material meeting the requirements of Section 301 for Subbase of Crushed

Gravel, Fine Graded. Crushed RAP generated from the project may be substituted for Subbase of

Crushed Gravel, Fine Graded.

For drives constructed via hand method, the existing edge of pavement shall be saw-cut or trimmed

by mechanical means to provide a vertical edge for placing bituminous concrete material.

Emulsified asphalt shall be applied as specified in Subsection 404.06(b).

If cross slope allows, as determined by the Engineer, existing paved drives shall be milled across

the entire drive width to the depth of the wearing course, not to exceed 2 inches. Unless the drive

is to be paved that work day, all vertical milled edges shall have temporary fillets placed the same

work day as milling takes place.

(c)Compaction. Leveling courses shall be compacted using a self-propelled pneumatic tired roller for

intermediate rolling, unless otherwise permitted in writing by the Engineer.

Tandem paving operations shall have an independent rolling train for each paver sufficient to

achieve compaction requirements.

When bituminous concrete pavement is to be placed on a bridge deck having a waterproofing

membrane, a rubber-tired or rubber-tracked paver shall be used to place the intermediate course of

pavement. Rollers shall operate in static mode when compacting bridge deck pavements.

Non-paver placed bituminous concrete pavement shall be rolled with a minimum 1-ton mechanical

roller with steel drums, or approved equal, until compacted to the satisfaction of the Engineer.

To prevent adhesion of the mixture to the rollers, the rollers shall be kept properly moistened with

water or water mixed with very small quantities of detergent or other approved material. Excess

liquid and petroleum products will not be permitted. If rolling causes undue displacement,

cracking, tearing, or shoving, no further material will be produced for or placed on the project until

a corrective action plan is proposed by the Contractor and accepted by the Engineer.

For places not accessible to the rollers, the mixture shall be thoroughly compacted with hand

tampers, smoothing irons, or mechanical tampers coated with a non-petroleum based bond release

agent.

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During paving, the Contractor shall take daily process control cores at locations approved by the

Engineer to verify the effectiveness of the proposed rolling pattern and correlate density gauge

equipment. The Contractor shall fill the core holes, at their expense, with hot bituminous concrete

pavement at a temperature of at least 200°F on the same work day that the cores are taken. Pending

results of the investigative cores, necessary adjustments to the proposed rolling pattern and

equipment shall be made by the Contractor to achieve densities to the satisfaction of the Engineer.

In the absence of a Mat Density Pay Adjustment on any project, this provision will be the sole

criterion governing compaction requirements. The Contractor shall provide the Engineer with all

compaction QC records in a format acceptable to the Engineer at the conclusion of each day’s

paving operations.

(d)Joints. All paving operations shall be conducted such that, to the extent possible, the full width of

a travel lane will be paved in a single pass. Longitudinal construction joints within any travel lane

will not be permitted. Screed extension to cover adjacent shoulders concurrent with any travel lane

will be permitted considering the requirement for auger extensions.

Joints between old and new pavements, or between each successive day’s work, shall have a

thorough and continuous bond between the old and new mixtures. Whenever the placement

process is interrupted long enough for the mixture to attain its initial stability, the paver shall be

removed from the mat and a transverse butt joint constructed.

Transverse butt joints shall be formed by cutting the pavement in a vertical plane, at a location

approved by the Engineer, where the pavement has a true surface as determined using a

straightedge at least 16 feet long. Otherwise, the transverse butt joint may be formed by trimming

using mechanical means such that the full design depth of bituminous material is present at the

trimmed joint. The transverse joint shall be thoroughly coated with emulsified asphalt just prior to

depositing the new paving mixture.

When constructing transverse tapered joints, care shall be taken in raking out and discarding the

coarser aggregate at the low end of the taper, and in rolling the taper. The taper area shall be

thoroughly coated with emulsified asphalt just prior to the resumption of paving operations. As

the paver places new mixture on the taper area, placement shall proceed such that an evenly

graduated deposit of mixture will complement the previously made taper. Shovels may be used to

add additional mixture if necessary. The joint shall be smoothed with a rake and properly rolled,

with coarse material discarded.

Transverse joints shall not be constructed within 12 inches of transverse joints constructed in lower

courses.

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Longitudinal joints that have become cold shall be coated with emulsified asphalt before the

adjacent mat is placed. If directed by the Engineer, such joints shall be cut back to a clean vertical

edge prior to coating with the emulsion. Unless otherwise directed by the Engineer, longitudinal

joints shall be offset at least 6 inches from any joint in the lower courses of pavement.

Wherever possible, the Contractor shall locate the joints such that, when the final pavement

markings are placed, there will be a 2-inch offset between the pavement markings and parallel

joints. The Contractor shall conduct paving operations such that the paving joint between the travel

lane and adjacent shoulder will be outside of all longitudinal pavement markings.

(e)Surface Tolerance. The finished surface will be tested by the Engineer using a straightedge at least

16 feet in length at selected locations parallel with the centerline. Any variations exceeding 1/8

inch between any two contact points shall be satisfactorily eliminated. A straightedge at least 10

feet in length may be used on a vertical curve. The straightedges shall be provided by the

Contractor in accordance with Subsection 631.04.

(f)Work Adjacent to the Pavement. When the Contractor proposes to perform work adjacent to the

pavement (e.g. guardrail installation) after the wearing course has been placed, they shall submit

a pavement protection plan. This plan shall be submitted at least 7 calendar days prior to

performing any work adjacent to the pavement, and work shall not commence until the Engineer

has approved the plan.

The plan shall outline methods of protecting the pavement during each proposed operation, as well

as procedures for remediation of any damage that may occur. At a minimum, the repair shall be

the full depth of the wearing course, but shall extend beyond that to the depth of the damage as

needed. All repairs shall be performed in accordance with the applicable requirements of this

section.

Spot patching will not be allowed as a method of remediation for repeated damage, and adjacent

work that causes frequent or repeated damage will not be allowed to continue. Areas of repeated

damage shall be repaved for the full lane width and for a minimum length of 250 feet, unless

otherwise directed by the Engineer.

If the pavement is damaged, the Contractor shall immediately perform repairs as outlined in the

pavement protection plan at no cost to the Agency. When the Pavement Roughness Pay

Adjustment is included in the Contract, repaired areas will not be excluded from analysis.

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406.10MIXTURE PROPERTIES PAY ADJUSTMENT. The Mixture Properties Pay Adjustment will

be based on the Mixture Properties Pay Factor calculated using the applicable equations specified below.

(a)Mixture Properties Pay Factor Determination for QA Tier I. For QA Tier I, the Mixture Properties

Pay Factor will be calculated based on the PWL or STD for air voids using the equations below.

(1)Percent Within Limits Evaluation.

For 90% ≤ PWLAV ≤ 100%

𝑃𝐹 𝑀𝑃 = 0.0020 𝑃𝑊𝐿 𝐴𝑉 − 0.1800

For 70% ≤ PWLAV < 90%

𝑃𝐹 𝑀𝑃 = 0.0025 𝑃𝑊𝐿 𝐴𝑉 − 0.2250

For 50% ≤ PWLAV < 70%

𝑃𝐹 𝑀𝑃 = 0.0075 𝑃𝑊𝐿 𝐴𝑉 − 0.5750

where:

PWLAV = Total percent within specification limits for air voids

PFMP = Mixture Properties Pay Factor

(2)Single Test Departure Evaluation.

For DAV ≥ 0

𝑃𝐹 𝑀𝑃 = 0

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For -1 ≤ DAV < 0

𝑃𝐹 𝑀𝑃 = 0.1000 𝐷 𝐴𝑉

where:

DAV = Single test departure for air voids

PFMP = Mixture Properties Pay Factor

(b)Mixture Properties Pay Factor Determination for QA Tier II. For QA Tier II, the Mixture

Properties Pay Factor will be calculated based on the PWL or STD for air voids using the equations

below.

(1)Percent Within Limits Evaluation.

For 90% ≤ PWLAV ≤ 100%

𝑃𝐹 𝑀𝑃 = 0.0020 𝑃𝑊𝐿 𝐴𝑉 − 0.1800

For 80% ≤ PWLAV < 90%

𝑃𝐹 𝑀𝑃 = 0

For 50% ≤ PWLAV < 80%

𝑃𝐹 𝑀𝑃 = 0.0067 𝑃𝑊𝐿 𝐴𝑉 − 0.5336

where:

PWLAV = Total percent within specification limits for air voids

PFMP = Mixture Properties Pay Factor

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(2)Single Test Departure Evaluation.

For DAV ≥ 0

𝑃𝐹 𝑀𝑃 = 0

For -1 ≤ DAV < 0

𝑃𝐹 𝑀𝑃 = 0.1000 𝐷 𝐴𝑉

where:

DAV = Single test departure for air voids

PFMP = Mixture Properties Pay Factor

(c)Mixture Properties Pay Factor Determination for QA Tier III. For QA Tier III, the Mixture

Properties Pay Factor will be calculated based on the single test departure for air voids using the

equations below.

For DAV ≥ 0

𝑃𝐹 𝑀𝑃 = 0

For -1 ≤ DAV < 0

𝑃𝐹 𝑀𝑃 = 0.1000 𝐷 𝐴𝑉

where:

DAV = Single test departure for air voids

PFMP = Mixture Properties Pay Factor

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(d)Mixture Properties Pay Adjustment Determination. The Mixture Properties Pay Adjustment will

be calculated using the equation below.

𝑃𝐴 𝑀𝑃 = 𝑃𝐹 𝑀𝑃 × 𝑄 × 𝐵

where:

PAMP = Mixture Properties Pay Adjustment (dollars)

PFMP = Mixture Properties Pay Factor

Q = Quantity of material (tons)

B = Contract bid price (dollars/ton)

The quantity of material (Q) will be the number of tons compacted in place for each lot. This

quantity will include all material used for shoulders, leveling courses, side roads, drives, and any

other miscellaneous mix.

406.11MAT DENSITY PAY ADJUSTMENT

(a)Mat Density Analysis Procedure. Each course of bituminous concrete pavement, excluding

leveling courses, placed on projects that contain the pay item for Mat Density Pay Adjustment will

be analyzed for density according to the procedures specified in this subsection and the

requirements of Subsection 406.03 for the applicable QA tier. If the Agency elects to not take cores

of any lot of material, the Mat Density Pay Factor (PFMD) for that lot will be set equal to zero.

Acceptance testing will be conducted by Agency personnel using cores provided by the Contractor

in accordance with the coring protocol below.

(b)Coring Protocol.

(1)Selecting Core Locations. Original core sampling locations will be determined by the

Engineer and will be restricted to travel lanes only. Cores will not be taken within 6 inches

of a longitudinal joint or within 50 feet of a transverse joint, except on bridges. Bridge

decks or approaches will not be cored within 10 feet of a bridge joint or transverse joint,

and bridges less than or equal to 20 feet in length will not be cored. Independent shoulder

and mat area core sampling locations may be selected by the Engineer to afford verification

as specified in Subsection 406.11(c).

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Original core sampling locations will be selected by the Engineer in accordance with ASTM

D3665 within 2 working days of the bituminous mixture being placed. The Contractor will

be advised in writing of the selected sampling locations.

The Contractor may challenge whether any specific original sample location is

representative of any specific lot by notifying the Engineer. This notification shall be made

immediately upon the core locations being selected and conveyed to the Contractor, and

prior to extracting the cores, and shall be further documented in any Contractor job records

citing just reasoning for recommending a reselection of original sample locations.

Upon receipt by the Engineer of a written challenge from the Contractor, the Engineer will

evaluate it within 1 working day and notify the Contractor in writing of either acceptance

or rejection of the challenge. Rejection of a challenge will result in the Engineer using the

original core sampling locations for the determination of density data in any compaction

pay factor calculations. Acceptance of a challenge will result in the Engineer selecting

alternate core sampling locations for those challenged samples.

Alternate core sampling locations will be selected by the Engineer by generating new

random numbers to determine both new longitudinal and transverse coordinates within the

sublot in question. The alternate core sampling locations will not be subject to further

challenge and will be used for the determination of density data in any compaction pay

factor calculations. The Contractor will be notified in writing of the final core sampling

locations.

(2)Taking and Delivering Cores. Core samples 6-inches in diameter shall be taken within one

working day of the final selection of the core sampling locations. The Contractor shall

extract cores in the presence of the Engineer and shall deliver the samples to the Engineer,

in a suitable container provided by the Contractor, on the same work day the samples are

taken. As necessary, the Contractor shall mark the cores for saw-cutting in the presence of

the Engineer for verification of cut locations. The Engineer will identify and record the

core samples. Agency personnel will process the core samples within 10 working days and

will relay the test results to both the Engineer and the Contractor.

Physical core samples will be retained for a period of 2 working days from the time that

the density test results are relayed to the Engineer and Contractor. In addition, any

subsequently retested or re-cored samples, as defined in Subsection 406.11(c), will be

retained to the point of fully satisfying the requirements of Subsection 406.11(c).

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Any cores not delivered in a suitable container will be rejected and new cores taken at the

Contractor’s expense. The Contractor shall fill the core holes, at their expense, with hot

bituminous concrete pavement at a temperature of at least 200°F on the same work day that

the cores are taken. Failure to comply with these provisions may result in payment being

withheld for the representative lot of bituminous material.

(3)Calculating Mat Density. The density of each core will be calculated using the following

formula.

𝐷 = 100 × 𝐺 𝑚𝑏

𝐺 𝑚𝑚

where:

D = Density (percent of maximum)

Gmb = Bulk specific gravity of compacted mixture

Gmm = Maximum specific gravity of the uncompacted mixture

Bulk specific gravity will be determined in accordance with AASHTO T 166, Method A,

and maximum specific gravity will be determined in accordance with AASHTO T 209, from

Agency acceptance tests. Should the sample absorb more than 2% of water by volume

when tested with AASHTO T 166, it will be retested in accordance with AASHTO T 331,

and the retested result will replace the original outlier sample results. Should the sample be

considered an outlier in accordance with ASTM E178, Table 1 at a 5% significance level,

it will be retested in accordance with AASHTO T 331, and the retested result will replace

the original outlier sample results.

(c)Core Result Verification. For any individual core considered to be an outlier, as determined in

accordance with ASTM E178, Table 1 at a 5% significance level, the Contractor or Agency may

elect to re-core, to verify the original core result. The re-coring location shall be at the same

transverse offset as the original location and shall be offset longitudinally forward 18 inches from

the original location. The re-cored sample test result will replace the original core result and shall

not cause any other core test result to become an outlier core subject to core result verification.

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(d)Mat Density Pay Factor Determination for QA Tier I. For QA Tier I, the Mat Density Pay Factor

for each lot of bituminous concrete pavement will be determined using the equations below.

For 90% ≤ PWLMD ≤ 100%

𝑃𝐹 𝑀𝐷 = 0.0030 𝑃𝑊𝐿 𝑀𝐷 − 0.2700

For 70% ≤ PWLMD < 90%

𝑃𝐹 𝑀𝐷 = 0.0050 𝑃𝑊𝐿 𝑀𝐷 − 0.4500

For 50% ≤ PWLMD < 70%

𝑃𝐹 𝑀𝐷 = 0.0100 𝑃𝑊𝐿 𝑀𝐷 − 0.8000

where:

PWLMD = Total percent within specification limits for mat density

PFMD = Mat Density Pay Factor

(e)Mat Density Pay Factor Determination for QA Tier II and QA Tier III. For QA Tier II and QA

Tier III, the Mat Density Pay Factor for each lot of bituminous concrete pavement will be

determined using the equations below.

For 80% ≤ PWLMD ≤ 100%

𝑃𝐹 𝑀𝐷 = 0.00150 𝑃𝑊𝐿 𝑀𝐷 − 0.1200

For 50% ≤ PWLMD < 80%

𝑃𝐹 𝑀𝐷 = 0.0050 𝑃𝑊𝐿 𝑀𝐷 − 0.4000

where:

PWLMD = Total percent within specification limits for mat density

PFMD = Mat Density Pay Factor

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(f)Mat Density Pay Adjustment Determination. The Mat Density Pay Adjustment will be calculated

using the following equation.

𝑃𝐴 𝑀𝐷 = 𝑃𝐹 𝑀𝐷 × 𝑄 × 𝐵

where:

PAMD = Mat Density Pay Adjustment (dollars)

PFMD = Mat Density Pay Factor

Q = Quantity of material (tons)

B = Contract bid price (dollars/ton)

The quantity of material (Q) will be the number of tons compacted in place for each lot. This

quantity will exclude all material used for shoulders paved separately from mainline, leveling

courses, side roads, and drives.

406.12LONGITUDINAL JOINT DENSITY PAY ADJUSTMENT

(a)General Requirements. For each course of bituminous concrete pavement, excluding leveling

courses, placed on projects that contain the pay item for Longitudinal Density Pay Adjustment, the

longitudinal joints will be analyzed for density according to the procedures specified in this

subsection and the requirements of Subsection 406.03 for the applicable QA tier. If the Agency

elects to not take cores of any portion of the material, that material will be excluded from the lot

and not subject to the Longitudinal Joint Density Pay Factor (PFJD).

Acceptance testing will be conducted by Agency personnel using cores provided by the Contractor

in accordance with the coring protocol below.

(b)Coring Protocol.

(1)Selecting Core Locations. Core sampling locations will be determined by the Engineer.

Joint core samples shall be taken between any adjacent travel lanes and between any travel

lane and shoulder, provided that the shoulder material was placed as a separate construction

operation. Cores will not be taken within 50 feet of a transverse joint, except on bridges.

Bridge decks or approaches will not be cored within 10 feet of a bridge joint or transverse

joint, and bridges less than or equal to 20 feet in length will not be cored.

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Sampling locations will be selected using a stratified random sampling procedure in the

longitudinal direction. The total project joint length will be subdivided into segments of

the length specified for the applicable QA tier, and one sample (core) taken from each

segment. The sampling location within each segment will be determined using ASTM

D3665. For a longitudinal butt joint, the transverse location of the sample shall be centered

on the visible surface joint line. For a tapered joint, the transverse location of the sample

shall be offset from the visible surface joint line by approximately 50% of the taper width

as directed by the Engineer.

Each individual core shall be a separate sample. Once selected according to the procedures

above, core locations will become final and not subject to revision, nor will any core sample

be subject to the provisions specified in Subsection 406.11(c).