ASPHALT BASE AND WEARING COURSES, PERCENT WITH LIMITS (PWL) 410.1-DESCRIPTION: 410.1.1-General: The Contractor shall note that this Section is to be used for Square Yard Paving operations; however, the proposal and / or plans may contain 401 and 402 items to be paid and measured by the Ton (TN). In instanc es where those items occur, they shall be constructed and measured in accordance with the applicable sections of the West Virginia Division of Highways Standard Specifications Roads and Bridges, current edition, and the Supplemental Specifications current when the contract is let. Additionally, the following Materials Procedures (MP’s) for Square Yard Paving can be found on the Materials Control, Soils and Testing (MCS&T) Division website: https://transportation.wv.gov/highways/mcst/Pages/WVDOH-Materials-Procedures.aspx.
a.MP 401.02.31 QC & Acceptance
b.MP 401.07.20 Sampling Loose Asphalt Pavement Mixtures
c.MP 401.07.21 Sampling Compacted Asphalt
d.MP 401.07.22 Thickness of Asphalt Concrete Using Cores
e.MP 401.07.23 Bond Strength
f.MP 401.07.24 Pavement Macrotexture
g.MP 401.07.25 Evaluation of Asphalt Pavements
h.MP 401.13.50 Determination of PWL 410.1.2-PWL Paving Description: This work shall consist of constructing one or more courses of asphalt, mixed mechanically in a plant, composed of aggregate and asphalt material designed in accordance with either the Marshall or Superpave Design System as specified in the contract documents, on a prepared foundation in accordance with these specifications and in reasonably close conformity with the lines, grades, weights or thicknesses, and cross sections shown on the Plans or established by the Engineer. The unit of measurement for asphalt will be by the ton, square yard, or cubic yard. The work will be accepted in accordance with these Specifications and the applicable requirements of Sections 105, 106, and 109. 410.2-MATERIALS: The materials shall conform to the following requirements: MATERIAL SUBSECTION Coarse Aggregate 703.1 thru 703.3 Note 1 & Note 2 (See MP 401.02.28 for exceptions and additions required for Superpave Items.) Fine Aggregate 702.3 (See MP 401.02.28 for additions required for Superpave Items) Mineral Filler 702.4 Performance Graded Binders 705.5 Note 1 The total shale, coal and other lightweight deleterious material and friable particles shall not exceed 3%. Note 2 When slag is specified in the contract, the coarse aggregate shall be slag which meets the requirements of 703.3, except as amended in this subsection. 410.2.1-Performance Graded Binder Grade: The standard grade for Performance Graded (PG) binders shall be PG 64S -22, any deviation will be noted in the contract documents. PG 64H-22 shall be used on projects specified with over 20 million ESALs over the design life. PG 64S-22 binder may be used in asphalt placed below the top two lifts in any pavement section, scratch course and patching-and-leveling are not identified as lifts. CONSTRUCTION METHODS 410.3-GENERAL: Construction methods to be used in performing the work shall be submitted to the Engineer for review prior to the start of work. This review may require modification of the proposed methods to provide the desired end product. All equipment, tools, machinery, and plant shall be maintained in a satisfactory working condition. 410.4-COMPOSITION OF MIXTURES: 410.4.1-General: The aggregate for use in the designated mixture shall consist of a mixture of aggregate (coarse, fine, reclaimed asphalt pavement (RAP) if desired, or mixture thereof) and mineral filler if required. It shall be the responsibility of the Con tractor to determine the percentage of RAP to be used in the mix. The amount and grade of virgin PG Binder to be used in the RAP designs shall be determined in accordance with Materials Procedure (MP) 401.02.24 and MP 401.02.28. 410.4.2-Job Mix Formula: Job Mix Formula (JMF) is the specification for a single mix produced at a single plant. This mix may be specific to a single project or be used on multiple projects if the basic design criteria (design compaction level and PG Binder grade) are the same. The Contractor shall submit a proposed JMF for each combination of aggregate and asphalt material for each asphalt mixture to be produced. Depending on the design type, the JMF gradations shall be within the tolerances set forth in either Table 410.4.2A or Table 410.4.2B. Marshall mix designs shall be developed in accordance with MP 401.02.22. Superpave mix designs shall be developed in accordance with MP 401.02.28. Each proposed JMF must be documented on the Division Form T400 or T400SP and the entire JMF package shall be forwarded for review to the District Materials Engineer/Supervisor. After the District reviews the T400/T400SP and JMF package shall then be transmitted to the Materials Control, Soils and Testing Division for final review. If the JMF requires revision, it will be returned to the designer through the District. The T400/T400SP Form shall contain the following information:
i.Identification of the source and type of materials used in the design. ii. The aggregate blend percentages and the percentage for each sieve fraction of aggregate considered the desirable target for that fraction. iii. The percentage of virgin asphalt binder to be blended with RAP and the total asphalt binder representing the optimum asphalt content for the JMF submitted, which is to be considered the desirable target percentage. iv. The temperature of the completed mixture at the plant which shall be within ± 25°F of the median mix temperature established by the temperature -viscosity chart or as recommended by the asphalt supplier.
v.The ratio (calculated to the nearest one-tenth percent) of the Fines to Asphalt (FA). For Marshall mixes the ratio is defined as the percentage of aggregate passing the No. 200 (75 µm) sieve, divided by the percentage of asphalt content calculated at the percentage optimum asphalt content of the design. For Superpave mixes the ratio is defined as the percentage of aggregate passing the 75 µm (No. 200) sieve, divided by the percentage of effective asphalt content calculated at the percentage optimum asphalt content of the design. TABLE 410.4.2A Design Aggregate Gradation Requirements for Marshall Mix Designs Type of Mix Base-I Base-II (Patch & Level) Wearing IV Wearing-I (Scratch-I) Wearing-III (Scratch-III) Sieve Size Nominal Maximum Size 1 ½ in (37.5 mm) ¾ in (19 mm) ¾ in (19 mm) 3/8 in (9.5 mm) No. 4 (4.75 mm) 2 in (50 mm) 100 – – – – 1 ½ in (37.5 mm) 90-100 – – – – 1 in (25 mm) 90 max 100 100 – – ¾ in (19 mm) – 90-100 90-100 – – ½ in (12.5 mm) – 90 max 90 max 100 – 3/8 in (9.5 mm) – – – 85-100 100 No. 4 (4.75 mm) – – 47 min 80 max 90-100 No. 8 (2.36 mm) 15-36 20-50 20-50 30-55 90 max No. 16 (1.18 mm) – – – – 40-65 No. 30 (600 µm) – – – – – No. 50 (300 µm) – – – – – No. 200 (75 µm) 1-6 2-8 2-8 2-9 3-11 TABLE 410.4.2B Design Aggregate Gradation Requirements for Superpave Mix Designs Type of Mix 37.5 25 19 Note 1 (Patch & Level) 12.5 9.5 (Scratch) 4.75 (Scratch) Standard Sieve Size Nominal Maximum Size 37.5 mm (1 ½ inch) 25 mm (1 inch) 19 mm (3/4 inch) 12.5 mm (1/2 inch) 9.5 mm (3/8 inch) 4.75 (No. 4) 50 mm (2”) 100 – – – – – 37.5 mm (1½”) 90-100 100 – – – – 25 mm (1”) 90 max 90-100 100 – – – 19 mm (3/4”) – 90 max 90-100 100 – – 12.5 mm (1/2”) – – 90 max 90-100 100 100 9.5 mm (3/8”) – – – 90 max 90-100 95-100 4.75 mm (No.4) – – – – 90 max 90-100 2.36 mm (No.8) 15-41 19-45 23- 49 28-58 32-67 1.18 mm (No.16) – – – – – 30-60 600 µm (No.30) – – – – – – 300 µm (No. 50) – – – – – – 75 µm (No.200) 0-6 1-7 2-8 2-10 2-10 6-12 Note 1 When a 19 mm mix is specified for use as a heavy duty surface mix, it shall be designed as a fine graded mix with the additional requirement of a minimum of 47% passing the 4.75 mm (No.4) screen. If it becomes necessary to change aggregate sources, a new mix design shall be developed and submitted for approval. When using neat (unmodified) PG Binders, the binder grade must always remain the same for each design, however the binder source may be changed without requiring a new mix design given that the replacem ent binder is provided from an approved source. If a source change results in the use of an additive enhanced modified binder of the same grade, a new mix design will be required. If a modified binder source is changed or if the modification process is changed, a new mix design shall be developed and submitted for approval. A source change to a new location with the original manufacturer/supplier and the original modification process will not require a new mix design. At no time shall different grades of PG Binders be mixed together in the same storage tank. When it is necessary to switch to a new binder grade the tank shall be drawn down as far as possible, normally to the top of heating coils, before refilling with the new binder. The new binder shall be circulated thoroughly before restarting production. 410.4.2.1-Warm Mix Asphalt: When the Contractor chooses to use an approved asphalt design to be produced as warm -mix asphalt (WMA) using the water injection system, the temperature of the completed mixture at the plant may be lowered to an established range that has previously been determined through trial production. The allowable temperature range specified on the approved T400 mix design form shall be adjusted accordingly when producing WMA. In ad dition, all references to the minimum compaction temperatures in Sections 410.10.3 and 410.10.4 of this specification, may be waived if it can be established that additional density can be obtained at lower temperatures without damaging the pavement. All testing requirements established for Hot Mix Asphalt mix designs and quality assurance/quality control testing shall also apply to WMA. 410.5-TESTING: 410.5.1-Test Methods: MP 700.00.06 Aggregate Sampling Procedures AASHTO T168 Sampling Hot-Mix Asphalt AASHTO T11 Materials Finer than No. 200 (75 µm) Sieve in Mineral Aggregates by Washing AASHTO T27 Sieve Analysis of Fine and Coarse Aggregates AASHTO T30 Mechanical Analysis of Extracted Aggregate AASHTO T164 Quantitative Extraction of Bitumen from Bituminous Paving Mixtures AASHTO T308 Asphalt Content of HMA by the Ignition Method (Test Method A) AASHTO T245 Resistance to Plastic Flow of Bituminous Mixtures Using Marshall Apparatus ASTM D5581 Resistance to Plastic Flow of Bituminous Mixtures Using Marshall Apparatus (For Base-I Marshall designs only) AASHTO T166 Bulk Specific Gravity of Compacted Bituminous Mixtures AASHTO T209 Maximum Specific Gravity of Bituminous Paving Mixtures AASHTO T312 Determining the Density of HMA Specimens by Means of the Superpave Gyratory Compactor AASHTO T331 Bulk Specific Gravity and Density of Compacted HMA Using Automatic Vacuum Sealing Method ASTM D7227 Rapid Drying of Compacted Asphalt Specimens Using Vacuum Drying Apparatus MP 401.02.31 Quality Control and Acceptance of Asphaltic Mixtures MP 401.07.20 Sampling Loose Asphaltic Mixtures in the Field MP 401.07.21 Sampling Compacted Asphaltic Mixtures in the Field MP 401.07.22 Measuring Thickness of Asphalt Pavement using Drilled Cores MP 401.07.23 Measuring Bond Strength of Cored Specimens MP 401.07.24 Measuring Asphaltic Pavement Macrotexture MP 401.07.25 Evaluation of Pavement with Substandard Properties MP 401.13.50 Determination of Percent Within Limits 410.6-CONTRACTORS QUALITY CONTROL: 410.6.1-Quality Control Testing : Quality control of the asphalt pavement is the responsibility of the Contractor. The Contractor shall maintain equip ment and qualified personnel including at least one certified Asphalt Plant Technician at each plant. The technician shall be in charge of all plant quality control activities such as mix proportioning and adjustment and all sampling and testing activities necessary to maintain the various properties of asphalt within the limits of the specification. The Contractor shall maintain necessary equipment and qualified personnel including at least one certified Asphalt Field and Compaction Technician at each project during paving operations. Additionally, a certified Asphalt Field and Compaction Technician with certification to perform nuclear density testing of asphalt pavements shall perform all testing necessary to assure compaction of the asphalt meets specification requirements. 410.6.2-Job Mix Formula Field Verification : For each JMF, a mix design field verification shall be conducted during the first days of plant production. For Marshall and Superpave designs, the verification shall be in accordance with the guidelines established in MP 401.02.31. The field verification is for the purpose of demonstrating that the JMF can be produced within the specified tolerances set forth in the MP 401.02.31. If the mix cannot be produce within these requirements, a new mix design will be required. 410.6.3-Quality Control Testing Requirements: After the JMF design field verification has been successfully completed, sampling frequency and test requirements for quality control shall be as set forth in MP 401.02.31 for Marshall and Superpave designs. If the Division determines th at a mix cannot be consistently produced within the tolerance limits of the specified design properties, approval of the mix may be revoked and the contractor will be required to provide a new mix design. 410.7-ACCEPTANCE TESTING: 410.7.1-Acceptance Testing of Asphalt: For Interstates and divided National Highway System (NHS) Highways, material from the paving of the traveled lanes and shoulders will be accepted in the field on a lot -by-lot basis. Lots will be established cumulatively and will be specific for each JMF. Each lot consists of five equal sublots (n=5). A completed sublot will have cores obtained for Pavement Density, and Bond Strength and a Loose Mixture sample for gradation and asphalt content. Samples for mat density and bond strength shall also be used to measure lift thickness prior to any preparation for density or bond strength. All field samples shall be obtained from locations determined as per MP 401.07.20 and MP 401.07.21. A normal lot size is 2,500 tons with five, 500 -ton sublots (n=5), unless operational conditions or project size dictate otherwise. If operational conditions or project size dictate, readjustment of the lot will be made as specified in Table 410.7.1. When lots are adjusted, all sublots shall be of equal size. Breakdowns or stoppages of short periods due to such causes as weather or equipment failure will not be considered as reason to adjust the lot size. The original lot will be continued when work resumes after stoppages of less than 5 days. If a lot is terminated due to a stoppage of 5 days or more, adjust the lot size and number of sublots as specified in Table 410.7.1. For two lane and non-divided NHS Routes, refer to Section 410.13.7.1. TABLE 410.7.1 Re-adjustment of Lot Size and Associated Number of Sublots Remaining Quantity Following Last Full Lot Action Less than 500 tons without a combination of one mixture acceptance sample and one density core Quantity combined with the previous lot, (n=5) Less than 500 tons with a combination of one mixture acceptance sample and one density core One new sublot defined and quantity combined with the previous lot, (n=6) 500 tons to less than 1,000 tons without a combination of two mixture acceptance samples and two density cores One new sublot defined and quantity combined with the previous lot, (n=6) 500 tons to less than 1,000 tons with a combination of two mixture acceptance samples and two density cores Two new sublots defined and quantity combined with the previous lot, (n=7) 1,000 tons to less than 1,500 tons without a combination of three mixture acceptance samples and three density cores Two new sublots defined and quantity combined with the previous lot, (n=7) 1,000 tons to less than 1,500 tons with a combination of three mixture acceptance samples and three density cores New lot defined, (n=3) 1,500 tons to less than 2,000 tons without a combination of four mixture acceptance samples and four density cores New lot defined, (n=3) 1,500 tons to less than 2,000 tons with a combination of four mixture acceptance samples and four density cores New lot defined, (n=4) 2,000 tons to less than 2,500 tons without a combination of five mixture acceptance samples and five density cores New lot defined, (n=4) 2,000 tons to less than 2,500 tons with a combination of five mixture acceptance samples and five density cores New lot defined, (n=5) Immediately after each sample is taken, it shall be identified by labeling or otherwise with the following information:
1.Contract ID
2.State Project Number
3.Sample Type (density, bond, loose, etc.)
4.Pavement Course (surface, base)
5.Lot Number
6.Sublot Number
7.Date
8.Sampled By A sample labeling standard is shown in MP 401.07.20 Sampling of Loose Asphaltic Pavement Mixtures and MP 401.07.21. Upon fully identifying, marking, or labeling, and securing, samples shall be transported to the District Materials Laboratory for testing unless otherwise indicated in the proposal. 410.7.1.1-Mixture Acceptance Samples: The Inspector will select sample locations in each sublot according to MP 401.07.20 Sampling of Loose Asphaltic Pavement Mixtures. The Inspector or in the presence of the Inspector, one loose mixture sample shall be obtained for each sublot. This sample is to be taken directly from the uncompacted mixture and immediately processed in accordance with the MP. 410.7.1.2-Compaction: Compaction testing for mat density shall be performed for all traveled lanes, ramps and shoulders. Work will be evaluated based on an Upper Specification Limit (USL) of 98.0 and a Lower Specification Limit (LSL) of 91.5 for all mats within travel lanes. Acceptance of mat density shall be in accordance with subsection
410.13 3.
Maximum density values that are supplied by the asphalt producer shall be verified by the District Materials st aff by determining the theoretical maximum specific gravity in accordance with AASHTO T209 Theoretical Maximum Specific Gravity (Gmm). This verification of Gmm shall be conducted once per lot for all mixes, or one in each five reported values from the asphalt producer. This Gmm value must be within 0.024 of the asphalt producer’s daily average. Any deviation of greater shall warrant special evaluation. Joint density testing is required. The joint density shall be evaluated based on a Lower Specification Limit (LSL) of 89% of a maximum density established by averaging the maximum densities for the paved mats adjacent to the constructed longitudinal joint. The joint density requirement shall only apply to the surface lift of the pavement structure. Lots for joint density shall also be established cumulatively and laid out as per the applicable provisions within MP 401.07.21. A normal lot size for evaluation of joint density is 10,000 linear feet of constructed joint with five, 2000 foot long sublots, unless operational conditions or project size dictate otherwise. Lots for joint density determined to be 4000 feet in length or less shall be incorporated into the previous full lot. If the length is 2000 feet or less, then on e sample shall be taken, and the lot be evaluated with six equal sublots (n=6). If the length is greater than 2000 feet, then two samples shall be taken, and the lot be evaluated with seven equal sublots (n=7). Lots for joint density that are greater than 4000 feet in length shall have samples taken representative of each 2000-foot long sublot or portion thereof. Acceptance for joint density shall be as per 410.13.4. Patching-and-leveling and scratch courses shall not be included in determining the total new pavement thickness to be tested for compaction. When asphalt is placed in areas that require a non -uniform thickness or is tapered to a thin edge, the method of acceptance testing shall be determined by the Engineer. Acceptance testing is not required on areas in which a full-size roller is restricted from compacting the mat properly. These areas shall be compacted to the satisfaction of the Engineer. 410.7.1.3-Shoulders and Ramps: As per MP 401.07.21, shoulders and ramp areas that are constructed simultaneously with the mainline are not included in the sampling plan. However, these simultaneously constructed shoulder and ramp areas shall be included in the lot of the adjacent mainline for the purposes of penalty calculations for compaction and mixture properties. Shoulders that are constructed independently of the mainline shall be tested as per MP 401.07.21. However, compaction penalty calculations for these independently constructed shoulders shall not apply. 410.7.1.4-Thickness: Thickness testing shall be performed on all traveled lanes, ramps and independently constructed shoulders. Cores obtained for mat density and bond strength will both be measured for thickness as per MP 410.07.22 Measurement for Thickness of Asphalt Pavement Using Drilled Cores, prior to those subsequent analyses. The core measurements which represent the thickness of the sampling units shall be analyzed to determine the average value of the pavement thickness. Pavement Thickness (T) shall include all of the pavemen t layers as specified excluding any patch and level course and scratch courses. This value will be used to determine the degree of compliance with the provisions and to develop certain factors to be used in the derivation of equitable deductions as set forth in Section 410.13.5, in the event the provisions of this Specification are not met. 410.7.1.5-Bond Strength : Bond Strength Testing shall be conducted to ensure the creation of a monolithic layered pavement; this is typically achieved by the application of a tack coat between pavement layers. Any tack coats applied by the Contractor shall be applied in accordance with Section 408. Bond Testing shall be performed on all surface layers beginning with the existing pavement layer and then all intermedi ate pavement layers called for in the proposal and plans, this testing shall be performed on all traveled lanes and shoulders. Bond Testing is not required for pavement layers placed on top of a granular type layer (aggregate base, rubblized concrete, macadam, etc.). If an asphalt pavement layer is to be placed atop a concrete surface, Bond Strength testing is not required however, a tack coat shall be applied in accordance with Section 408 to ensure complete coverage of the surface and to the satisfaction of the Engineer. Core bond strength shall exceed a minimum of 100 psi when tested in accordance to MP 410.07.23 Guide to Determining Interface Bond Shear Strength. 410.7.2-Surface Tolerance: Shall be in accordance with Section 720 on the finished mat. 410.7.3-Pattern Segregation: Pattern segregation is continuous or repeated areas of non- uniform distribution of coarse and fine aggregate particles in the finished mat. The Division will address pattern segregation as follows: 410.7.3.1-Evaluating Pattern Segregation: If the Engineer observes pattern segregation that may result in defective pavement, then:
i.The Inspector will notify the Contractor of the observed pattern segregation. ii. The Contractor may continue to work at their own risk while they immediately and continually adjust the operation to eliminate the pattern segregation from future work. iii. As a minimum and in the presence of the Engineer and the Contractor’s Representative, Division personnel shall determine the average depth of pavement surface macrotexture according to MP 401.07.24 in areas with the pattern segregation and in areas with non-segregated pavement. The pattern segregation is unacceptable if the difference in average pavement texture depth between the non- segregated and segregated areas exceeds the following:
a.For 9.5 mm or Wearing I mixes – 0.012 inch
b.For 12.5 mm mixes – 0.016 inch iv. The Engineer will determine if the pavement is defective as specified in Section 410.7.3.3. 410.7.3.2-Test Section : If the macrotexture tests identify unacceptable pattern segregation, then:
i.Immediately suspend placing the asphalt course. Evaluate the cause of pattern segregation according to the Paving Operation QC Plan. Provide proposed corrective actions to the Engineer and do not resume placing the asphalt course until after the Engineer reviews the proposed corrective actions and authorizes paving to continue. ii. Determine if the pattern segregation resulted in defective pavement as specified in iii. After the Engineer allows paving to resume, place a test section not to exceed 200 tons. If the corrective actions do not eliminate observed pattern segregation, the Department will suspend paving, even if it is before the Contractor places the entire test section. Propose additional corrective actions and construct another test section. Resume normal paving operations after constructing an entire test section without pattern segregation as determined by the Engineer. 410.7.3.3-Defective Pavement: At locations selected by the Engineer and with the Engineer present, drill three six (6) inch diameter cores from the area of pattern segregation and three cores from the pavement representing a non-segregated area. Do not compress, bend, or distort samples during cutting and handling and immediately provide the cores to the Inspector. The Inspector will transport cores to the producer’s laboratory. With the Engineer present, test the cores at the plant for density, asphalt content, and gradation. Additional cores and/or additional testing as per MP 401.07.24 Measuring Pavement Macrotexture Depth can be used to further evaluate the pavement. An area of pattern segregation contains defective pavement if:
a.the summation of absolute deviations from any two sieves is 20% or more from the JMF;
b.the core density is defective, the mixture is defective in asphalt content;
c.or the mixture is defective for percent passing the 75 μm (No. 200) sieve. The core density is defective, or the cores are defective for asphalt content or gradation of the 75 μm (No. 200) sieve if the PWL is less than 55 as determined in accordance with MP 401.13.50 and based on three samples (n=3). Remove and replace the full width of the affected lane and a minimum of five (5) feet beyond each end of the area with unacceptable pattern segregation. Construct replacement pavement conforming to the appropriate surface tolerances. 410.7.4-Flushing: Provide a mix that will not flush. Fl ushing is continuous or repeated areas of excessive asphalt on the pavement surface. The Division may recognize flushing until the Division approves the project through final inspection. The Division will address flushing as follows: 410.7.4.1-Evaluating Flushing: When the Engineer observes flushing, then:
i.The Engineer will immediately notify the Contractor of the observed flushing. ii. The Contractor may continue work at its own risk while it immediately and continually adjusts the operation to eliminate flushing from future work. iii. In the presence of the Engineer, determine the average depth of pavement surface macrotexture according to MP 401.07.24 in areas of suspected flushing. If the average texture depth is less than or equal to 0.006 inches, then the pavement will be considered to be flushed and is defective. 410.7.4.2-Test Section: If the macrotexture tests identify flushing, then:
i.Immediately suspend placing the paving course. Evaluate the cause of flushing according to the Paving Operation QC Plan and as directed. Provide proposed corrective actions to the Engineer and do not resume placing the paving course until after the Engineer reviews the proposed corrective actions and authorizes paving to continue. ii. Remove and replace the defective wearing course at no cost to the Division for the full width of the affected lane and a minimum of five (5) feet beyond each end of the area of defective wearing course. Construct replacement wearing course conforming to the appropriate surface tolerances. iii. After the Engineer allows paving to resume, place a test section not to exceed 200 tons. If the corrective actions do not eliminate observed flushing, the Division will suspend paving even if it is before the Contractor places the entire test section. Propose additional corrective actions and construct another test section. Resume normal paving operations after constructing an entire test section without flushing as determined by the Engineer. 410.8: Blank 410.9-EQUIPMENT: 410.9.1-Plants: All plants shall meet the general requirements set forth in AASHTO M156 unless it can be demonstrated to the satisfaction of the Engineer that a consistent quality mix can be produced with modifications to any of these requirements. All plants in West Virginia producing asphalt for the Division shall provide docu mented evidence of compliance with current requirements of the West Virginia Air Pollution Control Commission. All plants which are not in West Virginia but producing asphalt for the West Virginia Division of Highways shall provide documented evidence of compliance with current requirements of the laws and regulations of the State in which they are producing, applicable to air pollution. 410.9.2-Dust Collector: An efficient dust collecting system shall be provided to prevent the loss of fine material. The material collected may be returned to the mixture at a uniform rate or discarded. 410.9.3-Truck Scales: Truck scales shall be provided at each Plant, except that truck scales are not required at properly calibrated automatic batching plan t facilities which are equipped with digital printout equipment, and which load the trucks directly from the mixer or the weigh hopper in a surge or storage silo. A person designated as a weigher shall be provided by the producer. The weigher shall certify that the weight of the asphalt, as determined either by the truck scales or from the digital printout of the batch weights, is correct. Each truck shall be weighed empty prior to each load, except at automatic batch plants approved to operate without truck scales. All truck scales shall be mounted on solid foundations which will insure them remaining plumb and level. Approval and sealing of scales shall be conducted at the frequency determined by the West Virginia Division of Labor, Bureau of Weights and Measures, and when the plant is moved, or upon the request of the Engineer. The Engineer shall be notified of any scale malfunctions when material is being furnished to Division of Highways projects. The Division may, at its option, accept inspection and sealing by out-of-state agencies when the mixing plant is located outside West Virginia. A digital recorder shall be required on all truck scales. The digital recorder shall produce a printed record of the gross, tare and net weights, and the time, date, truck identification, and project number. Provision shall be made for constant zero compensation and further provision shall be made so that the scales may not be manually manipulated during the printing process. The system shall be interlocked so as to allow printing only when the scale has come to rest. In case of breakdown of the automatic equipment, the Engineer may permit manual operation for a reasonable time, normally not to exceed 48 hours, while the equipment is being repaired. The scales shall be of sufficient size and capacity to weigh the loaded trucks that are used for delivery of asphalt from the plant. 410.9.4-Test Weights: As part of its standard equipment, each plant which proportions aggregate by weight shall provide a minimum of ten 50-pound test weights for the purpose of verifying the continued accuracy of its weighing equipment. Plants which proportion asphalt material by weight shall furnish, in addition to the above, one five pound test weight. 410.9.5-Surge and Storage Silos: During the normal daily operation of the plant, asphalt may be stored in a surge or storage silo for a maximum of 6 hours, provided the silo has received prior evaluation and acceptance through the Dis trict plant inspection. The resulting temperature of the material at time of placement and compaction shall be sufficient to comply with subsection 410.10.1. 410.9.6-Inspection of Equipment and Plant Operations: The Engineer shall have access to the plant to assure the adequacy of the equipment in use, to inspect the conditions and operation of the plant, to verify weights, to verify the proportion and character of materials, and to determine if specified temperatures are being maintained in the p reparation of the mixture. 410.9.7-Trucks for Transporting Mixture: The use of diesel fuel, kerosene, or similar solvent-based products which can dissolve the asphalt film from the aggregate particles will not be permitted for use as a release agent. Any commercial release agent which is certified as harmless to the mix may be used; however, the Division reserves the right to restrict any release agent that is shown to cause problems during placement of the mix. All excess release agent shall be removed from the truck bed prior to loading the asphalt. All truck beds shall be insulated with approved material. No trucks shall be used which cause segregation of the materials, which show large oil leaks, or which cause undue delays in delivery of material . All trucks shall be provided with a waterproof cover and a hole in the body for the purpose of conveniently checking the temperature of the load. Covers shall be suspended slightly above the mixture, shall extend over the sides of the truck, and shall be securely fastened to eliminate air infiltration and to prevent water from coming in contact with the mixture. 410.9.8-Laboratory: A testing facility or laboratory, as described below, shall be provided within reasonable proximity of the asphalt plant. Plant operations must be visible from within the laboratory. The laboratory shall be of sufficient size to hold all laboratory test equipment and supplies with adequate floor space to allow the technicians to test samples in an efficient manner. T he laboratory shall be furnished and maintained with adequate ventilation, heat, light, water, sink and drainage, electrical or gas outlets, or both, work table, shelves, and supply cabinets. The laboratory shall be supplied with the equipment and materials listed below and these shall be maintained to meet the applicable requirements of AASHTO or ASTM:
i.Hot plate, gas or electric. ii. Large ovens (as needed for heating and drying samples), gas or electric. iii. Unit weight container, ½ cubic foot. Required for slag only. iv. Balances of sufficient capacity and accuracy for conducting specified tests and plant calibration.
v.Thermometers: dial type, liquid -in-glass, and digital as required for conducting standard test procedures and monitoring mix temperatures. Digital thermometers shall be equipped with an appropriate sturdy probe that can be pushed into a sample of hot asphalt to check the temperature of the mix. vi. Ro-Tap Sieve shaker or equivalent, with eight (8) and/or twelve (12) inch diameter screens. vii. Sample splitters for fine and coarse aggregates. viii. Miscellaneous items (including sample splitting trowels, scoops, square point shovel, aggregate sample pans, heat resistant gloves, measuring rules, brushes, flashlight, timing devices, and glassware as needed). ix. Expendable supplies necessary for performance of tests.
x.Equipment for determining the maximum specific gravity of asphalt mixtures as specified in AASHTO T209. xi. Non-contact infrared thermometer accurate to ± 2°F. xii. Equipment for determining the bulk specific gravity of asphalt mixtures using saturated surface dry specimens complying with AASHTO T166. xiii. Marshall equipment necessary to comply with AASHTO T245 and ASTM D5581, including a calibrated automatic testing apparatus having recording capabilities and compaction hammers. (Marshall designs only) xiv. Asphalt content ignition oven with built-in scale and printer meeting the requirements of AASHTO T308, Test Method A. xv. Calibrated Gyratory compactor meeting requirement of AASHTO T312 with computer (including software for data acquisition and test calculations) and printer. Compactor must be calibrated to the internal angle in accordance with AASHTO TP71 with annual verification (Superpave designs only). 410.9.9-Asphalt Paving Equipment: Asphalt paving equipment shall be self -contained and of sufficient size, power, and stability to receive, distribute and strike -off the asphalt mixture at rates and widths commensurate with the typical sections and other details shown on the plans. The paver shall be provided with an activated screed or strike-off assembly equipped to be heated. Approval of the paver by the Engineer will be based on the demonstrated capability of the equipment to place the mixture to the required cross -section, profile, and alignment in an acceptable, finished condition ready for compaction. The paver shall be equipped with means of preventing the segregation of the coarse aggregate particles when moving the mixture from the paver hopper to the paver augers. It shall also be capable of pushing a sufficient amount of the mixture under the auger gearbox to prevent streaking or tearing of the mat. Some paver models may require the installation of a manufacturer retrofit kit or equipment modification to accomplish this. Specialized equipment or hand methods approved by the Engineer may be employed to spread the asphalt mixture where the use of standard full-scale paver is impractical due to the size or irregularity of the area to be paved. Pavers shall be equipped with mechanical or automatic grade and slope controls. The use of automatic grade and slope controls with a traveling straight edge shall be required only when specified on the Plans or in the Proposal. Both the grade and slope controls shall be in working order at all times. In the event of failure of the automatic controls, the Contractor will be permitted to finish the day's work using manual controls but will not be allowed to resume work the following day until the grade and slope controls are in proper working order. 410.9.10-Compaction Equipment: Compaction may be performed by self -propelled steel-wheeled, pneumatic-tired and/or vibratory rollers. Hand -held rollers or vibrating plates may be used in small inaccessible areas if approved by the Engineer. Prior to use on any project, the roller shall be inspected to see that it is in good mechanical condition. The total weight, weight per inch of width (steel -wheeled), and average ground contact pressure (pneumatic-tired) shall be documented.
410.10 Paving Operations:
410.10.1 Spreading and Finishing: Before spreading any material, the contact surfaces
of curbs, gutters, manholes, and of adjacent Portland cement concrete pavement edges shall be painted or sealed with asphalt material. Exact edge of pavement, except on concrete, shall be established by a string or chalk line for a distance of not less than 500 feet ahead of the spreading operation. For projects where the existing pavement was mill ed prior to the placement of new asphalt, the edge of pavement shall be the edge of milled section. For mixes produced with neat (non -modified) asphalts (which may include PG 64H - 22, PG 64S -22, PG 58H -28, and PG 58S -28) the temperature of the mixture at the time of placement shall be within the temperature requirements of the JMF. The JMF temperature range shall be the liquid asphalt supplier’s specified mixing temperature ±45°F with a maximum mixing temperature of 338°F. Additional allowances will be made for water injection processes with a minimum mixing temperature of 220°F. The mix temperature shall be monitored by inserting a thermometer into the mix through the hole in the truck bed. The temperature of the completed mix, when measured at the plant, shall be within the tolerance as established by the JMF. The first load which demonstrates temperatures outside of that range shall be accepted, provided that the temperature is still within the master temperature range. No additional loads of material shall be run out until necessary steps are taken to reestablish the temperature of the mix within the plant tolerance. When measured at the project site, the temperature of the mix shall be within the tolerance established by the JMF. The first truck load of material which demonstrates temperatures outside of that range or any trucks in transit at that time shall be accepted provided temperatures are within the master temperature range. Any truckload of material which exceeds the master temperature range may be rejected by the Engineer. However, the plant shall immediately be notified that no additional loads of material are to be dispatched until necessary action is taken to reestablish temperature within JMF specification limits. When the surface temperature falls to within 10°F of the weather restrictions of Table 410.8, the mix temperature may be increased up to a maximum of 338°F unless otherwise specified by the asphalt supplier. The temperature of each truckload of material shall be monitored for compliance. Any truckload of material which exceeds this maximum temperature may be rejected by the Engineer. Mixes produced with asphalts that contain modifiers for high or low temperature performance enhancement shall meet the te mperature requirements recommended by the asphalt supplier, as determined using the mid-point of the mixing temperature range shown on the asphalt temperature-viscosity charts and allowing for ± 25°F.
410.10.2 Safety Edge: When the total specified lift thickness of pavement is 1.5 inches
or greater, asphalt safety edge shall be constructed on the outside pavement edge. The device utilized shall be a model listed on Division Approved Product Listing. The resulting finished surface of the safety edge shall be sufficiently consolidated so as to show no segregation or raveling of the aggregate and shall have the same surface profile and texture of the compacted mat surface. Safety edge is not to be used through intersections, against curb or barrier, or when directed by the Engineer. The paving operation shall allow for automatic and/or manual transitions at cross roads, driveways, and intersections. The Engineer may allow short sections of handwork for transitions at driveways, intersections, interchanges, and bridges.
410.11 Protection of Pavement and Traffic Control:
The Contractor shall be responsible for the protection of asphalt surfaces from damage by their equipment and personnel. When the construction of asphalt surfaces is undertaken on projects under public traffic and the road surface is sixteen (16) feet wide or greater and the ADT is 400 or greater, the Contractor shall place no passing signs, Interim pavement markings, and Temporary pavement markings to delineate the edge line, centerline, and/or lane line of the roadway as required herein and in the project plans. The provision of Section 336: Maintaining Traffic shall apply. Interim markings are described as markings applied to freshly resurfaced roadways between lifts and after placement of the final lift prior to opening the portion of the roadway being resurfaced to traffic. These markings are intended to provide the minimum amount of delineation required for safe navigation of the roadway and are to be succeeded by Temporary markings within a three (3) to fourteen (14) day period, based on the type of roadway and ADT, as specified herein. Interim and Temporary markings shall conform to the requirements of Section 663: Pavement Markings.
410.12 Method of Measurement:
Asphalt will be measured by the Square Yard (SY). The quantity will be determined by the Plan Quantity as provided for in the proposal unless otherwise directed by the Engineer. Any patching or leveling mixture placed on a subbase or base co urse constructed in the same Contract with the asphalt items shall be at the expense of the Contractor. No additional compensation will be allowed for the material or any work incidental to its placement unless otherwise approved by the Engineer. No additi onal measurement is necessary nor will addition compensation be allowed for the placement of Safety Edge.
410.13 Basis of Payment:
The quantities determine as provided above, will be paid for at the contract unit price for the items listed below, which prices and payment shall be full compensation for furnishing all the materials and doing all the work herein prescribed in a workmanlike and acceptable manner, including all labor, tools, equipment, field laboratory, supplies, tack coat, and incidentals necessary to complete the work and provide the performance criteria specified. There will be no additional compensation for Interim Pavement Markings.
410.13 1When a Lot of asphalt material is found not in compliance with the tolerance
requirements for asphalt content and gradation as shown in MP 401.02.31, it shall be subject to a price adjustment in accordance with the criteria for Determination of Percent Within Limits established in MP 401.13.50 and pay factors in Table 410.13.3.1.
410.13 2: Blank
410.13.3 For Interstates and divided NHS Highways, the unit price for each Lot of asphalt
pavement Mat shall be adjusted as follows in Table 410.13.3.1 in accordance with MP 401.13.50. For two -lane and non-divided NHS Routes, the pay factor for asphalt content and percent passing the 75 μm (No. 200) sieve shall be determined by Table 410.13.3.1. However, the mat density pay factor shall be determined by Table 410.13.7.2. TABLE 410.13.3.1 Percentage of Material Within Specification Limits (PWL) Lot Pay Factor (Percent of Contract Unit Price) 90-100 100 75-89 [(0.5)PWL]+55 Note 1 55-74 [(1.4)PWL]-12 Note 1 Material with a PWL less than 55 is considered defective and will be considered for removal and replacement of the lot. If only one lot characteristic has a percent within limits less than 55, the Engineer, may allow the Contractor to leave the defective lot in place. The decision to remove and replace the subject lot shall include evaluation of all lot characteristics for pay and surface characteristics as per guidelines set forth in MP
401.07.25 If the material is left in place, the Department will pay for the defective lot at
a value not to exceed 50% of the contract unit price of asphalt per square yard. (i.e., Contract unit price = $10 sy → $5 sy max)
410.13.3 1-Price Adjustment: The Division will compute the percent of the contract
unit price paid as follows: Lot Payment = CP (2PD + PB + PA) / 400 Where: CP = Contract unit price per lot (unit price times lot quantity) PD = Payment Factor Percentage for mat density PB = Payment Factor Percentage for asphalt content. PA = Payment Factor Percentage for percent passing the 75 μm (No. 200) sieve Shoulders and ramps shall be included in penalty calculations for mixture and compaction unless they are constructed independently, where the density requirements shall be waived. When compaction requirements are waived, PD will be minimum of 100.
410.13.4 Joint Density Adjustments: For Interstates and divided NHS Highways, joint
Density PWL calculations shall be in accordance with MP 401.13.50. Joint Density negative adjustments will be calculated for joint lots with a PWL less than or equal to 60 . Price adjustments shall be calculated using the formula below. There will be no adjustment for joint lots who’s PWL is greater than 60. Negative adjustment calculated as follows: 60 − PWL $T = X 12,500 60 Adjustments calculated for lots less than or greater than 10,000 feet in length shall be prorated directly proportional to the amount of length less than or greater than 10,000 feet. For two-lane and non-divided NHS Routes, refer to Section 410.13.7.3.
410.13.5 Thickness Adjustments: No payment will be made for pavement areas deficient
in thickness by more than 35% T. Pavement which is deficient in thickness by more than 50% T is considered to be inadequate to perform satisfactorily and shall be removed and replaced at no added cost to the Division. The balance of the item, the portion of the item not treated in the manner set forth above, will be treated in the manner set forth in 410.13.5.1 below.
410.13.5 1-Price Adjustments for Thickness : When all individual measurements
meet or exc eed the specified thickness, there will be no adjustment for payment. If any individual values or when the average value of the pavement thickness per lot is less than the specified total thickness, the quantity of pavement represented by this average thickness will be paid by a direct calculation as defined as follows: t Price Adjustment % = ( ) x100 T Where: T = Total Plan Thickness t = avg. lot thickness + 0.04 inch. This value is then applied to the unit price for the asphalt place in the lot, this adjustment shall remain separate from the PWL adjustments for AC, Gradation, Density, etc.
410.13.6 Bond Strength Adjustment: For Interstates and divided NHS Routes, bond
Strength PWL calculations shall be in accordance with MP 401.13.50, Guide to Statistical Analysis of Material Using Quality Level Analysis -Percent within Limits. However, for the purpose of relieving large standard deviations from abnormally strong samples, any sample with a strength exceeding 150 psi will be evaluated as 150 psi instead of the actual strength. The actual strength shall still be recorded as such on the reporting form. Bond Strength Negative adjustment will be calculated for lots with PWL less than or equal to 70. There is no adjustment for bond Strength lots who’s PWL is greater than 70. Negative adjustment calculated as follows: 70 − PWL $T = X 25,000 70 Adjustments calculate for lots less than or greater than the standard 2,500 tons shall be prorated directly proportional to the amount of tonnage less than or greater than 2,500 tons. This shall be calculated on the theoretical tonnage for the lot, not the actual tonnage used. For two-lane and non-divided NHS Routes, refer to Section 410.13.7.4.
410.13.7 Two-Lane and Non -divided NHS Route Exceptions : Due to the wide range
of variability on the roadway, the following exceptions for lot/sublot layout and analysis of existing condition dependent test results shall apply:
410.13.7 1-Acceptance Testing of Asphalt: A lot shall consist of three (3) to seven
7.equal sublots. A normal sublot size is 500 tons unless operational conditions and sublot size dictate otherwise. Determine the number of sublots on the project by converting the square yardage of the travel lanes and simultaneously paved shoulders to tonnage. Divide the tonnage by 500 and round to the nearest whole number (n). Use that numbe r (n) in Table 410.13.7.1 to determine the number of lots to be used for acceptance. TABLE 410.13.7.1 Number of Sublots (n) Number of Lots 3 to 7 1 Lot with (n) even sublots 8 2 Lots with 4 even sublots each 9 2 Lots - Lot 1, 5 Sublots / Lot 2, 4 Sublots 10 2 Lots with 5 even sublots each 11 2 Lots - Lot 1, 6 Sublots / Lot 2, 5 Sublots 12 2 Lots with 6 even sublots each 13 2 Lots - Lot 1, 7 Sublots / Lot 2, 6 Sublots 14 3 Lots - Lot 1, 5 Sublots / Lot 2, 5 Sublots / Lot 3, 4 Sublots 15 3 Lots with 5 even Sublots each Turn lanes, intersections, and independently constructed shoulders shall not be subject to price adjustments if the combined square yardage converts to less than 500 tons. If the square yardage converts to over 500 tons, then one additional sublot for asph alt content, percent passing the 75 μm (No. 200) sieve, and bond strength shall be added to the last lot constructed. Compaction shall be monitored, documented, and submitted to the Engineer by a certified Asphalt Field and Compaction Technician to assure that it meets specification requirements.
410.13.7 2-Basis of Payment: The payment factor for density shall be adjusted as
follows in Table 410.13.7.2. This payment factor (PD) will then be used in the Lot Payment calculation formula in Section 410.13.3.1. TABLE 410.13.7.2 Payment Factors for Pavement Mat Density Average Lot Percent Density Payment Factor (PD) Greater than 98 % Note 1 91.50% to 98.00% 100 88.00% to 91.49% = 100 – 4*(91.50% - Percent density) Less than 88% = 84 – 10*(88% - Percent density) Note 2 Note 1 High mat density is only a problem if it leads to asphalt flushing on the surface of the mat or rutting due to an unstable mix. The Division will make a special evaluation of the material and determine the appropriate action. Note 2 When the density decreases, the mat will be more susceptible to accelerated deterioration and a decrease in the expected service life of the pavement. For mat densities less than 88%, the percent of Contract Bid Price will be decreased by an additional 10% per percentage of mat density less than 88%, unless a Special evaluation performed by the Division determines a more appropriate action.
410.13.7 3-Joint Density Adjustments: The adjustment for joint density shall be
determined by Table 410.13.7.3. This adjustment is per linear foot and will be multiplied by the total number of linear feet in the lot to determine the total lot adjustment. This is calculated per lot and applied per Section 410.13.8.3. TABLE 410.13.7.3 Pay Adjustment for Pavement Joint Density per Linear Foot Average Lot Percent Density Price Adjustment ($ / LF) Greater than 97 % Note 3
89.00 % to 97.00% 0
88.00% to 88.99% -0.20 Less than 88% = [{0.50*(Percent Density – 88.00)} – 0.20] Note 3 Joint density slightly above 97% is normally only a problem if it leads to asphalt flushing on the surface of the mat or rutting due to an unstable mix. The Division will make a special evaluation of the material and determine the appropriate action.
410.13.7 4-Bond Strength Adjustments: The adjustment for bond strength shall be
determined by Table 410.13.7.4. This is calculated per lot and applied per Section 410.13.8.4. This shall be calculated on the theoretical tonnage for the lot, not the actual tonnage used. TABLE 410.13.7.4 Pay Adjustment for Bond Strength per 2500 Ton Lot Average Lot Bond Strength (PSI) Price Adjustment ($ / Lot)
100.00 and Greater 0
75.00 to 99.99 = [{1,000*(PSI - 75.00)} – 25,000]
Less than 75.00 – 25,000
410.13.8 Lot Payment Calculations: The pay factors that are calculated with in the
specification are to be applied in the following way:
410.13.8 1-PWL Factors: The calculated total PWL for a given lot is applied to the
bid unit price for the asphalt mixture in the lot. Once the unit pr ice has been adjusted the quantities can be calculated to arrive at the payment for the lot.
410.13.8 2-Thickness Adjustment: There is no adjustment for thickness greater than
the thickness that is specified in the plans. If there is a Price Adjustment (Section 410.13.5) for thickness this factor (percentage) is applied to the contract bid unit price times the quantity in the lot to arrive at a dollar amount penalty. This penalty is applied to the overall payment for the lot.
410.13.8 3-Joint Density Adjustment: If it is determined in Section 410.13.4 of this
specification that a Joint Density Adjustment is warranted the dollar amount determined in the formulas of Section 410.13.4 or Table 410.13.7.3 shall be applied to the overall payment for the lot.
410.13.8 4-Bond Strength Adjustment: If it is determined that a Bond Strength
Adjustment is warranted the formulas in Section 410.13.6 or Table 410.13.7.4 shall be used to calculate the adjustment. This adjustment shall be applied to the overall payment for the lot.
410.14 Pay Items:
ITEM DESCRIPTION UNIT 410001-* “design method” Asphalt Base Course, Type “mix type” Square Yard 410002-* “design method” Asphalt Wear Course, Type “mix type” Square Yard 410007-* “design method” Asphalt Skid Pavement, Type “mix type” Square Yard * Sequence number “design method” shall be either Marshall or Superpave “mix type” from Table 401.4.2A or 401.4.2B SECTION 411 THROUGH SECTION 414-BLANK
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Source: Standard Specifications for Roads and Bridges, 2023 Edition. Pages 214–234 of 1,006. View official source ↗