401Plant Mix Pavements and Recycled Plant Mix Pavements

Plant Mix Pavements and Recycled Plant Mix Pavements

401.1DESCRIPTION

1 This section describes the requirements for construction of one or more courses of plant mix pavement or recycled plant mix pavement placed on a prepared foundation.

401.2MATERIALS

401.2.1 Performance Graded Asphalt Binder

1 Provide performance graded asphalt binder (PGAB) of specified grade and meeting requirements of Subsection 804.1, Performance Graded Asphalt Binder. Use authorized source of PGAB, in accordance with Subsection 804.1, Performance Graded Asphalt Binder. A c urrent list of authorized suppliers is available on the Qualified Product List

2 The contractor may use a different grade of binder if:

temperature is decreased;

production begins; and

3 The engineer will test PGAB at the temperatures for the grade specified. The department will not pay extra for grade changes proposed by the contractor.

4 Ensure that asphalt binder and required modifier(s) are blended prior to delivery to the project.

5 Ensure the supplier performs binder testing and provides the Materials Program with test reports for applicable properties in accordance with Subsection 804.1, Performance Graded Asphalt Binder.

6 Ensure each load of PGAB is delivered to the project site, accompanied by a supplier - furnished shipping document that clearly indicates specification grade of PGAB, as well as test results.

401.2.2 Aggregates

1 Provide aggregates in accordance with Section 803, Aggregate.

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401.2.2.1 Recycled Plant Mix Pavement

1 Provide aggregates for recycled plant mix pavement in accordance with Section 803, Aggregate, with the gradation bands modified as specified. Use reclaimed asphalt pavement (RAP) from specified sources.

2 Excess RAP remains the property of the department.

401.2.3 Hydrated Lime

1 Provide hydrated lime in accordance with Section 820, Hydrated Lime and water in accordance with Section 814, Water.

401.2.4 Burner Fuel

1 Fuel mixing plants with natural gas, Nos. 1 or 2 fuel oil, butane, propane, or used oil. In the case of used oil, comply with 40 CFR 279, “Standards for the Management of Used Oil”; give the engineer copies of tests certified by the supplier showing that applicable requirements have been met.

401.2.5 Truck Bed Release Agent

1 Do not use a solvent or petroleum-based truck bed release agent.

401.3EQUIPMENT

401.3.1 Milling

1 Produce RAP with a milling machine that meets the requirements of Subsection 202.3, Equipment.

401.3.2 Crushing

1 Crush RAP with compression- type equipment such as jaws, rollers, or cones. Do not use impact or grinding-type crushers.

401.3.3 Mixing Plant

401.3.3.1 General

1 Use a batch or drum plant to make the plant mix. For projects with an estimated need for more than 5000 ton [5000 t], provide a mixing plant with a manufacturer-rated capacity no less than 100 ton/h [100 t/h]. Equip or provide the plant with the following:

aggregates and RAP, if specified, are blended in the proper proportions. Equip

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with an automatic plant shut -off or other means of control if the flow from any bin is stopped or restricted. Equip with calibration devices to readily check the aggregate delivery system. If blending aggregates from two or more bins at the cold feed, ensure and use a means of synchronized proportioning.

proportioning of asphalt binder in the mix.

maintains uniform production and temperature. During operation, ensure the aggregate is continuously agitated and that flames are properly adjusted to prevent damaging or coating the aggregate

operation. If a baghouse is used and the fines are reintroduced into the mixture, provide equipment using a positive means of controlling the addition rate, including a calibrated feeder tied to the plant controls and operating from a surge silo. Direct auguring from the baghouse does not constitute a positive means of control.

aggregates, lime, and asphalt binder separately and mixed.

speed. Arrange to ensure separate and adequate storage of each aggregate fraction and RAP, if specified. Do not allow bins to overflow; equip enclosed bins with overflow chutes to prevent spillage into other compartments or bins. Equip each compartment with an individual outlet gate that does not leak when closed and that cuts off quickly and complet ely. Provide separate dry storage for commercial additives and a means to feed the additives into the mixer.

material is delivered to the collecting conveyor.

system for heating and maintaining the binder at required temperatures without allowing flames to contact the tanks. Equip with a system to ensure the proper and continuous circulation of binder during the operation. Equip with a sampling valve at the discharge line, in accordance with the Materials Testing Manual . Equip with, and ensure the availability of, accurately marked dipsticks for measuring the tanks’ contents and a chart to convert the dipstick readings to gallons [cubic meters].

charging valve at the mixer unit or near the discharge end of the storage tank(s). Equip the dryer discharge chute with a temperature recording device that continuously registers the temperature of the heated aggregates. Also, equip the

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mixer with a temperature recording device that registers and records the temperature of the mixture as it is discharged.

401.3.3.2 Batch Plants

1 In addition to the requirements specified for all mixing plants in Subsection 401.3.3.1, Mixing Plant, General, equip or provide batch plants with the following:

sheet-metal cover. Ensure that the discharge opening or spray bar is at least three-fourths the length of the mixer and discharges directly into the mixer. Ensure adequate heating of the bucket, discharge valves, and spray bar; if used, ensure that steam jackets are drained and connections are constructed to not interfere with the operation of the asphalt binder scales. Ensure the presence of a heated, quick-acting, non-drip charging valve directly over the bucket.

Ensure that the bucket and indicator dial capacity exceed by at least 15 percent the quantity of asphalt binder to be used in a batch. Provide controls that can be secured at any dial setting and that automatically reset after the addition of asphalt binder to each batch. Place the dial in full view of the operator. Ensure a means to automatically begin the flow of asphalt binder when dry mixing is over and to complete the discharge in 15 seconds or less. Ensure that spray bar openings are sized and spaced to provide a uniform application of asphalt binder for the full length of the mixer.

than the full capacity of the mixer.

mixer box or equip with a hood to prevent the escape of dust. Allow no more than 1 in [25 mm] of clearance between the blades and other fixed or moving parts.

cycle and capable of being set at intervals of 5 seconds or less throughout a total cycle of up to 3 minutes. Ensure that the weigh box gate locks after the charging of the mixer and remains locked until the mixer gate closes at the end of the cycle. Ensure that the asphalt binder bucket locks during the interval between the opening of the weigh box gate and the first introduction of asphalt binder (the dry mixing period) and that the mixer gate locks and remains locked during this and the following period of wet mixing.

with a capacity to hold one full batch without overflowing. Equip with a tight-closing gate to prevent leakage of material while weighing.

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401.3.3.3 Drum Plants

1 In addition to the requirements specified for all mixing plants in Subsection 401.3.3.1, Mixing Plant, General, equip or provide drum plants as follows:

2 Weigh cold aggregate and RAP, when specified, continuously on an approved belt scale. Make provisions for determining the cold aggregate’s moisture content and correcting the wet weight [mass] to a dry weight [mass]. Provide an automatic printout and digital display of the weight [mass] of the dry aggregate and the asphalt binder prior to mixing and the time of discharge of the mixture. To ensure the asphalt binder content in the mix, provide a positive interlock between the system for weighing the aggregate and the system for delivering the binder. Provide equipment that will adjust the flow of binder as demanded by changes in the aggregate’s weight [mass]. Provide a means to dry and heat the aggregate to meet moisture and temperature requirements; include a temperature recording device at the discharge chute of the dryer. Ensure the production of a uniform mixture of aggregates and asphalt binder.

401.3.4 Hauling Equipment

401.3.4.1 Performance Graded Asphalt Binder

1 Equip tank trucks delivering PGAB with a sampling valve as specified in the Materials Testing Manual.

401.3.4.2 Plant Mix

1 Ensure that trucks hauling plant mix have tight, clean, smooth, metal beds. As needed, provide trucks with covers to protect the mix from the weather and maintain its temperature.

2 A material transfer device (MTD) is a self -propelled device that is used to store and transfer hot mix from a truck to a paver. When using a MTD:

capacity;

401.3.5 Plant Mix Pavers

1 Provide plant mix pavers that are self -propelled, have a heated, vibratory screed, and are capable of spreading and finishing the mix in widths applicable to the typical section and thicknesses specified. Equip the hopper with a distribution system to place the plant mix uniformly in front of the screed. If used, provide screed extensions that are heated,

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vibratory, in the same horizontal plane, at the same slope as the fixed portion of the screed, and equipped with full-width feed augers.

2 Equip pavers to automatically control the laying of the mix to the specified transverse slope and established longitudinal grade. Provide a paver control system that is automatically actuated from an independent line and grade control reference through a system of m echanical sensors and sensor -directed devices that maintain the paver screed at the proper transverse slope and height to establish the top surface of the compacted plant mix at the specified slope and grade. The independent line and grade control reference may be either of the following:

or

automatic screed control in reference to the base on which it is riding.

401.3.6 Rollers

1 Provide self -propelled rollers in accordance with Subsection 210.3.6, Roller, and capable of reversing direction without backlash. Equip pneumatic-tired rollers with covers to maintain tire temperature. Equip vibratory rollers with a variable amplitude and frequency system. Do not use rollers that adversely affect the sur face of the plant mix pavement.

401.3.7 Paving Leveler

1 Provide a Type A or Type B leveler, as follows:

of at least 50 ft [15 m] between caster-type support wheels and a frame of sufficient strength and rigidity to prevent deflection during operation. Equip with a blade mounted semi-rigidly on the frame within the middle third of the longitudinal span. Remove the screed from the paver when used with the leveling frame. Mount the paver ahead of the blade.

or a minimum 50 ft [15 m] traveling string line.

2 If the contract does not specify which type of leveler to use, either is acceptable.

401.3.8 PGAB Storage Tanks

1 Equip PGAB storage tanks with a sampling valve as specified in the Materials Testing Manual.

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401.4CONSTRUCTION

401.4.1 Composition of Plant Mix

401.4.1.1 General

1 Develop the construction mix design. Obtain the design from a qualified laboratory in accordance with Section 114, Laboratory, Personnel, and Correlation. Contact the Materials Program if questions on procedures or specifications occur during the mix design process.

2 The Materials Program will verify up to two proposed JMF’s for each class of mix design shown in the contract, including a JMF adjusted after verification failure at no cost to the contractor; however, the contractor will be charged $1,500 for each additional proposed JMF request needed to achieve a verified JMF for paving to commence.

3 Except for Level of Control 5 mixtures, submit the following items to the engineer a minimum of 14 calendar days prior to the start of paving. Ensure the submittal is in accordance with the details listed below:

accreditation for required applicable test procedures necessary to complete the job mix formula. Include in the submitted da ta for the mix design the mixture properties specified in Subsection 401.4.1.3, Mix Design.

material collected when sampling for the mix design. When RAP is specified, collect samples according to the procedures listed in the Materials Testing Manual.

4 For Level of Control 5 mixtures, at least 14 calendar days before start of paving, submit a mix design for the hot plant mix to the engineer for approval. Unless a Marshall or Superpave Mix Design is specified in the contract, material source requirements as listed in Section 106.3.3.3.1, General, and aggregate requirements as listed in Section 803, Aggregate, are not required.

401.4.1.2 Job Mix Formula

1 Supply the JMF and have it approved by the engineer. For each plant mix type, establish in the JMF a single value for:

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2 Ensure that the JMF and allowable tolerances are within the broad band specified.

3 For level of control 4 and 5 mixes, do not reintroduce a greater percentage of baghouse fines than the difference between the wide band upper limit percent on the No. 200 [75 μm] sieve and the total percent passing the No. 200 [75 μm] sieve (defined as the sum of the JMF’s No. 200 [75 μm] percent value and the percent lime). If reintroducing baghouse fines for a level of control 2 and 3 mixes, perform mix volumetric testing in accordance with Subsection 401.4.19.1, Quality Acceptance Testing General, for level of control 2.

4 When recycled plant mix is required, use the amount of RAP specified in the contract.

5 Do not furnish mix with virgin aggregate fractions that exceed the wide band limits or the tolerance ranges from the target JMF in accordance with Table 401.4. 1-1, Virgin Aggregate Tolerance.

Table 401.4.1-1 Virgin Aggregate Tolerance Virgin Aggregate Fractions (sieve size) Range (%) Passing No. 4 [4.75 mm] and larger -5 to +5 Passing No. 8 [2.36 mm] -4 to +4 Passing No. 30 [600 μm] -3 to +3 Passing No. 200 [75 μm] -2.0 to +2.0

6 For recycled mixes, ensure that combined RAP and virgin aggregate gradations are within the specified wide band.

7 Do not change the JMF without the engineer’s written approval. The engineer will approve a change of the JMF gradation limits without requiring a new mix design if the new target value on each sieve of the new design remains within the original JMF limits. The new limits become effective at the time of approval and are not retroactive except if the JMF is adjusted during the second lot, the adjustment will apply to the first lot. Issue a new JMF when performing a new mix design, or when significantly changing the mineral aggregate split to maintain proper air voids, VMA, or both. Do not change the asphalt content without the engineer's written approval.

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401.4.1.3 Mix Design

401.4.1.3.1 General

1 Design Superpave and Marshall mixes in accordance with the Materials Testing Manual. Test to determine each of the properties specified in Table 401.4.1- 2, Marshall and Superpave Plant Mix Properties, and Table 401.4.1- 3, Percent Voids in Mineral Aggregate. For the specified class of pavement, compose the plant mix of virgin aggregate, RAP (when specified), asphalt binder, and hydrated lime, and meet the requirements of the tables for the class of pavement specified.

Table 401.4.1-2 Marshall and Superpave Plant Mix Properties(1) Property Class I-M II-M III-M I-S II-S III-S Number of Marshall Blows 75 75 50 Marshall Stability (lbs [N]) minimum

[11 000]

[11 000]

[9000] Marshall Flow (0.01 in [0.25 mm]) 8–16 [8–16] 8–16 [8–16] 8–16 [8–16] Number of Superpave Gyrations 100 75 50 % Voids in Laboratory Mix

% Voids in Production Mix 5.0–6.0

4.0–6.0 4.0–5.0

3.0–5.0 4.0–5.0

2.5–5.0 4.0–5.0

3.0–5.0 4.0–5.0

3.0–5.0 4.0–5.0

2.5–5.0 Dust/Effective Asphalt Binder 0.8–1.4 0.8–1.4 0.8–1.4 0.8–1.4 0.8–1.4 0.8–1.4 Minimum % Asphalt Binder 4.5 4.5 4.5 4.5 4.5 4.5 Minimum Tensile Strength Retained % 75 75 75 75 75 75 Film Thickness µm (2) 6–12 6–12 6–12 6–12 6–12 6–12 Voids Filled with Asphalt Binder (VFA) 65–75 65–78 65–78 Aggregate/Lime Moisture Content, % Minimum 4.0 4.0 4.0 4.0 4.0 4.0 Mixture Moisture Content, % Maximum 0.5 0.5 0.5 0.5 0.5 0.5

the plant mix, except for air voids and VMA which are for laboratory batched and production mix requirements.

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Table 401.4.1-3 Percent Voids in Mineral Aggregate Class Voids in Mineral Aggregate (%) Maximum Nominal Size 1 in [25 mm] ¾ in [19 mm] ½ in [12.5 mm] ⅜ in [9.50 mm] Laboratory Mix I-M, II-M, I-S, II-S 12.0–15.0 13.0–16.0 14.0–17.0 14.0–17.0 III-M, III-S 11.0–14.0 12.0–15.0 13.0–16.0 13.0–16.0 Production Mix I-M, II-M, I-S, II-S 11.0–15.0 12.0–16.0 13.0–17.0 13.0–17.0 III-M, III-S 10.0–14.0 11.0–15.0 12.0–16.0 12.0–16.0

2 If submitting a request to reference a mix design, in accordance with Subsection 401.4.1.3.2, Mix Design Referencing Criteria, give supporting test data to and obtain approval from the engineer before use.

3 The engineer will evaluate the need for and may require a new mix design if, relative to the approved mix design, there are changes in the grade of asphalt binder or changes in aggregate splits, the JMF, or material sources.

401.4.1.3.2 Mix Design Referencing Criteria

2.1Using the same virgin aggregate source as the reference mix design and

the JMF is within 3 percent for No. 8 [2.36 mm] and larger sieves and 2 percent for sieves smaller than the No. 8 [2.36 mm] of the reference design;

2.2The percentage and source of RAP is the same as the reference design

and the engineer receives data on extraction and gradation properties for at least two samples that are representative of the source or stockpile;

2.3Using departmental procedures, a voidless unit weight is determined and it

is within 2 lb/ft 3 [32 kg/m3] of the reference design (use the reference design voidless unit weight for density control);

2.4The refe rence mix design was completed during the same construction

season; and

2.5Placing less than 5000 ton [5000 t] of plant mix.

was completed within the past two years.

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401.4.2 General

1 Before beginning any paving operations, schedule a prepaving conference with the engineer at a mutually agreeable time to discuss the materials, equipment, and procedures.

401.4.3 Weather and Seasonal Limitations

401.4.3.1 Plant Mix Without Warm Mix Additives

1 Place plant mix pavement surface courses between May 1 and October 15. In writing, the engineer may extend paving start or finish dates.

2 Do not place plant mix on wet surfaces; when weather prevents proper handling, compaction, or finishing. Place plant mix without warm mix additives when the base temperature, surface temperature, or air temperature are at or above the requirements specified in Table 401.4.3-1, Air Temperature Limitations.

Table 401.4.3-1 Air Temperature Limitations Compacted Thickness of Surface Course Being Placed Air Temperature Compacted thickness < 1 in [25 mm] 60 ºF [15 ºC] 1 in [25 mm] ≤ compacted thickness < 2 in [50 mm] 50 ºF [10 ºC] Compacted thickness ≥ 2 in [50 mm] 40 ºF [4 ºC] Leveling 50 ºF [10 ºC]

401.4.3.2 Warm Plant Mix With Warm Mix Additives

1 When placing plant mix at temperatures specified in Table 401.4. 3-2, Air Temperature Limitations Using Warm Mix, include a supplementary warm mix additive. Do not place plant mix when temperatures are below those shown in Table 401.4.3-2. If placing plant mix according to Table 401.4. 3-2, submit warm mix manufacturer’s information and recommendations and any changes to the mix design to the engineer. Add the warm mix additive to the binder according to the manufacturer’s recommendations.

Table 401.4.3-2 Air Temperature Limitations Using Warm Mix Compacted Thickness of Surface Course Being Placed Air Temperature Compacted thickness < 1 in [25 mm] 55 - 60 ºF [15 ºC] 1 in [25 mm] ≤ compacted thickness < 2 in [50 mm] 45 - 50 ºF [10 ºC] Compacted thickness ≥ 2 in [50 mm] 35 - 40 ºF [4 ºC] Leveling 45 - 50 ºF [10 ºC]

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401.4.4 Laboratory and Personnel Requirements

1 For quality control testing, quality acceptance testing, and performing mix designs, use a laboratory and personnel in accordance with Section 114, Laboratory, Personnel and Correlation.

401.4.5 Correlation

1 Correlation of laboratories (field testing and mix design) and personnel for aggregate tests and density tests is required in accordance with Section 114, Laboratory, Personnel and Correlation.

401.4.6 Resolution of Testing Discrepancies

1 Resolve discrepancies involving mix designs or field tests in accordance with Section 114, Laboratory, Personnel and Correlation.

401.4.7 Quality Control Testing

401.4.7.1 General

1 Perform quality control testing.

401.4.7.2 Performance Graded Asphalt Binder

1 Ensure PGAB supplier performs quality control procedures and provides documentation in accordance with Subsection 804.1, Performance Graded Asphalt Binder.

2 If PGAB is contaminated or mixed with other asphalt materials during storage, test the PGAB at no additional cost to the department. Select an independent, third party testing laboratory jointly with the engineer. The laboratory will:

with AASHTO R66;

Properties. Use averaged test results for each property; and,

401.4.7.3 Plant Mix

1 Provide and maintain a quality control system. Ensure the quality of the plant mix pavement materials and constructed pavements, whether produced and constructed by the contractor or procured from subcontractors or vendors.

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2 If, during virgin aggregate production or mix production, the result of a test performed in accordance with Table 401.4.23-1, Testing Requirements, falls outside the specification limits, retest the material immediately. If the result again falls outside the limits, adjust production until test results show the material is within limits.

401.4.8 Mixing

401.4.8.1 General

1 At least one week before delivery of binder, give the engineer the recommended mixing and compaction temperatures.

2 If the correlation testing for aggregate gradation has not been completed, test a split aggregate sample in accordance with Subsection 114.3.3.2, Aggregate Gradation, prior to beginning production.

3 Mix the hydrated lime and water with the aggregate before they enter the dryer.

4 Dry the aggregate lime mixture and heat to required temperature. Mix materials until aggregate is completely and uniformly coated and asphalt binder is uniformly distributed throughout the aggregate. Produce plant mix within temperatures specified in Subsection 401.4.9.2, Asphalt Binder.

5 When using the batch plant process, introduce the asphalt binder and aggregate into the mixer within the specified temperature range and within 25 ºF [15 ºC] of each other.

6 Set time intervals for batch plants in the presence of the engineer. Keep the case covering the timing device locked until changing the timing periods.

7 Determine the mixing temperature at the point of discharge from the mixer, and give the engineer a continuous record of the temperatures each day.

401.4.8.2 Performance Graded Asphalt Binder

1 Subsection 804.1.2, Authorization, applies to supplier of PGAB.

401.4.9 Asphalt Binder

401.4.9.1 General

1 Heat the asphalt binder to the specified temperature without local overheating, and provide a continuous supply to the mixer at a uniform temperature.

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2 Store and handle all PGAB to prevent contamination or mixing with other asphalt materials of different grades, types, or sources. If PGAB is contaminated or mixed with other asphalt materials during storage:

401.4.9.2 Mixing and Compaction Temperatures

1 For asphalt binders, maximum mixing and compaction temperatures are shown in Table 401.4.9-1, Maximum Mixing and Compaction Temperatures - Asphalt Binders.

Table 401.4.9-1 Maximum Mixing and Compaction Temperatures - Asphalt Binders Binder Grade Temperature, °F [°C ] Mixing Compaction PG 58-xx 310 [154] 285 [140] PG 64-xx 320 [160] 295 [146] PG 70-xx 330 [166] 305 [152] PG 76-xx 330 [166] 305 [152]

2 Ensure the temperature of the mixture before laydown is no more than 25 ° F [14 °C] less than the mixing temperature unless otherwise shown on the mix design.

401.4.10 Hauling

1 Provide weigh tickets in accordance with Subsection 109.1.4.2, Documentation.

2 Do not dump material on the ground and reload into trucks or directly into the paver.

401.4.11 Spreading and Finishing

1 Clean the surface of vegetation, loose materials, dirt, mud, and other extraneous material before placing plant mix.

2 For any single lift, range of thickness is in accordance with Table 401.4.11-1, Single Lift Thickness; excluding Hot Plant Mix Leveling and Hot Plant Mix Wearing Course.

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Table 401.4.11-1 Single Lift Thickness Nominal Maximum Aggregate Size (in [mm]) Lift Thickness (in [mm]) Minimum Maximum ⅜ [9] 1 [25] 2 [50] ½ [13] 1½ [38] 3 [75] ¾ [19] 2 [50] 3 [75]

3 Handle and place the plant mix to minimize segregation. Produce finished pavement with a uniform and dense appearance. Remove and replace segregated areas at no additional cost to the department.

4 When pavement is placed adjacent to curb and gutter, construct the top of the final lift of surfacing flush with the top of the front edge of the gutter or as directed by the engineer. If paving over a slotted drain, cover the openings to prevent foreign material from entering the slot, and ensure the slot does not extend above the paving.

5 Use plant mix pavers to distribute the plant mix to the established grade and transverse slope over the entire width or a partial width. Use a screed to produce the specified finished surface without tearing, shoving, segregating, or gouging the plant mix. Except on tapers, narrow median areas, shoulders, and similar areas of irregular shape, limited length, or restrictive width, control the paver screed by the automatic screed control. The engineer will set references for line and grade control (if required) at reasonable intervals.

6 Provide, place, and maintain materials, devices, and equipment required to provide specified independent line, grade control references, and other controls needed for proper execution of the work.

7 Control the placement of the first layer of pavement material by the independent control reference. Subsequent layers may be controlled by the mobile reference or a joint shoe if satisfactory results are obtained.

8 Position the longitudinal construction joint in the top lift of plant mix pavement on the lane line(s) unless a plant mix wearing course is specified, in which case offset the joint 6 in [150 mm] from the lane line(s). Offset the longitudinal construction joint in subsequent layers of plant mix 6 in [150 mm] and stagger so that no two coincide. Place longitudinal construction joints within 6 in [150 mm] of the specified lane line(s).

9 Form transverse joints by cutting back on the previous run of plant mix to expose the full depth of the course.

10 Before placing additional plant mix, apply tack coat material in accordance with Section 407, Tack Coat, to join contact surfaces.

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11 In areas where irregularities or obstacles make the use of mechanical spreading and finishing equipment impractical, place the material to produce a uniform surface finish and the required compacted thickness without tearing, shoving, gouging, or segregating.

12 When constructing pavements thicker than 1 in [25 mm] under traffic, do not leave a longitudinal exposed vertical drop- off between adjacent travel lanes at day’s end. A continuous, integral taper with a slope no greater than 1V:3H may be constructed the entire length of the face of the exposed longitudinal joint between adjacent travel lanes. Do not construct more than one day’s paving run with a taper before completing the plant mix pavement course on the adjacent travel lane. Taper transverse joint drop-offs with a slope of at least 1V:6H.

13 In case of failure of the control system, operate the paver by mechanical control only until the material produced prior to the failure is placed.

14 If paving is suspended because of bad weather, equipment breakdown, or other reason and a longitudinal vertical drop- off greater than 1 in [25 mm] exists between adjacent travel lanes, place temporary traffic controls in accordance with Section 703, Temporary Traffic Control. If the suspension is expected to last longer than 48 hours, construct a temporary taper with stable material and a slope of 1V:3H along the drop- off. At no additional cost to the department, remove the taper before placing plant mix pavement on the adjacent travel lane.

15 Provide and maintain temporary traffic control required because of negligence, breakdown of equipment, or convenience at no additional cost to the department.

16 Do not open the new pavement to traffic before the plant mix has cooled to 125 ºF [50 ºC] or less.

401.4.12 Compaction

401.4.12.1 General

1 Roll plant mix immediately after placement and until thoroughly and uniformly compacted. Continue rolling until density is reached and while the mix is workable. Ensure that compactive effort does not result in distress to the pavement. Provide rollers of sufficient number, weight, and types to obtain the required compaction without displacement, cracking, or shoving; operate with the drive wheels or drums nearest the paver. Do not use equipment that results in excessive crushing of the aggregate, and do not operate or park rollers in a manner that adversely affects the surface of the pavement.

2 When placing plant mix against previously placed material, begin rolling at the joint, then follow the pattern established from the test strip. On super-elevated curves, begin rolling at the low side and progress to the high side using overlapping longitudinal passes parallel to the centerline.

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3 Along forms, curbs, headers, walls, and other areas not accessible to the rollers, compact plant mix with hot hand or mechanical tampers. In depressed areas, a trench roller or cleated compression strips may be used under the roller to transmit compression.

401.4.12.2 Approaches

1 Compact approaches in accordance with the requirements of Table 401.4.23-2, In-Place Density Testing Requirements, for in- place density V. Use in- place density II requirements for approaches specified as “major.”

401.4.12.3 Temporary Surfacing

1 If placement of plant mix pavement has not been finished by October 15 or work on the project is suspended for any reason, provide and place temporary plant mix pavement on uncompleted portions and designated approaches before suspending work. Use temporary material with a mix design equivalent to the mainline paving mix or from a commercial source, if approved by the engineer. Place material at least 4 in [100 mm] thick or the design thickness, whichever is less, and at the specified width. Compact temporary surfaces in accordance with the requirements of Table 401.4. 23-2, In-Place Density T esting Requirements, for in- place density II. The department will assess liquidated damages in accordance with Table 108.8-1, Schedule of Liquidated Damages, for each working day after it has been determined that the project will be suspended, until the roadway is open to unrestricted traffic. Maintain the temporary surfacing, except for snow removal, until the engineer allows removal. Provide, place, maintain, remove, and dispose of temporary surfacing at no additional cost to the department, including associated traffic control costs.

401.4.13 Cold Milling Plant Mix Pavement

1 Remove the existing pavement specified as the source of the RAP in accordance with Subsection 202.4.5(2), Milling Plant Mix and Profile Milling Plant Mix. Weigh and stockpile the removed material in the designated plant site area.

401.4.14 Leveling of Existing Surface

1 If specified, use a leveler in accordance with Subsection 401.3.7, Paving Leveler, to level pavement before placing the first layer of plant mix. Spot fill depressions and swales separately to meet the profile gradeline. When specified, seal longitudinal and transverse joints and random cracks, and remove excess sealant before placing the leveling course.

2 Clean the surface of vegetation, loose materials, dirt, mud, and other extraneous material before placing the leveling course. Place layers of a compacted thickness no greater than 3 in [75 mm]; compact the plant mix using rollers as specified in Subsection 210.3.6, Rollers, operated at 4 mph [6.4 km/h]. Meet the requirements for in-place density IV in accordance with Table 401.4. 23-2, In-Place Density Test Requirements. Operate the steel wheel roller in vibratory mode unless otherwise approved by the engineer.

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401.4.15 Disposal of Baghouse Fines

1 Dispose of baghouse fines properly. If using the plant site for disposal, scarify the soil to a depth of 6 in [150 mm]. Spread the fines thinly over the area and disc thoroughly into the soil. Water may be added to reduce dust. When reclaiming the site, place topsoil or overburden over the disposal area. Ensure that the size of the area within the plant site used for disposal is in accordance with Table 401.4.15-1, Baghouse Fines Disposal Area.

Table 401.4.15-1 Baghouse Fines Disposal Area Fines Produced (ton [t]) Disposal Area (acre [hectare]) < 34,000 0.5 [0.2] 34,001 to 70,000 1.0 [0.4] 70,001 to 100,000 1.5 [0.6] 100,001 to 135,000 2.0 [0.8] > 135,000 3.0 [1.2]

401.4.16 Reclaiming Scrubber Ponds

1 Before placing topsoil, and using the methods described in Subsection 401.4. 15, Disposal of Baghouse Fines, spread residue from the pond over the plant site area in layers from 2 in to 3 in [50 mm to 75 mm] deep; scarify and disc immediately. A dewatering pad may be constructed by extending the pond liner so that soils can be placed next to the pond to allow water to drain back into the pond. After mixing residue with subsoil, spray scrubber pond water finely over the reclaimed site. Then, till the site to mix subsoil and water. Spread topsoil or overburden over the area where scrubber pond residue and water have been disposed. Dispose of scrubber pond liners in an approved landfill.

401.4.17 Mixing

401.4.17.1 General

1 At least one week before delivery of binder, give the engineer the recommended mixing and compaction temperatures.

2 If the correlation testing for aggregate gradation has not been completed, test a split aggregate sample in accordance with Subsection 114.3.3.2, Aggregate Gradation, prior to beginning production.

3 Dry the aggregate lime mixture and heat to required temperature. Mix materials until aggregate is completely and uniformly coated and asphalt binder is uniformly distributed throughout the aggregate. Produce plant mix within temperatures specified in Subsection 401.4.9.2, Asphalt Binder.

Plant Mix Pavements and Recycled Plant Mix Pavements SECTION 401

4 When using the batch plant process, introduce the asphalt binder and aggregate into the mixer within the specified temperature range and within 25 ºF [15 ºC] of each other.

5 Set time intervals for batch plants in the presence of the engineer. Keep the case covering the timing device locked until changing the timing periods.

6 Determine the mixing temperature at the point of discharge from the mixer, and give the engineer a continuous record of the temperatures each day.

401.4.18 Test Strip

401.4.18.1 General

1 If required by Table 401.4. 23-2, In-Place Density Test Requirements, construct a test strip to evaluate the mix design and rollers, and to determine the rolling pattern. Construct the strip as follows:

constitute the test strip. Produce the material at the normal plant rate. Do not place additional pavement of t he type in the test strip until the engineer accepts the strip; as necessary, construct additional test strips, for no additional pay for the item “Test Strip,” until specifications are met. Upon acceptance, the test strip will remain in place and become part of the pavement.

to obtain the specified density. Begin compaction immediately after placing the plant mix; compact continuously and uniformly over the entire test strip

randomly select sample locations for density tests, and will apply test procedures and statistical evaluation, in accordance with Subsection 114.3.3., Correlation.

engineer will include the test strip in the first lot. In accordance with Subsection 401.4.19.4 (2.2), In-Place Density, the test strip is one lot.

new test strip for no additional pay for the item “Test Strip.”

acceptable correlation in accordance with Subsection 401.4.18.2, Acceptance of Test Strip Materials.

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plant mix using the methods and procedures established from the test strip.

401.4.18.2 Acceptance of Test Strip Materials

1 The engineer will use the contractor’s quality acceptance tests for acceptance of the test strip if the engineer’s and contractor’s tests correlate.

2 The engineer will determine the pay factor for the seven density samples from the test strip in accordance with Subsection 401.5.3.3 (2), In- Place Density. The engineer will accept the test strip if the pay factor is 1.00 or greater. For pay factors less than 1.00 and greater than or equal to 0.50, the pavement may be left in place, as approved by the engineer, at the reduced price determined by the pay factor and construct a new test strip for no additional pay for the item “Test Strip.” For pay factors less than 0.50, remove the test strip from the roadway and dispose of it at no additional cost to the department. The in-place density pay factor for an accepted test strip will be 1.0.

3 The engineer will analyze aggregate gradation to determine a pay factor in accordance with Subsection 401.5.3.3(1), Virgin Aggregate Gradation.

4 The engineer may reject the test strip if the asphalt binder content varies more than 1.0 percent from the target established in the JMF.

401.4.19 Testing Requirements

401.4.19.1 Quality Acceptance Testing General

1 The engineer is responsible for acceptance of the materials; however, quality acceptance testing is the responsibility of the contractor except as specified in the following subsections.

2 The engineer will determine when to take a sample for quality acceptance, determine the sample location by random numbers, and mark location for acceptance tests. The engineer will not use samples or test results from samples taken in the engineer’s absence and will not accept materials represented by such samples.

3 Obtain samples for the acceptance of materials used in the production of plant mix in accordance with Subsection 800.2, Point of Sampling, and the Materials Testing Manual.

4 The engineer may adjust voidless unit weight used for density control based on mix verification results in accordance with the Materials Testing Manual.

401.4.19.2 Performance Graded Asphalt Binder

1 The department is responsible for PGAB quality acceptance testing.

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2 The Materials Program will randomly select and test one sublot sample per lot for all applicable properties described in Subsection 804.1.1, Binder Properties.

3 If a sample fails to meet the contract requirements, it is either invalid or non-specification.

1 Invalid Samples are any one of the following conditions:

1.1Contains any visible distillate when tested in accordance with AASHTO T

78.

1.2No sample submitted or samples have insufficient quantity of PGAB to

perform required tests.

The Materials Program will test all other samples in the lot for validity.

2 Non-specification Samples are valid but the lowest resulting pay factor is less than 1.00. The Materials Program will test all other samples in the lot only for the properties failing specification. When the difference between specified high- and low-grade temperatures is at least 90 and the sample fails to fully elongate in accordance with AASHTO T 301, the elastic recovery test equals zero.

The contractor may use, at no additional cost to the department, recovered PGAB for the samples of record when original samples indicate removal and replacement of plant mix pavement. Select an independent, third party laboratory jointly with the engineer. The laboratory will:

Obtain three to five core samples in accordance with ASTM D 5361 from

the appropriate portion of plant mix pavement corresponding to the original PGAB sample;

Extract and recover PGAB from core samples in accordance with AASHTO

T 319 with the test procedure modified to use a toluene-ethanol mixture as the solvent from beginning to end of the extraction. The ethanol will consist of 95 percent ethyl alcohol and 5 percent water;

Test recovered PGAB as RTFO residue for the applicable properties in

Subsection 804.1.1, Binder Properties, without additional RTFO aging. Use averaged test results for each property; and,

Provide test results to the contractor and the engineer

4 Results for each lot will be used to determine acceptance of that lot. If tested sample(s) meet contract requirements, the Materials Program will dispose of all samples, including referee samples. If not, the Materials Program will keep referee samples for a maximum of 12 months from issue date of the test results.

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5 In case of a discrepancy, the referee samples will be available if requested within the time frame specified above, for testing by an independent laboratory. The department will consider third party testing if the contractor provides certified test data from the supplier that differs statistically from department test results. For this purpose, “statistically different” results are those greater than the difference between the specification value and the value in the row for Pay Factor = 1.00 in Table 401.5.3- 1, PGAB Pay Factors. If third party testing is justified, select the laboratory jointly with the engineer; the department will only consider results for the property in question and will consider as binding only those results that differ statistically from its own—in which case it will use the third party results to recalculate the pay factor in accordance with Subsection 401.5.3.2, Performance Graded Asphalt Binder. If the recalculation produces an increase in the pay factor, the department will pay for the testing; otherwise, the contractor will pay for the testing.

401.4.19.3 Plant Mix

1 The contractor is responsible for quality acceptance testing as required by Table 401.4.23-1, Testing Requirements, and Table 401.4. 23-2, In -Place Density Test Requirements, for the level of control specified. Before using contractor test results for quality acceptance, the department will perform procedures for correlation as described in Section 114, Laboratories, Personnel, and Correlation.

2 Perform quality acceptance testing using the following procedure:

acceptance and the engineer may test the other sample for verification.

Test one sample for quality acceptance and the engineer may test the other sample for verification.

AASHTO-accredited laboratory using the department procedure for reheated samples in accordance with the Materials Testing Manual . If a mobile field lab is used, ensure that it is properly equipped to perform the required testing. When using a laboratory other than the original mix design laboratory, ensure the availability of records documenting the calibration of equipment in accordance with the AA SHTO Accreditation Program and yearly correlation with an AASHTO - accredited laboratory, prior to testing. Ensure that technicians performing the testing adhere to department procedures and include the following tests and parameters:

3.1Extracted gradation;

3.2Extracted asphalt binder content;

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3.3Voidless unit weight;

3.4Percent VMA; and

3.5Percent air voids

Use extracted gradation and extracted asphalt binder content for quality control purposes.

Report results determined according to the Materials Testing Manual , Table 401.4.1-2, Marshall and Superpave Plant Mix Properties, and Table 401.4. 1-3, Percent Voids in Mineral Aggregate, including technician name, testing facility and location, comments, and recommendations, to the engineer and the Materials Program no later than two calendar days after sampling.

engineer does not need samples for verification.

401.4.19.4 Lot Sizes

1 The department will define lots as follows:

quantities with numerical values not evenly divisible by 500, the lot sizes may vary from 300 ton to 700 ton [300 t to 700 t], with the number of sublots adjusted accordingly.

be accepted based on a quality analysis for individual lots of material. Each property will be analyzed independently.

Virgin Aggregate Gradation. The quantity of produced plant mix,

generally represented by five tests with a tonnage as shown for the specified level of control from Table 401.4. 23-1, Testing Requirements. A sublot is the quantity represented by one test. Tonnage controls lot size and a lot may span several days of production because exact tonnage may vary due to production suspension, construction schedules, or other acceptable reasons. When necessary due to changes in production quantities, changes in JMF, or production suspension, lots consisting from three to seven samples may be used. Include partial lots with less than three samples with the previous lot for analysis.

Include the material for the test strip as required by Subsection 401.4.18, Test Strip, in the first lot. Include material placed for approaches in the lot unless it has a different gradation than the mainline material.

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In-Place Density. The quantity of produced plant mix, represented by

seven tests with a tonnage as shown for the specified level of control from Table 401.4. 23-2, In -Place Density Test Requirements. Although the quantity of material represented may be changed, if necessary, because of changes in production, changes in the JMF, or production suspension, always represent a lot with seven samples. Tonnage controls lot size and a lot may span several days of production. For the purposes of acceptance and determination of a pay factor, the test strip is a lot.

Virgin Asphalt Binder Content. A lot is a day’s production of plant mix

Include material placed for plant mix pavements unless its asphalt binder content or grade differs from the mainline material.

401.4.19.5 Sampling

1 The engineer will direct sampling as follows:

the mixer as directed. Before taking samples, draw and discard at least 1 gal [4 L] of PGAB from the sampling valve.

The department defines a sample as two 1-quart [1 L] containers representing 100 ton [100 t] or one sublot of PGAB incorporated into the plant mix . Only sample PGAB incorporated into the plant mix, including plant mix supplied by commercial plants; sample randomly and in accordance with AASHTO R66. The engineer will keep all samples for a lot until receipt of the last sample and will then submit them together to the Materials Program. From each sample, the Materials Program will keep one container as a referee sample. Do not take samples for projects of less than 100 ton [100 t].

specified as levels of control 2 or 3 and in- place density I at the same time when sampling for acceptance.

Virgin Aggregate Gradation. Collect one sample to represent each sublot

The engineer will determine timing of the sample procurement at random. Collect samples from the belt or conveyor in accordance with the Materials Testing Manual. If using a mechanical sampler, correlate with belt samples in accordance with the Materials Testing Manual procedure.

In-Place Density. Perform core sampling and testing in accordance with

the applicable procedures in the Materials Testing Manual . The engineer will mark the sample location for the quality acceptance and verification cores with a 12 in × 12 in [300 mm × 300 mm] square painted at least 12 in [300 mm] from the pavement or ribbon edge. Obtain the samples from within the painted square.

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Virgin Asphalt Binder Content. If required in accordance with Table

401.4.23-1, Testing Requirements, determine the volume of asphalt binder remaining in the storage tank at the end of the day in the presence of the engineer. The engineer will convert to weight [mass] using methods from the Materials Testing Manual.

Mix Volumetrics. The engineer will determine the location for random

sampling. Samples may be obtained from the paver auger, the windrow, or the paver hopper. Collect three samples of plant -produced material from each location. Test one and give two to the engineer. The engineer may test one for verification and will keep the other as a referee sample. After the first four sample locations, collect two or three samples thereafter, as required by the engineer. Test one for quality acceptance, the engineer may test one for verification, and, if requested, retain the third sample as a referee sample.

401.4.20 Verification

1 The engineer or an AASHTO -accredited laboratory contracted by the department will perform the verification testing using different personnel from those performing the quality control and quality acceptance testing.

2 If specified, supply one field laboratory in accordance with Subsection 106.5, Field Laboratory, for use by department personnel in verification testing. Keep this laboratory independent of the laboratory used for quality control and quality acceptance testing; do not share equipment.

3 The engineer will verify testing procedures by testing one sample randomly from the sublot samples obtained to represent each acceptance lot. The differences between the contractor’s quality acceptance test result and the engineer’s corresponding verification test result will be evaluated in accordance with the values in the Materials Testing Manual and applied as follows:

be used for quality acceptance or

verification samples from the lot. Once the tests have been completed, the results will be evaluated using the statistical evaluation procedures for the correlation of testers to decide if both groups represent the sample population. If the contractor’s and engineer’s results represent the same sample population, the contractor’s test results will be used for quality acceptance.

If the contractor’s and the engineer’s results do not represent the same sample population, the engineer’s verification test results will be used for acceptance for the lot, and a new correlation will be performed on the next lot. The contractor’s

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test results will not be used for quality acceptance until the correlation is completed and is acceptable.

401.4.21 Independent Assurance

1 The engineer’s office will make independent assurance tests results available.

Materials Program will conduct an independent assurance program in accordance with the current WYDOT Independent Assurance Manual . Differences between quality acceptance, verification, and independent assurance tests will be evaluated and findings of bias will be investigated immediately.

will use the same methods specified in Subsection 401.4.19.1, Quality Acceptance Testing General, and if required, Subsection 401.4. 24, Corrective Action Plan. Respond to the results as specified in these two subsections.

401.4.22 Documentation and Reporting

1 Submit all quality control and quality acceptance test results to the engineer. Use department forms in accordance with the Materials Testing Manual.

401.4.22.1 Quality Control Charts

1 Provide quality control charts that include the control limits, each individual quality control test result, and the moving average of the last four tests in the control charts.

to the engineer at the field lab, if available, otherwise at a mutually agreeable location.

Record quality control test results on the control chart immediately after completing the test. Density results may be recorded at the end of the day . Record the following parameters on the control chart:

Gradation of the control sieves in the JMF;

Virgin asphalt binder content;

1.3Total asphalt binder content; and

1.4In-place density.

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parameters, record the following on the control chart:

Percent voids in the mineral aggregate and

Percent air voids

401.4.22.2 Quality Acceptance

1 Submit results of quality acceptance tests to the engineer the day after sampling. Prepare a weekly summary depicting results of all tests performed during the week, and give it to the engineer the following Monday or Tuesday if Monday is a holiday.

401.4.23 Testing Requirements

401.4.23.1 Performance Graded Asphalt Binder

1 Subsection 804.1.3, Testing, applies to the supplier of the PGAB.

401.4.23.2 Plant Mix

1 Table 401.4.23-1, Testing Requirements, and Table 401.4. 23-2, In-Place Density Test Requirements, show the department’s testing requirements for quality acceptance, verification, and density. For plant mix placed as temporary surfacing in accordance with Subsection 401.4.12.3, Temporary Surfacing, use the requirements for level-of-control 5 and in-place-density II.

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Table 401.4.23-1 Testing Requirements TEST PROCEDURE LVEL OF CONTROL 2 3 4 5 Quality Acceptance-Mix Production (5) Mix Volumetrics 2 locations on first day & 1 location each 5000 ton [5000 t] thereafter

2 locations on first day & 1 location each day thereafter until no further corrective actions are required No tests required No tests required Virgin Aggregate Gradation 1 lot/5000 ton [1 lot/5000 t] 1 lot/5000 ton [1 lot/5000 t] 1 lot/5000 ton [1 lot/5000 t] (6) No tests required Asphalt Binder Content 1/day 1/day 1/day No tests required Virgin Aggregate-LL; PI; Coarse Aggregate Angularity (Fractured Faces); Fine Aggregate Angularity; Flat & Elongated (7) 1/1000 ton [1/1000 t] min. 1/1000 ton [1/1000 t] min. No tests required No tests required Moisture Content of Virgin Aggregate/ Hydrated Lime; Moisture Content of Mix 1/day min. 1/day min. No tests required No tests required Verification— Mix Production Mix Volumetrics Split sample required but no test frequency specifically required Split sample required but no test frequency specifically required No tests required No tests required Virgin Aggregate Gradation 1/lot 1/lot No tests required No tests required Asphalt Binder Content No tests required No tests required No tests required No tests required Virgin Aggregate-LL, PI, Coarse and Fine Aggregate Angularity; Moisture Content of Virgin Aggregate/ Hydrated Lime; Moisture Content of Mix; Flat and Elongated

1/mix design (8) 1/mix design (8) No tests required No tests required

1 min/1000 ton [1 min/1000 t]

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are within specification, and there are no changes in the crushing process, test at a frequency of 1/10,000 ton [1/10 000 t].

weight includes the total weight of coarse aggregate, fine aggregate, and filler, if applicable, combined at the anticipated rates. Testing that applies only to material passing the No. 4 [4.75 mm] sieve (sand equivalent) will be performed on the combination of fines and filler combined at the anticipated rates and tested at the frequency determined by the total combined aggregate weight.

soundness applies to the coarse aggregate only.

angularity, and flat and elongated were within specification, the department will not require retesting.

Table 401.4.23-2 In-Place Density Test Requirements Requirement In-Place Density Designation I II III IV V In-Place Density (1) 1 lot/1500 ton [1 lot /1500 t] of produced material. All in place mix compacted to ≥ 92.0% of voidless unit weight. All in place mix compacted until a nuclear density gauge indicates the mix no longer increases in compaction. 5 passes (2) of a pneumatic tire and 5 passes (2) of a steel wheel roller in accordance with Subsection 210.3.6, Roller. ≥ 5 passes (2) of a steel wheel roller in vibratory mode in accordance with Subsection 210.3.6, Roller. Test Strip Required Not required Not required Not required Not required Quality Acceptance Testing 1 lot/1500 ton [1 lot/1500/t] 1 test/200 ton [1 test/200 t] No tests required No tests required No test required Verification Testing 1/lot No tests required No tests required No tests required No test required

in the contract.

of the area to be compacted.

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401.4.24 Corrective Action Plan

401.4.24.1 General

1 Take immediate corrective action when the production of material falls outside of specification parameters. Do not continue producing material that does not meet specifications.

lots have a pay factor less than 1.00 in accordance with Subsection 401.5.3, Determination of Pay Factors, make changes and adjustments to produce the specified material.

2 For the following properties, take the indicated actions if a single quality acceptance test in accordance with Subsection 401.4.19.1, Quality Acceptance Testing General, exceeds specification limits:

specification limits, begin valid corrective action(s) immediately. After corrective action, immediately resample and retest. Suspend production if two corrective actions fail to result in the production of specification material. Obtain the engineer’s approval of further proposed actions before resuming production.

The department considers the following as valid corrective actions:

A change in the percentage of aggregate addition from any one storage bin

by at least 5 percent;

A change in the target asphalt binder content by at least 0.2 percent;

A change in the minus No. 200 [75 μm] material in th e mix by at least 1

percent; or

Other actions approved by the engineer

Notify the engineer immediately when test results are outside mix design limits for percent air voids; dust/effective asphalt binder; film thickness in accordance with Table 401.4. 1-2, Marshall and Superpave Plant Mix Properties; VMA in accordance with Table 401.4. 1-3, Percent Voids in Mineral Aggregate; or the gradation is outside of the narrow bands established by the JMF. Corrective action may require a new mix design in accordance with Subsection 401.4. 1.3, Mix Design, a new JMF in accordance with Subsection 401.4.1.2, Job Mix Formula, or both.

Request that the engineer evaluates mix verification voidless unit weight tests for density control in accordance with Materials Testing Manual when

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current voidless unit weight is in question. If approved by the engineer, the department will adjust voidless unit weight using all available test results . For increases, adjustments will become effective for material produced subsequent to receipt of results. For decreases, adjustment will be applied retroactively back to beginning of production of that paving mixture.

immediately.

401.4.24.2 Adjustment of Baghouse Fines

1 If the amount of baghouse fines being reintroduced changes by more than ± 0.5 percent during production of level of control 2 and 3 mixes, verify that the plant mix meets the mix design volumetric control limits. With the engineer, choose at least two randomly selected sampling locations and perform testing in accordance with Subsection 401.4.19.1, Quality Acceptance Testing General, for mix volumetrics properties. If the samples with baghouse fines meet the mix design control limits, fines may be reintroduced.

401.4.25 Acceptance

1 The engineer may isolate and reject obviously defective material without regard to testing procedures. Otherwise, the engineer will accept or reject materials as follows:

Subsection 113.2, Acceptance of Asphalt Materials, and Subsection 401.5.3.2, Performance Graded Asphalt Binder.

If contaminated or mixed PGAB in a storage tank fails specification as described in Subsection 401.4. 7.2, Performance Graded Asphalt Binder, the engineer will reject all PGAB from the storage tank. The engineer will reject lots represented by invalid samples in accordance with Subsection 401.4.7.2, Per formance Graded Asphalt Binder.

Aggregate Gradation. Levels of control 2, 3, and 4 mixes in accordance

with Subsection 113.1, Acceptance of Aggregate, and level of control 5 mixes based on the tests taken during production.

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In-Place Density I. In accordance with Subsection 401.5.3.3 (2), In-Place

Density, and in- place density II, III, IV, and V in accordance with Table 401.4.12-2, In-Place Density Test Requirements.

Asphalt Binder Content. For levels of control 2, 3, and 4 mixes, in

accordance with Subsection 401.5.3.3 (3), Asphalt Binder Content.

Moisture Content of Virgin Aggregate/Hydrated Lime. Based on each

individual test and the quantity of water added.

Based on each individual test for:

2.5.1Liquid Limit and Plastic Index;

2.5.2Moisture Content of Plant Mix;

2.5.3Coarse and Fine Aggregate Angularity; and

2.5.4Mix Volumetrics

401.5MEASUREMENT and PAYMENT

401.5.1 General

1 The engineer will measure:

Subsection 109.1.3(8), Asphalt Materials, except :

No payment will be made for the asphalt binder used daily in excess of the

asphalt binder percentage shown in the contract plus 0.25 percent, or the approved contractor mix design value plus 0.25 percent, whichever is less.

When the department allows a change from an available material source in accordance with Subsection 106.3.2.2, Available Material Sources, no payment will be made for the asphalt binder percentage shown in the contract plus 0.25 percent, or the approved contractor mix design plus 0.25 percent, whichever is less.

Asphalt binder incorporated in level of control 5 mix will not be measured

directly for payment.

(Recycle), and Hot Plant Mix Leveling (Recycle) by the short ton [metric ton]. The

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cumulative weight [mass] of all batches of plant mix incorporated will be used for payment. The use of batch scales will be allowed.

2 The department will pay as follows:

Pay Item

Pay Unit

Measure to the Nearest Pay to the Nearest Asphalt Binder (PG ___ - ___ ) TON [t] 0.01 ton [0.01 t] 0.01 TON [0.01 t] Hot Plant Mix TON [t] 0.01 ton [0.05 t] 0.01 TON [0.05 t] Hot Plant Mix Approaches TON [t] 0.01 ton [0.05 t] 0.01 TON [0.05 t] Hot Plant Mix Leveling TON [t] 0.01 ton [0.05 t] 0.01 TON [0.05 t] Hot Plant Mix (Recycle) TON [t] 0.01 ton [0.05 t] 0.01 TON [0.05 t] Hot Plant Mix Leveling (Recycle) TON [t] 0.01 ton [0.05 t] 0.01 TON [0.05 t] Test Strip EA [Ea] EA [Ea] EA [Ea]

401.5.2 Referenced Sections For Direct Payment

1 When specified, the engineer will measure and pay for:

testing, and mix design requirements in accordance with Subsection 106.12, Contractor Testing.

401.5.3 Determination of Pay Factors

401.5.3.1 General

1 If warranted, a bonus will be paid when the engineer’s verification test results are used for acceptance for the first lot that the results of the contractor’s quality acceptance tests and the engineer’s verification tests differ. A bonus will not be paid on subsequent lots

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when verification tests differ from the contractor’s quality acceptance tests if correlation has not been completed and accepted.

401.5.3.2 Performance Graded Asphalt Binder

1 PGAB placed on the project which does not meet the contract requirements for the designated grade may be accepted and the price adjusted in accordance with Subsection 113.2, Acceptance of Asphalt Materials.

2 For each lot, the engineer will compute a pay factor for each applicable property and will use the lowest resulting pay factor for the entire lot. The applicable properties and corresponding pay factors in accordance with Table 401.5.3-1, PGAB Pay Factors, form the basis for acceptance

Table 401.5.3-1 PGAB Pay Factors Dynamic Shear (G*/Sinδ), High grade temp., kPa Creep Stiffness (S), MPa Creep Slope (m-value), unitless Elastic Recovery, 77 °F, % Phosphoric Acid,% wt Pay Factor Original binder RTFO residue PAV residue, Low grade temp. +10 °C RTFO residue Original binder ≥ 0.84 ≥ 1.75 ≤ 360 ≥ 0.280 ≥ 50 ≤ 1.00 1.00 0.83 - 0.81 1.74 - 1.66 361 - 372 0.279 - 0.276 49 - 48 1.01 - 1.1 0.90 0.80 - 0.78 1.65 - 1.57 373 - 384 0.275 - 0.272 47 - 46 1.11 - 1.2 0.80 0.77 - 0.74 1.56 - 1.48 385 - 396 0.271 - 0.268 45 - 44 1.21 - 1.3 0.70 0.73 - 0.71 1.47 - 1.39 397 - 408 0.267 - 0.264 43 - 42 1.31 - 1.4 0.60 0.70 - 0.68 1.38 - 1.30 409 - 420 0.263 - 0.260 41 - 40 1.41 - 1.5 0.50 < 0.68 < 1.30 > 420 < 0.260 < 40 > 1.50 REJECT

3 If elastic recovery is applicable and test result equals zero, pay factor for elastic recovery equals 0.50.

4 For non-specification PGAB with pay factor less than 1.00, the engineer will split the original lot into separate lots, each sample representing a single lot.

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401.5.3.3 Plant Mix

1 The engineer will determine a pay factor for aggregate gradation and asphalt binder content for level of control 2, 3 and 4 mixes, and a pay factor for in- place density for in- place density I pavements as follows:

in accordance with procedures in Subsection 113.1, Acceptance of Aggregate. A pay factor will be calculated for each lot.

acceptance tests in accordance with Subsection 401.4. 19.1, Quality Acceptance Testing General, the engineer will determine the percentage density in accordance with the Materials Testing Manual and round to the neares t 0.01 percent. Determine the average and sample standard deviation of the lot or test strip using the following formulas:

𝑥𝑥̅ = ∑ 𝑥𝑥𝑖𝑖 𝑛𝑛 𝑖𝑖=1 𝑛𝑛 = 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝐷𝐷𝐴𝐴𝐷𝐷𝐷𝐷 𝐷𝐷𝐷𝐷𝐷𝐷

𝐷𝐷 = ��

𝑛𝑛−1� ∑ (𝑥𝑥𝑖𝑖 − 𝑥𝑥̅)2n i=1

Where: 𝒙𝒙𝒊𝒊 = the percentage density of individual cores

n = the number of core densities

𝑥𝑥̅ = the average percentage density

s = the sample standard deviation of the percentage density

∑ = summation

Calculate the quality index as follows:

𝑄𝑄𝐼𝐼 = (𝑥𝑥̅ − 92.00) 𝑠𝑠

Where: 𝑄𝑄𝐼𝐼 = the quality index, rounded to the nearest 0.01

If the average density exceeds 96.00 percent, the pay factor will be the lesser of 1.00 and the pay factor determined from Table 401.5.3- 2, In-Place Density Pay Factors. If the quality index equals or exceeds 0.01 and the percent density is less than or equal to 96.00 percent, determine the pay factor from Table 401.5.3- 2, In-Place Density Pay Factors.

Plant Mix Pavements and Recycled Plant Mix Pavements SECTION 401

Table 401.5.3-2 In-Place Density Pay Factors Quality Index Pay Factor Quality Index Pay Factor Quality Index Pay Factor From To From To From To ≤ 0.00 Reject 0.50 0.53 0.67 1.08 1.11 0.85 0.01 0.01 0.50 0.54 0.56 0.68 1.12 1.14 0.86 0.02 0.04 0.51 0.60 0.59 0.69 1.15 1.18 0.87 0.05 0.07 0.52 0.63 0.62 0.70 1.19 1.21 0.88 0.08 0.10 0.53 0.66 0.65 0.71 1.22 1.25 0.89 0.11 0.13 0.54 0.70 0.69 0.72 1.26 1.28 0.90 0.14 0.16 0.55 0.73 0.72 0.73 1.29 1.31 0.91 0.17 0.19 0.56 0.76 0.75 0.74 1.32 1.34 0.92 0.20 0.22 0.57 0.79 0.78 0.75 1.35 1.37 0.93 0.23 0.25 0.58 0.83 0.82 0.76 1.38 1.40 0.94 0.26 0.28 0.59 0.86 0.85 0.77 141 1.43 0.95 0.29 0.31 0.60 0.89 0.88 0.78 1.44 1.46 0.96 0.32 0.34 0.61 0.92 0.91 0.79 1.47 1.49 0.97 0.35 0.37 0.62 0.96 0.95 0.80 1.50 1.52 0.98 0.38 0.40 0.63 0.98 0.98 0.81 1.53 1.55 0.99 0.41 0.43 0.64 0.99 1.01 0.82 1.56 3.57 1.00 0.44 0.46 0.65 1.02 1.04 0.83 ≥ 3.58 1.10 0.47 0.49 0.66 1.05 1.07 0.84

determining asphalt binder used as a percentage of plant mix produced. The binder’s weight [mass] will be determined from delivery invoices and the quantity of material remaining in the storage tank at the end of a day’s production. The calculation to determine content will include all material used during the day’s production of plant mix, including asphalt binder and plant mix not incorporated into the project. A pay factor will be determined in accordance with Table 401.5.3- 3, Asphalt Binder Content Pay Factors . The engineer will use a pay factor of 1.0 for lots of less than 1000 short tons [metric tons].

Table 401.5.3-3 Asphalt Binder Content Pay Factors Variance of Asphalt Binder Content from Design Content (%) Pay Factor 0.00-0.25 1.00 0.26-0.30 0.95 0.31-0.35 0.90 0.36-0.40 0.85 0.41-0.45 0.80 0.46-0.50 0.75 ≥0.51 Reject

Plant Mix Pavements and Recycled Plant Mix Pavements SECTION 401

401.5.4 Pay Adjustments

1 The engineer will calculate pay adjustments for aggregate gradation, in- place density, and asphalt binder content as follows:

Aggregate Gradation: PAA = 0.67 × PMP × (PFA -1) × (LSA -APQ) PAA = 0.67 × PMPAP × (PFA -1) × (LSA -MLQ)

Aggregate Gradation PAA = 0.67 × RPMP × (RPF -1) × (LSA -APQ) for Recycle: PAA = 0.67 × PMPAP × (RPF -1) × (LSA -MLQ)

In-Place Density: PA D = 1.33 × PMP × (PFD-1) × LSD

Asphalt Binder PA AC = 0.67 × PMP × (PFAC -1) × (LSAC -APQ) Content: PAAC = 0.67 × PMPAP × (PFAC -1) × (LSAC -MLQ)

Where: PAA = Pay Adjustment for Aggregate Gradation (dollars) PAD = Pay Adjustment for In-Place Density ($$) PAAC = Pay Adjustment for Asphalt Binder Content ($$) PMP = Unit Contract Price for the respective Plant Mix Pavement pay item ($$) PMPAP = Unit Contract Price for the respective Plant Mix Pavement Approaches pay item ($$) RPMP = Recycled Hot Plant Mix Pavement Unit Contract Price ($$) PFA = Aggregate Gradation Pay Factor for evaluated lot RPF = Virgin Aggregate Gradation Pay Factor for evaluated lot PFD = In-Place Density Pay Factor for evaluated lot PFAC = Asphalt Binder Content Pay Factor for evaluated lot LSA = Lot Size for Aggregate Gradation evaluated lot (short ton [metric ton]) LSD = Lot Size for In-Place Density evaluated lot (short ton [metric ton]) LSAC = Lot Size for Asphalt Binder Content evaluated lot (short ton [metric ton]) APQ = Quantity of Plant Mix Pavement from the lot placed as approach pavement (short ton [metric ton]) ML Q = Quantity of Plant Mix Pavement from the lot placed as mainline pavement (short ton [metric ton])

2 For the Hot Plant Mix Leveling, and Hot Plant Mix Leveling (Recycle) pay items, the engineer will make pay adjustments for aggregate gradation and asphalt binder content but not for in-place density.