Wisconsin WisDOT Standard Specifications (within FDM) — Section 460

Effective with the December 2018 Letting 176 2019 Standard Spec ifications Section 460 Hot Mix Asphalt Pavement

460.1Description

(1)This section describes HMA mix ture design, providing and maintaining a quality management program

for HMA mixtures, and constructing HMA pavem ent. Unless specifi cally indicated otherwise, references within 460 to H MA also apply to WMA.

460.2Materials

460.2.1 General

(1)Furnish a homogeneous mixture of coarse aggregate, fine aggregate, mineral filler if required, SMA

stabilizer if required, recycled material if used, warm mix asp halt additive or process if used, and asphaltic material. Design mixtures conforming to table 460-1 and table 460-2 to 4.0 percent air voids to establish the aggregate structure.

(2)Determine the target JMF asphalt binder content for production from the mix design data

corresponding to 3.0 percent air v oids (97 percent Gmm) target at the design the number of gyrations (Ndes). Add liquid asphalt to achieve the required air voids at Ndes.

(3)For SMA, determine the target J MF asphalt binder content for p roduction from the mix design data

corresponding to 4.0 percent air v oids (96 percent Gmm) target at Ndes. 460.2.2 Aggregates 460.2.2.1 General

(1)Provide coarse aggregates from a department-approved source as specified under 106.3.4.2 . Obtain

the engineer's approval of the aggregates before producing HMA mixtures.

(2)Furnish an aggregate blend cons isting of hard durable particles containing no more than a combined

total of one percent, by weight, of lumps of clay, loam, shale, soft particles, organ ic matter, adherent coatings, and other deleterious m aterial. Ensure that the aggre gate blend conforms to the percent fractured faces and flat & elongated requirements of table 460-2 . If the aggregate blend contains materials from different deposits or sources, ensure that mater ial from each deposit or source has an LA wear percent loss meeting the requirements of table 460-2 . 460.2.2.2 Freeze-Thaw Soundness

(1)If the aggregate blend contains m aterials from different depos its or sources, ensure that material from

each deposit or source has a freez e-thaw loss percentage meetin g the requirements of table 460-2 and 106.3.4.2.2.2. 460.2.2.3 Aggregate Gradation Master Range

(1)Ensure that the aggregate blend, including recycled material a nd mineral filler, conforms to the

gradation requirements in table 460-1. The values listed are de sign limits; production values may exceed those limits. TABLE 460-1 AGGREGATE GRADATION MASTER RANGE AND VMA REQUIREME NTS

SIEVE PERCENT PASSING DESIGNATED SIEVES NOMINAL SIZE No. 1 (37.5 mm) No. 2 (25.0 mm) No.3 (19.0 mm) No. 4 (12.5 mm) No. 5 (9.5 mm) SMA No. 4 (12.5 mm) SMA No. 5 (9.5 mm) 50.0-mm 1 00 37.5-mm 9 0 –100 1 00 25.0-mm 9 0 max 9 0 -100 1 00 19.0-mm ___ 90 max 90 -100 100 100 12.5-mm ___ ___ 90 max 90 -100 100 90 - 97 100 9.5-mm ___ ___ ___ 90 max 90 -100 58 - 72 90 - 100 4.75-mm ___ ___ ___ ___ 90 max 25 - 35 35 - 45 2.36-mm 15 - 41 19 - 45 23 - 49 28 - 58 32 - 67 15 - 25 18 - 28 75-µm 0 - 6.0 1.0 - 7.0 2.0 - 8.0 2.0 - 10. 0 2.0 - 10.0 8.0 - 1 2.0 10.0 - 14.0 % MINIMUM VMA 11.0 12.0 13.0 14.0[1] 15.0[2] 16.0 17.0 [1] 14.5 for LT and MT mixes. [2] 15.5 for LT and MT mixes.

Effective with the December 2018 Letting 177 2019 Standard Spec ifications 460.2.3 Asphaltic Binders

(1)The department will designate the grade of asphaltic binder in the HMA Pavement bid item. Use the

binder grade the bid item specifies. Do not change the PG binder grade without the engineer's written approval. The department will desi gnate the grade of virgin asp haltic binder in the contract, however, the contractor may use virgin binder, modified binder, a blend of virgin and recovered binder, or a blend of modified and recovered binder. When the percent asphal t binder replaced exceeds the allowable limits in 460.2.5 , provide test results from extra cted and recovered binder to e nsure that the resultant asphaltic binder confor ms to the contract specificati ons. 460.2.4 Additives 460.2.4.1 Hydrated Lime Antistripping Agent

(1)If used in HMA mixtures, furnis h hydrated lime conforming to ASTM C977 and containing no more

than 8 percent unhydrated oxides. Percent added is by weight of the total dry aggregate. 460.2.4.2 Liquid Antistripping Agent

(1)If used in HMA mixtures, add liquid antistripping agent to the asphaltic binder before introducing the

binder into the mixture. Provide documentation indicating that addition of liquid antistripping agent will not alter the characteristics of the original asphaltic binder performance grade (PG). 460.2.4.3 Stone Matrix Asphalt Stabilizer

(1)Add an organic fiber, an inorganic fiber, a polymer-plastic, a polymer-elastomer, or approved alternate

stabilizer to all SMA mixtures. If proposing an alternate, submit the proposed additive system, asphaltic binder, and stabilizer additive, along with samples o f the other mixture materials to the department at least 14 days before the project let date. The department will approve or reject that proposed alternate additive sys tem no later than 48 hours befor e the project let date.

(2)Use a single additive system fo r all SMA pavement in the contr act.

460.2.4.4 Warm Mix Asphal t Additive or Process

(1)Use additives or processes from the department's APL. Follow supplier or manufacturer

recommendations for additives and processes when producing WMA mixtures. 460.2.5 Recycled Asphaltic Materials

(1)The contractor may use recycled asphaltic materials from FRAP, RAP, and RAS in HMA mixtures.

Stockpile recycled materials separ ately from virgin materials and list each as individual JMF components.

(2)Control recycled materials used in HMA by evaluating the percent binder replacement, the ratio of

recovered binder to the total bi nder. Conform to the following: MAXIMUM ALLOWABLE PERCENT BINDER REPLACEMENT RECYCLED ASPHALTIC MATERIAL LOWER LAYERS UPPER LAYER RAS if used alone 25 20 RAP and FRAP in any combination 40 25 RAS, RAP, and FRAP in combination[1] 3 5 25 [1] When used in combination the RAS component cannot exceed 5 per cent of the total weight of the aggregate blend. 460.2.6 Recovered Asphaltic Binders Revise 460.2.6(1) to allow the use of the Asphalt AnalyzerTM.

(1)Establish the percent of recovered asphaltic binder from FRAP, RAP, and RAS for the mixture design

using an Asphalt AnalyzerTM or according to AASHTO T164 using the appropriate dust correction procedure. If production test res ults indicate a change in the percent of recovered asphaltic binder, the contractor or the engineer may r equest a change in the design r ecovered asphaltic binder. Provide the department with documentation of at least 2 recent extraction sa mples supporting that change. E nsure that those samples were prepare d by a WisDOT qualified laborato ry.

(2)The contractor may replace virgin binder with recovered binder up to the maximum percentage

allowed under 460.2.5 without changing the asphalti c binder grade. If using more tha n the maximum allowed under 460.2.5 , furnish test results indicating that the resultant binder mee ts the grade the contract originally specified.

Effective with the December 2018 Letting 178 2019 Standard Spec ifications 460.2.7 HMA Mixture Design Add footnote [7] to table 460-2 to specify the asphalt content for TSR testing. This change was implemented in ASP 6 effective with the December 2017 letting.

(1)For each HMA mixture type used under the contract, develop and submit an asphaltic mixture design

according to CMM 8-66 and conforming to the requirements of table 460-1 and table 460-2 . The values listed are design limits; production values may exceed those limits. The department will review mixture designs and report the results of that review to the de signer according to CMM 8-66 . TABLE 460-2 MIXTURE REQUIREMENTS

Mixture type LT MT HT SMA ESALs x 106 (20 yr design life) <2.0 2 - <8 >8 ___ LA Wear (AASHTO T96) 100 revolutions(max % loss) 13 13 13 13 500 revolutions(max % loss) 50 45 45 40 Soundness (AASHTO T104) (sodium sulfate, max % loss ) 12 12 12 12 Freeze/Thaw (AASHTO T103) (specified counties, max % loss) 18 18 18 18 Fractured Faces (ASTM D5821 as modified in CMM 8-60 ) (one face/2 face , % by count) 65/___ 75 / 60 98 / 90 100/90 Flat & Elongated ( ASTM D4791) (max %, by weight) 5 (5:1 ratio) 5 (5:1 ratio) 5 (5:1 ratio) 20 (3:1 ratio) Fine Aggregate Angularity (AASHTO T304, method A, min ) 40 43 45 45 Sand Equivalency (AASHTO T176, min) 40 40 45 50 Gyratory Compaction Gyrations for N ini 6 7 8 8 Gyrations for N des 40 75 100 65 Gyrations for N max 60 115 160 160 Air Voids, %V a (%G mm Ndes) 4.0 (96.0) 4.0 (96.0) 4.0 (96.0) 4.0 (96.0) % G mm Nini <= 91.5[1] <= 89.0[1] <= 89.0 ___ % G mm Nmax <= 98.0 <= 98.0 <= 98.0 ___ Dust to Binder Ratio[2] (% passing 0.075/P be) 0.6 - 1.2 0.6 - 1.2 0.6 - 1.2 1.2 - 2.0 Voids filled with Bin der (VFB or VFA, %) 68 - 80[4] [5] 65 - 75[3] [5] 65 - 75[3] [5] 70 - 80 Tensile Strength Ratio (TSR) (AASHTO T283)[6] [7] no antistripping additive 0.75 min 0 . 7 5 min 0 . 7 5 min 0.75 min with antistripping additive 0.80 min 0 . 8 0 min 0 . 8 0 min 0.80 min Draindown (AASHTO T305) (%) ___ ___ ___ 0.30 [1] The percent maximum density at initial compaction is only a gu ideline. [2] For a gradation that passes be low the boundaries of the cautio n zone (ref. AASHTO M323), the dust to binder ratio limits ar e 0.6 - 1.6. [3] For No. 5 (9.5mm) and No. 4 (12. 5 mm) nominal maximum size mix tures, the specified VFB range is 70 - 76 percent. [4] For No. 2 (25.0mm) nominal maxim um size mixes, the specified V FB lower limit is 67 percent. [5] For No. 1 (37.5mm) nominal maxim um size mixes, the specified V FB lower limit is 67 percent. [6] WisDOT eliminates freeze-thaw conditioning cycles from the TSR test procedure. [7] Run TSR at asphalt content corre sponding to 3.0% air void regre ssed design using distilled water for testing.

Effective with the December 2018 Letting 179 2019 Standard Spec ifications 460.2.8 Quality Management Program 460.2.8.1 General

(1)Provide and maintain a QC program defined as all activities, i ncluding mix design, process control

inspection, sampling and testing , and process adjustments related to producing and placing HMA pavement conforming to the specifications.

(2)The department will provide product quality verification as fo llows:

1.By conducting verification testing of independent samples.

2.By periodically observing co ntractor sampling and testing.

3.By monitoring required contro l charts exhibiting test results and control parameters.

4.By the engineer directing t he contractor to take additional samples at any time during production.

(3)Refer to CMM 8-36 for detailed guidance on sampling, testing, and documentation under the QMP.

460.2.8.2 Contractor Testing 460.2.8.2.1 Required Quality Control Program 460.2.8.2.1.1 Personnel Requirements Revise 460.2.8.2.1.1 to specify minimum HTCP certifi cations for contractors at HMA production facilities.

(1)Provide HTCP-certified sampling and testing personnel. Provide at least one full-time technician

minimally qualified as an HTCP-certified Hot Mix Asphalt, Technician I, Production Tester (HMA-IPT) at each plant site furnishing m aterial to the project. Before m ixture production begins, provide an organizational chart in the c ontractor's laboratory. Include the names, telephone num bers, and current certifications of personnel wit h QC responsibilities. Keep the chart updated.

(2)Ensure that sampling and testing personnel are minimally quali fied as follows[1]:

- HMA technician certified at a level appropriate for sampling , Transportation Materials Sampling Technician

(TMS).

- HMA technician certified at a level appropriate for production control testing (HMA-IPT) . - Assistant Certified Technician (ACT)[2]. [1] After informing the engineer, a non-certified person under the direct observation of an HTCP-certified HMA technician may sample for a period not to exceed 3 calendar days. [2] An HTCP-certified HMA technician must coordinate and take responsibility for the work an ACT performs. No more than one ACT can work under a single HTCP-certified techni cian.

(3)Have an HMA-IPT technician ensure that sampling and testing is performed corre ctly, analyze test

results, and post resulting data.

(4)Have an HTCP-certified Hot Mix Asphal t, Trouble Shooting, Process Control (HMA-TPC) technician or

HTCP-certified Hot Mix Asphalt, Mix Design, Report Submittals ( HMA-MD) technician available to make necessary process adjustments. 460.2.8.2.1.2 Laboratory Requirements

(1)Conduct QC testing in a facilit y conforming to the department' s laboratory qualification program.

(2)Ensure that testing equipment conforms to the equipment specif ications applicable to the required

testing methods. 460.2.8.2.1.3 Required Sampling and Testing 460.2.8.2.1.3.1 Contracts with 5000 Tons of Mixture or Greater

(1)Furnish and maintain a laboratory at the plant site fully equi pped for performing contractor QC testing.

Have the laboratory on-site and operational before beginning mi xture production.

(2)Obtain random samples and perform tests according to CMM 8-36. Obtain HMA mixture samples from

trucks at the plant. Perform tests the same day taking the sample.

(3)Retain the split portion of the contractor HMA mixture and ble nded aggregate samples for 14 calendar

days at the laboratory site in a dry, protected area. The engineer may decrease this 14-day retention period. At project completion t he contractor may dispose of rem aining samples if the engineer approves. Revise 460.2.8.2. 1.3.1(4) to eliminate the bucket me thod and allow only ignition oven, chemical ext raction, or Asphalt AnalyzerTM methods for determining AC content.

(4)Use the test methods identified below, or other methods the en gineer approves, to perform the

following tests at a frequency greater than or equal to that in dicated: Blended aggregate gradations:

Effective with the December 2018 Letting 180 2019 Standard Spec ifications Drum plants: - Field extraction by ignition o ven according to AASHTO T308 ( CMM 8-36.6.3.6 ), chemical extraction according to AASHTO T-164, or Asphalt AnalyzerTM according to manufacturer recommendations. Gradation of resulting aggregate sample determined according to AASHTO T30. - Belt samples, optional for virgin mixtures, obtained from sto pped belt or from the belt discharge using an engineer-app roved sampling device and performed according to AASHTO T11 and T27. Batch plants: - Field extraction by ignition o ven according to AASHTO T308 ( CMM 8-36.6.3.6 ), chemical extraction according to AASHTO T -164, or Asphalt Analyzer™ acco rding to manufacturer recommendations. Gradation of resulting aggregate sample determined according to AASHTO T30. Asphalt content (AC) in percent: AC by ignition oven according to AASHTO T308 ( CMM 8-36.6.3.6 ), chemical extraction according to AASHTO T-164, or As phalt Analyzer™ according to ma nufacturer recommendations. Gradation of resulting aggregate sample determ ined according to AASHTO T30. Bulk specific gravity of the comp acted mixture according to AAS HTO T166. Maximum specific gravity according to AASHTO T209. Air voids (V a) by calculation according to AASHTO T269. VMA by calculation according to AASHTO R35.

(5)Test each design mixture at a frequency at or above the following:

TOTAL DAILY PLANT PRODUCTION FOR DEPARTMENT CONTRACTS SAMPLES in tons PER DAY[1] 50 to 600 1 601 to 1500 2 1501 to 2700 3 2701 to 4200 4 greater than 4200 see footnote[2] [1] Frequencies are fo r planned production . If production is other than planned, conform to CMM 8-36. [2] Add a random sample for each add itional 1500 tons or fraction of 1500 tons. Revise 460.2.8.2.1. 3.1(6) to contractually mobilize the CMM for production TSR testing requirements. This change was implemented in ASP 6 effective with the December 2017 letting.

(6)Conduct TSR tests during mixture production according to CMM 8-36.6.14. Test each full 50,000 ton

production increment, or fraction of an increment, after the fi rst 5000 tons of production. Perform required increment testing in the first week of production of that increment. If production TSR values are below the limit specified in CMM 8-36.6.14 , notify the engineer. The engineer and contractor will jointly determine a corrective action. 460.2.8.2.1.3.2 Contracts with L ess Than 5000 Tons of Mixture

(1)Conform to 460.2.8.2.1.3.1 modified as follows:

- The contractor may conduct QC tests in an off-site laboratory . - No field tensile strength ratio testing is required. 460.2.8.2.1.3.3 Contracts with Less Than 500 Tons of Mixture

(1)The engineer may waive QC testing on contracts with less than 500 tons of mixture. If testing is

waived, acceptance will be by vi sual inspection unless defined otherwise by contract change order.

(2)If HMA density testing is waived under 460.3.3.3 , QC testing is also waived.

460.2.8.2.1.3.4 Temporary Pavements

(1)The engineer may waive all testi ng for temporary pavements, de fined for this purpose as pavements

that will be placed and removed before contract completion.

Effective with the December 2018 Letting 181 2019 Standard Spec ifications 460.2.8.2.1.4 Documentation 460.2.8.2.1.4.1 Records

(1)Document observations, inspecti on records, mixture adjustments , and test results daily. Note

observations and inspection rec ords in a perma nent field record as they occur. Record process adjustments and JMF changes. Subm it copies of the running avera ge calculation sheets for blended aggregate, mixture properties, and asphalt content along with m ixture adjustment records to the engineer each day. Submit testing records and control charts to the engineer in a neat and orderly manner within 10 days afte r paving is completed.

(2)Continue charts, recor ds, and testing frequencies, for a mixtu re produced at one plant site, from

contract to contract. 460.2.8.2.1.4.2 Control Charts

(1)Maintain standardized control charts at the laboratory. Record contractor test results on the charts the

same day as testing. Record dat a on the standardized control ch arts as follows: - Blended aggregate gr adation tests in percent passing. Of the following, plot those sieves the design specifications require: 37.5-mm , 25.0-mm, 19.0-mm, 12.5-mm, 9.5 -mm, 2.36-mm, and 75-µm. - Asphalt material content in percent. - Air voids in percent. - VMA in percent.

(2)Plot both the individual test point and the running average of the last 4 data points on each chart.

Show QC data in black with the running average in red. Draw the warning limits with a dashed green line and the JMF limits with a das hed red line. The contractor may use computer generated black-and- white printouts with a legend t hat clearly identifies the speci fied color coded components. 460.2.8.2.1.5 Control Limits

(1)Conform to the following control limits for the JMF and warnin g limits based on a running average of

the last 4 data points: ITEM JMF LIMITS WARNING LIMITS Percent passing given sieve: 37.5-mm +/- 6.0 +/- 4.5 25.0-mm +/- 6.0 +/- 4.5 19.0-mm +/- 5.5 +/- 4.0 12.5-mm +/- 5.5 +/- 4.0 9.5-mm +/- 5.5 +/- 4.0 2.36-mm +/- 5.0 +/- 4.0 75-µm +/- 2.0 +/- 1.5 Asphaltic content in percent - 0.3 - 0.2 Air voids in percent[1] +1.3/-1.0 +1.0/-0.7 VMA in percent[2] - 0.5 - 0.2 [1] For SMA, JMF limits are +/-1.3 and warning limits are +/-1.0. [2] VMA limits based on mi nimum requirement for mix design nominal maximum aggregate size in table 460-1 .

(2)Warning bands are defined as the area between the JMF limits a nd the warning limits.

460.2.8.2.1.6 Job Mix Formula Adjustment Revise 460.2.8.2.1.6 to speci fy minimum HTCP certification for QC HMA Technicians requesting adjustment to the JMF.

(1)The contractor may request adjustment of the JMF according to CMM 8-36.6.13.1 . Have an HTCP-

certified Hot Mix Asphalt, Trouble Shooting, Process Control (H MA-TPC) technician or HTCP-certified Hot Mix Asphalt, Mix Design, Repo rt Submittals (HMA-MD) technic ian submit a written JMF adjustment request. Ensure that t he resulting JMF is within spe cified master gradation bands. The department will have an HMA-MD technician review the proposed adjustment and, if acceptable, issue a revised JMF.

(2)The department will not allow adj ustments that do the followin g:

- Exceed specified JM F tolerance limits. - Reduce the JMF asphalt content unless the production VMA running average meets or exceeds the minimum VMA design requirement defined in table 460-1 for the mixture produced.

Effective with the December 2018 Letting 182 2019 Standard Spec ifications (3) Have an HMA-TPC technician make related process adjustments. If mixture redesign is neces sary, have an HMA-MD technician submit a new JMF, subject to the same specification requiremen ts as the original JMF. 460.2.8.2.1.7 Corrective Action

(1)When running average values tr end toward the warning limits, c onsider taking corrective action.

Document corrective action unde rtaken. Include test results in the contract files and in running average calculations.

(2)Notify the engineer if running aver age values exceed the warni ng limits. If two consecutive running

average values exceed the warni ng limits, stop production and m ake adjustments. Do not restart production until after notifyi ng the engineer of the adjustments made. Do not calculate a new running average until the fourth test afte r the required production sto p.

(3)If the process adjustment improves the property in question so that the running average after 4

additional tests is within the warning limits, the contractor m ay continue production with no reduction in payment.

(4)If the adjustment does not impro ve the properties and the running average after 4 additional tests

stays inside the warning bands, t he mixture is nonconforming an d subject to pay adjustment.

(5)If the contractor fails to stop production and make adjustments when required, all mixture produced

from the stop point to the point w hen the running average is ba ck inside the warning limits is nonconforming and subject to pay adjustment.

(6)If the running average values e xceed the JMF limits, stop prod uction and make adjustments. Do not

restart production until after notifying the engineer of the ad justments made. Continue calculating the running average after the production stop.

(7)If the air voids running average of 4 exceeds the JMF limits, the material is nonconforming. Remove

and replace unacceptable material. The engineer will determine the quantity of material to replace based on the testing data using the methods in CMM 8-36 and an inspection of the completed pavement. If the engineer allows the mixture to remain in place, the department will pay for the mixture and asphaltic material as specified in 460.5.2.1 .

(8)If the running average of 4 exceeds the JMF limits for other p roperties, and the engineer allows the

mixture to remain in place, the department will pay for the mixture as specified in 460.5.2.1 . The engineer will determine the quantit y of material subject to pay reduction based on the testing data and an inspection of the completed pavement. 460.2.8.3 Department Testing 460.2.8.3.1 Quality Verification Program 460.2.8.3.1.1 General

(1)The engineer will conduct QV tests to determine the quality of the final product and measure

characteristics that predi ct relative performance. 460.2.8.3.1.2 Personnel Requirements Revise 460.2.8.3.1.2 to sp ecify minimum HTCP certification for HMA Technicians working for the department.

(1)The department will provide at least one HTCP-certified Transportation Materials Sampling Technician

(TMS)technician to observe QV sampling of project mixtures.

(2)An HTCP-certified Hot Mix Asphalt, Technician I, Production Tester (HMA-IPT) or an HMA ACT

working under the HTCP-certified technician , will split samples and do the testing. An HMA-IPT technician will coordinate and take responsibility for the work an ACT performs. No more than one ACT can work under a single certified technician.

(3)An HMA-IPT technician will ensure that sampling and testing is performed correctly, a nalyze test

results, and post resulting data.

(4)The department will make an organizational chart available at the testing laboratory and to the

contractor before mixture produ ction begins. The department's c hart will include names, telephone numbers, and current certifications of QV testing personnel. The department will update the chart with appropriate changes, as they become effective. 460.2.8.3.1.3 Laboratory Requirements

(1)The department will furnish and ma intain a facility for QV tes ting conforming to the department's

laboratory qualification program requirements and fully equippe d to perform QV testing. In all cases, the department will conduct testi ng in a separat e laboratory fr om the contractor's laboratory.

Effective with the December 2018 Letting 183 2019 Standard Spec ifications 460.2.8.3.1.4 Department Verifi cation Testing Requirements

(1)HTCP-certified department personnel will obtain random samples by directly supervising HTCP-

certified contractor personnel sampling from trucks at the plan t. The department will sample according to CMM 8-36 . Sample size must be adequate to run the appropriate required tests in addition to one set of duplicate tests that may be required for dispute resolution. The engineer will split the sample for testing and retain the remaini ng portion for additional testing if needed.

(2)The department will verify produc t quality using the test meth ods specified in 460.2 .8.3.1.4(3), other

engineer-approved methods, or other methods the industry and de partment HMA technical team recognizes. The department will i dentify test methods before co nstruction starts and use only those methods during production of that material unless the engineer and contractor mutually agree otherwise.

(3)The department will perform testi ng conforming to the followin g standards:

Bulk specific gravity (G mb) of the compacted mixture according to AASHTO T166. Maximum specific gravity (G mm) according to AASHTO T209. Air voids (V a) by calculation according to AASHTO T269. VMA by calculation according to AASHTO R35.

(4)The department will randomly test each design mixture at the f ollowing minimum frequency:

FOR TONNAGES TOTALING: Less than 501 tons ............................................ ............................................................... ......... no tests required From 501 to 5,000 tons ............................................................................................................................ o ne test More than 5,00 0 tons .......................................... ............... add one test for each additional 5,000-ton increment 460.2.8.3.1.5 Documentation

(1)The engineer will document observations during QV sampling, an d review QC mixture adjustments

and QC test results daily. The engi neer will note results of observations and inspection records in a permanent field record as they occur. 460.2.8.3.1.6 Acceptable Verification Parameters

(1)The engineer will provide test r esults to the contractor withi n 2 mixture-production days after obtaining

the sample. The quality of the prod uct is acceptably verified i f it meets the following limits: - Va is within a range of 2.0 to 4.3 percent. For SMA, Va is wi thin a range of 2.7 to 5.3 percent. - VMA is within minus 0.5 of the minimum requirement for the mi x design nominal maximum aggregate size.

(2)If QV test results are outside the specified limits, the engin eer will investigate immediately through

dispute resolution procedures. The engineer may stop production while the investigation is in progress if the potential for a pavement failure is present.

(3)If production continues for that mixture desig n, the engineer will provide additional retained sample

testing at the frequency provided for in CMM 8-36 . This supplemental testi ng will continue until the material meets allowable differences or as the engineer and con tractor mutually agree. 460.2.8.3.1.7 Dispute Resolution

(1)When QV test results do not meet the specified limits, the bur eau's AASHTO accredited laboratory

and certified personnel will ref eree test the retained portion of the QV sample and the retained portion of the nearest available previous QC sample.

(2)The department will notify the contractor of the referee test results within 3 busin ess days after receipt

of the samples.

(3)The department will determine mixture conformance and acceptab ility by analyzing referee test

results, reviewing mixture proj ect data, and inspecting the com pleted pavement all according to CMM 8-36. 460.2.8.3.1.8 Corrective Action

(1)Remove and replace unacceptable material at no additional expe nse to the department.

(2)The department will reduce pay for the tonnage of nonconformin g mixture, as determined during QV

dispute resolution, if the engineer allows that mixture to rema in in place. If production of that mixture design continued duri ng the investigation, the department will also adjust pay for that mixture forward to the next conforming QV or Q C point. The department will pay for the affected mixture as specified in 460.5.2.1 .

Effective with the December 2018 Letting 184 2019 Standard Spec ifications 460.2.8.3.2 Independent Assurance Testing

(1)The department will evaluate bot h the contractor and departmen t testing personnel and equipment as

specified in 106.3.4.3.4 .

460.3Construction

460.3.1 General

(1)Construct HMA pavement of the type the bid item indicates encoded as follows:

Combined Bid Item Encoding

GRADATIONS (NMAS) TRAFFIC VOLUME BINDER DESIGNATION LEVEL 1 37.5 mm LT Low S Standard 2 25.0 mm MT Medium H Heavy 3 19.0 mm HT High V Very Heavy 4 12.5 mm E Extremely Heavy 5 9.5 mm 6 4.75 mm

(2)Construct HMA pavement conformi ng to the general provisions of 450.3 .

460.3.2 Thickness Revise 460.3.2 to reduce the minimum l ayer thickness for No. 5 (9.5 mm) aggregate from 1.5 inches to 1.25 inches.

(1)Provide the plan thickness for lower and upper layers limited as follows:

NOMINAL MINIMUM MAX LOWER MAX UPPER MAX SINGLE SIZE LAYER LAYER LAYER LAYER THICKNESS THICKNESS THICKNESS THICKNESS[3] (in inches) (in inches) (in inches) (in inches) No. 1 (37.5 mm) 4.5 6 4.5 6 No. 2 (25.0 mm) 3.0 5 4 6 No. 3 (19.0 mm 2.25 4 3 5 No. 4 (12.5 mm)[1] [4] 1 . 7 5 3[2] 2 .5 4 No. 5 (9.5 mm)[1] [4] 1.25 3[2] 2 3 [1] SMA mixtures use nominal size No. 4 (12.5 mm) or No. 5 (9.5 mm ). [2] SMA mixtures with nominal sizes of No. 4 (12.5 mm) and No. 5 ( 9.5 mm) have no maxi mum lower layer thickness specified. [3] For use on cross-ov ers and shoulders. [4] Can be used for a leveling laye r or scratch coat at a reduced thickness. 460.3.3 HMA Pavement Density Maximum Density Method 460.3.3.1 Minimum Required Density

(1)Compact all layers of HMA mixture to the density table 460-3 s hows for the applicable mixture,

location, and layer.

Effective with the December 2018 Letting 185 2019 Standard Spec ifications TABLE 460-3 MINIMUM REQUIRED DENSITY[1]

LOCATION LAYER PERCENT OF TARGET MAXIMUM DENSITY MIXTURE TYPE LT and MT HT SMA[5] TRAFFIC LANES[2] LOWER 93.0[3] 93.0[4] ___ UPPER 93.0 93.0 ___ SIDE ROADS, CROSSOVERS, TURN LANES, & RAMPS LOWER 93.0[3] 93.0[4] ___ UPPER 93.0 93.0 ___ SHOULDERS & APPURTENANCES LOWER 91.0 91.0 ___ UPPER 92.0 92.0 ___ [1] The table values are for aver age lot density. If any individua l density test result falls more than 3.0 percent below the minimum requ ired target maximum density, the engineer may investigate the acceptability of that material. [2] Includes parking lanes, bike lanes, and park-and-ride lots as defined by the contract plans. [3] Minimum reduced by 2.0 percent fo r a lower layer constructed d irectly on crushed aggre gate or recycled base courses. [4] Minimum reduced by 1.0 percent fo r a lower layer constructed d irectly on crushed aggre gate or recycled base courses. [5] The minimum required densities fo r SMA mixtures are determined according to CMM 8-15 . 460.3.3.2 Pavement Density Determination

(1)The engineer will determine the target maximum density using d epartment procedures described in

CMM 8-15 . The engineer will determine density as soon as practicable af ter compaction and before placement of subsequent layers or before opening to traffic.

(2)Do not re-roll compacted mixtures with deficient density test results. Do not operate continuously

below the specified minimum den sity. Stop production, identify the source of the problem, and make corrections to produce work meeting the specification requireme nts.

(3)A lot is defined in CMM 8-15 and placed within a single layer for each location and target maximum

density category indicated in table 460-3 . The lot density is the average o f all samples taken for that lot. The department determines t he number of tests per lot acco rding to either the linear sublot system or the nominal tonnage system defined in CMM 8-15. Revise 460.3.3.2(4) to specify minimum HTCP certifications for department or contractor nuclear density technicians.

(4)An HTCP-certified Nuclear Density Technician I (NUCDENSITYTEC-I) or a nuclear density ACT

working under a NUCDENSITYTEC-I technician, will locate samples and perform the testing. A NUCDENSITYTEC-I technician will coordinate and ta ke responsibility for the wor k an ACT performs. No more than one ACT can work under a single NUCDENSITYTEC-I technician. The responsible NUCDENSITYTEC-I technician will ensure that sampl e location and testing is perf ormed correctly, analyze test results, and provide density results to the contra ctor weekly. 460.3.3.3 Waiving Density Testing

(1)The engineer may waive density te sting for one or more of the following reasons:

1.It is impracticable to determine density by the lot system.

2.The contract contains less than 750 tons of a given mixture type placed within the same layer and target

maximum density category.

(2)If the department waives density testing notify the contractor before paving. The department will

accept the mixture by the ordinary compaction procedure as spec ified in 450.3.2.6.2.

(3)If HMA QC testing is waived under 460.2.8.2.1.3.3 , density testing is also waived.

460.4Measurement

(1)The department will measure the HM A Pavement bid items acceptably completed by the ton as

specified in 450.4 .

Effective with the December 2018 Letting 186 2019 Standard Spec ifications 460.5 Payment 460.5.1 General

(1)The department will pay for measured quantities at the contrac t unit price under the following bid

items: ITEM NUMBER DESCRIPTION UNIT

460.5000 - 5999 HMA Pavement ( gradation) LT (binder)(designation) TON

460.6000 - 6999 HMA Pavement ( gradation) MT (binder)(designation) TON

460.7000 - 7999 HMA Pavement ( gradation) HT (binder)(designation) TON

460.8000 - 8999 HMA Pavement (gr adation) SMA (binder)(designati on) TON

460.2000 Incentive Densit y HMA Pavement DOL

460.5.2 HMA Pavement 460.5.2.1 General

(1)The department will pay for the HM A Pavement bid items at the contract unit price subject to one or

more of the following adjustments:

1.Disincentive for density of H MA pavement as specified in 460.5.2.2 .

2.Incentive for density of H MA pavement as specified in 460.5.2.3 .

3.Reduced payment for nonconfo rming smoothness as specified i n 450.3.2.9 .

4.Reduced payment for nonconformi ng QMP HMA mixtures as speci fied in 460.2.8.2.1.7 .

(2)Payment for the HMA Pavement b id items is full compensation fo r providing HMA pavement including

binder; for mixture design; for preparing the foundation; and f or QMP and aggregate source testing.

(3)If provided for in the plan quantities, the department will pay for a leveling layer , placed to correct

irregularities in an existing paved surface before overlaying, under the pertinent paving bid item. Absent a plan quantity, the department will pay for a leveling layer as extra work.

(4)The department will administer pay reduction for nonconforming QMP mixture under the

Nonconforming QMP HMA Mixture administrative item. The departme nt will reduce pay based on the contract unit price for t he HMA Pavement bid item.

(5)The department will reduce pay fo r nonconforming QMP HMA mixtu res as specified in 460.2.8.2.1.7,

starting from the stop point to the point when the running aver age of 4 is back inside the warning limits. The engineer will determine the quantity of material su bject to pay reduction based on the testing data and an inspection of the completed pavement. The d epartment will reduce pay as follows: PAYMENT FOR MIXTURE[1] [2] PRODUCED WITHIN PRODUCED OUTSIDE ITEM WARNING BANDS JMF LIMITS Gradation 90% 75% Asphalt Content 85% 75% Air Voids 70% 50% VMA 90% 75% [1] For projects or plants where th e total production of each mixture design requires less than 4 tests refer to CMM 8-36. [2] Payment is in percent of the c ontract unit price for the HMA Pavement bid item. The department will reduce pay based on the nonconforming pr operty with lowest percent pay . [3] In addition to any pay adjustment listed in the table above, t he department will adjust pay for nonconforming binder under the Nonconforming QM P Asphaltic Material administr ative item. The department will deduct 25 percent of the contract unit price of the HMA Pavement bid item per ton of pavement placed with nonconforming PG binder the engineer allows to remain in place.

(6)If during a QV dispute resolution investigation the department discovers mixture with 1.5 > Va > 5.0 or

VMA more than 1.0 below the minimum allowed in table 460-1 , and the engineer allows that mixture to remain in place, the department will pay for the quantity of affected material at 50 percent of the contract price.

(7)If the department waives density testing under 460.3.3.3 , the department will not adjust pay under

either 460.5.2.2 or 460.5.2.3 .

(8)Restore the surface after cutti ng density samples as specified in 460.3.3.2(1) at no additional cost to

the department.

Effective with the December 2018 Letting 187 2019 Standard Spec ifications 460.5.2.2 Disincentive for HMA Pavement Density

(1)The department will administer density disincentives under the Disincentive Density HMA Pavement

administrative item. If the lot density is less than the specified minimum in table 460-3 , the department will reduce pay based on the cont ract unit price for the HMA Pa vement bid item for that lot as follows: DISINCENTIVE PAY REDUCTION FOR HMA PAVEMENT DENSITY PERCENT LOT DENSITY PAYMENT FACTOR BELOW SPECIFIED MINIMUM ( percent of contract price) From 0.5 to 1.0 inclusive 98 From 1.1 to 1.5 inclusive 95 From 1.6 to 2.0 inclusive 91 From 2.1 to 2.5 inclusive 85 From 2.6 to 3.0 inclusive 70 More than 3.0[1] ___ [1] Remove and replace the lot with a mixture at the specified den sity. When acceptably replaced, the department will pay for the replaced work a t the contract unit price. Alte rnatively the engineer may allow the nonconforming material to remain in place with a 50 percent payment factor.

(2)The department will not assess de nsity disincentives for pavem ent placed in cold weather because of

a department-caused delay as specified in 450.5.2(3) . 460.5.2.3 Incentive for HMA Pavement Density

(1)If the lot density is greater than the minimum specified in table 460-3 and all individual air voids test

results for that mixture placed during the same day are within 2.5 - 4.0 percent, the department will adjust pay for that lot as follows: INCENTIVE PAY ADJUSTMENT FOR HMA PAVEMENT DENSITY PERCENT LOT DENSITY ABOVE SPECIF IED MINIMUM PAY ADJUSTMENT PER TON[1] From -0.4 to 1.0 inclusive $0 From 1.1 to 1.8 inclusive $0.40 More than 1.8 $0.80 [1] The department will prorate the pay adjustment for a partial l ot.

(2)The department will adjust pay under the Incentive Density HMA Pavement bid item. Adjustment

under this item is not limited, e ither up or down, to the bid a mount the schedule of items shows.

(3)For shoulders paved integrally with the traffic lane, if the traffic lane does not meet incentive

requirements, the department will not pay incentive on the inte grally paved shoulder.

Effective with the December 2018 Letting 188 2019 Standard Spec ifications Section 465 Asphaltic Surface

465.1Description

(1)This section describes constru cting asphaltic surface for new construction including pavement, safety

islands, curb, rumble strip, and flumes. This section also desc ribes using asphaltic surface for patching, detours, and temporar y construction. The department w ill designate work under the bid items in this section only if the QMP provisions specified for HMA pavements under 460 are not required.

465.2Materials

(1)Under the Asphaltic Surface, Asphaltic Surface Detours, and As phaltic Surface Patching bid items;

submit a mix design. Furnish asp haltic mixture meeting the requ irements specified for either type LT or MT mix under 460.2 ; except the engineer will not require the contractor to confor m to the quality management program specified under 460.2.8.

(2)Under the other 465 bid items, the contractor need not submit a mix design. Furnish aggregates mixed

with a type AC asphaltic material. Use coarse and fine mineral aggregates uniformly coated and mixed with the asphaltic material i n an engineer-approved mixing plan t. The contractor may include reclaimed asphaltic pavement materials in the mixture. 465.3 Construction 465.3.1 General

(1)Prepare the foundation as specified for asphaltic surfacing in 211.

(2)Place using engineer-approved ma chine methods wherever practicable. Except for the surfacing bid

items, the contractor may place material by engineer-approved h and methods. Regardless of the placement technique, spread and sh ape the material to the requi red contour without segregation.

(3)Immediately after placement, compact the mixture to produce a dense smooth surface using ordinary

compaction procedures as specified in 450.3.2.6 except as follows: - Compact safety islands as the engineer directs. - Compact flumes using compac tors, tampers, or rollers. - Compact curb as specified in 465.3.2 .

(4)Ensure that the finished surfac e is smooth and contoured as th e plans show or engineer directs.

(5)Under the Asphaltic Surface, Asphaltic Surface Detours, and As phaltic Surface Temporary bid items;

straightedge the surface. Provi de a finished surface with no variation greater than 1/4 inch in 10 feet. Remove and replace out-of-tolerance material or correct the surface using engineer-approved methods. 465.3.2 Asphaltic Curb

(1)Construct asphaltic curb in one layer on a prepared asphaltic pavement or base foundation. Clean the

pavement surface area the curb will occupy to ensure a good bon d. Apply a tack coat to the area as the engineer directs.

(2)The contractor may place the cu rb by one of the following meth ods:

- With an engineer-approved curb laying machine that places and compacts the mixture and finishes the curb to the required shape , grade, and d imensions. - In forms fabricated to the curb shape. Place and thoroughly compact the mixture with vibratory compactors or mechanical tampers and screed to a smooth finish. - For small quantities, by hand placing and shaping. Form the b ack of the curb. Place, tamp, and shape with hand tools. Provide a smooth-finished surface on the curb face and top. 465.3.3 Rumble Strips

(1)Construct asphaltic rumble str ips by milling the asphaltic surface. Use a rotary head milling machine

with a cutting tip pattern that will produce a relatively smoot h cut of the size, shape, spacing, and smoothness the plans show. Cutti ng heads shall be on a suspensi on independent from the power unit to allow the heads to self-align with slopes and irregularities . The machine shall have a guidance system that consistently provi des the plan alignment of the rum ble strips.

(2)Before beginning the work, demonstrate to the engineer that th e operation achieves the desired

surface inside each depression without tearing or snagging the asphaltic pavement or surfacing. Place rumble strips in the pattern and shape the plans show. For shou lders carrying temporary traffic during construction, do not install rumble strips until after routing traffic back to the mainline.

(3)At the end of each work day, move equipment and material out of the clear zone and sweep or

vacuum the traveled way pavement and shoulder areas. Sweep away or vacuum up milling debris

Source: Wisconsin Standard Specifications for Highway and Structure Construction, 2019 Edition. Pages 185–196 of 601.

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455 Asphaltic Materials

465 Asphaltic Surface