403Plant Mix Pavement Crack Sealing

Plant Mix Pavement Crack Sealing

403.1DESCRIPTION

1 This section describes the requirements for sealing cracks in plant mix pavement.

403.2MATERIALS

1 Provide materials in accordance with the following:

Material Subsection Aggregate for Blotter* 803 Backer Rod 807.7 Hot-Poured Elastic Sealant 807.2

*Do not use on airport projects.

2 Other materials may be used as blotter material, including portland cement, fly ash, sawdust, blotter paper, or biodegradable, non-toxic, non-hazardous compounds designed to form a temporary protective barrier over the sealant to prevent tracking.

403.3EQUIPMENT

403.3.1 Removing Existing Sealant

1 Provide a plow, ripping tooth, wire brush, saw, or other equipment to remove existing sealant from cracks. Use carbide-tipped blades or better.

403.3.2 Rout Crack

1 Provide mechanical, power-driven routing equipment that produces a reservoir with vertical sides and a flat bottom to the required dimensions. Do not use star bit type routers or equipment designed to plow the cracks to size. Use carbide- tipped blades or better.

403.3.3 Clean and Dry Crack

1 Provide an air compressor that produces clean, oil-free, compressed air with an output of at least 125 ft³/min [3.5 m³/min]; equip with a ¾-inch [19 mm] diameter or smaller nozzle. Do not use backpack blowers. Provide compressed air heat lances that produce clean, oil- free, compressed air at least 750 ºF [400 ºC] at a velocity of at least 650 ft/s [200 m/s] . Do not use direct flame driers.

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403.3.4 Install Sealant

1 Provide a melting machine with a melting capacity of at least 100 gal/h [400L/h] while continuously maintaining the recommended sealant application temperature. Equip to continuously agitate and mix the sealant during application.

2 Apply sealant with a pressure-type applicator equipped with a wand with the tip attached to a fixed -sized nozzle or an inside diameter cup of 2 in ± 0.25 in [50 mm ± 6 mm] or an approved equal.

3 Provide a compressed air heater if required by conditions.

4 Provide a U-shaped squeegee for smoothing the sealant.

403.4CONSTRUCTION

403.4.1 General

1 Seal cracks between the dates specified as shown in Table 403 .1.1-1, Sealant restrictions for the type of sealant specified.

Table 403.4.1-1 Sealant Restrictions Sealant Type (ASTM D 6690, WY Modified) Installation Dates I Nov. 15 - May 15 (1) IV May 15 - Nov. 15 (2)

Table 403.4.1-2 Requirements for Crack Sealing Sealing Method Required Construction Operations Remove Existing Sealant Rout Crack Clean and Dry Crack Install Sealant

Blotter (1) Flush Recessed 1 X X X X 2 X X X 3 X X X X 4 X X X 5 X X X X X 6 X X X X 7 X X X X X 8 X X X X

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on pavement surface at airports such as runways, taxiways, taxilanes, aircraft parking aprons, transitional surfaces, and other airport operations and aircraft movement areas (i.e., airside operations).

403.4.2 Removing Existing Sealant

1 Remove existing sealant from cracks without damaging the pavement.

2 For airport pavement surfaces, remove raveled edges in the plant mix pavement by saw cutting or other methods as approved by the engineer. For the sealing method specified, use the construction sequence in Table 403.4.1-2, Requirements for Crack Sealing.

403.4.3 Routing

1 Rout no more than can be sealed each day, and in accordance with Table 403.4.3-1, Routing Dimensions.

Table 403.4.3-1 Routing Dimensions

Crack Width Sealant AASHTO M 324 Type 1 WY Modified AASHTO M 324 Type IV WY Modified < ⅛ in [3 mm] does not need routing or sealing ⅛ in to less than ½ in [3 mm to less than 12 mm] rout to ½ in wide × ¾ in deep [12 mm wide × 19 mm deep] rout to ¾ in wide × ¾ in deep [19 mm wide × 19 mm deep] ½ in to ¾ in [12 mm to 19 mm]

does not need routing > ¾ in [19 mm] does not need routing

403.4.4 Clean and Dry Crack

1 Use compressed air to clean cracks and reservoirs of dust, dirt, and other deleterious materials. Prepare cracks by using compressed air heat lances, but do not overheat the pavement. Before applying sealant, clean and dry cracks exposed to precipitation. The engineer will inspect prepared cracks before sealing.

2 Before reopening the roadway to traffic, remove debris using a power broom or other approved means. Remove swept material from curb and gutter areas.

3 For airport pavement surfaces, remove from the project site all joint material that is either blown out of the cracks or saw cut out of the joints. Waste and loose material referred to

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as Foreign Object Debris (FOD) includes, but is not limited to, trash, material generated by routing, removed crack sealant material, excess crack sealant material, dirt, mud, vegetative matter, etc. Do not place or leave FOD on or near active aircraft areas. Remove FOD continuously and completely. Dispose of FOD in areas designated by the engineer. Do not sweep FOD off of pavement onto adjacent areas. If the engineer determines removal of FOD in an area is incomplete or inadequate, re-clean area until it is acceptable to engineer before starting a new area.

403.4.5 Lot Sizes, Sampling, and Testing

403.4.5.1 Certification

1 Ensure certification from sealant manufacturer/supplier specifically states compliance with appropriate ASTM specification for sealant type as described in Table 807.2-1, Hot- Poured Elastic Sealant Specification Limits. Include quality control data from sealant manufacturer/supplier for production run of crack sealant. The department defines “production run” as weight [mass] of sealant produced during one cycle from startup to shutdown of manufacturer’s equipment. For quality control data, use format and units described in Table 807.2- 1, Hot -Poured Elastic Sealant Specification Limits. Report results for bond test as sum of successful extensions for all three specimen blocks for required number of complete cycles specified in Table 807.2- 1, Hot -Poured Elastic Sealant Specification Limits.

403.4.5.2 Lot Sizes

403.4.5.2.1 Quantity Equal to or Less Than 45,000 lb [20 400 kg] or 450 ft 3 [13 m3] or 180,000 ft [54 900m] or Incidental

1 Submit written certification 14 calendar days before sealing.

403.4.5.2.2 Quantity Greater Than 45,000 lb [20 400 kg] or 450 ft 3 [13 m3] or 180,000 ft [54 900 m]

1 Submit written certification 14 calendar days before sealing and samples during construction in accordance with Subsection 403 .4.5.3, Sampling, for lots and sublots as defined in Table 403.4.5.2-1, Lot and Sublot Sizes:

Table 403.4.5.2-1 Lot and Sublot Sizes Measurement Basis Maximum Quantity Lot (3 tests) Sublot (1 test) Weight [Mass], lb [kg] 90,000 [40 800] 30,000 [13 600] Volume, ft3 [m3] 900 [25] 300 [9] Length, ft [m] 360,000 [109 800] 120,000 [36 600]

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2 The engineer will determine the exact lot size, which may vary due to project length, production suspension, construction schedules, material source changes, or other acceptable reasons. Except in unusual situations, the engineer will use lots consisting of three samples. When necessary due to production, project size, material source changes, or suspension, lots of from three to five samples may be used. Partial lots with less than three samples will be included with the previous lot for analysis. Lot size will be controlled by the project size or changes in the material source and may span several days of production.

403.4.5.3 Sampling

1 Obtain one sample for each sublot in the presence of the engineer; do so directly from the applicator nozzle during sealing and once the melting equipment has stabilized for temperature and agitation/mixing. For each sample, provide two boxes that have a silicone release coating on the inside surfaces, each filled with 5 lb [2.3 kg] of sealant. Document the sample with the contractor’s name, sealant manufacturer’s name and address, lot and sublot number, total sublot quantity, type of sealant, department project number, and project location. Submit the sample to the engineer; one box of sealant will be for referee testing if necessary.

403.4.5.4 Testing

1 One test for a sample includes each applicable property for the type of sealant as shown in Table 807.2-1, Hot-Poured Elastic Sealant Specification Limits.

403.4.6 Install Sealant

403.4.6.1 General

1 Provide the engineer two copies of the sealant man ufacturer’s recommendations for preparation, handling, mixing, and application 14 calendar days before sealing.

2 Seal cracks only in dry weather . Ensure that pavement inside the crack is at least 40 ºF [5 ºC] unless the manufacturer requires a higher temperature; if necessary, heat the pavement. Keep the sealant at the manufacturer recommended application temperature. Do not begin installing sealant until the equipment has stabilized for temperature and agitation/mixing.

3 Seal cracks or portions of cracks greater than ⅛ in [3 mm] wide, unless otherwise approved by the engineer . Apply sealant from the bottom up. When using the cup attachment, hold it firmly against the roadway surface during application. When using squeegees, smooth sealant tightly against the pavement . Center the squeegeed band on the crack so that the width on either side of the crack is no more than 1 in [25 mm].

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4 Seal cracks so that the finished, cured surface is to the configuration specified:

by shrinkage.

squeegees or wands with a 2 in [50 mm] inside diameter cup.

5 If sealant flows out the end of the crack, plug or dike the end as approved by the engineer. Remove spilled sealant, and reseal properly . Remove excess sealant from roadway while it is still liquid. If sealant pulls out or tracking occurs, apply blotter material to minimize damage. Do not use blotter on any pavement surface at airports such as runways, taxiways, taxilanes, aircraft parking aprons, transitional surfaces, and other airport operations and aircraft movement areas (i.e., airside operations). Replace sealant damaged by tracking at no additional cost to the department.

6 Do not mix sealant from different manufacturers in the sealing machine. Purge the machine (empty the kettle, hoses, etc.) of sealant before switching sealants . Follow manufacturer recommendations for mixing sealant from different production runs.

403.4.6.2 Backer Rod

1 Install backer rod only when

2 Install backer rod with the top edge recessed :¾ in [19 mm] below the pavement. Install AASHTO M 324 Type IV WY Modified sealant.

403.4.7 Crack Seal Acceptance

1 The engineer will accept crack sealant material as follows:

ft [54 900 m] or Incidental to Other Pay Items. Based on the written certification of production sealant in accordance with Subsection 403.4.5, Certification, Lot Sizes, Sampling and Testing.

900 m]. Based on written certification, random samples and a quality analysis to determine a pay factor for each lot when tested in accordance with Subsection 403.4.5, Lot Sizes, Sampling, and Testing . If the pay factor for a lot is less than

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0.50, the engineer will evaluate the material for acceptance in accordance with Subsection 113.2, Acceptance of Asphalt Material, paragraph 2.

403.5MEASUREMENT and PAYMENT

403.5.1 General

1 The engineer will measure Crack Seal (Plant Mix) by the pound [kilogram] or foot [meter]. When the pay unit is cubic foot [cubic meter], the engineer will measure Crack Seal (Plant Mix) by the pound [kilogram]; convert to cubic foot [cubic meter] for each lot separately according to the following:

Volume LOT, ft3 [m3] = (Quantity, lb [kg]) (Density, lb/ft3 [kg/m3])

Where density is the actual bulk density of the lot as determined by the Materials Program in accordance with ASTM D71 WY Modified.

2 The department will pay as follows:

Pay Item

Pay Unit Measure to the Nearest Pay to the Nearest Crack Seal (Plant Mix) LB, CF, FT [kg, m3, m] Lb,lb,ft [kg,kg,m] LB, CF, FT [kg, m3, m]

403.5.2 Determination of Pay Factor and Pay Adjustment

403.5.2.1 General

1 For projects with a quantity greater than 45,000 lb [20 000 kg] or 450 ft 3 [13 m3] or 180,000 ft [54 900 m], the engineer will determine by quality analysis a pay factor for each applicable property and the lowest pay factor of all the properties will be the pay factor for the lot. Relative density only applies when the pay unit is by the pound.

2 The engineer will evaluate the sealant using the compliance limits in accordance with Table 403.5.2- 1 Hot -Poured Elastic Sealant Compliance Limits, to establish the pay factor.

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Table 403.5.2-1 Hot-Poured Elastic Sealant Compliance Limits(1) COMPLIANCE LIMITS ASTM D 6690 ASTM D 6690 PROPERTY Type I Type IV WY Modified WY Modified Lower Upper Lower Upper Cone Penetration — 97 83 162 Bond 5 — — — Bond, 200% extension — — 3 — Relative Density — 1.200 — 1.120 Softening Point, ºF [ ºC] — — 165.0 [74.0] —

Specification Limits.

3 For lots with a pay factor less than 1.00, the engineer will keep corresponding referee samples for 1 year from the issue date of report. Referee samples will not be kept for lots having a pay factor of 1.00 or greater.

403.5.2.2 Quality Level Analysis (Except Bond Test)

1 The engineer will compute quality level analysis for each lot, except for the bond test, as follows:

Point, 0.001 for Relative Density).

x� = ∑ xi n i=1 n

Where: 𝑥𝑥̅ = arithmetic mean Σ = summation xi = individual test value from each test series n = total number of test values

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Softening Point).

s = �∑ (xi − x�)2n i=1 n − 1

Where: s = sample standard deviation 𝑥𝑥̅ = arithmetic mean Σ = summation xi = individual test value from each test series n = total number of test values

QU = CLU−x� S

Where: Q U = upper quality index CLU = upper compliance limit or maximum 𝑥𝑥̅ = arithmetic mean s = sample standard deviation

QL = x�−CLLS Where: Q L = lower quality index 𝑥𝑥̅ = arithmetic mean CLL = lower compliance limit or minimum s = sample standard deviation

corresponding to a given Q U) from Table 113.1- 1, Quality Level Analysis by the Standard Deviation Method. If a CLU is not specified, then PU = 100.

corresponding to a given Q L) from Table 113.1- 1, Quality Level Analysis by the Standard Deviation Method. If a CLL is not specified, then PL = 100.

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limits), rounded to the nearest whole number. Quality Level = (PU + PL) – 100

Where: P U = theoretical percentage below the upper compliance limit corresponding to a given QU

PL = theoretical percentage above the lower compliance limit corresponding to a given QL

quality level and number of sublot samples.

403.5.2.3 Quality Level Analysis (Bond Test)

1 For the bond test, the engineer will compute quality level analysis for each lot as follows:

cycles for all sample blocks, rounded to the nearest whole number.

𝑄𝑄𝑄𝑄𝑄𝑄𝑄𝑄𝑄𝑄𝑄𝑄𝑄𝑄 𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿 𝑄𝑄 = [

∑ Completed Bond Cycles block n block 1 (n x CLL) ] x 100

Where: Σ = summation of completed cycles for test blocks 1 through n (includes all test series) n = total number of test blocks in the lot or (number of sublots in lot) × (3 blocks per sublot) CLL= lower compliance limit or minimum

samples using Table 403.5.2-2, Pay Factor.

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Table 403.5.2-2 Pay Factor Pay Factor Minimum Required Quality Level Sample Size = number of sublots n = 3 n = 4 n = 5 1.03 97 98 99 1.02 90 93 96 1.01 84 89 93 1.00 68 74 78 0.97 66 73 78 0.94 64 72 77 0.90 61 71 77 0.87 59 68 74 0.85 58 67 73 0.83 57 66 71 0.80 54 64 69 0.78 53 62 67 0.76 52 61 66 0.73 50 59 64 0.70 48 57 61 0.69 47 56 60 0.67 46 55 59 0.64 44 52 56 0.63 43 51 55 0.61 41 49 53 0.59 40 47 51 0.57 38 45 49

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Table 403.5.2-2 Pay Factor Pay Factor Minimum Required Quality Level Sample Size = number of sublots n = 3 n = 4 n = 5 0.55 36 43 47 0.52 34 40 43 0.50 32 38 41

403.5.2.4 Pay Factor Adjustment for Relative Density

1 If the average relative density is greater than the compliance limit described in Table 403.5.2-1, Hot-Poured Elastic Sealant Compliance Limits, the engineer will adjust the pay factor as follows, rounding to the nearest 0.01:

Where: PF Quality Analysis = 1.00 or lowest pay factor as determined from quality analysis of all applicable properties.

x̅ = average relative density

CL U = upper compliance limit for relative density

403.5.2.5 Pay Adjustment

2 The engineer will compute payment adjustment for each lot separately using the following equation:

PA = (PF-1.00) × (CONTRACT UNIT PRICE) × (ACTUAL QUANTITY)

Where: PA = pay adjustment PF = pay factor from quality analysis, adjusted if necessary in accordance with, 403.5.2.4, Pay Factor Adjustment for Relative Density Pay Factor = (PF Quality Analysis) - [ the GREATER of 0.01 or x̅ - CLU ] CLU