SSH TBL FAD SPE - 03specs

DIVISION 32 00 00 EXTERIOR IMPROVEMENTS
SECTION 32 01 16 FLEXIBLE PAVING REHABILITATION
SUB-SECTION 32 01 16.71 COLD MILLING ASPHALT PAVING
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The
publications are referred to within the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM C 136 (2006) Standard Test Method for Sieve Analysis

of Fine and Coarse Aggregates
1.2 SYSTEM DESCRIPTION
Maintain in a satisfactory working condition equipment, tools, and machines used in the
performance of the work.
1.2.1 Cold-Milling Machine
Provide a cold-milling machine which is self-propelled, capable of milling the pavement to a

specified depth and smoothness and of establishing grade control; with means of controlling
transverse slope and dust produced during the pavement milling operation. The machine
shall have the ability to remove the millings or cuttings from the pavement and load them
into a truck. The milling machine shall not cause damage to any part of the pavement
structure that is not to be removed.
1.2.2 Cleaning Equipment
Provide cleaning equipment suitable for removing and cleaning loose material from the
pavement surface.
1.2.3 Straightedge
Furnish and maintain at the site, in good condition, one 3.66 meter straightedge or other
suitable device for each milling machine, for testing the finished surface. Make straightedge
available for Contractor use. Straightedges shall be constructed of aluminum or other
lightweight metal, with blades of box or box-girder cross section with flat bottom reinforced
to insure rigidity and accuracy. Straightedges shall have handles to facilitate movement on
the pavement.
Development of Sharm El Sheikh International Airport 32 01 16.71 COLD MILING ASPHALT PAVING
Final Terminal Building Design- Airfield SSH-TBL-FAD-SPE_02 -Page 1

1.3 QUALITY ASSURANCE
1.3.1 Grade
Conform the finished milled surfaces to the lines, grades, and cross sections indicated. The
finished milled-pavement surfaces shall vary not more than 0 mm from the established plan
grade line and elevation. Finished surfaces at a juncture with other pavements shall coincide
with the finished surfaces of the abutting pavements. The deviations from the plan grade
line and elevation will not be permitted in areas of pavements where closer conformance
with planned grade and elevation is required for the proper functioning of appurtenant
structures involved.
1.3.2 Surface Smoothness
Finished surfaces shall not deviate from the testing edge of a straightedge more than 6 mm
in the transverse or longitudinal direction.
1.3.3 Traffic Control
Provide all necessary traffic controls during milling operations.
1.4 ENVIRONMENTAL REQUIREMENTS
Milling shall not be performed when there is accumulation of snow or ice on the pavement
surface.
1.5 WARRANTY
Two plus one years, as follows:
- After testing and commissioning of Airfield works, the Provisional Reception Certificate will
be signed.
- Two (2) years warranty period will start from the date of the signage of the Provisional
Reception Certificate.
- During these two (2) years of warranty, the main Contractor will Maintain and Operate,
above mentioned systems.
- After the finishing of this period, the Final Reception Certificate will be signed.
- One (1) year of additional warranty period will start from the date of the signage of the
Final Reception Certificate.
PART 2 PRODUCTS
Not Applicable

PART 3 EXECUTION
3.1 PREPARATION OF SURFACE
Clean the pavement surface of excessive dirt, clay, or other foreign material immediately
prior to milling the pavement.
3.2 MILLING OPERATION
A minimum of seven days notice is required, prior to start work, for the Contracting Officer
to coordinate the milling operation with other activities at the site. Make sufficient passes so
that the designated area is milled to the grades and cross sections indicated. The milling
shall proceed with care and in depth increments that will not damage the pavement below
the designated finished grade. Repair or replace, as directed, items damaged during milling
such as manholes, valve boxes, utility lines, pavement that is torn, cracked, gouged, broken,
or undercut. The milled material shall be removed from the pavement and loaded into
trucks. Removed material shall have a minimum of 95 percent by weight passing a sieve
when tested in accordance with ASTM C 136.
3.3 GRADE AND SURFACE-SMOOTHNESS TESTING
3.3.1 Grade-Conformance Tests
Test the finished milled surface of the pavement for conformance with the plan-grade
requirements and for acceptance by the Contracting Officer by running lines of levels at
intervals of 7.5 meters longitudinally and 7.5 meters transversely to determine the elevation
of the completed pavement. Correct variations from the designated grade line and elevation
in excess of the plan-grade requirements as directed. Skin patching for correcting low areas
will not be permitted. Remove and replace the deficient low area. Remove sufficient material
to allow at least 25 mm of asphalt concrete to be placed.
3.3.2 Surface-Smoothness Tests
After completion of the final milling, the finished milled surface will be tested by the
Contractor with a straightedge. Other approved devices may be used, provided that when
satisfactorily and properly operated, such devices reveal all surface irregularities exceeding
the tolerances specified. Correct surface irregularities that depart from the testing edge by
more than 6 mm. Skin patching for correcting low areas will not be permitted. Remove and
replace the deficient low area. Remove sufficient material to allow at least 25 mm of asphalt
concrete to be placed.
3.4 REMOVAL OF MILLED MATERIAL
Material that is removed shall be placed in the disposal area as specified.
END OF SUB-SECTION 32 01 16.71

END OF SECTION 32 01 16

SECTION 32 01 17 FLEXIBLE PAVING REPAIR
PART 1 GENERAL
1.1. REFERENCES
ASTM C 509 (2006) Elastomeric Cellular Preformed Gasket

and Sealing Material
ASTM D 6690 (2007) Standard Specification for Joint and Crack

Sealants, Hot Applied, for Concrete and Asphalt
Pavements
ASTM D 789 (2007) Determination of Relative Viscosity and

Moisture Content of Polyamide (PA)
Machines, tools, and equipment used in the performance of the work required by this
section shall be approved before the work is started and shall be maintained in satisfactory
condition at all times.
1.2.1 Routing Equipment
Provide routing equipment which is a self-powered machine operating a power driven tool or
bit specifically designed for routing bituminous pavements. The bit shall rotate about a
vertical axis at sufficient speed to cut a smooth vertical-walled reservoir in the pavement
surface and shall maintain accurate cutting without damaging the sides or top edges of the
reservoir. Provide a router capable of following the trace of the crack without deviation. The
use of rotary impact routing devices may be permitted if vertical-sided carbide tipped bits
are used.
1.2.2. Concrete Saw
Provide a self-propelled power saw with small diameter (152 mm or less) water-cooled
diamond or abrasive saw blades for cutting cracks to the depths and widths specified and for
removing filler that is embedded in the cracks or adhered to the crack faces. The diameter
of the saw blade shall be small enough to allow the saw to closely follow the trace of the
crack.
1.2.3. Sandblasting Equipment
Include in the sandblasting equipment an air compressor, hose, and long-wearing venture-
type nozzle of proper size, shape and opening. The maximum nozzle opening shall not
Development of Sharm El Sheikh International Airport 32 01 17 FLEXIBLE PAVING REPAIR

exceed 6.4 mm. The air compressor shall be portable; and shall be capable of furnishing not
less than 0.071 cubic meters/second and maintaining a line pressure of not less than 621
kPa at the nozzle while in use. Demonstrate compressor capability under job conditions
before approval. The compressor shall be equipped with traps that will maintain the
compressed air free of oil and water. The nozzle shall have an adjustable guide that will hold
the nozzle aligned with the crack about 25 mm above the pavement surface. Adjust the
height, angle of inclination and the size of the nozzle as necessary to secure satisfactory
results.
1.2.4. Waterblasting Equipment
Include with the waterblasting equipment a trailer-mounted water tank, pumps, high-
pressure hose, wand with safety release cutoff control, nozzle, and auxiliary water resupply
equipment. The water tank and auxiliary resupply equipment shall be of sufficient capacity
to permit continuous operations. The hose, wand, and nozzle shall be capable of cleaning
the crack faces and the pavement surface on both sides of the crack for a width of at least
13 mm. A pressure gauge mounted at the pump shall show at all times the pressure in kPa
at which the equipment is operating.
1.2.5. Hand Tools
Hand tools may be used, when approved, for removing defective sealant from cracks and
repairing or cleaning the crack faces.
1.2.6 Crack Sealing Equipment
Provide unit applicators, used for heating and installing the hot-poured crack sealant
materials, that are mobile and equipped with a double-boiler, agitator-type kettle with an oil
medium in the outer space for heat transfer; a direct-connected pressure-type extruding
device with a nozzle shaped for inserting in the crack to be filled; positive temperature
devices for controlling the temperature of the transfer oil and sealant; and a recording type
thermometer for indicating the temperature of the sealant. Allow the sealant to circulate
through the delivery hose and return to the inner kettle when not in use, due to the
applicator unit design.
1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-03 Product Data
Installation of Sealant
Manufacturer's instructions 60 days prior to the use of the material on the project.
Installation of the material will not be allowed until the instructions are received.
SD-04 Samples
until it has been approved.

SD-06 Test Reports
Test Requirements
Reports of all tests. Perform testing of the materials in an approved, independent

laboratory; submit certified copies of the test reports for approval 60 days prior to the
use of the materials at the job site. Samples will be retained by the Employer for
possible future testing, should the materials appear defective during or after
application.]
Test the crack sealant and backup material, when required, for conformance with the
referenced applicable material specification. The materials will be tested by the Employer.
The cost of the first test of samples will be borne by the Employer. If the samples fail to
meet specification requirements, replace the materials represented by the sample and test
the new materials at the Contractor's expense. Furnish samples of materials, in sufficient
quantity to be tested upon request. Conformance with the test requirements of the
laboratory tests specified will not constitute final acceptance of the materials. Final
acceptance will be based on the performance of the in-place materials.
1.5 DELIVERY, STORAGE, AND HANDLING
Inspect materials delivered to the job site for defects; unload, and store them with a
minimum of handling to avoid damage. Provide storage facilities at the job site to protect
materials from weather and to maintain them at the temperatures recommended by the
manufacturer.
The ambient air temperature and the pavement temperature within the joint wall shall be a
minimum of 10 degrees C and rising at the time of application of the materials. Do not apply
sealant if moisture is observed in the crack.
1.7 WARRANTY
be signed.

PART 2 PRODUCTS
2.1 SEALANTS
Provide sealants conforming to ASTM D 6690, Type II or ASTM D 6690, Type I.
2.2 BACKUP MATERIALS
Provide backup material that is a compressible, nonshrinking, nonstaining, nonabsorptive

material and nonreactive with the crack sealant. The melting point of the backing material
shall be at least 2 degrees C greater than the maximum pouring temperature of the sealant
being used, when tested in accordance with ASTM D 789. The material shall have a water
absorption of not more than 5 percent by weight when tested in accordance with ASTM C
509. The backup material shall be 25 percent (plus or minus 5 percent) larger in diameter
than the nominal width of the crack.
PART 3 EXECUTION
3.1 PREPARATION OF CRACKS
Immediately before the installation of the crack sealant, thoroughly clean the cracks to
remove oxidized pavement, loose aggregate and foreign debris. The preparation shall be as
follows:
3.1.1 Cracks
Hairline Cracks
Cracks that are less than 6 mm wide do not need to be sealed.
Small Cracks
Cracks that are 6 to 20 mm wide shall be routed to a nominal width 3 mm greater

than the existing nominal width and to a depth not less than 20 mm, sandblasted and
cleaned using compressed air.
3.1.1.3 Medium Cracks
Cracks that are 20 to 50 mm wide shall be sandblasted and cleaned using compressed air.
3.1.1.4 Large Cracks
Cracks that are greater than 50 mm wide shall be repaired using pothole repair techniques
instead of sealing.

3.1.2 Existing Sealant Removal
Cut loose the in-place sealant from both crack faces and to a depth shown on the drawings,
using a concrete saw or hand tools as specified in paragraph EQUIPMENT. Depth shall be
sufficient to accommodate any backup material that is required to maintain the depth of new
sealant to be installed. Prior to further cleaning operations, remove all old loose sealant
remaining in the crack opening by blowing with compressed air.
3.1.3 Routing
Perform routing of the cracks using a rotary router with a bit that is at least 3 mm wider than
the nominal width of the crack to remove all residual old sealant (resealing), oxidized
pavement and any loose aggregate in the crack wall.
3.1.4 Sawing
Perform sawing of the cracks using a power-driving concrete saw as specified in paragraph
EQUIPMENT. Stiffen the blade as necessary with suitable dummy (or used) blades or
washers. Immediately following the sawing operation, clean the crack opening using a water
jet to remove all saw cuttings and debris.
3.1.5 Sandblasting
Sandblast clean the crack faces and the pavement surfaces extending a minimum of 13 mm
from the crack edges. Use a multiple-pass technique until the surfaces are free of dust, dirt,
old sealant residue, or foreign debris that might prevent the sealant material from bonding
to the asphalt pavement. After final cleaning and immediately prior to sealing, blow out the
cracks with compressed air and leave yhem completely free of debris and water. Ensure that
sandblasting does not damage the pavement.
3.1.6 Backup Material
Use backup material on all cracks that have a depth greater than 19 mm. Insert the backup
material into the lower portion of the crack as shown on the drawings. Ensure that the
backup material is placed at the specified depth and is not stretched or twisted during
installation.
3.1.7 Rate of Progress of Crack Preparation
Limit the stages of crack preparation, which include routing, sandblasting of the crack faces,
air pressure cleaning and placing of the backup material, to only that linear footage that can
be sealed during the same day.
3.2 PREPARATION OF SEALANT
Do not heat hot-poured sealants in excess of the safe heating temperature recommended by
the manufacturer, as shown on the sealant containers. Withdraw and waste sealant that has
been overheated or subjected to application temperatures for over 4 hours or that has
remained in the applicator at the end of the day's operation.

3.3 INSTALLATION OF SEALANT
3.3.1 Time of Application
Seal cracks immediately following final cleaning of the crack walls and following the
placement of the backup material (when required). Cracks that cannot be sealed under the
conditions specified, or when rain interrupts sealing operations, shall be recleaned and
allowed to dry prior to installing the sealant.
3.3.2 Sealing the Crack
Immediately preceding, but not more than 15 m ahead of the crack sealing operations,
perform a final cleaning with compressed air. Fill the cracks from the bottom up to 3 mm
below the pavement surface. Remove excess or spilled sealant from the pavement by
approved methods and discard it. Install the sealant in a manner which prevents the
formation of voids and entrapped air. Several passes with the applicator wand may be
necessary to obtain the specified sealant depth from the pavement surface. Do not use
gravity methods or pouring pots to install the sealant material. Traffic shall not be permitted
over newly sealed pavement until authorized by the Contracting Officer. Cracks shall be
checked frequently to ensure that the newly installed sealant is cured to a tack-free
condition within 3 hours.
3.4 CRACK SEALANT INSTALLATION TEST SECTION
Prior to the cleaning and sealing of the cracks for the entire project, construct a test section
at least 60 m long using the specified materials and approved equipment, to demonstrate the
proposed sealing of all cracks of the project. Following the completion of the test section and
before any other crack is sealed, inspect the test section to determine that the materials and
installation meet the requirements specified. If materials or installation do not meet
requirements, remove the materials and reclean and reseal the cracks at no cost to the
Employer. When the test section meets the requirements, it may be incorporated into the
permanent work and paid for at the contract unit price per linear foot for sealing items
scheduled. Seal all other cracks in the manner approved for sealing the test section.
3.5 CLEANUP
Upon completion of the project, remove unused materials from the site and leave the
pavement in a clean condition.
3.6 QUALITY CONTROL PROVISIONS
3.6.1 Crack Cleaning
Provide quality control provisions during the crack cleaning process to correct improper
equipment and cleaning techniques that damage the bituminous pavement in any manner.
Cleaned cracks shall be approved prior to installation of the crack sealant.

3.6.2 Crack Seal Application Equipment
Inspect the application equipment to ensure conformance to temperature requirements and

proper installation. Evidences of bubbling, improper installing, and failing to cure or set will
cause to suspend operations until causes of the deficiencies are determined and corrected.
3.6.3 Crack Sealant
Inspect the crack sealant for proper cure and set rating, bonding to the bituminous
pavement, cohesive separation within the sealant, reversion to liquid, and entrapped air and
voids. Sealants exhibiting any of these deficiencies, at any time prior to the final acceptance
of the project, shall be removed from the crack, wasted, and replaced as specified herein at
no additional cost to the Employer.

SUB-SECTION 32 01 17.62 STRESS-ABSORBING MEMBRANE INTERLAYER
PART 1 GENERAL
1.1 REFERENCES

ASTM D 1777 (1996; R 2007) Thickness of Textile Materials
ASTM D 2397 (2005) Standard Specification for Cationic

Emulsified Asphalt
ASTM D 3381 (2009a) Viscosity-Graded Asphalt Cement for Use

in Pavement Construction
ASTM D 3776/D 3776M (2009a) Standard Test Method for Mass Per Unit
Area (Weight) of Fabric
ASTM D 3910 (2007) Design, Testing, and Construction of

Slurry Seal
ASTM D 4632 (2008) Grab Breaking Load and Elongation of

Geotextiles ASTM D 946 (2009a) Penetration-
Graded Asphalt Cement for Use in Pavement
Construction
ASTM D 977 (2005) Emulsified Asphalt
1.2 STATE STANDARD SPECIFICATIONS
Materials and workmanship specified herein with the reference State Standard specifications
(SSS) shall be in accordance with the referenced articles, sections and paragraphs of the
standard except that contractural and payment provisions do not apply. Where the term
"Engineer" is used, it shall mean the Contracting Officer. Where the term "state" is used, it
shall mean "Federal Contractor."
1.3 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:
SD-05 Design Data Asphalt concrete mix design Emulsified asphalt slurry
Development of Sharm El Sheikh International Airport 32 01 17.62 STRESS ABSORBING MEMBRANE INTERLA.

SD-06 Test Reports Gradation for sand for emulsified asphalt slurry in accordance with ASTM
C 136.
SD-07 Certificates Asphalt cement Emulsified asphalt Sealant Reinforcing fabric underseal
1.4 DELIVERY AND STORAGE
Deliver materials to job site in original unopened rolls, packages, cartons, bundles, or
containers. Prevent damage to materials during loading, transporting, and unloading.
Inspect materials for contamination. Protect materials against dampness. Store aggregates
so as to prevent segregation and contamination. Replace defective or damaged materials.
Remove rejected materials from Contractor property.
1.5 EQUIPMENT
1.5.1 Asphalt Distributor
Provide a distributor capable of spraying asphalt cement at the prescribed application rate
without streaking, skipping, or dripping. Equip distributor with hand spray having single
nozzle and positive shut-off valve. Provide calibrated instruments for determining both
temperature of asphaltic material in distributor and temperature at which it is applied, and
for securing uniformity at junction of two distributor loads. Calibrated instruments shall have
been recalibrated by an approved calibration laboratory within 12 months prior to
commencing work and every month, thereafter during the term of the contract.
1.5.2 Fabric Handling Equipment
Provide mechanical or manual laydown equipment capable of laying fabric smoothly without
wrinkles or folds.
1.5.3 Vacuum Sweeper
Self-propelled, vacuum pickup capable of completely removing loose material and debris
from pavement surface.
1.5.4 Miscellaneous Equipment
Additional equipment shall include, but not be limited to, stiff bristle brooms; squeegees to
spread asphalt cement; rollers to smooth fabric; scissors or blades to cut fabric; and brushes
for applying cement at fabric overlaps.
1.5.5 Condition of Equipment
Storage tanks, piping, retorts, booster tanks, and distributors used in storing and handling
asphalt material shall be kept clean and in good operating condition. Do not allow
contamination of asphaltic material with foreign material in equipment during operation.
Provide and maintain a recording thermometer in good working order in storage heating
unit.

1.6.1 Design Conformance Submit asphalt concrete mix design conforming to the requirements of
Section 32 12 15 HOT MIX ASPHALT PAVEMENT.
1.7 WARRANTY
be signed.
PART 2 PRODUCTS
2.1 MATERIALS
2.1.1 Asphalt Cement Viscosity-Graded Residue AR-1000: ASTM D 3381.
2.1.2 Emulsified Asphalt SS-1; ASTM D 977.
2.1.3 Sand for Emulsified Asphalt Slurry
Free of dirt, debris, and organic matter, conforming to ASTM D 3910, Type I gradation.
2.1.4 Asphalt Concrete Provide in accordance with Section 32 12 15 HOT MIX ASPHALT PAVEMENT.
2.1.5 Sealant FS SS-S-1401.
2.1.6 Reinforcing Fabric Underseal
Provide 100 percent woven or nonwoven polypropylene or polyester fabric, resistant to rot
and mildew.

2.1.6.1 Fabric
Determine asphalt retention and potential change in fabric area as follows:
Select at random from a test sample fabric of 300 mm wide by roll width, three machine
direction and three cross machine direction specimens measuring 100 by 200 mm. Condition
individual test specimens by bringing them to approximate moisture equilibrium in standard
atmosphere for testing (65 percent plus or minus 5 percent relative humidity, 21 degrees
plus or minus one degree C. Weigh test specimens individually to nearest 0.1 gram, then
submerge individual test specimens in specified asphalt cement for 30 minutes maintained at
a temperature of 135 degrees plus or minus 2 degrees C in a mechanical convection oven.
After submersion test, remove asphalt cement coated-saturated test specimens and hang to
drain (long axis vertical) in oven for an additional 30 minutes at 135 degrees plus or minus 2
degrees C. Remove specimens from oven and hang to drain (long axis vertical) for one hour
at a temperature of 25 plus or minus 2 degrees C. Trim off edge drippings.
Weigh asphalt coated specimens to nearest 0.1 gram and then place in naphtha heated to
44 degrees plus or minus 3 degrees C for 30 minutes. Fresh naphtha contained in trays at
specified temperature may be alternated during 30 minute period to remove asphalt cement
from specimens. Blot specimens with paper towels and allow to air dry to remove naphtha.
Measure area of specimens for determination of percent change in area. Calculate asphalt
retention and change in area as follows:
Asphalt Retention, G per sq. m =
wt. in grams of asphalt cement retained

area of specimen after test in sq.
Change in Areas, percent =
100 -(area of specimen after test in sq. m) X 100

(original area of specimen in sq. m)

2.1.7 Emulsified Asphalt Slurry
ASTM D 3910, Type I mixture.
PART 3 EXECUTION
3.1 PREPARATION
3.1.1 Cracks
Clean cracks of loose or spalled pieces of asphaltic concrete, vegetation, and debris by use
of a power broom and compressed air jet of not less than 620 kPa.
3.1.1.1 Crack Sealing 3 to 6 Millimeters
Seal with emulsified asphalt. Level material with the pavement surface.
3.1.1.2 Crack Sealing Over 6 Millimeters
Seal with emulsified asphalt slurry level with the existing pavement. Make two passes if
necessary to fill void.
3.1.2 Potholes
Remove surface pavement and base course as indicated. Make cut square or rectangular
with vertical straight faces. Make one pair of faces at right angles to traffic flow. Spray
vertical surfaces with emulsified asphalt. Fill with asphalt concrete, and compact patch level
with existing pavement using a vibratory compactor for small patches or a roller for large
patches.
3.1.3 Surface Preparation
Cold-mill existing pavement in accordance with Section 32 01 16FLEXIBLE PAVING

REHABILITATION. Clean pavement surfaces with a power broom and a power blower using
compressed air following brooming.
3.2 FABRIC INSTALLATION
3.2.1 Placement Conditions
Place fabric under the following conditions:
a. Ambient air temperature above 4.5 degrees C and rising
b. Dry pavement surface temperature above 4.5 degrees C and rising.
c. When wind velocity does not exceed kph.

3.2.2 Binder
Spray area to receive fabric with asphalt cement at rate of 1.0 -1.31 L per square meter.
Minimum width of asphalt application shall be fabric width plus 100 mm. Minimize time
interval between placing asphalt cement and placing fabric so that temperature loss of
asphalt cement does not cause loss of adhesion. Keep newly placed binder areas shall be
free of traffic and debris until asphalt overlay is complete.
3.2.3 Fabric Placement
Place fabric free of wrinkles and folds. Place fabric manually on areas where it cannot be
mechanically installed. In the event of improper alignment which causes the fabric to wrinkle
or fold during placement, slit the fabric and realign by overlapping the previous material and
proceed as before. Overlap the fabric a minimum of 100 mm at all joints , except as
otherwise shown. Do not lap joints with more than two fabric layers. Construct transverse
joints so as to prevent fabric disturbance by paver. Roll fabric in a manner that air bubbles
that form under the fabric will be removed. In case binder bleeds through fabric, blot binder
with sand before overlay is placed. Remove excess sand before placing overlay. Neatly cut
and contour fabric at joints. Remove and replace damaged fabric before resurfacing.
3.2.3.1 Traffic Control
Prohibit vehicles, except handling equipment, from traveling on fabric. Limit equipment
speed to 8 kph. At intersections and corners, turn equipment gradually to avoid damaging
fabric.
3.2.3.2 Additional Asphalt Cement
After fabric placement and prior to placement of overlay, ensure sufficient binder exists to
bond subsequent overlay. If fabric lacks tackiness, apply additional binder of at least 0.09 L
per square meter to fabric surface.
3.2.4 Asphalt Concrete Overlay
Place overlay in accordance with Section 32 12 15 HOT MIX ASPHALT PAVEMENT. Paving
operation shall closely follow fabric placement. Do not place fabric that cannot be covered
with overlay the same day.


SECTION 32 11 23 AGGREGATE BASE COURSES
PART 1 GENERAL
1.1 REFERENCES
publications are referred to in the text by basic designation only.
FAA / ICAO REGULATIONS
AC 150/5370 10e (2009) Crushed Aggregate Base Course (P-209)

for airfield pavements (runways, taxiways or
apron).
ICAO Annex 14 (2010) Volume I: Aerodrome Design and

Operations.
ICAO DOC 9137 (2005) Airport Services Manual, Part 2
AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION

OFFICIALS (AASHTO)
AASHTO T 180 (2009) Standard Method of Test for Moisture-

Density
Relations of Soils Using a 4.54-kg (10-lb)

Rammer and a 457-mm (18-in.) Drop
AASHTO T 224 (2010) Standard Method of Test for Correction

for Coarse Particles in the Soil Compaction Test
ASTM C 117 (2004) Standard Test Method for Materials Finer

than 75-um (No. 200) Sieve in Mineral
Aggregates by Washing
ASTM C 127 (2007) Standard Test Method for Density,

Relative Density (Specific Gravity), and
Absorption of Coarse Aggregate
ASTM C 128 (2007a) Standard Test Method for Density,

Absorption of Fine Aggregate
ASTM C 131 (2006)Standard Test Method for Resistance to

Degradation of Small-Size Coarse Aggregate by
Abrasion and Impact in the Los Angeles Machine

Development of Sharm El Sheikh International Airport 32 11 23 AGGREGATE BASE COURSES

ASTM C 29/C 29M (2009) Standard Test Method for Bulk Density
("Unit Weight") and Voids in Aggregate
ASTM C 88 (2005) Standard Test Method for Soundness of

Aggregates by Use of Sodium Sulfate or
Magnesium Sulfate
ASTM D 1556 (2007) Density and Unit Weight of Soil in Place

by the Sand-Cone Method
ASTM D 1557 (2009) Standard Test Methods for Laboratory

Compaction Characteristics of Soil Using Modified
Effort (56,000 ft-lbf/ft3) (2700 kN-m/m3)
ASTM D 2167 (2008) Density and Unit Weight of Soil in Place

by the Rubber Balloon Method
ASTM D 2487 (2010) Soils for Engineering Purposes (Unified

Soil Classification System)
ASTM D 422 (1963; R 2007) Particle-Size Analysis of Soils
ASTM D 4318 (2010) Liquid Limit, Plastic Limit, and Plasticity

Index of Soils
ASTM D 5821 (2001; R 2006) Standard Test Method for

Determining the Percentage of Fractured
Particles in Coarse Aggregate
ASTM D 6938 (2010) Standard Test Method for In-Place

Density and Water Content of Soil and Soil-
Aggregate by Nuclear Methods (Shallow Depth)
ASTM D 75/D 75M (2009) Standard Practice for Sampling

Aggregates
ASTM E 11 (2009) Wire Cloth and Sieves for Testing

Purposes Particles in Coarse Aggregate
ASTM D 6938 (2010) Standard Test Method for In-Place

Density and Water Content of Soil and Soil-
Aggregate by Nuclear Methods (Shallow Depth)

Aggregates
ASTM E 11 (2009) Wire Cloth and Sieves for Testing

Purposes
1.2 DEFINITIONS
For the purposes of this specification, the following definitions apply.

1.2.1 Aggregate Base Course
Aggregate base course (ABC) is well graded, durable aggregate uniformly moistened and
mechanically stabilized by compaction.
1.2.2 Graded-Crushed Aggregate Base Course
Graded-crushed aggregate (GCA) base course is well graded, crushed, durable aggregate
uniformly moistened and mechanically stabilized by compaction. GCA is similar to ABC, but it
has more stringent requirements and it produces a base course with higher strength and
stability.
1.2.3 Degree of Compaction
Degree of compaction required, except as noted in the second sentence, is expressed as a

percentage of the maximum laboratory dry density obtained by the test procedure presented
in ASTM D 1557 abbreviated as a percent of laboratory maximum dry density. Since ASTM D
1557 applies only to soils that have 30 percent or less by weight of their particles retained
on the 19.0 mm sieve, the degree of compaction for material having more than 30 percent
by weight of their particles retained on the 19.0 mm sieve are expressed as a percentage of
the laboratory maximum dry density in accordance with AASHTO T 180 Method D and
corrected with AASHTO T 224.
All plant, equipment, and tools used in the performance of the work will be subject to
approval before the work is started and shall be maintained in satisfactory working condition
at all times. Submit a ist of proposed equipment, including descriptive data. Provide
adequate equipment having the capability of producing the required compaction, meeting
grade controls, thickness control, and smoothness requirements as set forth herein.
1.4 SUBMITTALS
SD-03 Product Data
Plant, Equipment, and Tools Waybills and Delivery Tickets
SD-06 Test Reports
Sampling and Testing
Field Density Tests
Sampling and testing are the responsibility of the Contractor and performed by a testing
laboratory approved in accordance with Section 01 45 00 QUALITY CONTROL. Work
requiring testing will not be permitted until the testing laboratory has been inspected and

approved. Test the materials to establish compliance with the specified requirements;
perform testing at the specified frequency. The Contracting Officer may specify the time and
location of the tests. Furnish copies of test results to the Contracting Officer within 24 hours
of completion of the tests.
1.5.1 Sampling
Take samples for laboratory testing in conformance with ASTM D 75/D 75M. When deemed
necessary, the sampling will be observed by the Contracting Officer.
1.5.2 Tests
Perform the following tests in conformance with the applicable standards listed.
1.5.2.1 Sieve Analysis
Make sieve analysis in conformance with ASTM C 117 and ASTM C 136. Sieves shall conform
to ASTM E 11. Particle-size analysis of the soils shall also be completed in conformance with
ASTM D 422.
1.5.2.2 Liquid Limit and Plasticity Index
Determine liquid limit and plasticity index in accordance with ASTM D 4318.
1.5.2.3 Moisture-Density Determinations
Determine the laboratory maximum dry density and optimum moisture content in
accordance with AASHTO T 180, Method D and corrected with AASHTO T 224.
1.5.2.4 Field Density Tests
Measure field density in accordance with ASTM D 1556, ASTM D 2167 or ASTM D 6938. For
the method presented in ASTM D 6938 check the calibration curves and adjust them, if
necessary, using only the sand cone method as described in paragraph Calibration, of the
ASTM publication. Tests performed in accordance with ASTM D 6938 result in a wet unit
weight of soil, and ASTM D 6938 shall be used to determine the moisture content of the soil.
The calibration curves furnished with the moisture gauges shall also be checked along with
density calibration checks as described in ASTM D 6938. The calibration checks of both the
density and moisture gauges shall be made by the prepared containers of material method,
as described in paragraph Calibration of ASTM D 6938, on each different type of material
being tested at the beginning of a job and at intervals as directed.
a. Submit certified copies of test results for approval not less than 30days before material
is required for the work.
b. Submit calibration curves and related test results prior to using the device or
equipment being calibrated.
c. Submit copies of field test results within 24 hours after the tests are performed.

1.5.2.5 Wear Test
Perform wear tests on ABC and GCA course material in conformance with ASTM C 131.
1.5.2.6 Soundness Perform soundness tests on GCA in accordance with ASTM C 88.
1.5.2.7 Weight of Slag
Determine weight per cubic meter of slag in accordance with ASTM C 29/C 29M on the ABC
and GCA course material.
1.5.3 Testing Frequency

1.5.3.1 Initial Tests
Perform one of each of the following tests, on the proposed material prior to commencing
construction, to demonstrate that the proposed material meets all specified requirements
when furnished. If materials from more than one source are going to be utilized, this testing
shall be completed for each source.
a. Sieve Analysis including the 0.02 mm sieve.
b. Liquid limit and plasticity index.
c. Moisture-density relationship.
d. Wear.
e. Soundness.
f. Weight per cubic meter of Slag.
1.5.3.2 In Place Tests
Perform each of the following tests on samples taken from the placed and compacted ABC
and GCA. Samples shall be taken and tested at the rates indicated. Perform sampling and
testing of recycled concrete aggregate at twice the specified frequency until the material
uniformity is established.
a. Perform density tests on every lift of material placed and at a frequency of one set of
tests for every 250 square meters, or portion thereof, of completed area.
b. Perform sieve analysis including the 0.02 mm sieve on every lift ofmaterial placed and
at a frequency of one sieve analysis for every 500 square meters, or portion thereof,
of material placed.
c. Perform liquid limit and plasticity index tests at the same frequency as the sieve
analysis.

d. Measure the total thickness of the base course at intervals, in such a manner as to
ensure one measurement for each 500 square meters of base course. Measurements
shall be made in 75 mm diameter test holes penetrating the base course.
1.5.4 Approval of Material
Select the source of the material 30 days prior to the time the material will be required in the
work. Tentative approval of material will be based on initial test results. Final approval of the
materials will be based on sieve analysis, liquid limit, and plasticity index tests performed on
samples taken from the completed and fully compacted course(s).
Perform construction when the atmospheric temperature is above 2 degrees C. When the
temperature falls below 2 degrees C, protect all completed areas by approved methods
against detrimental effects of freezing. Correct completed areas damaged by freezing,
rainfall, or other weather conditions to meet specified requirements.
1.7 WARRANTY
be signed.
PART 2 PRODUCTS
2.1 AGGREGATES
Provide ABC and GCA consisting of clean, sound, durable particles of crushed stone, crushed
slag, crushed gravel, angular sand, or other approved material. ABC shall be free of lumps of
clay, organic matter, and other objectionable materials or coatings. GCA shall be free of silt
and clay as defined by ASTM D 2487, organic matter, and other objectionable materials or
coatings. The portion retained on the 4.75 mmsieve is known as coarse aggregate; that
portion passing the 4.75 mm sieve is known as fine aggregate.

2.1.1 Coarse Aggregate
Provide coarse aggregates with angular particles of uniform density. When the coarse
aggregate is supplied from more than one source, aggregate from each source shall meet
the specified requirements and shall be stockpiled separately.
a. Crushed Gravel: Crushed gravel shall be manufactured by crushing gravels, and shall
meet all the requirements specified below.
b. Crushed Stone: Provide crushed stone consisting of freshly mined quarry rock,
meeting all the requirements specified below.
c. Crushed Recycled Concrete: Provide crushed recycled concrete consisting of

previously hardened portland cement concrete or other concrete containing pozzolanic
binder material. The recycled material shall be free of all reinforcing steel, bituminous
concrete surfacing, and any other foreign material and shall be crushed and
processed to meet the required gradations for coarse aggregate. Reject recycled
concrete aggregate exceeding this value. Crushed recycled concrete shall meet all
other applicable requirements specified below.
d. Crushed Slag: Crushed slag shall be an air-cooled blast-furnaceproduct having an air

dry unit weight of not less than 1120 kg/cubic meter as determined by ASTM C 29/C
29M, and shall meet all the requirements specified below.
2.1.1.1 Aggregate Base Course
ABC coarse aggregate shall not show more than 50 percent loss when subjected to the Los
Angeles abrasion test in accordance with ASTM C 131. The amount of flat and elongated
particles shall not exceed 30 percent. A flat particle is one having a ratio of width to
thickness greater than 3; an elongated particle is one having a ratio of length to width
greater than 3. In the portion retained on each sieve specified, the crushed aggregates shall
contain at least 50 percent by weight of crushed pieces having two or more freshly fractured
faces determined in accordance with ASTM D 5821. When two fractures are contiguous, the
angle between planes of the fractures must be at least 30 degrees in order to count as two
fractured faces. Crushed gravel shall be manufactured from gravel particles 50 percent of
which, by weight, are retained on the maximum size sieve listed in TABLE 1.
2.1.1.2 Graded-Crushed Aggregate Base Course
GCA coarse aggregate shall not show more than 40 percent loss when subjected to the Los
Angeles abrasion test in accordance with ASTM C 131. GCA coarse aggregate shall not
exhibit a loss greater than 18 percent weighted average, at five cycles, when tested for
soundness in magnesium sulfate, or 12 percent weighted average, at five cycles, when
tested in sodium sulfate in accordance with ASTM C 88. The amount of flat and elongated
particles shall not exceed 20 percent for the fraction retained on the 12.5 mm sieve nor 20
percent for the fraction passing the12.5 mm sieve. A flat particle is one having a ratio of
width to thickness greater than 3; an elongated particle is one having a ratio of length to
width greater than 3. In the portion retained on each sieve specified, the crushed aggregate
shall contain at least 90 percent by weight of crushed pieces having two or more freshly

fractured faces determined in accordance with ASTM D 5821. When two fractures are
contiguous, the angle between planes of the fractures must be at least 30 degrees in order
to count as two fractured faces. Crushed gravel shall be manufactured from gravel particles
90 percent of which by weight are retained on the maximum size sieve listed in TABLE 1.
2.1.2 Fine Aggregate
Fine aggregates shall be angular particles of uniform density. When the fine aggregate is
supplied from more than one source, aggregate from each source shall meet the specified
requirements.
2.1.2.1 Aggregate Base Course
ABC fine aggregate shall consist of screenings, angular sand, crushed recycled concrete fines,
or other finely divided mineral matter processed or naturally combined with the coarse
aggregate.
2.1.2.2 Graded-Crushed Aggregate Base Course
Provide GCA fine aggregate consisting of angular particles produced by crushing stone, slag,
[recycled concrete,] or gravel that meets the requirements for wear and soundness specified
for GCA coarse aggregate. Fine aggregate shall be produced by crushing only particles larger
than 4.75 mm sieve in size. The fine aggregate shall contain at least 90 percent by weight of
particles having two or more freshly fractured faces in the portion passing the 4.75 mm sieve
and retained on the 2 mm sieve, and in the portion passing the 2 mm sieve and retained on
the 0.425 mm sieve.
2.1.3. Gradation Requirements
Apply the specified gradation requirements to the completed base course. The aggregates
shall be continuously well graded within the limits specified in TABLE 1. Sieves shall conform
to ASTM E 11.
TABLE 1. GRADATION OF AGGREGATES

Percentage by Weight Passing Square-Mesh Sieve
Roads and service roads
Sieve Designation No. 1 No. 2 No. 3
50.0 mm 100 --- ---
37.5 mm 70-100 100 ---
25.0 mm 45-80 60-100 100
12.5 mm 30-60 30-65 40-70
4.75 mm 20-50 20-50 20-50

2.00 mm 15-40 15-40 15-40
0.425 mm 5-25 5-25 5-25
0.075 mm 0-8 0-8 0-8
Sieve Designation Airport pavements
50.0 mm ---
37.5 mm 95-100
25.0 mm 70-95
19.0 mm 55-85
12.5 mm
4.75 mm 30-60
0.60 mm 12-30
0.075 mm 0-8
NOTE 1: Particles having diameters less than 0.02 mm shall not be in excess of 3 percent by
weight of the total sample tested.
NOTE 2: The values are based on aggregates of uniform specific gravity. If materials from
different sources are used for the coarse and fine aggregates, they shall be tested in
accordance with ASTM C 127 and ASTM C 128 to determine their specific gravities. If the
specific gravities vary by more than 10 percent, the percentages passing the various sieves
shall be corrected as directed by the Contracting Officer.
2.2. LIQUID LIMIT AND PLASTICITY INDEX
Apply liquid limit and plasticity index requirements to the completed course and to any
component that is blended to meet the required gradation. The portion of any component or
of the completed course passing the 0.425 mm sieve shall be either nonplastic or have a
liquid limit not greater than 25 and a plasticity index not greater than 5.
PART 3 EXECUTION
3.1 GENERAL REQUIREMENTS
When the ABC or GCA is constructed in more than one layer, clean the previously
constructed layer of loose and foreign matter by sweeping with power sweepers or power
brooms, except that hand brooms may be used in areas where power cleaning is not
practicable. Provide adequate drainage during the entire period of construction to prevent

water from collecting or standing on the working area. Provide line and grade stakes as
necessary for control. Grade stakes shall be in lines parallel to the centerline of the area
under construction and suitably spaced for string lining.
3.2 OPERATION OF AGGREGATE SOURCES
Clearing, stripping, and excavating are the responsibility of the Contractor. Operate the
aggregate sources to produce the quantity and quality of materials meeting the specified
requirements in the specified time limit. Upon completion of the work, the aggregate sources
on Contractor property shall be conditioned to drain readily and shall be left in a satisfactory
condition. Aggregate sources on private lands shall be conditioned in agreement with local
laws or authorities.
3.3 STOCKPILING MATERIAL
Clear and level storage sites prior to stockpiling of material. Stockpile all materials, including
approved material available from excavation and grading, in the manner and at the locations
designated. Aggregates shall be stockpiled on the cleared and leveled areas designated by
the Contracting Officer to prevent segregation. Materials obtained from different sources
shall be stockpiled separately.
3.4 PREPARATION OF UNDERLYING COURSE
Prior to constructing the base course(s), the underlying course or subgrade shall be cleaned
of all foreign substances. At the time of construction of the base course(s), the underlying
course shall contain no frozen material. The surface of the underlying course or subgrade
shall meet specified compaction and surface tolerances. The underlying course shall conform
to Division 31 00 00 EARTHWORK and Section 32 11 16 SUBBASE COURSES. Ruts or soft
yielding spots in the underlying courses, areas having inadequate compaction, and
deviations of the surface from the requirements set forth herein shall be corrected by
loosening and removing soft or unsatisfactory material and by adding approved material,
reshaping to line and grade, and recompacting to specified density requirements. For
cohesionless underlying courses containing sands or gravels, as defined in ASTM D 2487, the
surface shall be stabilized prior to placement of the base course(s). Stabilization shall be
accomplished by mixing ABC or GCA into the underlying course and compacting by approved
methods. The stabilized material shall be considered as part of the underlying course and
shall meet all requirements of the underlying course. The finished underlying course shall
not be disturbed by traffic or other operations and shall be maintained in a satisfactory
condition until the base course is placed.
3.5 INSTALLATION
3.5.1 Mixing the Materials
Mix the coarse and fine aggregates in a stationary plant, or in a traveling plant or bucket
loader on an approved paved working area. Make adjustments in mixing procedures or in
equipment, as directed, to obtain true grades, to minimize segregation or degradation, to
obtain the required water content, and to insure a satisfactory base course meeting all
requirements of this specification.

3.5.2 Placing
Place the mixed material on the prepared subgrade or subbase in layers of uniform thickness
with an approved spreader. When a compacted layer 150 mm or less in thickness is required,
place the material in a single layer. When a compacted layer in excess of 150 mm is
required, place the material in layers of equal thickness. No layer shall be thicker than 150
mm or thinner than 75 mm when compacted. The layers shall be so placed that when
compacted they will be true to the grades or levels required with the least possible surface
disturbance. Where the base course is placed in more than one layer, the previously
constructed layers shall be cleaned of loose and foreign matter by sweeping with power
sweepers, power brooms, or hand brooms, as directed. Such adjustments in placing
procedures or equipment shall be made as may be directed to obtain true grades, to
minimize segregation and degradation, to adjust the water content, and to insure an
acceptable base course.
3.5.3 Grade Control
The finished and completed base course shall conform to the lines, grades, and cross
sections shown. Underlying material(s) shall be excavated and prepared at sufficient depth
for the required base course thickness so that the finished base course and the subsequent
surface course will meet the designated grades.
3.5.4 Edges of Base Course
The base course(s) shall be placed so that the completed section will be a minimum of 600
mm wider, on all sides, than the next layer that will be placed above it. Additionally, place
approved fill material along the outer edges of the base course in sufficient quantities to
compact to the thickness of the course being constructed, or to the thickness of each layer in
a multiple layer course, allowing in each operation at least a 600 mm width of this material
to be rolled and compacted simultaneously with rolling and compacting of each layer of base
course. If this base course material is to be placed adjacent to another pavement section,
then the layers for both of these sections shall be placed and compacted along this edge at
the same time.
3.5.5 Compaction
Compact each layer of the base course, as specified, with approved compaction equipment.
Maintain water content during the compaction procedure to within plus or minus 2 percent
of the optimum water content determined from laboratory tests as specified in this Section.
Begin rolling at the outside edge of the surface and proceed to the center, overlapping on
successive trips at least one-half the width of the roller. Alternate trips of the roller shall be
slightly different lengths. Speed of the roller shall be such that displacement of the
aggregate does not occur. In all places not accessible to the rollers, the mixture shall be
compacted with hand-operated power tampers. Continue compaction until each layer has a
degree of compaction that is at least 100 percent of laboratory maximum density through
the full depth of the layer. Make such adjustments in compacting or finishing procedures as
may be directed to obtain true grades, to minimize segregation and degradation, to reduce
or increase water content, and to ensure a satisfactory base course. Any materials that are

found to be unsatisfactory shall be removed and replaced with satisfactory material or
reworked, as directed, to meet the requirements of this specification.
Under runways, taxiways and apron pavements, compaction must be 100% of

modified proctor.
3.5.6 Thickness
Construct the compacted thickness of the base course as indicated. No individual layer shall
be thicker than 150 mm nor be thinner than 75 mm in compacted thickness. The total
compacted thickness of the base course(s) shall be within 13 mm of the thickness indicated.
Where the measured thickness is more than 13 mm deficient, correct such areas by
scarifying, adding new material of proper gradation, reblading, and recompacting as
directed. Where the measured thickness is more than 13 mm thicker than indicated, the
course shall be considered as conforming to the specified thickness requirements. Average
job thickness shall be the average of all thickness measurements taken for the job, but shall
be within 6 mm of the thickness indicated. The total thickness of the base course shall be
measured at intervals in such a manner as to ensure one measurement for each 500 square
meters of base course. Measurements shall be made in 75 mm diameter test holes
penetrating the base course.
3.5.7 Proof Rolling
Proof rolling of the areas indicated shall be in addition to the compaction specified and shall
consist of the application of coverages with a heavy pneumatic-tired roller having four or
more tires, each loaded to a minimum of 13,600 kg and inflated to a minimum of 1034 kPa.
In areas designated, apply proof rolling to the top of the underlying material on which the
base course is laid and to each layer of base course top of the completed ABC GCA course.
Maintain water content of the underlying material at optimum or at the percentage directed
from start of compaction to completion of proof rolling of that layer. Water content of each
layer of the base course shall be maintained at the optimum percentage directed from start
of compaction to completion of proof rolling. Any base course materials or any underlying
materials that produce unsatisfactory results by proof rolling shall be removed and replaced
with satisfactory materials, recompacted and proof rolled to meet these specifications.
3.5.8 Finishing
The surface of the top layer of base course shall be finished after final compaction and proof
rolling by cutting any overbuild to grade and rolling with a steel-wheeled roller. Thin layers of
material shall not be added to the top layer of base course to meet grade. If the elevation of
the top layer of base course is 13 mm or more below grade, then the top layer should be
scarified to a depth of at least 75 mm and new material shall be blended in and compacted
to bring to grade. Adjustments to rolling and finishing procedures shall be made as directed
to minimize segregation and degradation, obtain grades, maintain moisture content, and
insure an acceptable base course. Should the surface become rough, corrugated, uneven in
texture, or traffic marked prior to completion, the unsatisfactory portion shall be scarified,
reworked and recompacted or it shall be replaced as directed.

3.5.9 Smoothness
The surface of the top layer shall show no deviations in excess of 10 mm when tested with a
3.66 meter straightedge. Take measurements in successive positions parallel to the
centerline of the area to be paved. Measurements shall also be taken perpendicular to the
centerline at 15 meter intervals. Deviations exceeding this amount shall be corrected by
removing material and replacing with new material, or by reworking existing material and
compacting it to meet these specifications.
3.6 TRAFFIC
Completed portions of the base course may be opened to limited traffic, provided there is no
marring or distorting of the surface by the traffic. Heavy equipment shall not be permitted
except when necessary to construction, and then the area shall be protected against marring
or damage to the completed work.
3.7 MAINTENANCE
Maintain the base course in a satisfactory condition until the full pavement section is
completed and accepted. Maintenance shall include immediate repairs to any defects and
shall be repeated as often as necessary to keep the area intact. Any base course that is not
paved over prior to the onset of winter, shall be retested to verify that it still complies with
the requirements of this specification. Any area of base course that is damaged shall be
reworked or replaced as necessary to comply with this specification.
3.8 DISPOSAL OF UNSATISFACTORY MATERIALS
Any unsuitable materials that must be removed shall be disposed of in waste disposal areas
indicated. No additional payments will be made for materials that must be replaced.

SECTION 32 11 36 CONCRETE BASE COURSES
SUB-SECTION 32 11 36.13 LEAN CONCRETE BASE COURSES
PART 1 GENERAL
1.1 REFERENCES
AC 150/5370 10e (2009) Econocrete Base Course (P-306) for

airfield pavements (runways, taxiways or apron).
ACI INTERNATIONAL (ACI)
ACI 304R (2000; R 2009) Guide for Measuring, Mixing,

Transporting, and Placing Concrete
ACI 305R (1999; Errata 2006) Specification for Hot

Weather Concreting
ACI 306R (1988; R 2002) Cold Weather Concreting

ASTM C 138/C 138M (2010a) Standard Test Method for Density ("Unit
Weight"), Yield, and Air Content (Gravimetric) of
Concrete
ASTM C 143/C 143M (2010) Standard Test Method for Slump of

Hydraulic-Cement Concrete
ASTM C 150/C 150M (2009) Standard Specification for Portland

Cement
ASTM C 171 (2007) Standard Specification for Sheet Materials

for Curing Concrete
ASTM C 172 (2008) Standard Practice for Sampling Freshly

Mixed Concrete
ASTM C 173/C 173M (2010a) Standard Test Method for Air Content of
Freshly Mixed Concrete by the Volumetric Method
ASTM C 174/C 174M (2006) Standard Test Method for Measuring

Thickness of Concrete Elements Using Drilled
Concrete Cores
Development of Sharm El Sheikh International Airport 32 11 36.13 LEAN CONCRETE BASE COURSES

ASTM C 192/C 192M (2007) Standard Practice for Making and Curing
Concrete Test Specimens in the Laboratory
ASTM C 231 (2009b) Standard Test Method for Air Content of

Freshly Mixed Concrete by the Pressure Method
ASTM C 260 (2006) Standard Specification for Air-Entraining

Admixtures for Concrete
ASTM C 309 (2007) Standard Specification for Liquid

Membrane-Forming Compounds for Curing
Concrete
ASTM C 31/C 31M (2009) Standard Practice for Making and Curing
Concrete Test Specimens in the Field
ASTM C 33/C 33M (2008) Standard Specification for Concrete

Aggregates
ASTM C 39/C 39M (2009a) Standard Test Method for Compressive

Strength of Cylindrical Concrete Specimens
ASTM C 42/C 42M (2010) Standard Test Method for Obtaining and
Testing Drilled Cores and Sawed Beams of
Concrete
ASTM C 494/C 494M (2010) Standard Specification for Chemical

ASTM C 595/C 595M (2010) Standard Specification for Blended

Hydraulic Cements
ASTM C 618 (2008a) Standard Specification for Coal Fly Ash

and Raw or Calcined Natural Pozzolan for Use in
Concrete
ASTM C 94/C 94M (2009a) Standard Specification for Ready-Mixed

Concrete
ASTM C 989 (2009a) Standard Specification for Slag Cement

for Use in Concrete and Mortars

Aggregates
1.2 SUBMITTALS

PROCEDURES:
SD-05 Design Data
Mix design At least 30 days prior to mixing and placing econocrete, submit design mix
for approval. Furnish a complete list of materials including type, brand, source and

amount of cement, pozzolan, ground granulated blast-furnace slag, admixtures,
applicable reference specifications, and results of 28-day compressive strength test of
the econocrete. Compressive strength test specimens shall be prepared in accordance
with ASTM C 192/C 192M and tested in accordance with ASTM C 39/C 39M.
SD-06 Test Reports
Mix design review Aggregate tests Concrete slump tests Air content tests Temperature
Yield Surface Base course thickness tests Compressive strength tests
Submit testing results as required in paragraph entitled "Field Quality Control."
SD-07 Certificates Ready-mixed concrete plant identification Batch ticket information Cement
Aggregates Admixtures Curing materials
1.3 DELIVERY
Do not deliver econocrete until ready for placement.
1.4 STORAGE
1.4.1 Cement, Aggregate, and Admixture
Materials Store in conformance with recommendations of ACI 304R.
1.4.2 Curing Compounds and Bond Breaker
Inspect materials for contamination and damage. Unload and store with a minimum of
handling.
1.5.1 Required Information
Submit name and location of the ready-mixed concrete plant. Submit batch ticket
information as specified in ASTM C 94/C 94M.
1.5.2 Required Review
Before econocrete is placed at the job site, submit a mix design review accomplished by a
Contractor-approved independent commercial engineering testing laboratory. Include
cement factor, standard deviation used in the design of the mix, water-cement ratio (by
weight), percentage of fine aggregate to total aggregate by weight, weight in kilograms of
saturated surface-dry aggregates (fine and coarse) per sack of cement, volume of
admixtures and yield for one cubic meter of concrete.
1.6 WARRANTY

be signed.
PART 2 PRODUCTS
2.1 MIX DESIGN
The mix design shall be as specified herein under "Submittals" and conform to the following.
a. 28-day compressive strength MPa 8.27 minimum. Additionally, The following FAA
recommendation must be satisfied:
b. Cement factor kg per cubic meter: 120 minimum.
The minimum cement factor indicated is for concrete durability only and shall be
increased as necessary to meet minimum compressive strength requirements.
c. Air content (percent by volume): following FAA regulations:
d. Water-cement ratio: 0.6 maximum.
e. Slump: 25 mm minimum to 75 mm maximum for fixed form; 38 mm maximum for

slip-forming.

2.2 MATERIALS
2.2.1 Cement ASTM C 150/C 150M, Type(s) I. ASTM C 595/C 595M, Type IS or IP.
2.2.2 Water Fresh, clean and potable.
2.2.3 Aggregates
Stone or gravel, crushed or uncrushed, or crushed portland cement concrete pavement. The
fine aggregate shall be that naturally contained in the aggregate material or may be sand.
The aggregates shall consist of hard, durable particles, free from objectionable matter.
2.2.3.1 Gradation
The aggregate shall conform to any one of the gradations shown in Table 1 when tested in
accordance with ASTM C 136, except the gradation may be modified to suit locally available
aggregate, provided the strength requirements are met. The recommended gradation is C
(max 25 mm in FAA Table 1) A gradation is not included in FAA regulations.
TABLE 1: Recommended aggregate gradation
Percentage by weight passing the sieve

Sieve size
B / 37.5 mm maximum C / 25 mm maximum
51 mm - -
37.5 mm 100 -
25 mm 70-95 100
19 mm 55-85 70-100
4.75 mm 30-60 35-65
425 μm 10-30 15-30
75 μm 0-15 0-15
2.2.3.2 Deleterious Substances
Aggregates shall not contain any substance which may be deleteriously reactive with the
alkalies in the cement, except as permitted in ASTM C 33/C 33M.
2.2.4 Admixtures
Where not shown or specified, admixtures may be used subject to written approval of the
Contracting Officer.

2.2.4.1 Air-Entraining Admixtures ASTM C 260.
2.2.4.2 Retarding Admixtures ASTM C 494/C 494M, Type B or D.
2.2.4.3 Water-Reducing Admixtures ASTM C 494/C 494M, Type A, D, E, F, or G.
2.2.4.4 Accelerating Admixtures ASTM C 494/C 494M, Type C.
2.2.4.5 Pozzolans
Class N, F, or C ASTM C 618, except that the maximum allowable loss on ignition shall be 6
percent for Classes N and F.
2.2.4.6 Ground Granulated Blast-Furnace Slag ASTM C 989, Grade 120. 2.2.5 Curing Materials
2.2.5.1 Waterproof Paper
ASTM C 171, white color.
2.2.5.2 Polyethylene Sheeting
ASTM C 171, white color.
2.2.5.3 Polyethylene-Coated Burlap
ASTM C 171.
2.2.5.4 Liquid Membrane-Forming Compound
ASTM C 309, white-pigmented Type 2, Class B, or clear or translucent Type 1-D, Class B
with white fugitive dye.
2.2.6 Bond Breaker
Liquid membrane-forming curing compound as specified.
PART 3 EXECUTION
3.1 PREPARATION
Before placing econocrete, compact underlying surface to within 12 mm 0.04 foot of finish
grade and elevations shown. Wet underlying material in advance of placing econocrete to
ensure a firm, moist condition at time econocrete is placed. Do not permit equipment, other
than econocrete delivery or paving equipment on prepared underlying material.
3.2 FIXED FORMS
Set forms for full bearing on foundation for entire length and width and in alignment with
edge of base course. Support forms during entire operation of placing, compaction, and
finishing. Maximum vertical and horizontal deviation of form, including joints, shall not

exceed 6 mm from a 3.65 m straightedge. Provide stake sockets and interlocking devices
that will prevent movement of the form.
3.3 JOINTS
Shall be located as required to provide a minimum of 150 mm 6 inches from joints in

overlying course.
3.4 MEASURING, MIXING, AND TRANSPORTING ECONOCRETE
ASTM C 94/C 94M, except as modified herein. Provide batch ticket information for each load
of econocrete. Begin mixing within 30 minutes after the cement has been added to the
aggregates. Place econocrete within 90 minutes of either addition of mixing water to cement
and aggregates or addition of cement to aggregates if the air temperature is less than 29.5
degrees C. Reduce placement time to 60 minutes if the air temperature is greater than 29.5
degrees C. Additional water may be added, provided that both the specified maximum slump
and water-cement ratio are not exceeded.
3.5 PLACING ECONOCRETE
3.5.1 General
Econocrete placement will not be permitted when weather conditions prevent proper
placement and consolidation. Maintain drainage ditches, gutters and side drains to drain the
subgrade during the construction of the base. Place econocrete in one continuous operation
for the full width and depth of the section between transverse joints with slip form or fixed
form equipment.
3.5.2 Econocrete Placement
Deposit econocrete in its final location within time limits specified hereinbefore and before
initial set. Deposit in a manner that will require a minimum of rehandling. Work incidental to
handling and placing of econocrete shall be done in a manner that will not damage the
underlying surface. Place econocrete continuously at a uniform rate without unscheduled
stops except for equipment failure or other emergencies. Avoid contamination of plastic
econocrete with foreign material on construction equipment or workman's footwear.
Econocrete spread by hand shall be done with shovels and not with rakes.
3.5.3 Consolidation
Consolidate immediately after spreading with internal vibrators and vibrating screeds as
needed.
3.5.4 Hot Weather
Econocrete temperature from initial mixing through final cure shall not exceed 32 degrees C.
Cool ingredients before mixing, or substitute chip ice for part of required mixing water or use
other suitable means to control econocrete temperature to prevent rapid drying of newly
placed econocrete. Shade the fresh econocrete and start curing as soon as the surface is

sufficiently hard to permit curing without damage. Adhere to practices recommended in ACI
305R.
3.5.5 Protection Against Rain
Halt mixing and batching operations and cover unhardened econocrete surface. Length of
base to be protected shall extend back to a point where rain is not indenting base surface.
When slipform construction is used, install side forms in areas of base where edge cannot
otherwise be protected to prevent edge erosion. After rain ceases, install side forms as
required to prevent excessive edge slump, and remove protective covering without delay.
Remove remaining water without using cement. Refinish or replace areas damaged by rain.
3.6 FINISHING
Start finishing operations immediately after consolidation. Use finishing machine, except that
hand finishing may be used in emergencies and for econocrete in inaccessible locations or of
such shapes that machine finishing is impracticable. Finish base surface on both sides of a
joint to the same grade. Make as many finish trips over each area of base and at such
intervals as necessary to retain coarse aggregate near finished surface, and produce a
smooth surface true to grade and crown. Excessive operation over an area, which results in
an excess of mortar and water being brought to the surface, will not be permitted.
3.6.1 Surface Correction and Testing
After finishing is completed but while econocrete is still plastic, use straightedges to
eliminate minor irregularities and score marks. Use straightedges 3 m in length and operated
from sides of base and from bridges. Check surface for trueness with straightedge held in
successive positions parallel and at right angles to centerline of pavement. Advance
straightedge along pavement in successive stages of not more than one-half the length of
the straightedge. Immediately fill depressions with freshly mixed econocrete, strike off,
consolidate, and refinish. Strike off and refinish projections above required elevation.
Continue straightedge testing and finishing until entire surface of econocrete is free of
defects and meets specified requirements.
3.6.2 Surface Finish
Apply a uniform, smooth surface finish to econocrete base. Textured surface will not be
allowed.
3.7 CURING AND PROTECTION
Protect econocrete from injurious action by sun, rain, flowing water, frost, or mechanical
injury. At completion of finishing and at the time econocrete surface has hardened enough
to prevent the surface being marred by the curing material, cure by one or more of the
following methods. Use fresh water for curing. Keep base moist and at a temperature above
0 degree C F, for a full curing period of 7 days. Protect base from damage during removal of
form work and from injury resulting from storage or transportation of materials and
equipment during construction. Protect exposed vertical faces of econocrete with curing
compound or by other suitable means.

3.7.1 Moist Curing
Wet econocrete surface with a fine spray of water and cover with waterproof paper,
polyethylene-coated burlap, or polyethylene sheeting. Thoroughly saturate polyethylene-
coated burlap with water before placing. Select size of sheets that are at least 300 mm
longer than necessary to cover the entire width and edges of base. Place sheets with light-
colored side up. Overlap adjacent sheets not less than 300 mm with the lapped edges
securely weighted down or the sheets lapped 150 mm and cemented or tapered to form a
continuous cover and a closed joint. Weight cover down to prevent displacement or billowing
from winds. Fold coverings down over the exposed edges and secure with a continuous bank
of earth or other approved means. Use covers in good condition when placed and
immediately repair tears and holes they occur during the 7-day curing period.
3.7.2 Liquid Membrane-Forming Compound Curing
Apply compound immediately after surface loses its water sheen and has a dull appearance.
Mechanically agitate curing compound during use. Apply at a maximum rate of 5.0 square
meters per liter of compound. If compound lacks a uniform continuous, coherent films, or
exhibits checks, cracks, peels, or pinholes, apply an additional coat of compound to areas
where film is defective. Have readily available impervious sheet curing for use to protect
freshly placed econocrete in the event conditions occur to prevent correct application of
compound at the proper time. Re-spray surfaces with curing compound after rainfall. Apply
at same rate required above.
3.7.3 Protection of Treated Surfaces
Protect econocrete surfaces from foot and vehicular traffic and other sources of abrasion for
a minimum of 72 hours. Maintain continuity of applied curing method for the entire curing
period.
3.8 BOND BREAKER
Prior to placement of overlying portland cement concrete pavement, the surface of the
econocrete base shall be coated with a bond breaker to prevent bonding to the overlay
pavement. Bond breaker shall consist of a double application of liquid membrane-forming
curing compound. Each application shall be at the rates specified for curing. The first
application may be the econocrete curing application. The second application shall be placed
no more than 24 hours prior to placement of the overlying course.
3.9 FIELD QUALITY CONTROL
3.9.1 Sampling
3.9.1.1 Aggregates
Sample aggregates prior to delivery to the batch plant. During econocrete placement sample
aggregates for each 500 metric tons. Use sampling methods in accordance with ASTM D
75/D 75M. Identify each sample for conformance tests. When test results indicate that the

aggregates consistently meet the specified gradation requirements, the rate of sampling
may be reduced if approved by the Contracting Officer.
3.9.1.2 Econocrete
Obtain samples of plastic econocrete in accordance with ASTM C 172. Quality Control
samples may be taken at the econocrete batch plant; however, samples for verification of
econocrete strength and slump for submittal to the Contractor shall be taken at the job site
as the econocrete is delivered. From each sample, mold the required number of cylinders for
each group of test specimens.
3.9.2 Testing
3.9.2.1 Aggregate Tests
Without delay perform gradation tests on each sample. Make other aggregate tests on initial
source samples, and repeat tests whenever there is a change of source.
3.9.2.2 Econocrete Testing
Perform tests with aggregates and cement to be used in the project. During the course of
construction, if there is a deficiency in strength of the econocrete produced, perform
additional tests at the Contractor's expense and make adjustments in the mix, as required to
obtain the specified strength.
a. Slump: Test consistency of econocrete slump in accordance with ASTM C 143/C 143M.
Determine consistency of econocrete at the start of each day's placement and for
each group of cylinder test specimens.
b. Air content: Determine air content at the start of econocrete placement and for each
group of cylinder test specimens. Record results with test specimens. Determine air
content in accordance with ASTM C 173/C 173M or ASTM C 231.
c. Temperature tests: Determine temperature of plastic econocrete in-place during hot

weather periods, at frequent intervals, until uniform and acceptable temperature
control is established as specified.
d. Yield tests: Perform yield tests in accordance with ASTM C 138/C 138M, twice per day
on econocrete, and whenever materials or mix proportions are changed.
e. Surface tests: After curing, test the surface of the pavement with a straightedge or
device which will reveal irregularities in the econocrete surface. Remove and replace
the econocrete, mechanically grind the econocrete surface, or correct the surface as
approved, of any portion of the pavement in a longitudinal or transverse direction
which shows irregularities greater than 0.6 mm in 300 mm.
f. Test of base course thickness: The Contractor shall obtain 100 mm diameter core
samples to determine the in place thickness of the econocrete base course. Cores
shall be obtained in accordance with ASTM C 42/C 42M. The cores shall be removed
from the pavement at varying intervals but in no case shall there be less than one

core for each 1670 square meters. Repair the core holes with non-shrink grout. A
tolerance in base course thickness of 13 mm will be permitted for any individual core;
however, the average length of cores must be at least the base course thickness
shown. When determining the average, cores with a length of more than 13 mm
greater than the specified base thickness shall be assigned a length of the specified
thickness plus 13 mm. If the measured base course thickness is less than that shown
on the drawings by more than 13 mm, the deficient areas shall be removed and
replaced with econocrete of the specified strength, quality and thickness at no
additional cost to the Contractor. When a core indicates unsatisfactory thickness, the
limits of the base course to be removed and replaced shall be determined as follows:
One core shall be taken every 4.5 m of the lane in question in both directions from
the unsatisfactory core until satisfactory thickness is indicated; base course shall be
removed and replaced for the full width of the lane where a core indicated
unsatisfactory thickness. Length of cores shall be determined in accordance with
ASTM C 174/C 174M. Copies of each of the reports of corings shall be submitted, in
triplicate, to the Contracting Officer and shall include the following information.
(1) Date econocrete represented by core was placed.
(2) Date core was taken.
(3) Location of core -lane number, station number.
(4) Length of core.
(5) Condition of core -appearance, concrete texture, honeycombed.
(6) Disposition of core -In Contracting Officer or Contractor possession.
g. Compressive strength tests: ASTM C 39/C 39M. Make three test cylinders for each set
of tests in accordance with ASTM C 31/C 31M. Test one cylinder at 7 days for
information only and two at 28 days. Sample sets shall be taken not less than once a
day, nor less than once for each 380 cubic meters of econocrete. Strength test result
shall be the average of two cylinders from the same econocrete sample tested at 28
days. If any 28-day strength test result is less than the specified minimum strength,
or any individual cylinder strength result falls below the specified minimum strength
by more than 690 kPa, take a minimum of three ASTM C 42/C 42M core samples from
the in-place work represented by the low test results and test. Econocrete
represented by core tests shall be considered adequate if the average of three cores
falls within the specified strength limits and if no single core varies from the specified
strength limits by more than 690 kPa. Locations represented by erratic core tests shall
be retested. Remove econocrete not meeting specified strength and provide new
acceptable econocrete. Repair core holes with non shrink grout.


SECTION 32 12 13 PREPARATORY COATS
PART 1 GENERAL
1.1 REFERENCES

OFFICIALS (AASHTO)
AASHTO M 20 (1970; R 2004) Penetration-Graded Asphalt

Cement
AASHTO M 226 (1980; R 2008) Standard Specification for

Viscosity-Graded Asphalt Cement

Cutback Asphalt (Rapid-Curing Type)

Cutback Asphalt (Medium-Curing Type)
AASHTO T 102 (2009) Standard Method of Test for Spot Test of

Asphaltic Materials
AASHTO T 40 (2002; R 2006) Sampling Bituminous Materials
ASTM D 1250 (2008) Standard Guide for Use of the Petroleum

Measurement Tables

Bituminous Materials
ASTM D 2026 (1997; R 2010) Cutback Asphalt (Slow-Curing

Type)
ASTM D 2027 (1997; R 2004) Cutback Asphalt (Medium-Curing

Type)
ASTM D 2028 (1997; R 2004) Cutback Asphalt (Rapid-Curing

Type)

Emulsified Asphalt
Development of Sharm El Sheikh International Airport 32 12 13 PREPARATORY COATS

ASTM D 2995 (1999; R 2009) Determining Application Rate of
Bituminous Distributors
ASTM D 3381 (2009a) Viscosity-Graded Asphalt Cement for

Use in Pavement Construction
ASTM D 946 (2009a) Penetration-Graded Asphalt Cement for

AASHTO T 40 (2002; R 2006) Sampling Bituminous Materials
ASTM D 1250 (2008) Standard Guide for Use of the Petroleum

Measurement Tables

ASTM D 2026 (1997; R 2010) Cutback Asphalt (Slow-Curing

Type)
ASTM D 2027 (1997; R 2004) Cutback Asphalt (Medium-Curing

Type)
ASTM D 2028 (1997; R 2004) Cutback Asphalt (Rapid-Curing

Type)

Emulsified Asphalt
ASTM D 2995 (1999; R 2009) Determining Application Rate of

Bituminous Distributors


U.S. GREEN BUILDING COUNCIL (EMPLOYER)
LEED (2002; R 2005) Leadership in Energy and

Environmental Design(tm) Green Building Rating
System for New Construction (LEED-NC)

1.2.1 General Requirements
Plant, equipment, machines and tools used in the work are subject to approval and shall be
maintained in a satisfactory working condition at all times. Calibrated equipment such as
asphalt distributors, scales, batching equipment, spreaders and similar equipment, should
have been recalibrated by a calibration laboratory within 12 months prior to commencing
work .
1.2.2. Bituminous Distributor
Provide a distributor with pneumatic tires of such size and number that the load produced on
the base surface does not exceed 295 kg/25 mm of tire width to prevent rutting, shoving or
otherwise damaging the base surface or other layers in the pavement structure. Design and
equip the distributor to spray the bituminous material in a uniform coverage at the specified
temperature, at readily determined and controlled rates from 0.23 to 9.05 L/square meter,
with a pressure range of 172.4 to 517.1 kPa and with an allowable variation from the
specified rate of not more than plus or minus 5 percent, and at variable widths. Include with
the distributor equipment a separate power unit for the bitumen pump, full-circulation spray
bars, tachometer, pressure gauges, volume-measuring devices, adequate heaters for
heating of materials to the proper application temperature, a thermometer for reading the
temperature of tank contents, and a hand hose attachment suitable for applying bituminous
material manually to areas inaccessible to the distributor. Equip the distributor to circulate
and agitate the bituminous material during the heating process.
1.2.3 Heating Equipment for Storage Tanks
The equipment for heating the bituminous material shall be steam, electric or hot oil
heaters. Provide steam heaters consisting of steam coils and equipment for producing
steam, so designed that the steam cannot get into the material. Fix an armored
thermometer to the tank with a temperature range from 4.4 to 204.4 degrees C so that the
temperature of the bituminous material may be determined at all times.
1.2.4 Power Brooms and Power Blowers
Use power brooms and power blowers suitable for cleaning the surfaces to which the
bituminous coat is to be applied.
1.3 SUBMITTALS
SD-03 Product Data
Waybills and Delivery Tickets
Waybills and delivery tickets, during progress of the work.
Local/Regional Materials

Documentation indicating distance between manufacturing facility and the project
site. Indicate distance of raw material origin from the project site.
SD-06 Test Reports
Sampling and Testing
Copies of all test results for emulsified asphalt, and bituminous materials, within 24
hours of completion of tests. Certified copies of the manufacturer's test reports
indicating temperature viscosity relationship for cutback asphalt, compliance with
applicable specified requirements, not less than 30 days before the material is required
in the work.
Use Local/Regional Materials or products extracted, harvested, or recovered, as well as

manufactured, within a 800 km radius from the project site, if available from a minimum of
three sources
Inspect the materials delivered to the site for contamination and damage. Unload and store
the materials with a minimum of handling.
Apply bituminous coat only when the surface to receive the bituminous coat is dry. Apply
bituminous coat only when the atmospheric temperature in the shade is 10 degrees C or
above and when the temperature has not been below 2 degrees C for the 12 hours prior to
application, unless otherwise directed.
1.7 WARRANTY
be signed.

PART 2 PRODUCTS
2.1 PRIME COAT
Provide asphalt conforming to AASHTO M 81 AASHTO M 82, and specified in the following
two subparagraphs.
Asphaltic prime coat (MC-30) (1.5 Kg/m2) on granular surface for later bituminous
extension.
2.1.1 Cutback Asphalt
Provide cutback asphalt conforming to ASTM D 2027, Grade MC-30.
2.1.2 Emulsified Asphalt
Provide emulsified asphalt conforming to ASTM D 977, Type SS-1.
2.2 TACK COAT
Provide asphalt conforming to ASTM D 2028 ASTM D 946 ASTM D 3381 ASTM D 977 ASTM
D 2397 or AASHTO M 81 AASHTO M 20 AASHTO M 226 .
Anionic asphalt emulsion for tack coat or cutbacks (SS-1) (0.5 Kg/m2).
2.2.1 Cutback Asphalt
Provide cutback asphalt conforming to ASTM D 2027, Grade MC-30.
2.2.2 Emulsified Asphalt
Provide emulsified asphalt conforming to ASTM D 977, Type SS-1 between bituminous
layers. Dilute the emulsified asphalt with equal parts of water. The base asphalt used to
manufacture the emulsion shall show a negative spot when tested in accordance with
AASHTO T 102 using standard naphtha.
PART 3 EXECUTION
3.1 PREPARATION OF SURFACE
Immediately before applying the bituminous coat, remove all loose material, dirt, clay, or
other objectionable material from the surface to be treated by means of a power broom or
blower supplemented with hand brooms. The surface shall be dry and clean at the time of
treatment.
3.2 APPLICATION RATE
The exact quantities within the range specified, which may be varied to suit field conditions,
will be determined by the Contracting Officer.

3.2.1 Tack Coat
Apply bituminous material for the tack coat in quantities of not less than 0.20 L nor more
than 0.70 L/square meter of pavement surface.
3.2.2 Prime Coat
Apply bituminous material for the prime coat in quantities of not less than 0.70 L nor more
than 1.80 L/square meter of pavement surface.
3.3 APPLICATION TEMPERATURE
3.3.1 Viscosity Relationship
Asphalt application temperature shall provide an application viscosity between 10 and 60

seconds, Saybolt Furol, or between 20 and 120 square mm/sec, kinematic. Furnish the
temperature viscosity relation to the Contracting Officer.
3.3.2 Temperature Ranges
The viscosity requirements determine the application temperature to be used. The following
is a normal range of application temperatures:
Liquid Asphalts
[SC-250 75-132 degrees C]
[MC-30 29-87 degrees C]
[RC-70 50-90 degrees C*]
[RC-250 75-12 degrees C*]
Paving Grade Asphalts
Penetration Grades
[200-300 plus 130 degrees C]
Viscosity Grades
[AC 2.5 plus 132 degrees C]
[AC 5 plus 137 degrees C]
[AC 10 plus 137 degrees C]
[AR 1000 plus 135 degrees C]
Emulsions

[RS-1 20-60 degrees C]
[MS-1 20-70 degrees C]
[HFMS-1 20-70 degrees C]
[SS-1 20-70 degrees C]
[SS-1h 20-70 degrees C]
[CRS-1 52-85 degrees C]
[CSS-1 20-70 degrees C]
[CSS-1h 20-70 degrees C]
These temperature ranges exceed the flash point of the material and care should be taken in
their heating.
3.4 APPLICATION
3.4.1 General
Following preparation and subsequent inspection of the surface, apply the bituminous prime
or tack coat with the Bituminous Distributor at the specified rate with uniform distribution
over the surface to be treated. Properly treat all areas and spots missed by the distributor
with the hand spray. Until the succeeding layer of pavement is placed, maintain the surface
by protecting the surface against damage and by repairing deficient areas at no additional
cost to the Employer. If required, spread clean dry sand to effectively blot up any excess
bituminous material. No smoking, fires, or flames other than those from the heaters that are
a part of the equipment are permitted within 8 meters of heating, distributing, and
transferring operations of bituminous material other than bituminous emulsions. Prevent all
traffic, except for paving equipment used in constructing the surfacing, from using the
underlying material, whether primed or not, until the surfacing is completed. The bituminous
coat shall conform to all requirements as described herein.
3.4.2 Prime Coat
Apply a prime coat at locations shown on the Drawings. The prime coat is required if it will be
at least 7 days before the surfacing (Asphalt cement hot mix concrete) layer is constructed
on the underlying (base course, etc.) compacted material. The type of liquid asphalt and
application rate will be as specified herein. Protect the underlying from any damage (water,
traffic, etc.) until the surfacing is placed. If the Contractor places the surfacing within seven
days, the choice of protection measures or actions to be taken is at the Contractor's option.
Repair (recompact or replace) damage to the underlying material caused by lack of, or
inadequate, protection by approved methods at no additional cost to the Employer. If the
Contractor opts to use the prime coat, apply as soon as possible after consolidation of the
underlying material. Apply the bituminous material uniformly over the surface to be treated
at a pressure range of 172.4 to 517.1 kPa and at the rate of not less than 0.91 L not more
than 1.36 L/square m. To obtain uniform application of the prime coat on the surface
treated at the junction of previous and subsequent applications, spread building paper on
the surface for a sufficient distance back from the ends of each application to start and stop
the prime coat on the paper and to ensure that all sprayers will operate at full force on the
surface to be treated. Immediately after application remove and destroy the building paper.

3.4.3 Tack Coat
Apply tack coat at the locations shown on the drawings. Apply the tack coat when the
surface to be treated is dry. Immediately following the preparation of the surface for
treatment, apply the bituminous material by means of the bituminous distributor, within the
limits of temperaturespecified herein and at a rate of not less than 0.23 L nor more than 0.68
L of diluted emulsion per square meter. Apply the bituminous material so that uniform
distribution is obtained over the entire surface to be treated. Treat lightly coated areas and
spots missed by the distributor with the bituminous material. Following the application of
bituminous material, allow the surface to cure without being disturbed for period of time
necessary to permit setting of the tack coat. Apply the bituminous tack coat only as far in
advance of the placing of the overlying layer as required for that day's operation. Maintain
and protect the treated surface from damage until the succeeding course of pavement is
placed.
3.5 CURING PERIOD
Following application of the bituminous material and prior to application of the succeeding
layer of pavement, allow the bituminous coat to cure and to obtain evaporation of any
volatiles or moisture. Maintain the coated surface until the succeeding layer of pavement is
placed, by protecting the surface against damage and by repairing and recoating deficient
areas. Allow the prime coat to cure without being disturbed for a period of at least 48 hours
or longer, as may be necessary to attain penetration into the treated course. Furnish and
spread enough sand to effectively blot up and cure excess bituminous material.
Samples of the bituminous material shall be tested for compliance with the applicable
specified requirements. .
3.7 SAMPLING AND TESTING
Perform sampling and testing by an approved commercial testing laboratory or by facilities

furnished by the Contractor. No work requiring testing will be permitted until the facilities
have been inspected and approved.
3.7.1 Sampling
The samples of bituminous material, unless otherwise specified, shall be in accordance with
ASTM D 140/D 140M or AASHTO T 40. Sources from which bituminous materials are to be
obtained shall be selected and notification furnished the Contracting Officer within 15 days
after the award of the contract.
3.7.2 Calibration Test
Furnish all equipment, materials, and labor necessary to calibrate the bituminous distributor.
Calibration shall be made with the approved job material and prior to applying the
bituminous coat material to the prepared surface. Calibrate the bituminous distributor in
accordance with ASTM D 2995.

3.7.3 Trial Applications
Before providing the complete bituminous coat, apply three lengths of at least 30 meters for
the full width of the distributor bar to evaluate the amount of bituminous material that can
be satisfactorily applied.
3.7.3.1 Tack Coat Trial Application Rate
Unless otherwise authorized, apply the trial application rate of bituminous tack coat
materials in the amount of 0.20 L/square meter. Other trial applications shall be made using
various amounts of material as may be deemed necessary.
3.7.3.2 Prime Coat Trial Application Rate

Unless otherwise authorized, apply the trial application rate of bituminous materials in the
amount of 1.10 L/square meter. Other trial applications shall be made using various
amounts of material as may be deemed necessary.
3.7.4 Sampling and Testing During Construction
Perform quality control sampling and testing as required in paragraph FIELD QUALITY
CONTROL.
3.8 TRAFFIC CONTROLS
Keep traffic off surfaces freshly treated with bituminous material. Provide sufficient warning
signs and barricades so that traffic will not travel over freshly treated surfaces.

SECTION 32 12 15 HOT-MIX ASPHALT (HMA) FOR AIRFIELDS
PART 1 GENERAL
1.1 REFERENCES
AC 150/5370 10e (2009) Plant mix bitouminous pavement (P-401)

for airfield pavements (runways, taxiways or
apron).
ICAO Annex 14 (2010) Volume I: Aerodrome Design and

Operations.
ICAO DOC 9137 (2005) Airport Services Manual, Part 2

OFFICIALS (AASHTO)
AASHTO M 156 (1997: R 2009) Standard Specification for

Requirements for Mixing Plants for Hot-Mixed,
Hot-Laid Bituminous Paving Mixtures
AASHTO M 320 (2009) Standard Specification for Performance-

Graded Asphalt Binder
AASHTO T 308 (2009) Standard Method of Test for Determining

the Asphalt Binder Content of Hot Mix Asphalt
(HMA) by the Ignition Method
AASHTO T 329 (2008) Standard Test Method for Moisture

Content of Hot Mix Asphalt (HMA) by Oven
Method
ASPHALT INSTITUTE (AI)
AI MS-02 (1997 6th Ed) Mix Design Methods

ASTM C 1252 (2006) Standard Test Methods for Uncompacted

Void Content of Fine Aggregate (as Influenced by
Particle Shape, Surface Texture, and Grading)
Development of Sharm El Sheikh International Airport 32 12 15 HMA FOR AIRFIELDS


ASTM C 131 (2006) Standard Test Method for Resistance to


ASTM C 142 (1997; R 2004) Standard Test Method for Clay

Lumps and Friable Particles in Aggregates
ASTM C 566 (1997; R 2004) Standard Test Method for Total

Evaporable Moisture Content of Aggregate by
Drying

Magnesium Sulfate

ASTM D 1461 (1985; R 2006) Moisture or Volatile Distillates in

Bituminous Paving Mixtures
ASTM D 2041 (2003a) Theoretical Maximum Specific Gravity

and Density of Bituminous Paving Mixtures
ASTM D 2172 (2005) Quantitative Extraction of Bitumen from

ASTM D 2419 (2009) Sand Equivalent Value of Soils and Fine

Aggregate
ASTM D 242/D 242M (2009) Mineral Filler for Bituminous Paving

Mixtures
ASTM D 2489/D 2489M (2008) Estimating Degree of Particle Coating of

Bituminous-Aggregate Mixtures
ASTM D 2726 (2010) Bulk Specific Gravity and Density of Non-

Absorptive Compacted Bituminous Mixtures
ASTM D 3203 (2005) Percent Air Voids in Compacted Dense

and Open Bituminous Paving Mixtures

ASTM D 3381 (2009a) Viscosity-Graded Asphalt Cement for Use
in Pavement Construction
ASTM D 3665 (2007) Random Sampling of Construction

Materials
ASTM D 3666 (2009a) Minimum Requirements for Agencies

Testing and Inspecting Road and Paving
Materials
ASTM D 4125 (2005) Asphalt Content of Bituminous Mixtures

by the Nuclear Method
ASTM D 4791 (2005e1) Flat Particles, Elongated Particles, or

Flat and Elongated Particles in Coarse Aggregate
ASTM D 4867/D 4867M (2009) Effect of Moisture on Asphalt Concrete

Paving Mixtures
ASTM D 5444 (2008) Mechanical Size Analysis of Extracted

Aggregate
ASTM D 6307 (2005; R 2010) Asphalt Content of Hot Mix

Asphalt by Ignition Method
ASTM D 6925 (2009) Standard Test Method for Preparation and

Determination of the Relative Density of Hot Mix
Asphalt (HMA) Specimens by Means of the
Superpave Gyratory Compactor
ASTM D 6926 (2004) Standard Practice for Preparation of

Bituminous Specimens Using Marshall Apparatus
ASTM D 6927 (2006) Standard Test Method for Marshall

Stability and Flow of Bituminous Mixtures

ASTM D 979 (2001; R 2006e1) Sampling Bituminous Paving

Mixtures
STATE OF CALIFORNIA DEPARTMENT OF TRANSPORTATION (CDT)
CDT Test 526 (2002) Operation of California Profilograph and

Evaluation of Profiles
Perform the work consisting of pavement courses composed of mineral aggregate and
asphalt material heated and mixed in a central mixing plant and placed on a prepared
course. HMA designed and constructed in accordance with this section shall conform to the
lines, grades, thicknesses, and typical cross sections shown on the drawings. Construct each
course to the depth, section, or elevation required by the drawings and rolled, finished, and

approved before the placement of the next course. Submit proposed Placement Plan,
indicating lane widths, longitudinal joints, and transverse joints for each course or lift.
1.2.1 Asphalt Mixing Plant
Plants used for the preparation of hot-mix asphalt shall conform to the requirements of
AASHTO M 156 with the following changes:
a. Truck Scales. Weigh the asphalt mixture on approved scales furnished by the
Contractor, or on certified public scales at the Contractor's expense. Scales shall be
inspected and sealed at least annually by an approved calibration laboratory.
b. Testing Facilities. Provide laboratory facilities at the plant for the use of the Engineer's
acceptance testing and the Contractor's quality control testing.
c. Inspection of Plant. The Engineer shall have access at all times, to all areas of the
plant for checking adequacy of equipment; inspecting operation of the plant; verifying
weights, proportions, and material properties; checking the temperatures maintained
in the preparation of the mixtures and for taking samples. Provide assistance as
requested, for the Engineer to procure any desired samples.
d. Storage Bins. The asphalt mixture may be stored in non-insulated storage bins for a
period of time not exceeding 3 hours. The asphalt mixture may be stored in insulated
storage bins for a period of time not exceeding 8 hours. The mix drawn from bins
shall meet the same requirements as mix loaded directly into trucks.
1.2.2 Hauling Equipment
Trucks used for hauling hot-mix asphalt shall have tight, clean, and smooth metal beds. To
prevent the mixture from adhering to them, the truck beds shall be lightly coated with a
minimum amount of paraffin oil, lime solution, or other approved material. Petroleum based
products shall not be used as a release agent. Each truck shall have a suitable cover to
protect the mixture from adverse weather. When necessary to ensure that the mixture will
be delivered to the site at the specified temperature, truck beds shall be insulated or heated
and covers (tarps) shall be securely fastened.
1.2.3 Material Transfer Vehicle (MTV)
Material transfer Vehicles shall be required due to the improvement in smoothness and
decrease in both physical and thermal segregation. To transfer the material from the hauling
equipment to the paver, use a self-propelled, material transfer vehicle that can deliver
material to the paver without making contact with the paver. The MTV shall be able to move
back and forth between the hauling equipment and the paver providing material transfer to
the paver, while allowing the paver to operate at a constant speed. The Material Transfer
Vehicle will have remixing and storage capability to prevent physical and thermal
segregation.
1.2.4 Asphalt Pavers

Mechanical spreading and finishing equipment shall consist of a self-powered paver, capable
of spreading and finishing the mixture to the specified line, grade, and cross section. The
screed of the paver shall be capable of laying a uniform mixture to meet the specified
thickness, smoothness, and grade without physical or temperature segregation, the full
width of the material being placed. The screed will be equipped with a compaction device
and it will be used during all placement.
1.2.4.1 Receiving Hopper
The paver shall have a receiving hopper of sufficient capacity to permit a uniform spreading
operation. The hopper shall be equipped with a distribution system to place the mixture
uniformly in front of the screed without segregation. The screed shall effectively produce a
finished surface of the required evenness and texture without tearing, shoving, or gouging
the mixture.
1.2.4.2 Automatic Grade Controls
If an automatic grade control device is used, the paver shall be equipped with a control
system capable of automatically maintaining the specified screed elevation. The control
system shall be automatically actuated from either a reference line and/or through a system
of mechanical sensors or sensor-directed mechanisms or devices which will maintain the
paver screed at a predetermined transverse slope and at the proper elevation to obtain the
required surface. The transverse slope controller shall be capable of maintaining the screed
at the desired slope within plus or minus 0.1 percent. A transverse slope controller shall not
be used to control grade. The controls shall be capable of working in conjunction with any of
the following attachments:
a. Ski-type device of not less than 9.14 m in length.
b. Taut stringline set to grade.
c. Short ski or shoe for joint matching.
d. Laser control.
1.2.5 Rollers
Rollers shall be in good condition and shall be operated at slow speeds to avoid
displacement of the asphalt mixture. The number, type, and weight of rollers shall be
sufficient to compact the mixture to the required density while it is still in a workable
condition. Equipment which causes excessive crushing of the aggregate shall not be used.
1.3 SUBMITTALS
Quality Control approval. Submit the following in accordance with Section 01 33 00

SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Placement Plan;

SD-03 Product Data
Mix Design;
Contractor Quality Control;
SD-04 Samples
Asphalt Cement Binder Aggregates
SD-06 Test Reports
Aggregates QC Monitoring
SD-07 Certificates
Asphalt Cement Binder Testing Laboratory
The Engineer's quality assurance (QA) program for this project is separate and distinct from
the Contractor's quality control (QC) program specified in Part 3. Testing for acceptability of
work will be performed by the Engineer or by an independent laboratory hired by the
Engineer, except for grade and smoothness testing which shall be performed by the
Contractor. Acceptance of the plant produced mix and in-place requirements will be on a lot
to lot basis. A standard lot for all requirements will be equal to 2000 metric tons. Where
appropriate, adjustment in payment for individual lots of hot-mix asphalt will be made based
on in-place density, laboratory air voids, grade and smoothness in accordance with the
following paragraphs. Grade and surface smoothness determinations will be made on the lot
as a whole. Exceptions or adjustments to this will be made in situations where the mix
within one lot is placed as part of both the intermediate and surface courses, thus grade and
smoothness measurements for the entire lot cannot be made. In order to evaluate
laboratory air voids and in-place (field) density, each lot will be divided into four equal
sublots.
1.4.1 Sublot Sampling
One random mixture sample for determining laboratory air voids, theoretical maximum
density, and for any additional testing the Engineer desires, will be taken from a loaded
truck delivering mixture to each sublot, or other appropriate location for each sublot. All
samples will be selected randomly, using commonly recognized methods of assuring
randomness conforming to ASTM D 3665 and employing tables of random numbers or
computer programs. Laboratory air voids will be determined from three laboratory
compacted specimens of each sublot sample in accordance with ASTM D 6926. The
specimens will be compacted within 2 hours of the time the mixture was loaded into trucks
at the asphalt plant. Samples will not be reheated prior to compaction and insulated
containers will be used as necessary to maintain the temperature.

1.4.2 Additional Sampling and Testing
The Engineer reserves the right to direct additional samples and tests for any area which
appears to deviate from the specification requirements. The cost of any additional testing
will be paid for by the /Owner. Testing in these areas will be treated as a separate lot.
Payment will be made for the quantity of HMA represented by these tests in accordance with
the provisions of this section.
1.4.3 In-place Density
For determining in-place density, one random core (100 mm or 150 mm in diameter) will be
taken by the Engineer from the mat (interior of the lane) of each sublot, and one random
core will be taken from the joint (immediately over joint) of each sublot, in accordance with
ASTM D 979. Each random core will be full thickness of the layer being placed. When the
random core is less than 25 mm thick, it will not be included in the analysis. In this case,
another random core will be taken. After air drying to meet the requirements for laboratory-
prepared, thoroughly dry specimens, cores obtained from the mat and from the joints will be
used for in-place density determination in accordance with ASTM D 2726.
Use one of the following methods to test and evaluate surface smoothness of the finished
surface of the pavement final grade. All testing shall be performed in the presence of the
Engineer. Detailed notes of the results of the testing shall be kept and a copy furnished to
the Engineer immediately after each day's testing. The profilograph method shall be used for
all longitudinal and transverse testing, except where the runs would be less than 60 m in
length and the ends where the straightedge shall be used. Where drawings show required
deviations from a plane surface (crowns, drainage inlets, etc.), the surface shall be finished
to meet the approval of the Engineer.
1.4.4.1 Smoothness Requirements
a. Straightedge Testing: The finished surfaces of the pavements shall have no abrupt
change of 3 mm or more, and all pavements shall be within the tolerances specified in
Table 3 when checked with an approved 4 m straightedge.
Table 3. Straightedge Surface Smoothness--Pavements
Pavement category Direction of testing Tolerance (mm)
Longitudinal 3
RWY and TWY
Transverse 6
Longitudinal 3
Calibration hardstands and compass swinging bases
Transverse 3
All other airfield and helicopter paved areas Longitudinal 6

Pavement category Direction of testing Tolerance (mm)
Transverse 6
b. Profilograph Testing: The finished surfaces of the pavements shall have no abrupt
change of 3 mm or more, and all pavement shall have a Profile Index not greater than
specified in Table 4 when tested with an approved California-type profilograph. If the
extent of the pavement in either direction is less than 60 m, that direction shall be
tested by the straightedge method and shall meet requirements specified above.
Table 4. Profilograph Surface Smoothness—Pavements
Maximum Specified Profile

Pavement category Direction of testing
Index (mm/km)
Longitudinal 110
RWY
Transverse (use straight edge)
Longitudinal 140
TWY
Transverse (use straight edge)
Calibration hardstands and

compass swinging bases (use straight edge)
All other airfield and Longitudinal 140

helicopter paved areas
Transverse 140
1.4.4.2 Testing Method
After the final rolling, but not later than 24 hours after placement, the surface of the
pavement in each entire lot shall be tested in such a manner as to reveal all surface
irregularities exceeding the tolerances specified above. Separate testing of individual sublots
is not required. If any pavement areas are diamond ground, these areas shall be retested
immediately after grinding. The area corrected by grinding shall not exceed 10 percent of
the total area of the lot. The entire area of the pavement shall be tested in both a
longitudinal and a transverse direction on parallel lines. The transverse lines shall be 4.5 m
15 feet or less apart, as directed. The longitudinal lines shall be at the centerline of each
paving lane for lines less than 6.1 m 20 feet and at the third points for lanes 6.1 m 20 feet
or greater. Other areas having obvious deviations shall also be tested. Longitudinal testing
lines shall be continuous across all joints.
a. Straightedge Testing. The straightedge shall be held in contact with the surface and
moved ahead one-half the length of the straightedge for each successive
measurement. The amount of surface irregularity shall be determined by placing the
freestanding (unleveled) straightedge on the pavement surface and allowing it to rest

upon the two highest spots covered by its length, and measuring the maximum gap
between the straightedge and the pavement surface in the area between these two
high points.
b. Profilograph Testing. Profilograph testing shall be performed using approved

equipment and procedures described in CDT Test 526. The equipment shall utilize
electronic recording and automatic computerized reduction of data to indicate "must-
grind" bumps and the Profile Index for the pavement. The "blanking band" shall be 5
mm wide and the "bump template" shall span 25 mm with an offset of 10 mm. The
profilograph shall be operated by an approved, factory-trained operator on the
alignments specified above. A copy of the reduced tapes shall be furnished the
Engineer at the end of each day's testing.
c. Bumps ("Must Grind" Areas). Any bumps ("must grind" areas) shown on the
profilograph trace which exceed 10 mm in height shall be reduced by diamond
grinding until they do not exceed 7.5 mm when retested. Such grinding shall be
tapered in all directions to provide smooth transitions to areas not requiring grinding.
The following will not be permitted: (1) skin patching for correcting low areas, (2)
planing or milling for correcting high areas. At the Contractor's option, pavement
areas, including ground areas, may be rechecked with the profilograph in order to
record a lower Profile Index.
The hot-mix asphalt shall not be placed upon a wet surface or when the surface
temperature of the underlying course is less than specified in Table 5. The temperature
requirements may be waived by the Engineer, if requested; however, all other requirements,
including compaction, shall be met.
Table 5. Surface Temperature Limitations of Underlying Course
Base Temperature (minimum)

Main thickness
Deg. C
7.5 cm or greater 4
Greater than 2.5 cm but less than

7
7.5 cm
2.5 cm or less 10
1.6 WARRANTY
be signed.

PART 2 PRODUCTS
2.1 AGGREGATES
Aggregates shall consist of crushed stone, crushed gravel, crushed slag, screenings, natural
sand and mineral filler, as required. The portion of material retained on the 4.75 mm sieve is
coarse aggregate. The portion of material passing the 4.75 mm sieve and retained on the
0.075 mm sieve is fine aggregate. The portion passing the 0.075 mm sieve is defined as
mineral filler. Submit sufficient materials to produce 90 kg of blended mixture for mix design
verification. All aggregate test results and samples shall be submitted to the Engineer at
least 14 days prior to start of construction. Aggregate testing shall have been performed
within 90 days of performing the mix design.
Coarse aggregate shall consist of sound, tough, durable particles, free from films of material
that would prevent thorough coating and bonding with the asphalt material and free from
organic matter and other deleterious substances. The coarse aggregate particles shall meet
the following requirements:
a. The percentage of loss shall not be greater than 40 percent after 500 revolutions
when tested in accordance with ASTM C 131.
b. The sodium sulfate soundness loss shall not exceed 12 percent, or the magnesium
sulfate soundness loss shall not exceed 18 percent after five cycles when tested in
accordance with ASTM C 88.
c. At least 75 percent by weight of coarse aggregate shall have at least two or more
fractured faces when tested in accordance with COE CRD-C 171. Fractured faces shall
be produced by crushing.
d. The particle shape shall be essentially cubical and the aggregate shall not contain
more than 20 percent, by weight, of flat and elongated particles (3:1 ratio of
maximum to minimum) when tested in accordance with ASTM D 4791.
e. Slag shall be air-cooled, blast furnace slag, and shall have a compacted weight of not
less than 1200 kg/cubic meter when tested in accordance with ASTM C 29/C 29M.

f. Clay lumps and friable particles shall not exceed 0.3 percent, by weight, when tested
in accordance with ASTM C 142.
g. Maximum Los Angeles resistance to degradation will be:
Area L. A. abrasion
Runway surface course 15
TWY surface course 25
Binder courses 25
2.1.2 Fine Aggregate
Fine aggregate shall consist of clean, sound, tough, durable particles. The aggregate
particles shall be free from coatings of clay, silt, or any objectionable material and shall
contain no clay balls. The fine aggregate particles shall meet the following requirements:
a. The quantity of natural sand (noncrushed material) added to the aggregate blend
shall not exceed 15 percent by weight of total aggregate.
b. The individual fine aggregate sources shall have a sand equivalent value greater than
45 when tested in accordance with ASTM D 2419.
c. The fine aggregate portion of the blended aggregate shall have an uncompacted void
content greater than 45.0 percent when tested in accordance with ASTM C 1252
Method A.
d. Clay lumps and friable particles shall not exceed 0.3 percent, by weight, when tested
2.1.3 Mineral Filler
Mineral filler shall be nonplastic material meeting the requirements of ASTM D 242/D 242M.
2.1.4 Aggregate Gradation
The combined aggregate gradation shall conform to gradations specified in Table 6, when
tested in accordance with ASTM C 136 and ASTM C 117, and shall not vary from the low
limit on one sieve to the high limit on the adjacent sieve or vice versa, but grade uniformly
from coarse to fine. The JMF shall be within the specification limits; however, the gradation
can exceed the limits when the allowable devaluation form the JMF shown in Tables 9 and
10 are applied.
Table 6. Aggregate Gradations
M.B.C.
Sieve size
(mm) % passing each sieve

Gap graded
Binder TWY surface
(RWY surface)
25 100 - -
20 (19) 80-95 100 -
12,5 64-79 80-95 100
8 (9.5) 50-66 64-79 56-80
4 (4.75 35-50 44-59 30-43
2 (2.36) 24-38 31-46 27-37
0.5 (0.6) 11-21 16-27 14-23
0.25 (0.3) 7-15 11-20 -
0.125 (0.15) 5-10 6-12 -
0.063 (0.075) 3-7 4-8 6-11
filler/binder
1,2 1,3 1,3
proportion
Cellulose fiber / / 0.25-0.40%
2.2 ASPHALT CEMENT BINDER
Asphalt cement binder shall conform to AASHTO M 320 Performance Grade (PG) . As an
alternate, ASTM D 3381 Table 2, Viscosity Grade or ASTM D 946 Penetration Grade may be
used. Test data indicating grade certification shall be provided by the supplier at the time of
delivery of each load to the mix plant. Copies of these certifications shall be submitted to the
Engineer. The supplier is defined as the last source of any modification to the binder. The
Engineer may sample and test the binder at the mix plant at any time before or during mix
production. Samples for this verification testing shall be obtained in accordance with ASTM D
140/D 140M and in the presence of the Engineer. These samples shall be furnished to the
Engineer for the verification testing, which shall be at no cost to the Contractor. Submit 20 L
sample of the asphalt cement specified for mix design verification and approval not less than
14 days before start of the test section.
2.3 MIX DESIGN
Develop the mix design. The Job Mix formula (JMF)shall have been developed and
aggregates tested no earlier than 6 monnths before contract award. The asphalt mix shall be
composed of a mixture of well-graded aggregate, mineral filler if required, and asphalt
material. The aggregate fractions shall be sized, handled in separate size groups, and
combined in such proportions that the resulting mixture meets the grading requirements of

Table 6. No hot-mix asphalt for payment shall be produced until a JMF has been approved.
Laboratory compaction temperatures for Polymer Modified Asphalts shall be as
recommended by the asphalt cement manufacturer. If the Tensile Strength Ratio (TSR) of
the composite mixture, as determined by ASTM D 4867/D 4867M is less than 75, the
aggregates shall be rejected or the asphalt mixture treated with an anti-stripping agent. The
amount of anti-stripping agent added shall be sufficient to produce a TSR of not less than
75. If an antistrip agent is required, it shall be provided at no additional cost to the
Contractor. Sufficient materials to produce 90 kg of blended mixture shall be provided to the
Engineer for verification of mix design at least 14 days prior to construction of test section.
2.3.1 JMF Requirements
Submit the proposed JMF in writing, for approval, at least 14 days prior to the start of the
test section, including as a minimum:
a. Percent passing each sieve size.
b. Percent of asphalt cement.
c. Percent of each aggregate and mineral filler to be used.
d. Asphalt viscosity grade, penetration grade, or performance grade.
e. Laboratory mixing temperature.
f. Lab compaction temperature.
g. Temperature-viscosity relationship of the asphalt cement.
h. Plot of the combined gradation on the 0.45 power gradation chart, stating the nominal
maximum size.
i. Graphical plots and summary tabulation of air voids, voids in the mineral aggregate,
and unit weight versus asphalt content as shown in AI MS-02. Summary tabulation
shall include individual specimen data for each specimen tested.
j. Specific gravity and absorption of each aggregate.
k. Percent natural sand.
l. Percent particles with two or more fractured faces (in coarse aggregate).
m. Fine aggregate angularity.
n. Percent flat or elongated particles (in coarse aggregate).
o. Tensile Strength Ratio and wet/dry specimen test results.
p. Antistrip agent (if required).

q. List of all modifiers.
r. Percentage and properties (asphalt content, binder properties, and aggregate

properties) of RAP in accordance with paragraph RECYCLED HOT-MIX ASPHALT, if
RAP is used. (4)
Table 8. Minimum Percent Voids in Mineral Aggregate (VMA)
Minimum voids in Mineral

Maximum Particle size, Mm
Aggregate, percent
12.5 16
19.0 15
25 14
37.5 13
2.3.2 Adjustments to JMF
The JMF for each mixture shall be in effect until a new formula is approved in writing by the
Engineer. Should a change in sources of any materials be made, a new mix design shall be
performed and a new JMF approved before the new material is used. The Contractor will be
allowed to make minor adjustments within the specifcation limits to the JMF to optimize mix
volumetric properties. Adjustments to the original JMF shall be limited to plus or minus 4
percent on the 4.75 mm and coarser sieves; plus or minus 3 percent on the 2.36 mm to
0.30 mm sieves; and plus or minus 1 percent on the 0.15 mm sieve. Adjustments to the JMF
shall be limited to plus or minus 1.0 percent on the 0.075 mm sieve. Asphalt content
adjustments shall be limited to plus or minus 0.40 from the original JMF. If adjustments are
needed that exceed these limits, a new mix design shall be developed.
2.4 RECYCLED HOT MIX ASPHALT
Recycled HMA shall consist of reclaimed asphalt pavement (RAP), coarse aggregate, fine
aggregate, mineral filler, and asphalt cement. The RAP shall be of a consistent gradation and
asphalt content and properties. RAP stockpiles shall be free from contamination, including
coal-tar sealers. When RAP is fed into the plant, the maximum RAP chunk size shall not
exceed 50 mm. The individual aggregates in a RAP chunk shall not exceed the maximum
size aggregate of the gradation specified in Table 6. The recycled HMA mix shall be designed
using procedures contained in AI MS-02. The job mix shall meet the requirements of
paragraph MIX DESIGN. RAP shall only be used for shoulder surface course mixes and for
any intermediate courses. The amount of RAP shall be limited to 30 percent.
2.4.1 RAP Aggregates and Asphalt Cement
The blend of aggregates used in the recycled mix shall meet the requirements of paragraph
AGGREGATES. The percentage of asphalt in the RAP shall be established for the mixture
design according to ASTM D 2172 using the appropriate dust correction procedure.

2.4.2 RAP Mix
The blend of new asphalt cement and the RAP asphalt binder shall meet the penetration
requirements in paragraph ASPHALT CEMENT BINDER. The virgin asphalt cement shall not
be more than two standard asphalt material grades different than that specified in
paragraph ASPHALT CEMENT BINDER.
PART 3 EXECUTION
3.1 CONTRACTOR QUALITY CONTROL
3.1.1 General Quality Control Requirements
Submit the approved Quality Control Plan. Hot-mix asphalt for payment shall not be
produced until the quality control plan has been approved. The plan shall address all
elements which affect the quality of the pavement including, but not limited to:
a. Mix Design and unique JMF identification code
b. Aggregate Grading
c. Quality of Materials
d. Stockpile Management and procedures to prevent contamination
e. Proportioning
f. Mixing and Transportation
g. Correlation of mechanical hammer to hand hammer. Determine the number of blows

of the mechanical hammer required to provide the same density of the JMF as
provided by the hand hammer. Use the average of three specimens per trial blow
application.
h. Mixture Volumetrics
i. Moisture Content of Mixtures
j. Placing and Finishing
k. Joints
l. Compaction, including HMA-PCC joints
m. Surface Smoothness
n. Truck bed release agent

3.1.2 Testing Laboratory
Provide a fully equipped asphalt laboratory located at the plant or job site. It shall be
equipped with air conditioning units to maintain a temperature of 24 plus or minus 2.3
degrees C. Laboratory facilities shall be kept clean and all equipment shall be maintained in
proper working condition. The Engineer shall be permitted unrestricted access to inspect the
Contractor's laboratory facility, to witness quality control activities, and to perform any check
testing desired. The Engineer will advise the Contractor in writing of any noted deficiencies
concerning the laboratory facility, equipment, supplies, or testing personnel and procedures.
When the deficiencies are serious enough to adversely affect test results, the incorporation
of the materials into the work shall be suspended immediately and will not be permitted to
resume until the deficiencies are corrected.
3.1.3 Quality Control Testing
Perform all quality control tests applicable to these specifications and as set forth in the
Quality Control Program. The testing program shall include, but shall not be limited to, tests
for the control of asphalt content, aggregate gradation, temperatures, aggregate moisture,
moisture in the asphalt mixture, laboratory air voids, stability, flow, in-place density, grade
and smoothness. A Quality Control Testing Plan shall be developed as part of the Quality
Control Program.
3.1.3.1 Asphalt Content
A minimum of two tests to determine asphalt content will be performed per lot (a lot is
defined in paragraph QUALITY ASSURANCE) by one of the following methods: extraction
method in accordance with ASTM D 2172, Method A or B, the ignition method in accordance
with the AASHTO T 308, ASTM D 6307, or the nuclear method in accordance with ASTM D
4125, provided each method is calibrated for the specific mix being used. For the extraction
method, the weight of ash, as described in ASTM D 2172, shall be determined as part of the
first extraction test performed at the beginning of plant production; and as part of every
tenth extraction test performed thereafter, for the duration of plant production. The last
weight of ash value obtained shall be used in the calculation of the asphalt content for the
mixture.
3.1.3.2 Aggregate Properties
Aggregate gradations shall be determined a minimum of twice per lot from mechanical
analysis of recovered aggregate in accordance with ASTM D 5444 or ASTM D 6307. For
batch plants, aggregates shall be tested in accordance with ASTM C 136 using actual batch
weights to determine the combined aggregate gradation of the mixture. The specifc gravity
of each aggregate size grouping shall be determined for each 18,000 metric tons in
accordance with ASTM C 127 or ASTM C 128. Fractured faces for gravel sources shall be
determined for each 18,000 metric tons in accordance with COE CRD-C 171. The
uncompacted void content of manufactured sand shall be determined for each 18,000 metric
tons in accordance with ASTM C 1252 Method A.

3.1.3.3 Temperatures
Temperatures shall be checked at least four times per lot, at necessary locations, to
determine the temperature at the dryer, the asphalt cement in the storage tank, the asphalt
mixture at the plant, and the asphalt mixture at the job site.
3.1.3.4 Aggregate Moisture
The moisture content of aggregate used for production shall be determined a minimum of
once per lot in accordance with ASTM C 566.
3.1.3.5 Moisture Content of Mixture
The moisture content of the mixture shall be determined at least once per lot in accordance
with AASHTO T 329.
3.1.3.6 Laboratory Air Voids, VMA
Mixture samples shall be taken at least four times per lot and compacted into specimens,
After compaction, the laboratory air voids and VMA of each specimen shall be determined..
The VMA shall be within the limits of Table 8.
3.1.3.7 In-Place Density
Conduct any necessary testing to ensure the specified density is achieved. A nuclear gauge
or other non-destructive testing device may be used to monitor pavement density.
3.1.3.8 Grade and Smoothness
Conduct the necessary checks to ensure the grade and smoothness requirements are met in
accordance with paragraph QUALITY ASSURANCE.
3.1.3.9 Additional Testing
Friction level: RWY friction level must be higher than the design objective established by
ICAO. Test must be done to prove this condition in the new RWY whit one of the following
equipment:

Any additional testing, which the Contractor deems necessary to control the process, may be
performed at the Contractor's option.
3.1.3.10 QC Monitoring
Submit all QC test results to the Engineer on a daily basis as the tests are performed. The
Engineer reserves the right to monitor any of the Contractor's quality control testing and to
perform duplicate testing as a check to the Contractor's quality control testing.
3.1.4 Sampling
When directed by the Engineer, sample and test any material which appears inconsistent
with similar material being produced, unless such material is voluntarily removed and
replaced or deficiencies corrected by the Contractor. All sampling shall be in accordance with
standard procedures specified.
3.1.5 Control Charts
For process control, establish and maintain linear control charts on both individual samples
and the running average of last four samples for the parameters listed in Table 9, as a
minimum. These control charts shall be posted as directed by the Engineer and shall be kept
current at all times. The control charts shall identify the project number, the test parameter
being plotted, the individual sample numbers, the Action and Suspension Limits listed in
Table 9 applicable to the test parameter being plotted, and the Contractor's test results.
Target values (JMF) shall also be shown on the control charts as indicators of central
tendency for the cumulative percent passing, asphalt content, and laboratory air voids
parameters. When the test results exceed either applicable Action Limit, take immediate
steps to bring the process back in control. When the test results exceed either applicable

Suspension Limit, halt production until the problem is solved. When the Suspension Limit is
exceeded for individual values or running average values, the Contracting Officer Engineer
has the option to require the Contractor to remove and replace the material represented by
the samples or to leave in place and base acceptance on mixture volumetric properties and
in place density. Use the control charts as part of the process control system for identifying
trends so that potential problems can be corrected before they occur. Decisions concerning
mix modifications shall be made based on analysis of the results provided in the control
charts. The Quality Control Plan shall indicate the appropriate action which shall be taken to
bring the process into control when certain parameters exceed their Action Limits.
Table 9. Action and Suspension Limits for the Parameters to be Plotted on Individual and Running
Average Control Charts
Parameter to be plotted Individual Samples Running Average of

Last Four Samples
Action Limit Suspension Action Suspension

Limit L Limit
i
m
i
t
4.75 mm sieve, Cumulative % 6 8 4 5

Passing, deviation from JMF target; plus or
6 8 4 5
minus values
0.6 mm sieve, Cumulative % 4 6 3 4

Passing, deviation from JMF target; plus or
4 6 3 4
minus values
0.075 mm sieve, Cumulative % 1.4 2.0 1.1

1.5 Passing, deviation from JMF target; plus
1.4 2.0 1.1 1.5
or minus values
Asphalt content, % deviation 0.4 0.5 0.2 0.3

from JMF target; plus or minus value 0.4 0.5 0.2 0.3
Laboratory Air Voids, % deviation from JMF No specific action and suspension limits set since this
target value parameter is used to determine percent payment
In-place Mat Density, % of TMD No specific action and suspension limits set since this
parameter is used to determine percent payment
In-place Joint Density, % of TMD No specific action and suspension limits set since this
parameter is used to determine percent payment

3.2 PREPARATION OF ASPHALT BINDER MATERIAL
The asphalt cement material shall be heated avoiding local overheating and providing a
continuous supply of the asphalt material to the mixer at a uniform temperature. The
temperature of unmodified asphalts shall be no more than 160 degrees C 325 degrees F
when added to the aggregates. Performance Graded (PG) asphalts shall be within the
temperature range of to degrees C F when added to the aggregates.
3.3 PREPARATION OF MINERAL AGGREGATE
The aggregate for the mixture shall be heated and dried prior to mixing. No damage shall
occur to the aggregates due to the maximum temperature and rate of heating used. The
temperature of the aggregate and mineral filler shall not exceed 175 degrees C when the
asphalt cement is added. The temperature shall not be lower than is required to obtain
complete coating and uniform distribution on the aggregate particles and to provide a
mixture of satisfactory workability.
3.4 PREPARATION OF HOT-MIX ASPHALT MIXTURE
The aggregates and the asphalt cement shall be weighed or metered and introduced into
the mixer in the amount specified by the JMF. The combined materials shall be mixed until
the aggregate obtains a thorough and uniform coating of asphalt binder (testing in
accordance with ASTM D 2489/D 2489M may be required by the Contracting Officer) and is
thoroughly distributed throughout the mixture. The moisture content of all hot-mix asphalt
upon discharge from the plant shall not exceed 0.5 percent by total weight of mixture as
measured by ASTM D 1461.
3.5 PREPARATION OF THE UNDERLYING SURFACE
Immediately before placing the hot mix asphalt, the underlying course shall be cleaned of
dust and debris. A prime coat and/or tack coat shall be applied in accordance with the
contract specifications.
3.6 TEST SECTION
Prior to full production, place a test section for each JMF used. Construct a test section
consisting of a maximum of 250 tons and two paver passes wide placed in two lanes, with a
longitudinal cold joint. The test section shall be of the same depth as the course which it
represents. The underlying grade or pavement structure upon which the test section is to be
constructed shall be the same as the remainder of the course represented by the test
section. The equipment used in construction of the test section shall be the same equipment
to be used on the remainder of the course represented by the test section. The test section
shall be placed as part of the project pavement as approved by the Engineer.
3.6.1 Sampling and Testing for Test Section
One random sample shall be taken at the plant, triplicate specimens compacted, and tested
for stability, flow, laboratory air voids, and Tensile Strength Ratio (TSR). A portion of the
same sample shall be tested for theoretical maximum density (TMD), aggregate gradation

and asphalt content. Four randomly selected cores shall be taken from the finished
pavement mat, and four from the longitudinal joint, and tested for density. Random
sampling shall be in accordance with procedures contained in ASTM D 3665. The test results
shall be within the tolerances or exceed the minimum values shown in Table 10 for work to
continue. If all test results meet the specified requirements, the test section shall remain as
part of the project pavement. If test results exceed the tolerances shown, the test section
shall be removed and replaced at no cost to the Owner and another test section shall be
constructed.
Table 10. Test Section Requirements for Material and Mixture Properties
Property Specification limit
4.75 mm and larger JMF plus or minus 8
2.36, 1.18, 0.6 and 0.3 mm JMF plus or minus 6
0.15 and 0.075 mm JMF plus or minus 2.0
Asphalt content, percent JMF plus or minus 0.5

(average of 3 specimens)
VMA percent (average of 3 JMF plus or minus 1.0

specimens)
Laboratory air voids, See table 8

percent (average of 3
specimen)
Tensile strength ratio Min. 75%.
Mat density, percent of 92.0 – 96.0

TMD (average of 4 random
cores)
Joint density, percent of Min. 90.5

TMD (average of 4 random
cores)
3.6.2 Additional Test Sections
If the initial test section should prove to be unacceptable, the necessary adjustments to the
JMF, plant operation, placing procedures, and/or rolling procedures shall be made. A second
test section shall then be placed. Additional test sections, as required, shall be constructed
and evaluated for conformance to the specifications. Full production shall not begin until an
acceptable section has been constructed and accepted.

3.7 TESTING LABORATORY
The laboratories used to develop the JMF, perform Contractor Quality Control testing, and
for Engineer acceptance testing shall meet the requirements of ASTM D 3666. All required
test methods shall be performed by an accredited laboratory. Submit a certification of
compliance signed by the manager of the laboratory stating that it meets these
requirements to the Engineer prior to the start of construction. The certification shall contain
as a minimum:
a. Qualifications of personnel; laboratory manager, supervising technician, and testing

technicians.
b. A listing of equipment to be used in developing the job mix.
c. A copy of the laboratory's quality control system.
d. Evidence of participation in the AASHTO Materials Reference Laboratory (AMRL)

program.
3.8 TRANSPORTING AND PLACING
3.8.1 Transporting
The hot-mix asphalt shall be transported from the mixing plant to the site in clean, tight
vehicles. Deliveries shall be scheduled so that placing and compacting of mixture is uniform
with minimum stopping and starting of the paver. Adequate artificial lighting shall be
provided for night placements. Hauling over freshly placed material will not be permitted
until the material has been compacted as specified, and allowed to cool to 60 degrees C.
3.8.2 Placing
The mix shall be placed in lifts of adequate thickness and compacted at a temperature
suitable for obtaining density, surface smoothness, and other specified requirements. Upon
arrival, the mixture shall be placed to the full width by an asphalt paver; it shall be struck off
in a uniform layer of such depth that, when the work is completed, it shall have the required
thickness and conform to the grade and contour indicated. Waste mixture shall not be
broadcast onto the mat or recycled into the paver hopper. Collect waste mixture and dispose
off site. The speed of the paver shall be regulated to eliminate pulling and tearing of the
asphalt mat. Placement of the mixture shall begin along the centerline of a crowned section
or on the high side of areas with a one-way slope. The mixture shall be placed in
consecutive adjacent strips having a minimum width of 3 m. The longitudinal joint in one
course shall offset the longitudinal joint in the course immediately below by at least 300
mm; however, the joint in the surface course shall be at the centerline of the pavement.
Transverse joints in one course shall be offset by at least 3 m from transverse joints in the
previous course. Transverse joints in adjacent lanes shall be offset a minimum of 3 m. On
isolated areas where irregularities or unavoidable obstacles make the use of mechanical
spreading and finishing equipment impractical, the mixture may be spread and luted by
hand tools.

3.9 COMPACTION OF MIXTURE
3.9.1 General
a. After placing, the mixture shall be thoroughly and uniformly compacted by rolling. The
surface shall be compacted as soon as possible without causing displacement,
cracking or shoving. The sequence of rolling operations and the type of rollers used
are at the discretion of the Contractor, with the exception that application of more
than three passes with a vibratory roller in the vibrating mode is prohibited. The
speed of the roller shall, at all times, be sufficiently slow to avoid displacement of the
hot mixture and be effective in compaction. Correct at once any displacement
occurring as a result of reversing the direction of the roller, or from any other cause.
b. Furnish sufficient rollers to handle the output of the plant. Continue rolling until the
surface is of uniform texture, true to grade and cross section, and the required field
density is obtained. To prevent adhesion of the mixture to the roller, keep the wheels
properly moistened, but excessive water will not be permitted. In areas not accessible
to the roller, thoroughly compact the mixture with hand tampers. Remove the full
depth of any mixture that becomes loose and broken, mixed with dirt, contains check-
cracking, or is in any way defective, replace with fresh hot mixture and immediately
compact to conform to the surrounding area. This work shall be done at the
Contractor's expense. Skin patching will not be allowed.
3.9.2 Segregation
The Engineer can sample and test any material that looks deficient. When the in-place
material appears to be segregated, the Engineer has the option to sample the material and
have it tested and compared to the aggregate gradation, asphalt content, and in-place
density requirements in Table 10. If the material fails to meet these specification
requirements, the extent of the segregated material will be removed and replaced the full
depth of the layer of asphalt mixture at no additional cost to the Contractor. When
segregation occurs in the mat, take appropriate action to correct the process so that
additional segregation does not occur.
3.10 JOINTS
The formation of joints shall be made ensuring a continuous bond between the courses and
to obtain the required density. All joints shall have the same texture as other sections of the
course and meet the requirements for smoothness and grade.
3.10.1 Transverse Joints
The roller shall not pass over the unprotected end of the freshly laid mixture, except when
necessary to form a transverse joint. When necessary to form a transverse joint, it shall be
made by means of placing a bulkhead or by tapering the course. The tapered edge shall be
cut back to its full depth and width on a straight line to expose a vertical face prior to
placing the adjacent lane. The cutback material shall be removed from the project. In both
methods, all contact surfaces shall be given a light tack coat of asphalt material before
placing any fresh mixture against the joint.

3.10.2 Longitudinal Joints
Longitudinal joints which are irregular, damaged, uncompacted, cold (less than 80 degrees C
at the time of placing the adjacent lane), or otherwise defective, shall be cut back a
maximum of 75 mm from the top edge of the lift with a cutting wheel to expose a clean,
sound, near vertical surface for the full depth of the course. All cutback material shall be
removed from the project. Cutting equipment that uses water as a cooling or cutting agent
shall not be permitted. All contact surfaces shall be given a light tack coat of asphalt
material prior to placing any fresh mixture against the joint.
3.10.3 HMA-Portland Cement Concrete Joints
Avoid spalling portland cement concrete (PCC) pavement when compacting HMA at a HMA-
PCC joint. Pneumatic-tire rollers should be used and the HMA shall be rolled parallel to the
joint. All procedures, including repair of damaged PCC, shall be in accordance with the
approved Quality Control Plan.

SECTION 32 12 16 ASPHALT PAVING
PART 1 GENERAL
1.1 UNIT PRICES
1.1.2 Basis of Payment
Quantities of hot-mix asphalt mixtures, determined as specified above, will be paid for at
respective contract unit prices or at reduced prices adjusted in accordance with paragraphs
MATERIAL ACCEPTANCE and PERCENT PAYMENT. Payment will constitute full compensation
for furnishing all materials, equipment, plant, and tools; and for all labor and other
incidentals necessary to complete work required by this section of the specification.
1.1.3 Percent Payment
When a lot of material fails to meet the specification requirements for 100 percent pay as
outlined in the following paragraphs, that lot shall be removed and replaced, or accepted at
a reduced price which will be computed by multiplying the unit price by the lot's pay factor.
The lot pay factor is determined by taking the lowest computed pay factor based on either
laboratory air voids, in-place density, grade or smoothness (each discussed below). At the
end of the project, an average of all lot pay factors will be calculated. If this average lot pay
factor equals or exceeds 95.0 percent, and no individual lot has a pay factor less than 75.1
percent, then the percent payment for the entire project will be 100 percent of the unit bid
price. If the average lot pay factor is less than 95.0 percent, then each lot will be paid for at
the unit price multiplied by the lot's pay factor. For any lots which are less than 2000 metric
tons, a weighted lot pay factor will be used to calculate the average lot pay factor.
1.1.4 Laboratory Air Voids and Theoretical Maximum Density
Laboratory air voids will be calculated by determining the Marshall or Superpave density of
each lab compacted specimen using the laboratory-prepared, thoroughly dry method of
ASTM D 2726 and determining the theoretical maximum density of every other sublot sample
using ASTM D 2041. Laboratory air void calculations for each sublot will use the latest
theoretical maximum density values obtained, either for that sublot or the previous sublot.
The mean absolute deviation of the four laboratory air void contents (one from each sublot)
from the JMF air void content will be evaluated and a pay factor determined from Table 1.
All laboratory air void tests will be completed and reported within 24 hours after completion
of construction of each lot.
1.1.5 Mean Absolute Deviation
An example of the computation of mean absolute deviation for laboratory air voids is as
follows: Assume that the laboratory air voids are determined from 4 random samples of a lot
(where 3 specimens were compacted from each sample). The average laboratory air voids
for each sublot sample are determined to be 3.5, 3.0, 4.0, and 3.7. Assume that the target
air voids from the JMF is 4.0. The mean absolute deviation is then:
Development of Sharm El Sheikh International Airport 32 12 16 ASPHALT PAVING

Mean Absolute Deviation = (|3.5 - 4.0| + |3.0 - 4.0| + |4.0 - 4.0| + |3.7 - 4.0|/4
= (0.5 + 1.0 + 0.0 + 0.3)/4 = (1.8)/4 = 0.45
The mean absolute deviation for laboratory air voids is determined to be 0.45. It can be
seen from Table 1 that the lot's pay factor based on laboratory air voids, is 100 percent.
Table 1. Pay Factor Based on Laboratory Air Voids

Mean Absolute Deviation of Lab Air Voids from JMF Pay Factor, %
O.60 or less 100
0.61 - 0.80 98
0.81 - 1.00 95
1.01 - 1.20 90
Above 1.20 reject (0)
1.1.6 In-place Density
For determining in-place density, one random core (100 mm or 150 mm in diameter) will be
taken by the Government from the mat (interior of the lane) of each sublot, and one random
core will be taken from the joint (immediately over joint) of each sublot. Each random core
will be full thickness of the layer being placed. When the random core is less than 25 mm
thick, it will not be included in the analysis. In this case, another random core will be taken.
After air drying to a constant weight, cores obtained from the mat and from the joints will be
used for in-place density determination.
1.1.7 Mat and Joint Densities
The average in-place mat and joint densities are expressed as a percentage of the average
TMD for the lot. The TMD for each lot will be determined as the average TMD of the two
random samples per lot. The average in-place mat density and joint density for a lot are
determined and compared with Table 2 to calculate a single pay factor per lot based on in-
place density, as described below. First, a pay factor for both mat density and joint density
are determined from Table 2. The area associated with the joint is then determined and will
be considered to be
1.5 m wide times the length of completed longitudinal construction joint in the lot. This area
will not exceed the total lot size. The length of joint to be considered will be that length
where a new lane has been placed against an adjacent lane of hot-mix asphalt pavement,
either an adjacent freshly paved lane or one paved at any time previously. The area
associated with the joint is expressed as a percentage of the total lot area. A weighted pay
factor for the joint is determined based on this percentage (see example below). The pay
factor for mat density and the weighted pay factor for joint density is compared and the
lowest selected. This selected pay factor is the pay factor based on density for the lot. When
the TMD on both sides of a longitudinal joint is different, the average of these two TMD will
be used as the TMD needed to calculate the percent joint density. All density results for a lot
will be completed and reported within 24 hours after the construction of that lot.

Table 2.Pay Factor Based on In-place Density
Average Mat Density Average Joint Density
(4 Cores) Pay Factor, % (4 Cores)
(% of TMD) (% of TMD)
94.0 - 96.0 100.0 92.5 or above
93.9 100.0 92.4
93.8 or 96.1 99.9 92.3
93.7 99.8 92.2
93.6 or 96.2 99.6 92.1
93.5 99.4 92.0
93.4 or96.3 99.1 91
93.3 98.7 91
93.2 or 96.4 98.3 91
93.1 97.8 91
93.0 or 96.5 97.3 91
92.9 96.3 91
92.8 or 96.6 94.1 91
92.7 92.2 91
92.6 or 96.7 90.3 91
92.5 87.9 91
92.4 or 96.8 85.7 90
92.3 83.3 90
92.2 or 96.9 80.6 90
92.1 78.0 90
92.0 or 97.0 75.0 90
below 92.0 or above 97.0 0.0 (reject) Below 90.5
1.1.8 Pay Factor Based on In-place Density
An example of the computation of a pay factor (in I-P units only) based on in-place density,
is as follows: Assume the following test results for field density made on the lot: (1) Average
mat density = 93.2 percent of TMD. (2) Average joint density = 91.5 percent of TMD. (3)
Total area of lot = 30,000 square feet. (4) Length of completed longitudinal construction
joint = 2000 feet.
a. Step 1: Determine pay factor based on mat density and on joint density, using Table
2:
1. Mat density of 93.2 percent = 98.3 pay factor.
2. Joint density of 91.5 percent = 97.3 pay factor.

b. Step 2: Determine ratio of joint area (length of longitudinal joint x 5 ft) to mat area
(total paved area in the lot): Multiply the length of completed longitudinal construction
joint by the specified 5 ft. width and divide by the mat area (total paved area in the
lot).
(1) (2000 ft. x 5 ft.)/30000 sq.ft. mat area (ratio).
c. Step 3: Weighted pay factor (wpf) for joint is 0.3333 ratio of joint area to determined
as indicated below:
wpf = joint pay factor + (100 - joint pay factor) (1 - ratio) wpf = 97.3 + (100-97.3) (1-
.3333) = 99.1%
d. Step 4: Compare weighted pay factor for joint density to pay factor for mat density
and select the smaller:
Pay factor for mat density: 98.3%. Weighted pay factor for joint density: 99.1%
Select the smaller of the two values as pay factor based on density: 98.3%
1.1.9 Pay Factor for Grade

When more than 5 percent of all measurements made within a lot are outside the 15 mm
tolerance, the pay factor based on grade for that lot will be 95 percent. In areas where the
grade exceeds the tolerance by more than 50 percent, remove the surface lift full depth and
replace the lift with hot-mix asphalt to meet specification requirements, at no additional cost
to the Government.
1.1.10 Payment Adjustment for Smoothness
a. Straightedge Testing. Record location and deviation from straightedge for all
measurements. When between 5.0 and 10.0 percent of all measurements made within
a lot exceed the tolerance specified in paragraph Smoothness Requirements above,
after any reduction of high spots or removal and replacement, the computed pay
factor for that lot based on surface smoothness, will be 95 percent. When more than
10.0 percent of all measurements exceed the tolerance, the computed pay factor will
be 90 percent. When between 15.0 and 20.0 percent of all measurements exceed the
tolerance, the computed pay factor will be 75 percent. When 20.0 percent or more of
the measurements exceed the tolerance, the lot shall be removed and replaced at no
additional cost to the Government. Regardless of the above, any small individual area
with surface deviation which exceeds the tolerance given above by more than 50
percent, shall be corrected by diamond grinding to meet the specification requirements
above or shall be removed and replaced at no additional cost to the Government.
b. Profilograph Testing. Record location and data from all profilograph measurements.
When the Profile Index of a 0.1 km segment of a lot exceeds the tolerance specified in
paragraph Smoothness Requirements above by 16 mm/km, but less than 32 mm/km,
after any reduction of high spots or removal and replacement, the computed pay
factor for that lot based on surface smoothness will be 95 percent. When the Profile
Index exceeds the tolerance by 32 mm/km, but less than 47 mm/km, the computed

pay factor will be 90 percent. When the Profile Index exceeds the tolerance by 47
mm/km, but less than 63 mm/km, the computed pay factor will be 75 percent. When
the Profile Index exceeds the tolerance by 63 mm/km or more, the lot shall be
removed and replaced at no additional cost to the Government. Regardless of the
above, any small individual area with surface deviation which exceeds the tolerance
given above by more than 79 mm/km or more, shall be corrected by grinding to meet
the specification requirements above or shall be removed and replaced at no
additional cost to the Government.
c. Bumps ("Must Grind" Areas). Any bumps ("must grind" areas) shown on the
profilograph trace which exceed 7.5 mm in height shall be reduced by diamond
grinding until they do not exceed 7.5 mm when retested. Such grinding shall be
tapered in all directions to provide smooth transitions to areas not requiring grinding.
The following will not be permitted: (1) skin patching for correcting1.2 low areas, (2)
planing or milling for correcting high areas. At the Contractor's option, pavement
areas, including ground areas, may be rechecked with the profilograph in order to
record a lower Profile Index.
1.2. REFERENCES

OFFICIALS (AASHTO)
AASHTO M 320 (2009) Standard Specification for Performance-

Graded Asphalt Binder
ASPHALT INSTITUTE (AI)
AI MS-02 (1997 6th Ed) Mix Design Methods
AI MS-22 (2001; 2nd Ed) Construction of Hot-Mix Asphalt

Pavements
AI SP-2 (2001; 3rd Ed) Superpave Mix Design

ASTM C 1252 (2006) Standard Test Methods for Uncompacted

Void Content of Fine Aggregate (as Influenced
by Particle Shape, Surface Texture, and Grading)



ASTM C 131 (2006)Standard Test Method for Resistance to


ASTM C 142 (1997; R 2004) Standard Test Method for Clay

Lumps and Friable Particles in Aggregates
ASTM C 566 (1997; R 2004) Standard Test Method for Total

Evaporable Moisture Content of Aggregate by
Drying

Magnesium Sulfate

ASTM D 1461 (1985; R 2006) Moisture or Volatile Distillates in

ASTM D 2041 (2003a) Theoretical Maximum Specific Gravity

and Density of Bituminous Paving Mixtures
ASTM D 2172 (2005) Quantitative Extraction of Bitumen from

ASTM D 2419 (2009) Sand Equivalent Value of Soils and Fine

Aggregate
ASTM D 242/D 242M (2009) Mineral Filler for Bituminous Paving

Mixtures
ASTM D 2489/D 2489M (2008) Estimating Degree of Particle Coating of

Bituminous-Aggregate Mixtures
ASTM D 2726 (2010) Bulk Specific Gravity and Density of Non-

Absorptive Compacted Bituminous Mixtures

ASTM D 2950 (2009) Density of Bituminous Concrete in Place
by Nuclear Methods

ASTM D 3665 (2007) Random Sampling of Construction

Materials
ASTM D 3666 (2009a) Minimum Requirements for Agencies

Testing and Inspecting Road and Paving
Materials
ASTM D 4125 (2005) Asphalt Content of Bituminous Mixtures

by the Nuclear Method
ASTM D 4791 (2005e1) Flat Particles, Elongated Particles, or

Flat and Elongated Particles in Coarse Aggregate
ASTM D 4867/D 4867M (2009) Effect of Moisture on Asphalt Concrete

Paving Mixtures
ASTM D 5444 (2008) Mechanical Size Analysis of Extracted

Aggregate
ASTM D 6307 (2005; R 2010) Asphalt Content of Hot Mix

Asphalt by Ignition Method
ASTM D 6925 (2009) Standard Test Method for Preparation

and Determination of the Relative Density of Hot
Mix Asphalt (HMA) Specimens by Means of the
Superpave Gyratory Compactor
ASTM D 6926 (2004) Standard Practice for Preparation of

Bituminous Specimens Using Marshall Apparatus
ASTM D6927 (2006) Standard Test Method for Marshall

Stability and Flow of Bituminous Mixtures

ASTM D 995 (1995b; R 2002) Mixing Plants for Hot-Mixed,

Hot-Laid Bituminous Paving Mixtures
STATE OF CALIFORNIA DEPARTMENT OF TRANSPORTATION (CDT)
CDT Test 526 (2002) Operation of California Profilograph and

Evaluation of Profiles

Perform the work consisting of pavement courses composed of mineral aggregate and
asphalt material heated and mixed in a central mixing plant and placed on a prepared
course. HMA designed and constructed in accordance with this section shall conform to the
lines, grades, thicknesses, and typical cross sections shown on the drawings. Construct each
course to the depth, section, or elevation required by the drawings and roll, finish, and
approve it before the placement of the next course.
1.3.1 Asphalt Mixing Plant
Plants used for the preparation of hot-mix asphalt shall conform to the requirements of
ASTM D 995 with the following changes:
a. Truck Scales. Weigh the asphalt mixture on approved, certified scales at the
Contractor's expense. Inspect and seal scales at least annually by an approved
calibration laboratory.
b. Testing Facilities. Provide laboratory facilities at the plant for the use of the
Government's acceptance testing and the Contractor's quality control testing.
c Inspection of Plant. Provide the Contracting Officer with access at all times, to all
areas of the plant for checking adequacy of equipment; inspecting operation of the
plant; verifying weights, proportions, and material properties; checking the
temperatures maintained in the preparation of the mixtures and for taking samples.
Provide assistance as requested, for the Government to procure any desired samples.
d. Storage Bins. Use of storage bins for temporary storage of hot-mix asphalt will be
permitted as follows:
1. The asphalt mixture may be stored in non-insulated storage bins for a period of
time not exceeding 3 hours.
2. The asphalt mixture may be stored in insulated storage bins for a period of time
not exceeding 8 hours. The mix drawn from bins shall meet the same
requirements as mix loaded directly into trucks.
1.3.2 Hauling Equipment
Provide trucks for hauling hot-mix asphalt having tight, clean, and smooth metal beds. To
prevent the mixture from adhering to them, the truck beds shall be lightly coated with a
minimum amount of paraffin oil, lime solution, or other approved material. Petroleum based
products shall not be used as a release agent. Each truck shall have a suitable cover to
protect the mixture from adverse weather. When necessary to ensure that the mixture will
be delivered to the site at the specified temperature, truck beds shall be insulated or heated
and covers (tarps) shall be securely fastened.

1.3.3 Asphalt Pavers
Provide asphalt pavers which are self-propelled, with an activated screed, heated as
necessary, and capable of spreading and finishing courses of hot-mix asphalt which will
meet the specified thickness, smoothness, and grade. The paver shall have sufficient power
to propel itself and the hauling equipment without adversely affecting the finished surface.
1.3.3.1 Receiving Hopper
Provide paver with a receiving hopper of sufficient capacity to permit a uniform spreading
operation and equipped with a distribution system to place the mixture uniformly in front of
the screed without segregation. The screed shall effectively produce a finished surface of the
required evenness and texture without tearing, shoving, or gouging the mixture.
1.3.3.2 Automatic Grade Controls
If an automatic grade control device is used, equip the paver with a control system capable
of automatically maintaining the specified screed elevation. The control system shall be
automatically actuated from either a reference line and/or through a system of mechanical
sensors or sensor-directed mechanisms or devices which will maintain the paver screed at a
predetermined transverse slope and at the proper elevation to obtain the required surface.
The transverse slope controller shall be capable of maintaining the screed at the desired
slope within plus or minus 0.1 percent. A transverse slope controller shall not be used to
control grade. Provide controls capable of working in conjunction with any of the following
attachments:
a. Ski-type device of not less than 9.14 m in length.
b. Taut stringline set to grade.
c. Short ski or shoe for joint matching.
d. Laser control.
1.3.4 Rollers
Rollers shall be in good condition and shall be operated at slow speeds to avoid displacement
of the asphalt mixture. The number, type, and weight of rollers shall be sufficient to
compact the mixture to the required density while it is still in a workable condition. Do not
use equipment which causes excessive crushing of the aggregate.
1.4 SUBMITTALS
SD-03 Product Data

Mix Design
Proposed JMF.Contractor Quality Control
Quality control plan.Material Acceptance

Acceptance test results.Percent Payment
Pay calculations.
SD-04 Samples
Asphalt Cement Binder
A 20 L sample for mix design verification.
Aggregates
Sufficient materials to produce 90 kg of blended mixture for mix design verification.
SD-06 Test Reports
Aggregates
QC Monitoring
Aggregate and QC test results.
SD-07 Certificates
Asphalt Cement Binder
Copies of certified test data.
Amount, type and description of any modifiers blended into theasphalt cement binder
Testing Laboratory
Certification of compliance.
Plant Scale Calibration Certification
1.5 ENVIRONMENTAL REQUIRENMENTS
Do not place the hot-mix asphalt upon a wet surface or when the surface temperature of the
underlying course is less than specified in Table 3. The temperature requirements may be
waived by the Contracting Officer, if requested; however, all other requirements, including
compaction, shall be met.
Table 3. Surface Temperature Limitations of Underlying Course

Mat Thickness, mm Degrees C
75 or greater 4
Less than 75 7
1.6 WARRANTY
be signed.

PART 2 PRODUCTS
2.1 AGGREGATES
Provide aggregates consisting of crushed stone, crushed gravel, crushed slag, screenings,
natural sand and mineral filler, as required. The portion of material retained on the 4.75 mm
sieve is coarse aggregate. The portion of material passing the 4.75 mm sieve and retained
on the 0.075 mm sieve is fine aggregate. The portion passing the 0.075 mm sieve is defined
as mineral filler. Submit all aggregate test results and samples to the Contracting Officer at
least 14 days prior to start of construction.
Provide coarse aggregate consisting of sound, tough, durable particles, free from films of
material that would prevent thorough coating and bonding with the asphalt material and free
from organic matter and other deleterious substances. All individual coarse aggregate
sources shall meet the following requirements:
a. The percentage of loss shall not be greater than 40 percent after 500 revolutions when
tested in accordance with ASTM C 131.
b. The percentage of loss shall not be greater than 18 percent after five cycles when
tested in accordance with ASTM C 88 using magnesium sulfate or 12 percent when
using sodium sulfate.
c. At least 75 percent by weight of coarse aggregate shall have at least two or more
fractured faces when tested in accordance with COE CRD-C 171. Fractured faces shall
be produced by crushing.
d. The particle shape shall be essentially cubical and the aggregate shall not contain
more than 20% percent, by weight, of flat and elongated particles (3:1 ratio of
maximum to minimum) when tested in accordance with ASTM D 4791.
e. Slag shall be air-cooled, blast furnace slag, with a compacted weight of not less than
1200 kg/cubic meter when tested in accordance with ASTM C 29/C 29M.
f. Clay lumps and friable particles shall not exceed 0.3 percent, by weight, when tested in
accordance with ASTM C 142.
2.1.2. Fine Aggregate
Fine aggregate shall consist of clean, sound, tough, durable particles free from coatings of
clay, silt, or any objectionable material and containing no clay balls.

a. All individual fine aggregate sources shall have a sand equivalent value not less than
45 when tested in accordance with ASTM D 2419.
b. The fine aggregate portion of the blended aggregate shall have an uncompacted void
content not less than 45.0 percent when tested in accordance with ASTM C 1252
Method A.
c. The quantity of natural sand (noncrushed material) added to the aggregate blend
shall not exceed 25 percent by weight of total aggregate.
d. Clay lumps and friable particles shall not exceed 0.3 percent, by weight, when tested
in accordance with ASTM C 142
2.1.3. Mineral Filler
Mineral filler shall be nonplastic material meeting the requirements of ASTM D 242/D 242M.
2.1.4. Aggregate Gradation
The combined aggregate gradation shall conform to gradations specified in Table 4, when
tested in accordance with ASTM C 136 and ASTM C 117, and shall not vary from the low
limit on one sieve to the high limit on the adjacent sieve or vice versa, but grade uniformly
from coarse to fine.
Table 4. Aggregate Gradations
Gradation 1 Gradation 2 Gradation 3
Percent Percent Percent

Passing Passing Passing
Sieve Size, mm by Mass by Mass by Mass
25.0 100 --- ---
19.0 76-96 100 ---
12.5 68-88 79-96 100
9.5 60-82 69-89 76-96
4.75 45-67 53-73 58-78
2.36 32-54 38-60 40-60
1.18 22-44 26-48 28-48
0.60 15-35 18-38 18-38

0.30 9-25 11-27 11-27
0.15 6-18 6-18 6-18
0.075 3-6 3-6 3-6
2.2 ASPHALT CEMENT BINDER
Asphalt cement binder shall conform to AASHTO M 320 Performance Grade. As an alternate,
ASTM D 3381 Table 4, Viscosity Grade or ASTM D 946 penetration grade may be used. Test
data indicating grade certification shall be provided by the supplier at the time of delivery of
each load to the mix plant. Submit copies of these certifications to the Contracting Officer.
The supplier is defined as the last source of any modification to the binder. The Contracting
Officer may sample and test the binder at the mix plant at any time before or during mix
production. Obtain samples for this verification testing in accordance with ASTM D 140/D
140M and in the presence of the Contracting Officer. Furnish these samples to the
Contracting Officer for the verification testing, which shall be at no cost to the Contractor.
Submit samples of the asphalt cement specified for approval not less than 14 days before
start of the test section.
2.3 MIX DESIGN
a. Develop the mix design. The asphalt mix shall be composed of a mixture of well-
graded aggregate, mineral filler if required, and asphalt material. The aggregate
fractions shall be sized, handled in separate size groups, and combined in such
proportions that the resulting mixture meets the grading requirements of the job mix
formula (JMF). Do not produce hot-mix asphalt for payment until a JMF has been
approved. The hot-mix asphalt shall be designed in accordance with Marshall (MS-02),
Superpave (SP-2), or Hveem (MS-02) procedures and the criteria shown in Table 5.
Use the hand-held hammer to compact the specimens for Marshall mix design. If the
Tensile Strength Ratio (TSR) of the composite mixture, as determined by ASTM D
4867/D 4867M is less than 75, the aggregates shall be rejected or the asphalt mixture
treated with an approved anti-stripping agent. The amount of anti-stripping agent
added shall be sufficient to produce a TSR of not less than 75. Provide an antistrip
agent, if required, at no additional cost. Sufficient materials to produce 90 kg of
blended mixture shall be provided to the Contracting Officer for verification of mix
design at least 14 days prior to construction of test section.
b. At the option of the Contractor, a currently used DOT Superpave hot mix may be used
in lieu of developing a Marshall hot mix design as described herein. Design the
Superpave volumetric mix in accordance with AI SP-2 and ASTM D 6925. The nominal
maximum aggregate size (NMAS) shall be25.0 mm. Other DOT hot mix design
methods (Hveem, etc.) may be suitable, as determined by the Contracting Officer.
The number of compaction gyrations, Ndes, shall be based on a design traffic of
equivalent single axle loads (EASLs).
c. Design Superpave mixes with the number of gyrations specified in Table 5, unless the
DOT option is chosen.

2.3.1 JMF Requirements
Submit in writing the job mix formula for approval at least 14 days prior to the start of the
test section including as a minimum:
a. Percent passing each sieve size.
b. Percent of asphalt cement.
c. Percent of each aggregate and mineral filler to be used.
d. Asphalt viscosity grade, penetration grade, or performance grade.
e. Number of blows of hand-held hammer per side of molded specimen. (NA for
Superpave)
f. Number of gyrations of Superpave gyratory compactor, (NA for Marshall mix design)
g. Laboratory mixing temperature.
h. Lab compaction temperature.
i. Temperature-viscosity relationship of the asphalt cement.
j. Plot of the combined gradation on the 0.45 power gradation chart, stating the nominal
maximum size.
k. Graphical plots of stability (NA for Superpave), flow (NA for Superpave), air voids, voids
in the mineral aggregate, and unit weight versus asphalt content as shown in AI MS-02.
l. Specific gravity and absorption of each aggregate.
m. Percent natural sand.
n. Percent particles with 2 or more fractured faces (in coarse aggregate).
o. Fine aggregate angularity.
p. Percent flat or elongated particles (in coarse aggregate).
q. Tensile Strength Ratio(TSR).
r. Antistrip agent (if required) and amount.
s. List of all modifiers and amount.
t. Correlation of hand-held hammer with mechanical hammer (NA for Superpave).
u. Percentage and properties (asphalt content, binder properties, and aggregate

properties) of reclaimed asphalt pavement (RAP) in accordance with paragraph
RECYCLED HOT-MIX ASPHALT, if RAP is used.

Table 5. Mix Design Criteria
Test Property 50 Blows Mix or 50 Gyrations 75 Blows Mix or 75 Gyrations
Stability, newtons, minimum *4450 *8000

(NA for Superpave)
Flow, 0.25 mm (NA for 8-18 8-16

Superpave)
Air voids, percent 3-5 3-5
Percent Voids in mineral

aggregate (VMA), (minimum)
Gradation 1 13.0 13.0
TSR, minimum percent 75 75
* This is a minimum requirement. The average during construction shall be significantly higher than
this number to ensure compliance with the specifications.
** Calculate VMA in accordance with AI MS-02, based on ASTM C 127 and ASTM C 128 bulk
specific gravity for the aggregate.
2.3.2 Adjustments to Field JMF
Keep the Laboratory JMF for each mixture in effect until a new formula is approved in
writing by the Contracting Officer. Should a change in sources of any materials be made,
perform a new laboratory jmf design and a new JMF approved before the new material is
used. The Contractor will be allowed to adjust the Laboratory JMF within the limits specified
below to optimize mix volumetric properties with the approval of the Contracting Officer.
Adjustments to the Laboratory JMF shall be applied to the field (plant) established JMF and
limited to those values as shown. Adjustments shall be targeted to produce or nearly
produce 4 percent voids total mix (VTM).

TABLE 6. Field (Plant) Established JMF Tolerances Sieves
Adjustments (plus or minus), percent
12.5 mm 3
4.75 mm 3
2.36 mm 3
0.075 mm 1
Binder Content 0.4
If adjustments are needed that exceed these limits, develop a new mix design. Tolerances
given above may permit the aggregate grading to be outside the limit shown in Table 4,
while not desirable, this is acceptable, except for the 0.075 mm sieve, which shall remain
within the aggregate grading of Table 4.
2.4 RECYCLED HOT MIX ASPHALT
Recycled HMA shall consist of reclaimed asphalt pavement (RAP), coarse aggregate, fine
aggregate, mineral filler, and asphalt cement to produce a consistent gradation and asphalt
content and properties. When RAP is fed into the plant, the maximum RAP chunk size shall
not exceed 50 mm. Design the recycled HMA mix using procedures contained in AI MS-02
and AI MS-22. The job mix shall meet the requirements of paragraph MIX DESIGN. The
amount of RAP shall not exceed 30 percent.
2.4.1 RAP Aggregates and Asphalt Cement
The blend of aggregates used in the recycled mix shall meet the requirements of paragraph
AGGREGATES. Establish the percentage of asphalt in the RAP for the mixture design
according to ASTM D 2172 or ASTM D 6307 using the appropriate dust correction procedure.
2.4.2 RAP Mix
The blend of new asphalt cement and the RAP asphalt binder shall meet penetration
requirements in paragraph ASPHALT CEMENT BINDER. The virgin asphalt cement shall not
be more than two standard asphalt material grades different than that specified in paragraph
ASPHALT CEMENT BINDER.
PART 3 EXECUTION
3.1 PREPARATION OF ASPHALT BINDER MATERIAL
Heat the asphalt cement material avoiding local overheating and providing a continuous
supply of the asphalt material to the mixer at a uniform temperature. The temperature of
unmodified asphalts shall be no more than 160 degrees C when added to the aggregates.

Performance-Graded (PG) asphalts shall be within the temperature range of 35 degreesC
when added to the aggregate.
3.2 PREPARATION OF MINERAL AGGREGATE
Heat and dry the aggregate for the mixture prior to mixing. No damage shall occur to the
aggregates due to the maximum temperature and rate of heating used. The temperature of
the aggregate and mineral filler shall not exceed 175 degrees C when the asphalt cement is
added. The temperature shall not be lower than is required to obtain complete coating and
uniform distribution on the aggregate particles and to provide a mixture of satisfactory
workability.
3.3 PREPARATION OF HOT-MIX ASPHALT MIXTURE
The aggregates and the asphalt cement shall be weighed or metered and introduced into
the mixer in the amount specified by the JMF. Mix the combined materials until the
aggregate obtains a uniform coating of asphalt binder and is thoroughly distributed
throughout the mixture. Wet mixing time shall be the shortest time that will produce a
satisfactory mixture, but no less than 25 seconds for batch plants. Establish the wet mixing
time for all plants based on the procedure for determining the percentage of coated particles
described in ASTM D 2489/D 2489M, for each individual plant and for each type of
aggregate used. The wet mixing time will be set to at least achieve 95 percent of coated
particles. The moisture content of all hot-mix asphalt upon discharge from the plant shall not
exceed 0.5 percent by total weight of mixture as measured by ASTM D 1461.
3.4 PREPARATION OF THE UNDERLYING SURFACE
Immediately before placing the hot mix asphalt, clean the underlying course of dust and
debris. Apply a prime coat and/or tack coat in accordance with the contract specifications.
3.5 TEST SECTION
Prior to full production, place a test section for each JMF used. Construct a test section 75 -
150 m long and two paver passes wide placed for two lanes, with a longitudinal cold joint.
The test section shall be of the same thickness as the course which it represents. The
underlying grade or pavement structure upon which the test section is to be constructed shall
be the same as the remainder of the course represented by the test section. The equipment
and personnel used in construction of the test section shall be the same equipment to be
used on the remainder of the course represented by the test section. Place the test section
as part of the project pavement, as approved by the Contracting Officer.
3.5.1 Sampling and Testing for Test Section
Take one random sample at the plant, triplicate specimens compacted, and tested for
stability, flow, and laboratory air voids. Test a portion of the same sample for theoretical
maximum density (TMD), aggregate gradation and asphalt content. Take four randomly
selected cores from the finished pavement mat, and four from the longitudinal joint, and
tested for density. Random sampling shall be in accordance with procedures contained in
ASTM D 3665. The test results shall be within the tolerances shown in Table 7 for work to

continue. If all test results meet the specified requirements, the test section shall remain as
part of the project pavement. If test results exceed the tolerances shown, the test section
shall be removed and replaces at no cost to the Government and another test section shall
be constructed. The test section shall be paid for with the first lot of paving.
Table 7. Test Section Requirements for Material and Mixture Properties

Property Specification Limit
Aggregate Gradation Percent Passing (Individual Test Result)
4.75 mm and larger JMF plus or minus 8
2.36, 1.18, 0.60, and 0.30 mm JMF plus or minus 6
0.15 and 0.075 mm JMF plus or minus 2.0
Asphalt Content, Percent (Individual Test Result) JMF plus or minus 0.5
Laboratory Air Voids, Percent (Average of 3 specimens) JMF plus or minus 1.0
VMA, Percent (Average of 3 specimens) 13 minimum
Stability, newtons (Average of 3 specimens) 4450 minimum for 50 blows
(NA for Superpave) 8000 minimum for 75 blows
Flow, 0.25 mm (Average of 3 specimens) 8-18 for 50 blows
(NA for Superpave) 8-16 for 75 blows
Mat Density, Percent of TMD (Average of 4 Random Cores) 92.0-96.0
Joint Density, Percent of TMD (Average of 4 Random Cores) 90.5-92.5
3.5.2. Additional Test Sections
If the initial test section should prove to be unacceptable, make the necessary adjustments
to the JMF, plant operation, placing procedures, and/or rolling procedures and place a
second test section. Additional test sections, as required, shall be constructed and evaluated
for conformance to the specifications. Full production shall not begin until an acceptable
section has been constructed and accepted.
3.6 TESTING LABORATORY
Use a laboratory to develop the JMF that meets the requirements of ASTM D 3666. The
Government will inspect the laboratory equipment and test procedures prior to the start of
hot mix operations for conformance to ASTM D 3666. The laboratory shall maintain the
Corps certification for the duration of the project. A statement signed by the manager of the
laboratory stating that it meets these requirements or clearly listing all deficiencies shall be
submitted to the Contracting Officer prior to the start of construction. The statement shall
contain as a minimum:
a. Qualifications of personnel; laboratory manager, supervising technician, and testing

technicians.
b. A listing of equipment to be used in developing the job mix.
c. A copy of the laboratory's quality control system.

d. Evidence of participation in the AASHTO Materials Reference Laboratory (AMRL)
program.
3.7 TRANSPORTING AND PLACING
3.7.1 Transporting
Transport the hot-mix asphalt from the mixing plant to the site in clean, tight vehicles.
Schedule deliveries so that placing and compacting of mixture is uniform with minimum
stopping and starting of the paver. Provide adequate artificial lighting for night placements.
Hauling over freshly placed material will not be permitted until the material has been
compacted as specified, and allowed to cool to 60 degrees C. To deliver mix to the paver,
use a material transfer vehicle operated to produce continuous forward motion of the paver.
3.7.2 Placing
Place and compact the mix at a temperature suitable for obtaining density, surface
smoothness, and other specified requirements. Upon arrival, place the mixture to the full
width by an asphalt paver; it shall be struck off in a uniform layer of such depth that, when
the work is completed, it will have the required thickness and conform to the grade and
contour indicated. Regulate the speed of the paver to eliminate pulling and tearing of the
asphalt mat. Unless otherwise permitted, placement of the mixture shall begin along the
centerline of a crowned section or on the high side of areas with a one-way slope. Place the
mixture in consecutive adjacent strips having a minimum width of 3 m. The longitudinal joint
in one course shall offset the longitudinal joint in the course immediately below by at least
300 mm; however, the joint in the surface course shall be at the centerline of the pavement.
Transverse joints in one course shall be offset by at least 3 m from transverse joints in the
previous course. Transverse joints in adjacent lanes shall be offset a minimum of 3 m. On
isolated areas where irregularities or unavoidable obstacles make the use of mechanical
spreading and finishing equipment impractical, the mixture may be spread and luted by
hand tools.
3.8 COMPACTION OF MIXTURE
After placing, the mixture shall be thoroughly and uniformly compacted by rolling. Compact
the surface as soon as possible without causing displacement, cracking or shoving. The
sequence of rolling operations and the type of rollers used shall be at the discretion of the
Contractor. The speed of the roller shall, at all times, be sufficiently slow to avoid
displacement of the hot mixture and be effective in compaction. Any displacement occurring
as a result of reversing the direction of the roller, or from any other cause, shall be corrected
at once. Furnish sufficient rollers to handle the output of the plant. Continue rolling until the
surface is of uniform texture, true to grade and cross section, and the required field density
is obtained. To prevent adhesion of the mixture to the roller, keep the wheels properly
moistened but excessive water will not be permitted. In areas not accessible to the roller,
the mixture shall be thoroughly compacted with hand tampers. Any mixture that becomes
loose and broken, mixed with dirt, contains check-cracking, or is in any way defective shall
be removed full depth, replaced with fresh hot mixture and immediately compacted to
conform to the surrounding area. This work shall be done at the Contractor's expense. Skin
patching will not be allowed.

3.9 JOINTS
The formation of joints shall be performed ensuring a continuous bond between the courses
and to obtain the required density. All joints shall have the same texture as other sections of
the course and meet the requirements for smoothness and grade.
3.9.1 Transverse Joints
Do not pass the roller over the unprotected end of the freshly laid mixture, except when
necessary to form a transverse joint. When necessary to form a transverse joint, it shall be
made by means of placing a bulkhead or by tapering the course. The tapered edge shall be
cut back to its full depth and width on a straight line to expose a vertical face prior to
placing material at the joint. Remove the cutback material from the project. In both
methods, all contact surfaces shall be given a light tack coat of asphalt material before
placing any fresh mixture against the joint.
3.9.2 Longitudinal Joints
Longitudinal joints which are irregular, damaged, uncompacted, cold (less than 80 degrees C
at the time of placing adjacent lanes), or otherwise defective, shall be cut back a maximum
of 75 mm from the top of the course with a cutting wheel to expose a clean, sound vertical
surface for the full depth of the course. All cutback material shall be removed from the
project. All contact surfaces shall be given a light tack coat of asphalt material prior to
placing any fresh mixture against the joint. The Contractor will be allowed to use an
alternate method if it can be demonstrated that density, smoothness, and texture can be
met.
3.10 CONTRACTOR QUALITY CONTROL
3.10.1 General Quality Control Requirements
Develop an approved Quality Control Plan. Do not produce hot-mix asphalt for payment until
the quality control plan has been approved addressing all elements which affect the quality
of the pavement including, but not limited to:
a. Mix Design
b. Aggregate Grading
c. Quality of Materials
d. Stockpile Management
e. Proportioning
f. Mixing and Transportation
g. Mixture Volumetrics
h. Moisture Content of Mixtures

i. Placing and Finishing
j. Joints
k. Compaction
l. Surface Smoothness
3.10.2 Testing Laboratory
Provide a fully equipped asphalt laboratory located at the plant or job site and meeting the
pertinent requirements in ASTM D 3666. Laboratory facilities shall be kept clean and all
equipment maintained in proper working condition. The Contracting Officer shall be
permitted unrestricted access to inspect the Contractor's laboratory facility, to witness
quality control activities, and to perform any check testing desired. The Contracting Officer
will advise the Contractor in writing of any noted deficiencies concerning the laboratory
facility, equipment, supplies, or testing personnel and procedures. When the deficiencies are
serious enough to adversely affect test results, the incorporation of the materials into the
work shall be suspended immediately and will not be permitted to resume until the
deficiencies are corrected.
3.10.3 Quality Control Testing
Perform all quality control tests applicable to these specifications and as set forth in the
Quality Control Program. The testing program shall include, but shall not be limited to, tests
for the control of asphalt content, aggregate gradation, temperatures, aggregate moisture,
moisture in the asphalt mixture, laboratory air voids, stability (NA for Superpave), flow (NA
for Superpave), in-place density, grade and smoothness. Develop a Quality Control Testing
Plan as part of the Quality Control Program.
3.10.3.1 Asphalt Content
A minimum of two tests to determine asphalt content will be performed per lot (a lot is
defined in paragraph MATERIAL ACCEPTANCE and PERCENT PAYMENT) by one of the
following methods: the extraction method in accordance with ASTM D 2172, Method A or B,
the ignition method in accordance with ASTM D 6307, or the nuclear method in accordance
with ASTM D 4125. Calibrate the ignition oven or the nuclear gauge for the specific mix
being used. For the extraction method, determine the weight of ash, as described in ASTM D
2172, as part of the first extraction test performed at the beginning of plant production; and
as part of every tenth extraction test performed thereafter, for the duration of plant
production. The last weight of ash value obtained shall be used in the calculation of the
asphalt content for the mixture.
3.10.3.2 Gradation
Determine aggregate gradations a minimum of twice per lot from mechanical analysis of
recovered aggregate in accordance with ASTM D 5444. When asphalt content is determined
by the ignition oven or nuclear method, aggregate gradation shall be determined from hot
bin samples on batch plants, or from the cold feed on drum mix plants. For batch plants,

test aggregates in accordance with ASTM C 136 using actual batch weights to determine the
combined aggregate gradation of the mixture.
3.10.3.3 Temperatures
Check temperatures at least four times per lot, at necessary locations, to determine the
temperature at the dryer, the asphalt cement in the storage tank, the asphalt mixture at the
plant, and the asphalt mixture at the job site.
3.10.3.4 Aggregate Moisture
Determine the moisture content of aggregate used for production a minimum of once per lot
3.10.3.5 Moisture Content of Mixture
Determine the moisture content of the mixture at least once per lot in accordance with
ASTM D 1461 or an approved alternate procedure.
3.10.3.6 Laboratory Air Voids, Marshall Stability and Flow
Take mixture samples at least four times per lot compacted into specimens, using 50 blows
per side with the hand-held Marshall hammer as described in ASTM D 6926. When the
Superpave gyratory compactor is used, mixes will be compcted to 50 gyrations in
accordance with ASTM D 6925. Hot-mix provided under the DOT Superpave option shall be
compacted in accordance with the DOT requirements. After compaction, determine the
laboratory air voids of each specimen. Stability and flow shall be determined for the
Marshall-compacted specimens, in accordance with ASTM D 6927.
3.10.3.7 In-Place Density
Conduct any necessary testing to ensure the specified density is achieved. A nuclear gauge
may be used to monitor pavement density in accordance with ASTM D 2950.
3.10.3.8 Grade and Smoothness
Conduct the necessary checks to ensure the grade and smoothness requirements are met in
accordance with paragraphs MATERIAL ACCEPTANCE and PERCENT PAYMENT.
3.10.3.9 Additional Testing
Any additional testing, which the Contractor deems necessary to control the process, may be
performed at the Contractor's option.
3.10.3.10 QC Monitoring
Submit all QC test results to the Contracting Officer on a daily basis as the tests are
performed. The Contracting Officer reserves the right to monitor any of the Contractor's
quality control testing and to perform duplicate testing as a check to the Contractor's quality
control testing.

3.10.4 Sampling
When directed by the Contracting Officer, sample and test any material which appears
inconsistent with similar material being produced, unless such material is voluntarily removed
and replaced or deficiencies corrected by the Contractor. All sampling shall be in accordance
with standard procedures specified.
3.10.5 Control Charts
For process control, establish and maintain linear control charts on both individual samples
and the running average of last four samples for the parameters listed in Table 8, as a
minimum. These control charts shall be posted as directed by the Contracting Officer and
kept current at all times. The control charts shall identify the project number, the test
parameter being plotted, the individual sample numbers, the Action and Suspension Limits
listed in Table 8 applicable to the test parameter being plotted, and the Contractor's test
results. Target values from the JMF shall also be shown on the control charts as indicators of
central tendency for the cumulative percent passing, asphalt content, and laboratory air
voids parameters. When the test results exceed either applicable Action Limit, take
immediate steps to bring the process back in control. When the test results exceed either
applicable Suspension Limit, halt production until the problem is solved. Use the control
charts as part of the process control system for identifying trends so that potential problems
can be corrected before they occur. Make decisions concerning mix modifications based on
analysis of the results provided in the control charts. The Quality Control Plan shall indicate
the appropriate action to be taken to bring the process into control when certain parameters
exceed their Action Limits.
Table 8. Action and Suspension Limits for the Parameters to be Plotted on Individual and Running
Average Control Charts
Individual Samples Running Average of Last

Four Samples
Parameter to be Plotted Action Suspension Action Suspension

Limit Limit Limit Limit
4.75 mm sieve, Cumulative % Passing, 6 8 4 5

deviation from JMF target; plus or minus
values
0.6 mm sieve, Cumulative % Passing, 4 6 3 4

values
0.075 mmsieve, Cumulative % Passing, 1.4 2.0 1.1 1.5

values
Flow, 0.25 mm (NA for Superpave)
75 Blow JMF 8 min. 7 min. 9 min. 8 min.

16 max. 17 max. 15 max. 16 max.
50 Blow JMF 8 min. 7 min. 9 min. 8 min.
16 max. 17 max. 15 max. 16 max.
Asphalt content, % deviation from JMF 0.4 0.5 0.2 0.3

target; plus or minus value
Laboratory Air Voids, % deviation from No specific action and suspension limits set since
JMF target value this parameter is used to determine percent
payment
In-place Mat Density, % of TMD No specific action and suspension limits set since
this parameter is used to determine percent
payment
In-place Joint Density, % of TMD No specific action and suspension limits set since
this parameter is used to determine percent
payment
3.11 MATERIAL ACCEPTANCE
Testing for acceptabil ity of work will be performed by an independent laboratory hired by
the Contractor. Forward test results and payment calculations daily to the Contracting
Officer. Acceptance of the plant produced mix and in.place requirements will be on a lot to
lot basis. A standard lot for all requirements will be equal to 2000 metric tons. Where
appropriate, adjustment in payment for individual lots of hot-mix asphalt will be made based
on in-place density, laboratory air voids, grade and smoothness in accordance with the
following paragraphs. Grade and surface smootheness determinations will be made o the lot
as a whole. Exceptions or adjunstments to this will be made in situations where the mix
within one lot is placed as part of both the intermediate and surface courses, thus grade and
smoothness measurements for the entire lot cannot be made. In order to evaluate
laboratory air voids and in-place (field) density, each lot will be divided into four equal
sublots.
3.11.1 Sublot Sampling
One random mixture sample for determining laboratory air voids, theoretical maximum
density, and for any additional testing the Contracting Officer desires, will be taken from a
loaded truck delivering mixture to each sublot, or other appropriate location for each sublot.
All samples will be selected randomly, using commonly recognized methods of assuring
randomness conforming to ASTM D 3665 and employing tables of random numbers or
computer programs. Laboratory air voids will be determined from three laboratory
compacted specimens of each sublot sample in accordance with ASTM D 6926. The
specimens will be compacted within 2 hours of the time the mixture was loaded into trucks
at the asphalt plant. Samples will not be reheated prior to compaction and insulated
containers will be used as necessary to maintain the temperature.

3.11.2 Additional Sampling and Testing
The Contracting Officer reserves the right to direct additional samples and tests for any area
which appears to deviate from the specification requirements. The cost of any additional
testing will be paid for by the Government. Testing in these areas will be in addition to the
lot testing, and the requirements for these areas will be the same as those for a lot.
3.11.3 Grade
The final wearing surface of pavement shall conform to the elevations and cross sections
shown and shall vary not more than 15 mm from the plan grade established and approved
at site of work. Finished surfaces at juncture with other pavements shall coincide with
finished surfaces of abutting pavements. Deviation from the plan elevation will not be
permitted in areas of pavements where closer conformance with planned elevation is
required for the proper functioning of drainage and other appurtenant structures involved.
The grade will be determined by running lines of levels at intervals of 7.6 m, or less,
longitudinally and transversely, to determine the elevation of the completed pavement
surface. Within 5 working days, after the completion of a particular lot incorporating the final
wearing surface, test the final wearing surface of the pavement for conformance with the
specified plan grade. Diamond grinding may be used to remove high spots to meet grade
requirements. Skin patching for correcting low areas or planing or milling for correcting high
areas will not be permitted.
Use one of the following methods to test and evaluate surface smoothness of the pavement.
Perform all testing in the presence of the Contracting Officer. Keep detailed notes of the
results of the testing and furnish a copy to the Government immediately after each day's
testing. Where drawings show required deviations from a plane surface (crowns, drainage
inlets, etc.), the surface shall be finished to meet the approval of the Contracting Officer.
3.11.4.1 Smoothness Requirements
a. Straightedge Testing: The finished surfaces of the pavements shall have no abrupt
change of 6 mm or more, and all pavements shall be within the tolerances of 6 mm in
both the longitudinal and transverse directions, when tested with an approved 4 m
straightedge.
b. Profilograph Testing: The finished surfaces of the pavements shall have no abrupt
change of 3 mm or more, and each 0.1 km segment of each pavement lot shall have
a Profile Index not greater than 140 mm/km when tested with an approved California-
type profilograph. If the extent of the pavement in either direction is less than 60 m,
that direction shall be tested by the straightedge method and shall meet requirements
specified above.
3.11.4.2 Testing Method
After the final rolling, bay not later than 24 hours after placement, test the surface of the
pavement in each entire lot in such a manner as to reveal all surface irregularities exceeding

the tolerances specified above. Separate testing of individual sublots is not required. If any
pavement areas are ground, these areas shall be retested immediately after grinding. Test
each lot of the pavement in both a longitudinal and a transverse direction on parallel lines.
Set the transverse lines 4.5 m or less apart, as directed. The longitudinal lines shall be at the
centreline of each paving lane for lanes less than 6.1 m wide and at the third points for
lanes 6.1 m or wider. Also test other areas having obvious deviations, Longitudinal testing
lines shall be continuous across all joints.
a. Straightedge Testing. Hold the straightedge in contact with the surface and move it
ahead one-half the length of the straightedge for each successive measurement.
Determine the amount of surface irregularity by placing the freestanding (unleveled)
straightedge on the pavement surface and allowing it to rest upon the two highest
spots covered by its length, and measuring the maximum gap between the
straightedge and the pavement surface in the area between these two high points.
b. Profilograph Testing. Perform profilograph testing using approved equipment and

procedures described in CDT Test 526. The equipment shall utilize electronic recording
and automatic computerized reduction of data to indicate "must-grind" bumps and the
Profile Index for each 0.1 km segment of each pavement lot. Grade breaks on parking
lots shall be accomodated by breaking the profile segment into shorter sections and
repositioning the blanking band on each segment. The "blanking band" shall be 5 mm
wide and the "bump template" shall span 25 mm with an offset of 7.5 mm. Compute
the Profile Index for each pass of the profilograph in each 0.1 km segment. The Profile
Index for each segment shall be the average of the Profile Indices for each pass in each
segment. The profilograph shall be operated by a DOT approved operator. Furnish a
copy of the reduced tapes to the Government at the end of each day's testing.

SECTION 32 13 13 CONCRETE PAVING
PART 1 GENERAL
1.1 REFERENCES
ACI INTERNATIONAL (ACI)
ACI 211.1 (1991; R 2009) Standard Practice for Selecting

Proportions for Normal, Heavyweight and Mass
Concrete
ACI 301 (2005; Errata 2008) Specifications for Structural

Concrete
ACI 305R (1999; Errata 2006) Specification for Hot

Weather Concreting
ACE 306.1 (1990; R 2002) Standard Specification for Cold

Weather Concreting
AMERICAN WATER WORKS ASSOCIATION (AWWA)
AWWA C215 (2004; R 2010) Extruded Polyolefin Coatings for

the Exterior of Steel Water Pipelines
ASTM A 184/A 184M (2006) Standard Specification for Fabricated

Deformed Steel Bar Mats for Concrete
Reinforcement
ASTM A 615/A 615M (2009b) Standard Specification for Deformed

and Plain Carbon-Steel Bars for Concrete
Reinforcement
ASTM A 775/A 775M (2007b) Standard Specification for Epoxy-Coated

Steel Reinforcing Bars
ASTM A 966/A 966M (2008) Standard Test Method for Magnetic

Particle Examination of Steel Forgings Using
Alternating Current
ASTM C 1077 (2010c) Standard Practice for Laboratories

Testing Concrete and Concrete Aggregates for
Use in Construction and Criteria for Laboratory
Development of Sharm El Sheikh International Airport 32 13 13 CONCRETE PAVING

Evaluation
ASTM C 1260 (2007) Standard Test Method for Potential Alkali

Reactivity of Aggregates (Mortar-Bar Method)
ASTM C 143/C 143M (2010) Standard Test Method for Slump of

Hydraulic-Cement Concrete
ASTM C 150/C 150M (2009) Standard Specification for Portland

Cement
ASTM C 171 (2007)Standard Specification for Sheet Materials

for Curing Concrete
ASTM C 172 (2007)Standard Practice for Sampling Freshly

Mixed Concrete
ASTM C 231 (2009b) Standard Test Method for Air Content of

Freshly Mixed Concrete by the Pressure Method
ASTM C 260 (2006)Standard Specification for Air-Entraining

ASTM C 309 Standard Specification for Liquid Membrane-

Forming Compounds for Curing Concrete
ASTM C 31/C 31M (2009) Standard Practice for Making and

Curing Concrete Test Specimens in the Field
ASTM C 33/C 33M (2008) Standard Specification for Concrete

Aggregates
ASTM C 494/C 494M (2010) Standard Specification for Chemical

ASTM C 595/C 595M (2010) Standard Specification for Blended

Hydraulic Cements
ASTM C 618 (2008a) Standard Specification for Coal Fly Ash

and Raw or Calcined Natural Pozzolan for Use in
Concrete
ASTM C 78 (2009) Standard Test Method for Flexural

Strength of Concrete (Using Simple Beamwith
Third-Point Loading)
ASTM C 94/C 94M (2009a) Standard Specification for Ready-Mixed

Concrete
ASTM C 989 (2009a) Standard Specification for Slag Cement

for Use in Concrete and Mortars
ASTM D 6270 (2008e1) Use of Scrap Tires in Civil Engineering

Applications
1.2 RELATED SECTIONS
Pervious pavement systems shall use Section 32 11 23 AGGREGATE BASE COURSES, in

addition to this section.
1.3 SUBMITTALS

PROCEDURES:
SD-03 Product Data
Curing materials
Admixtures
Dowel
Reinforcement
Submit a complete list of materials including type, brand and applicable reference
specifications.
SD-04 Samples
Field-Constructed Mockup
SD-05 Design Data
Concrete mix design
Thirty days minimum prior to concrete placement, submit a mix design, with
applicable tests, for each strength and type of concrete for approval. Submit a
complete list of materials including type; brand; source and amount of cement, fly
ash, slag, and admixtures; and applicable reference specifications. Provide mix
proportion data using at least three different water-cement ratios for each type of
mixture, which will produce a range of strength encompassing those required for each
class and type of concrete required. Submittal shall clearly indicate where each mix
design will be used when more than one mix design is submitted. Obtain
acknowledgement of approvals prior to concrete placement. Submit a new mix design
for each material source change.
SD-06 Test Reports
Aggregate tests

Concrete slump tests
Air content tests
Flexural strength tests
Cementitious materials
SD-07 Certificates
Ready-mixed concrete plant
Batch tickets
Cementitious materials
SD-11 Closeout Submittals
Local/Regional Materials
Cementitious Materials
Aggregate
Albedo
ASTM C 94/C 94M.
1.5.1 Ready-mixed Concrete Plant Certification
Provide documentation that the ready-mix plant is certified by the National Ready-Mix
Concrete Association (NRMCA).
1.5.2 Required Information
Submit copies of laboratory test reports showing that the mix has been successfully tested
to produce concrete with the properties specified and that mix will be suitable for the job
conditions. The laboratory test reports shall include mill test and all other test for
cementitious materials, aggregates, and admixtures. Provide maximum nominal aggregate
size, gradation analysis, percentage retained and passing sieve, and a graph of percentage
retained verses sieve size. Test reports shall be submitted along with the concrete mix
design. Sampling and testing of materials, concrete mix design, sampling and testing in the
field shall be performed by a commercial testing laboratory which conforms to ASTM C 1077.
The laboratory shall be approved in writing by the Employer.

1.5.3 Batch Tickets
ASTM C 94/C 94M. Submit mandatory batch ticket information for each load of ready-mixed
concrete.
1.5.4 Field-Constructed Mockup
Install minimum 21 square meters to demonstrate typical joints, surface finish, texture,
color, permeability, and standard of workmanship. When Contracting Officer determines that
mockup does not meet requirements, demolish and remove it from the site and install
another until the mockup is accepted. Keep accepted mockup undisturbed during
construction as a standard for judging completed paving. Accepted mockup may be
incorporated into final work when approved by Contracting Officer.
1.6 SUSTAINABLE DESIGN REQUIREMENTS
1.6.1 Local/Regional Materials
Use materials or products extracted, harvested, or recovered, as well as manufactured, within

a 800 kilometer radius from the project site, if available from a minimum of three sources.
1.7 WARRANTY
be signed.
PART 2 PRODUCTS
2.1 MATERIALS
2.1.1 Cementitious Materials
Cementitious materials in concrete mix shall be 50 percent non-portland cement pozzolanic

materials by weight. Provide test data demonstrating compatibility and performance of
concrete satisfactory to Contracting Officer.

2.1.1.1 Cement
ASTM C 150/C 150M, Type I or II or ASTM C 595/C 595M, Type IS, IP, or P with maximum
alkali content of 0.60%. Cement certificate shall include test results in accordance with
ASTM C 150/C 150M, including equivalent alkalies indicated in the Supplementary Optional
Chemical Requirements.
2.1.1.2 Fly Ash and Pozzolan
ASTM C 618, Type F, except that the maximum allowable loss on ignition shall be 6%,
maximum available alkalies content shall be 1.5%, and maximum calcium oxide (CaO)
content 8%. Fly ash certificates shall include test results in accordance with ASTM C 618,
including available alkalies indicated in the Supplementary Optional Chemical Requirements.
2.1.1.3 Slag
ASTM C 989, Ground Granulated Blast Furnace Slag (GGBFS), Grade 100 or 120. Certificates
shall include test results in accordance with ASTM C 989.
2.12 Water ASTM C 94/C 94M, fresh, clean, and potable.
2.1.3 Aggregate
Aggregate shall contain a minimum of 5 percent post-consumer recycled content, or a

minimum of 20 percent post-industrial recycled content. Aggregate may contain post-
consumer or post-industrial recycled content.
2.1.3.1 Alkali Reactivity Test
Aggregates to be used in all concrete shall be evaluated and tested by the Contractor for
alkali-aggregate reactivity in accordance with ASTM C 1260. The types of aggregates shall
be evaluated in a combination which matches the contractors' proposed mix design
(including Class F fly ash or GGBF slag), utilizing the modified version of ASTM C 1260. Test
results of the combination shall have a measured expansion of less than 0.08 percent at 16
days. Should the test data indicate an expansion of greater than 0.08%, the aggregate(s)
shall be rejected and the contractor shall submit new aggregate sources for retesting or may
submit additional test results incorporating Lithium Nitrate for consideration.
ASTM C 1260 shal1l be modified as follows to include one of the following options:
a. Utilize the contractor's proposed low alkali Portland cement and Class F fly ash in
combination for the test proportioning. The laboratory shall use the contractor's
proposed percentage of cement and fly ash.
b. Utilize the contractor's proposed low alkali Portland cement and ground granulated
blast furnace (GGBF) slag in combination for the test proportioning. The laboratory
shall use the contractor's proposed percentage of cement and GGBF.
c. Utilize the contractor's proposed low alkali Portland cement and Class F fly ash and
ground granulated blast furnace (GGBF) slag in combination for the test

proportioning. The laboratory shall use the contractor's proposed percentage of
cement, fly ash and GGBF.
2.1.3.2 Fine Aggregates
ASTM C 33/C 33M.
2.1.3.3 Coarse Aggregates
ASTM C 33/C 33M.
2.1.4 Admixtures
ASTM C 494/C 494M: Type A, water reducing; Type B, retarding; Type C, accelerating; Type
D, water-reducing and retarding; and Type E, water-reducing and accelerating admixture.
Do not use calcium chloride admixtures. Where not shown or specified, the use of
admixtures is subject to written approval of the Contracting Officer.
ASTM C 260: Air-entraining.
2.1.5 Reinforcement
2.1.5.1 Dowel Bars
Bars shall conform to ASTM A 615/A 615M, Grade 300 for plain billet-steel bars of the size
and length indicated. Remove all burrs and projections from the bars.
2.1.5.2 Coated Dowel Bars
Bars shall conform to ASTM A 615/A 615M, Grade 300 for plain billet-steel bars of the size
and length indicated. Remove all burrs or projections from the dowel bars. Coating system
shall conform to AWWA C215, Type 2. Coat the bars with a double coat system or an epoxy
coating system for resistance to penetration of oil and salt solutions. The systems shall be in
accordance with manufacturer's recommendation for coatings which are not bondable to
concrete. Bond the coating to the dowel bar to resist laps or folds during movement of the
joint. Coating thickness shall be 0.175 mm minimum and 0.5 mm maximum.
2.1.5.3 Tie Bars
Bars shall be billet or axle steel deformed bars and conform to ASTM A 615/A 615M or ASTM
A 966/A 966M Grade 300. Epoxy coated in accordance with ASTM A 775/A 775M.
2.1.5.4 Reinforcement
Deformed steel bar mats shall conform to ASTM A 184/A 184M. Bar reinforcement shall
conform to ASTM A 615/A 615M ASTM A 966/A 966M, Grade 300.

2.1.6 Curing Materials
2.1.6.1 White-Burlap-Polyethylene Sheet
ASTM C 171, 0.10 mm thick white opaque polyethylene bonded to 0.31 kg per meter (1.0
meter) wide burlap.
2.1.6.2 Liquid Membrane-Forming Compound
ASTM C 309, white pigmented, Type 2, Class B, free of paraffin or petroleum.
2.1.6.3 Liquid Chemical Sealer-Hardener Compound
Compound shall be magnesium fluosilicate which when mixed with water seals and hardens
the surface of the concrete. Do not use on exterior slabs exposed to freezing conditions.
Compound shall not reduce the adhesion of resilient flooring, tile, paint, roofing,
waterproofing, or other material applied to concrete.
2.1.77 Joint Fillers and Sealants
New joints shall match existing alignment.
2.1.8 Edge Restraints Edge restraints for pervious systems shall be concrete.
2.2 CONCRETE PAVEMENT
2.2.1 Permeability
Installed system shall have a minimum permeability rate of 60percent.
2.3 CONTRACTOR-FURNISHED MIX DESIGN
Contractor-furnished mix design concrete shall be designed in accordance with ACI 211.1
except as modified herein, and the mix design shall be as specified herein under paragraph
entitled "Submittals." The concrete shall have a minimum flexural strength of 4.48MPa at 90
days. The concrete may be air entrained. If air entrainment is used the air content shall be
5.0 plus or minus 1.5 percent. Maximum size aggregate for slip forming shall be 38 mm. The
minimum cementitious factor is 335 kg per cubic meter and slump shall be 25 mm to 75 mm
(or less when slip form is used.
If the cementitious material is not sufficient to produce concrete of the flexural strength
required it shall be increased as necessary, without additional compensation under the
contract. The cementitious factor shall be calculated using cement, Class F fly ash, and or
GGBF slag. The mix shall use a cement replacement (by weight) of 25%-35% Class F fly
ash, or 40%-50% GGBF slag, or a combination of the two. In the combination, each 5% of
Class F fly ash shall be replaced by 8% GGBF slag.

PART 3 EXECUTION
3.1 PREPARATION FOR PERVIOUS SYSTEMS
Verify compacted subgrade, granular base or stabilized soil is acceptable and ready to
support paving and imposed loads. Install edge restraints per the drawings and
manufacturer's recommendations.
3.2 FORMS
3.2.1 Construction
Construct forms to be removeable without damaging the concrete.
3.2.2 Coating
Before placing the concrete, coat the contact surfaces of forms except existing pavement
sections where bonding is required, with a non-staining mineral oil, non-staining form
coating compound, or two coats of nitro-cellulose lacquer. When using existing pavement as
a form, clean existing concrete and then coat with asphalt emulsion bondbreaker before
concrete is placed.
3.2.3 Grade and Alignment
Check and correct grade elevations and alignment of the forms immediately before placing
the concrete.
3.3 REINFORCEMENT
3.3.1 Dowel Bars
Install bars accurately aligned, vertically and horizontally, at indicated locations and to the
dimensions and tolerances indicated. Before installation thoroughly grease the sliding portion
of each dowel. Dowels must remain in position during concrete placement and curing.
3.3.2 Coated Dowel Bars
Install bars, accurately aligned vertically and horizontally, at indicated locations and to the
dimensions and tolerances indicated. Reject coatings which are perforated, cracked or
otherwise damaged. While handling avoid scuffing or gouging of the coatings.
3.3.3 Tie Bars
Install bars, accurately aligned horizontally and vertically, at indicated locations. For slipform
construction, insert bent tie bars by hand or other approved means.
3.3.4 Setting Slab Reinforcement
Reinforcement shall be positioned on suitable chairs prior to concrete placement. At

expansion, contraction and construction joints, place the reinforcement as indicated.

Reinforcement, when placed in concrete, shall be free of mud, oil, scale or other foreign
materials. Place reinforcement accurately and wire securely. The laps at splices shall be300
mm minimum and the distances from ends and sides of slabs and joints shall be as indicated.
3.4 MEASURING, MIXING, CONVEYING, AND PLACING CONCRETE
3.4.1. Measuring
ASTM C 94/C 94M.
3.4.2. Mixing
ASTM C 94/C 94M, except as modified herein. Begin mixing within 30 minutes after cement
has been added to aggregates. When the air temperature is greater than 29.4 degrees C,
reduce mixing time and place concrete within 60 minutes. Additional water may be added to
bring slump within required limits as specified in Section 11.7 of ASTM C 94/C 94M, provided
that the specified water-cement ratio is not exceeded.
3.4.3 Conveying
ASTM C 94/C 94M.
3.4.4 Placing
Follow guidance of ACI 301, except as modified herein. Do not exceed a free vertical drop of
0.90 m from the point of discharge. Place concrete continuosly at a uniform rate, with
minimum amount of segregation, without damage to the grade and without unscheduled
stops except for equipment failure or other emegencies. If this occurs within 3 m of a
previously placed expansion joint, remove concrete back to joint, repair any damage to
grade, install a construction joint and continue placing concrete only after cause of the stop
has been corrected.
3.4.5 Vibration
Immediately after spreading concrete, consolidate concrete with internal type vibrating
equipment along the boundaries of all slabs regardless of slab thickness, and interior of all
concrete slabs 150 mm or more in thickness. Limit duration of vibration to that necessary to
produce consolidation of concrete. Excessive vibration will not be permitted. Vibrators shall
not be operated in concrete at one location for more than 15 seconds. At the option of the
Contractor, vibrating equipment of a type approved by the Contracting Officer may be used
to consolidate concrete in unreinforced pavement slabs less than 150 mm thick.
3.4.5.1 Vibrating Equipment
Operate equipment, except hand-manipulated equipment, ahead of the finishing machine.

Select the number of vibrating units and power of each unit to properly consolidate the
concrete. Mount units on a frame that is capable of vertical movement and, when necessary,
radial movement, so vibrators may be operated at any desired depth within the slab or be
completely withdrawn from the concrete. Clear distance between frame-mounted vibrating
units that have spuds that extend into the slab at intervals across the paving lane shall not

exceed 750 mm. Distance between end of vibrating tube and side form shall not exceed 50
mm. For pavements less than 250 mm thick, operate vibrators at mid-depth parallel with or
at a slight angle to the subbase. For thicker pavements, angle vibrators toward the vertical,
with vibrator tip preferably about 50 mm from subbase, and top of vibrator a few mm below
pavement surface. Vibrators may be pneumatic, gas driven, or electric, and shall be
operated at frequencies within the concrete of not less than 8,000 vibrations per minute.
Amplitude of vibration shall be such that noticeable vibrations occur at 450 mm radius when
the vibrator is inserted in the concrete to the depth specified.
3.4.6 Hot Weather
Maintain required concrete temperature in accordance with Figure 2.1.5 in ACI 305R to
prevent evaporation rate from exceeding 0.98 kg of water per square meter of exposed
concrete per hour. Cool ingredients before mixing or use other suitable means to control
concrete temperature and prevent rapid drying of newly placed concrete. After placement,
use fog spray, apply monomolecular film, or use other suitable means to reduce the
evaporation rate. Start curing when surface of fresh concrete is sufficiently hard to permit
curing without damage. Cool underlying material by sprinkling lightly with water before
placing concrete. Follow practices found in ACI 305R.
3.5 PAVING
Install pervious paving system in accordance with manufacturer's recommendations and as

indicated. Install surface elevation of the paving system 3 to 6 mm above adjacent drainage
inlets, concrete collars, or channels. Manufacturer's recommendations shall take precedence
over the specifications in the event of conflicting requirements between the two. Pavement
shall be constructed with paving and finishing equipment utilizing slipforms.
3.5.1 Consolidation
The paver vibrators shall be inserted into the concrete not closer to the underlying material
than 50 mm. The vibrators or any tamping units in front of the paver shall be automatically
controlled so that they shall be stopped immediately as forward motion ceases. Excessive
vibration shall not be permitted. Concrete in small, odd-shaped slabs or in locations
inaccessible to the paver mounted vibration equipment shall be vibrated with a hand-
operated immersion vibrator. Vibrators shall not be used to transport or spread the concrete.
3.5.2 Operation
When the paver is operated between or adjacent to previously constructed pavement (fill-in
lanes), provisions shall be made to prevent damage to the previously constructed pavement,
including keeping the existing pavement surface free of any debris, and placing rubber mats
beneath the paver tracks. Transversely oscillating screeds and extrusion plates shall overlap
the existing pavement the minimum possible, but in no case more than 200 mm.
3.5.3 Required Results
The paver-finisher shall be operated to produce a thoroughly consolidated slab throughout,

true to line and grade within specified tolerances. The paver-finishing operation shall

produce a surface finish free of irregularities, tears, voids of any kind, and any other
discontinuities. It shall produce only a very minimum of paste at the surface. Multiple passes
of the paver-finisher shall not be permitted. The equipment and its operation shall produce a
finished surface requiring no hand finishing, other than the use of cutting straightedges,
except in very infrequent instances. No water, other than true fog sprays (mist), shall be
applied to the concrete surface during paving and finishing.
3.5.4 Fixed Form Paving
Forms shall be steel, except that wood forms may be used for curves having a radius of 45
m or less, and for fillets. Forms may be built up with metal or wood, added only to the base,
to provide an increase in depth of not more than 25 percent. The base width of the form
shall be not less than eight-tenths of the vertical height of the form, except that forms 200
mm or less in vertical height shall have a base width not less than the vertical height of the
form. Wood forms for curves and fillets shall be adequate in strength and rigidly braced.
Forms shall be set on firm material cut true to grade so that each form section when placed
will be firmly in contact with the underlying layer for its entire base. Forms shall not be set
on blocks or on built-up spots of underlying material. Forms for overlay pavements and for
other locations where forms must be set on existing pavements shall be held securely in
place with stakes or by other approved methods. Holes in existing pavements for form
stakes shall be carefully drilled without cracking or spalling the existing pavement. Prior to
setting forms for paving operations, the Contractor shall demonstrate the proposed form
setting procedures at an approved location and shall not proceed further until the proposed
method is approved. Forms shall remain in place at least 12 hours after the concrete has
been placed. Forms shall be removed without injuring the concrete.
3.5.5 Slipform Paving
The slipform paver shall shape the concrete to the specified and indicated cross section in
one pass, and shall finish the surface and edges so that only a very minimum amount of
hand finishing is required.
Dowels shall not be installed by dowel inserters attached to the paver or by any other means
of inserting the dowels into the plastic concrete. If a keyway is required, a 0.45 to 0.55 mm
thick metal keyway liner shall be installed as the keyway is extruded. The keyway liner shall
be protected and shall remain in place and become part of the joint.
3.5.6 Placing Reinforcing Steel
Reinforcement shall be positioned on suitable chairs securely fastened to the subgrade prior
to concrete placement. If reinforcing for Continuously Reinforced Concrete Pavement (CRCP)
is required, the entire operating procedure and equipment proposed shall be submitted for
approval at least 30 days prior to proposed start of paving.
3.5.7 Placing Dowels and Tie Bars
Dowels shall be installed with alignment not greater than 1 mm per 100 mm. Except as
otherwise specified below, location of dowels shall be within a horizontal tolerance of plus or
minus 15 mm and a vertical tolerance of plus or minus 5 mm. The portion of each dowel

intended to move within the concrete or expansion cap shall be painted with one coat of rust
inhibiting primer paint, and then oiled just prior to placement. Dowels and tie bars in joints
shall be omitted when the center of the tie bar is located within a horizontal distance from
an intersecting joint equal to or less than one-fourth of the slab thickness.
3.5.7.1 Contraction Joints
Dowels and tie bars in longitudinal and transverse contraction joints within the paving lane
shall be held securely in place by means of rigid metal basket assemblies. The dowels and tie
bars shall be welded to the assembly or held firmly by mechanical locking arrangements that
will prevent them from becoming distorted during paving operations. The basket assemblies
shall be held securely in the proper location by means of suitable anchors.
3.5.7.2 Construction Joints-Fixed Form Paving
Installation of dowels and tie bars shall be by the bonded-in-place method, supported by
means of devices fastened to the forms. Installation by removing and replacing in preformed
holes will not be permitted.
3.5.7.3 Dowels Installed in Hardened Concrete
Installation shall be by bonding the dowels into holes drilled into the hardened concrete.
Holes approximately 3 mm greater in diameter than the dowels shall be drilled into the
hardened concrete. Dowels shall be bonded in the drilled holes using epoxy resin injected at
the back of the hole before installing the dowel and extruded to the collar during insertion of
the dowel so as to completely fill the void around the dowel. Application by buttering the
dowel shall not be permitted. The dowels shall be held in alignment at the collar of the hole,
after insertion and before the grout hardens, by means of a suitable metal or plastic collar
fitted around the dowel. The vertical alignment of the dowels shall be checked by placing
the straightedge on the surface of the pavement over the top of the dowel and measuring
the vertical distance between the straightedge and the beginning and ending point of the
exposed part of the dowel. Where tie bars are required in longitudinal construction joints of
slipform pavement, bent tie bars shall be installed at the paver, in front of the transverse
screed or extrusion plate. If tie bars are required, a standard keyway shall be constructed,
and the bent tie bars shall be inserted into the plastic concrete through a 0.45 to 0.55 mm
thick metal keyway liner. Tie bars shall not be installed in preformed holes. The keyway liner
shall be protected and shall remain in place and become part of the joint. Before placement
of the adjoining paving lane, the tie bars shall be straightened, without spalling the concrete
around the bar.
3.5.7.4 Expansion Joints
Dowels in expansion joints shall be installed by the bonded-in-place method or by bonding

into holes drilled in hardened concrete, using procedures specified above.
3.6 FINISHING CONCRETE
Start finishing operations immediately after placement of concrete. Use finishing machine,
except hand finishing may be used in emergencies and for concrete slabs in inaccessible

locations or of such shapes or sizes that machine finishing is impracticable. Finish pavement
surface on both sides of a joint to the same grade. Finish formed joints from a securely
supported transverse bridge. Provide hand finishing equipment for use at all times.
Transverse and longitudinal surface tolerances shall be 6 mm in 3 m.
3.6.1 Side Form Finishing
Strike off and screed concrete to the required slope and cross-section by a power-driven
transverse finishing machine. Transverse rotating tube or pipe shall not be permitted unless
approved by the Contracting Officer. Elevation of concrete shall be such that, when
consolidated and finished, pavement surface will be adequately consolidated and at the
required grade. Equip finishing machine with two screeds which are readily and accurately
adjustable for changes in pavement slope and compensation for wear and other causes.
Make as many passes over each area of pavement and at such intervals as necessary to give
proper compaction, retention of coarse aggregate near the finished surface, and a surface of
uniform texture, true to grade and slope. Do not permit excessive operation over an area,
which will result in an excess of mortar and water being brought to the surface.
3.6.1.1 Equipment Operation
Maintain the travel of machine on the forms without lifting, wobbling, or other variation of
the machine which tend to affect the precision of concrete finish. Keep the tops of the forms
clean by a device attached to the machine. During the first pass of the finishing machine,
maintain a uniform ridge of concrete ahead of the front screed for its entire length.
3.6.1.2 Joint Finish
Before concrete is hardened, correct edge slump of pavement, exclusive of edge rounding, in
excess of 6 mm. Finish concrete surface on each side of construction joints to the same
plane, and correct deviations before newly placed concrete has hardened.
3.6.1.3 Hand Finishing
Strike-off and screed surface of concrete to elevations slightly above finish grade so that
when concrete is consolidated and finished pavement surface is at the indicated elevation.
Vibrate entire surface until required compaction and reduction of surface voids is secured
with a strike-off template.
3.6.1.4 Longitudinal Floating
After initial finishing, further smooth and consolidate concrete by means of hand-operated
longitudinal floats. Use floats that are not less than 3.65 m long and 150 mm wide and
stiffened to prevent flexing and warping.
3.6.2 Texturing
Before the surface sheen has disappeared and before the concrete hardens, the surface of
the pavement shall be given a texture as described herein. Following initial texturing on the
first day of placement, the Placing Foreman, Contracting Officer representative, and a

representative of the Using Agency shall inspect the texturing for compliance with design
requirements. After curing is complete, all textured surfaces shall be thoroughly power
broomed to remove all debris. Any type of transverse texturing shall produce grooves in
straight lines across each lane within a tolerance of plus or minus 13 mm of a true line. The
concrete in areas of recesses for tie-down anchors, lighting fixtures, and other outlets in the
pavement shall be finished to provide a surface of the same texture as the surrounding area.
3.6.2.1 Burlap Drag Finish
Before concrete becomes non-plastic, finish the surface of the slab by dragging on the
surface a strip of clean, wet burlap measuring from 0.91 to 3 m long and 600 mm wider than
the width of the pavement. Select dimension of burlap drag so that at least 0.91 m of the
material is in contact with the pavement. Drag the surface so as to produce a finished
surface with a fine granular or sandy texture without leaving disfiguring marks.
3.6.2.2 Brooming
Finish the surface of the slab by brooming the surface with a new wire broom at least 450
mm wide. Gently pull the broom over the surface of the pavement from edge to edge just
before the concrete becomes non-plastic. Slightly overlap adjacent strokes of the broom.
Broom perpendicular to centerline of pavement so that corrugations produced will be
uniform in character and width, and not more than 2 mm in depth. Broomed surface shall be
free from porous spots, irregularities, depressions, and small pockets or rough spots such as
may be caused by accidentally disturbing particles of coarse aggregate embedded near the
surface.
3.6.2.3 Wire-Comb Texturing
Surface texture transverse to the pavement center line shall be applied using a mechanical
wire comb drag. The comb shall be capable of traversing the full width of the pavement in a
single pass at a uniform speed and with a uniform pressure. Successive passes of the comb
shall be overlapped the minimum necessary to obtain a continuous and uniformly textured
surface. The scores shall be 2 to 5 mm deep, 1.5 to 3 mm wide, and spaced 10 mm apart.
3.6.2.4 Surface Grooving
The areas indicated on the drawings shall be grooved with a spring tine drag producing
individual grooves 6 mm deep and 6 mm wide at a spacing between groove centerlines of
50 mm. These grooves shall be cut perpendicular to the centerline. Before grooving begins,
the concrete shall be allowed to stiffen sufficiently to prevent dislodging of aggregate.
Grooves shall not be cut within 150 mm of a transverse joint or crack.
3.6.3 Edging
At the time the concrete has attained a degree of hardness suitable for edging, carefully
finish slab edges, including edges at formed joints, with an edge having a maximum radius
of 3 mm. When brooming is specified for the final surface finish, edge transverse joints
before starting brooming, then operate broom to obliterate as much as possible the mark left
by the edging tool without disturbing the rounded corner left by the edger. Clean by

removing loose fragments and soupy mortar from corners or edges of slabs which have
crumbled and areas which lack sufficient mortar for proper finishing. Refill voids solidly with
a mixture of suitable proportions and consistency and refinish. Remove unnecessary tool
marks and edges. Remaining edges shall be smooth and true to line. Install edge restraints
of pervious systems per the drawings and manufacturer's recommendations.
3.6.4 Repair of Surface Defects
Follow guidance of ACI 301.
3.7 CURING AND PROTECTION
Protect concrete adequately from injurious action by sun, rain, flowing water, mechanical
injury, tire marks and oil stains, and do not allow it to dry out from the time it is placed until
the expiration of the minimum curing periods specified herein. Use White-Burlap-
Polyethylene Sheet or liquid membrane-forming compound, except as specified otherwise
herein. Do not use membrane-forming compound on surfaces where its appearance would
be objectionable, on surfaces to be painted, where coverings are to be bonded to concrete,
or on concrete to which other concrete is to be bonded. Maintain temperature of air next to
concrete above 5 degrees C for the full curing periods.
3.7.1 White-Burlap-Polyethylene Sheet
Wet entire exposed surface thoroughly with a fine spray of water, saturate burlap but do not
have excessive water dripping off the burlap and then cover concrete with White-Burlap-
Polyethylene Sheet, burlap side down. Lay sheets directly on concrete surface and overlap
300 mm. Make sheeting not less than 450 mm wider than concrete surface to be cured, and
weight down on the edges and over the transverse laps to form closed joints. Repair or
replace sheets when damaged during curing. Check daily to assure burlap has not lost all
moisture. If moisture evaporates, resaturate burlap and re-place on pavement (re-saturation
and re-placing shall take no longer than 10 minutes per sheet). Leave sheeting on concrete
surface to be cured for at least 7 days.
3.7.2 Liquid Membrane-Forming Compound Curing
Apply compound immediately after surface loses its water sheen and has a dull appearance
and before joints are sawed. Agitate curing compound thoroughly by mechanical means
during use and apply uniformly in a two-coat continuous operation by suitable power-
spraying equipment. Total coverage for the two coats shall be at least 4 liters of undiluted
compound per 20 square meters. Compound shall form a uniform, continuous, coherent film
that will not check, crack, or peel and shall be free from pinholes or other imperfections.
Apply an additional coat of compound immediately to areas where film is defective. Respray
concrete surfaces that are subject to heavy rainfall within 3 hours after curing compound
has been applied in the same manner.
3.7.2.1 Protection of Treated Surfaces
Keep concrete surfaces to which liquid membrane-forming compounds have been applied
free from vehicular traffic and other sources of abrasion for not less than 72 hours. Foot

traffic is allowed after 24 hours for inspection purposes. Maintain continuity of coating for
entire curing period and repair damage to coating immediately.
3.7.3 Liquid Chemical Sealer-Hardener
Apply sealer-hardener to interior floors not receiving floor covering and floors located under
access flooring. Apply the sealer-hardener in accordance with manufacturer's
recommendations. Seal or cover joints and openings in which joint sealant is to be applied
as required by the joint sealant manufacturer. The sealer-hardener shall not be applied until
the concrete has been moist cured and has aged for a minimum of 30 days. Apply a
minimum of two coats of sealer-hardener.
3.8.1 Sampling
The Contractor's approved laboratory shall collect samples of fresh concrete in accordance
with ASTM C 172 during each working day as required to perform tests specified herein.
Make test specimens in accordance with ASTM C 31/C 31M.
3.8.2 Consistency Tests
The Contractor's approved laboratory shall perform concrete slump tests in accordance with
ASTM C 143/C 143M. Take samples for slump determination from concrete during
placement. Perform tests at the beginning of a concrete placement operation and and for
each batch (minimum) or every 16 cubic meters (maximum) of concrete to ensure that
specification requirements are met. In addition, perform tests each time test beams and
cylinders are made.
3.8.3 Flexural Strength Tests
The Contractor's approved laboratory shall test for flexural strength in accordance with ASTM
C 78. Make four test specimens for each set of tests. Test two specimens at 28 days, and
the other two at 90 days. Concrete strength will be considered satisfactory when the
minimum of the 90-day test results equals or exceeds the specified 28-day flexural strength,
and no individual strength test is less than 3.79 MPa. If the ratio of the 28-day strength test
to the specified 90-day strength is less than 65 percent, make necessary adjustments for
conformance. Frequency of flexural tests on concrete beams shall be not less than four test
beams for each 38 cubic meters of concrete, or fraction thereof, placed. Concrete which is
determined to be defective, based on the strength acceptance criteria therein, shall be
removed and replaced with acceptable concrete.
3.8.4 Air Content Tests
Test air-entrained concrete for air content at the same frequency as specified for slump
tests. Determine percentage of air in accordance with ASTM C 231 on samples taken during
placement of concrete in forms.

3.8.5 Surface Testing
Surface testing for surface smoothness , edge slump and plan grade shall be performed as
indicated below by the Testing Laboratory. The measurements shall be properly referenced
in accordance with paving lane identification and stationing, and a report given to the
Employer within 24 hours after measurement is made. A final report of surface testing,
signed by a Registered Engineer, containing all surface measurements and a description of
all actions taken to correct deficiencies, shall be provided to the Employer upon conclusion
of surface testing.
3.8.5.1 Surface Smoothness Requirements
The finished surfaces of the pavements shall have no abrupt change of 3 mm or more, and
all pavements shall be within the tolerances specified when checked with a 4 meter
straightedge: 5 mm longitudinal and 6.5 mm transverse directions for roads and streets and
6.5 mm for both directions for other concrete surfaces, such as parking areas.variations in
final pervious surface shall not be more than 10mm under a 3.0 m straightedge.
3.8.5.2 Surface Smoothness Testing Method
The surface of the pavement shall be tested with the straightedge to identify all surface
irregularities exceeding the tolerances specified above. The entire area of the pavement
shall be tested in both a longitudinal and a transverse direction on parallel lines
approximately 4.5 m apart. The straightedge shall be held in contact with the surface and
moved ahead one-half the length of the straightedge for each successive measurement. The
amount of surface irregularity shall be determined by placing the straightedge on the
pavement surface and allowing it to rest upon the two highest spots covered by its length
and measuring the maximum gap between the straightedge and the pavement surface, in
the area between these two high points.
3.8.6 Plan Grade Testing and Conformance
The surfaces shall vary not more than 18 mm above or below the plan grade line or
elevation indicated. Each pavement category shall be checked by the Contractor for
conformance with plan grade requirements by running lines of levels at intervals to
determine the elevation at each joint intersection.
3.8.7 Test for Pavement Thickness
Measure during concrete placement to determine in-place thickness of concrete pavement.
3.8.8 Reinforcement
Inspect reinforcement prior to installation to assure it is free of loose flaky rust, loose scale,
oil, mud, or other objectionable material.
3.8.9 Dowels
Inspect dowel placement prior to placing concrete to assure that dowels are of the size
indicated, and are spaced, aligned and painted and oiled as specified. Dowels shall not

deviate from vertical or horizontal alignment after concrete has been placed by more than 3
mm per 300 mm.
3.9 WASTE MANAGEMENT

In accordance with the Waste Management Plan. Protect excess material from
contamination and return to manufacturer, or reuse on-site for walkways, patching, ditch
beds, speed bumps, or curbs.

SECTION 32 17 23 PAVEMENT MARKINGS
PART 1 GENERAL
1.1 REFERENCES
publications are referred to in the text by the basic designation only.
ASTM D 2240 (2005) Standard Test Method for Rubber

Property - Durometer Hardness
ASTM D 2621 (1987; R 2005) Infrared Identification of Vehicle

Solids from Solvent-Reducible Paints
ASTM D 2697 (2003; R 2008) Volume Nonvolatile Matter in

Clear or Pigmented Coatings
ASTM D 3335 (1985a; R 2009) Low Concentrations of Lead,

Cadmium, and Cobalt in Paint by Atomic
Absorption Spectroscopy
ASTM D 3718 (1985a; R 2005) Low Concentrations of

Chromium in Paint by Atomic Absorption
Spectroscopy
ASTM D 3924 (1980; R 2005) Standard Environment for

Conditioning and Testing Paint, Varnish,
Lacquer, and Related Materials
ASTM D 3960 (2005) Determining Volatile Organic Compound

(VOC) Content of Paints and Related Coatings
ASTM D 4280 (2008) Extended Life Type, Nonplowable,

Raised, Retroreflective Pavement Markers
ASTM D 4505 (2005) Preformed Retroflective Pavement

Marking Tape for Extended Service Life
ASTM D 4541 (2009) Pull-Off Strength of Coatings Using

Portable Adhesion Testers
ASTM D 471 (2006e1) Standard Test Method for Rubber

Property - Effect of Liquids
ASTM D 522 (1993a; R 2008) Mandrel Bend Test of Attached
Development of Sharm El Sheikh International Airport 32 17 23 PAVEMENT MARKINGS

Organic Coatings
ASTM D 711 (1989; R 2004) No-Pick-Up Time of Traffic Paint
ASTM D 792 (2008) Density and Specific Gravity (Relative

Density) of Plastics by Displacement
ASTM D 823 (1995; R 2007) Producing Films of Uniform

Thickness of Paint, Varnish, and Related
Products on Test Panels.
ASTM E 28 (1999; R 2009) Softening Point of Resins

Derived from Naval Stores by Ring and Ball
Apparatus
ASTM G 53 (1996) Operating Light- and Water-Exposure

Apparatus (Fluorescent UV-Condensation Type)
for Exposure of Nonmetallic Materials
INTERNATIONAL CONCRETE REPAIR INSTITUTE (ICRI)
ICRI 03732 (1997) Selecting and Specifying Concrete

Surface Preparation for Sealers, Coatings, and
Polymer Overlays
1.2 SUBMITTALS

PROCEDURES:
SD-03 Product Data
Reflective media for airfields
Reflective media for roads and streets
Paints for airfields
Paints for roads and streets
High Build Acrylic Coating (HBAC); G
Thermoplastic compound
Raised Pavement Markers and Adhesive
Equipment; G
Lists of proposed equipment, including descriptive data, and notifications of proposed

Contractor actions as specified in this section. List of removal equipment shall include

descriptive data indicating area of coverage per pass, pressure adjustment range, tank
and flow capacities, and safety precautions required for the equipment operation.
Qualifications
Documentation on personnel qualifications, as specified.
SD-06 Test Reports
High Build Acrylic Coating (HBAC); G
Raised Pavement Markers and Adhesive
Certified reports from sampling and testing made in accordance with paragraph
entitled "Sampling and Testing" prior to the use of the materials at the jobsite. Testing
shall be performed in an approved independent laboratory.
SD-07 Certificates
Volatile Organic Compound, (VOC)
Certificate stating that the proposed pavement marking paint meets the VOC
regulations of the local Air Pollution Control District having jurisdiction over the
geographical area in which the project is located.
Construction equipment list
SD-08 Manufacturer's Instructions

Submit manufacturer's Material Safety Data Sheets.
1.3 DELIVERY AND STORAGE
Deliver paints, paint materials and thermoplastic compound materials in original sealed
containers that plainly show the designated name, specification number, batch number,
color, date of manufacture, manufacturer's directions, and name of manufacturer. Provide
storage facilities at the job site for maintaining materials at temperatures recommended by
the manufacturer. Make available paint stored at the project site or segregated at the source
for sampling not less than 30 days prior to date of required approval for use to allow
sufficient time for testing.
1.4 WEATHER LIMITATIONS
Apply paint to clean, dry surfaces, and unless otherwise approved, only when the air and
pavement surface temperature is at least 2.7 degrees C above the dew point and the air and
pavement temperatures are above 5 degrees C and less than 35 degrees C for oil-based
materials; above 10 degrees C and less than 43 degrees Cfor water-based materials.
Maintain paint temperature within these same limits.
1.5 EQUIPMENT
Machines, tools, and equipment used in the performance of the work shall be approved by
the Contracting Officer and maintained in satisfactory operating condition. Submit
construction equipment list for approval by the Contracting Officer.
1.5.1 Mobile and Maneuverable
Application equipment shall be mobile and maneuverable to the extent that straight lines can
be followed and normal curves can be made in a true arc.
1.5.2 Paint Application Equipment
1.5.2.1 Hand-Operated, Push-Type Machines
Provide hand-operated push-type applicator machine of a type commonly used for

application of paint to pavement surfaces. Paint applicator machine shall be acceptable for
marking small street and parking areas. Applicator machine shall be equipped with the
necessary paint tanks and spraying nozzles, and shall be capable of applying paint uniformly
at coverage specified. Applicator for water-based markings shall be equipped with non-stick
coated hoses; metal parts in contact with the paint material shall be constructed of grade
302, 304, 316, or equal stainless steel.
1.5.2.2 Self-Propelled or Mobile-Drawn Pneumatic Spraying Machines

Provide self-propelled or mobile-drawn pneumatic spraying machine with suitable
arrangements of atomizing nozzles and controls to obtain the specified results. Provide
machine having a speed during application capable of applying the stripe widths indicated at
the paint coverage rate specified herein and of even uniform thickness with clear-cut edges.
Provide equipment used for marking streets and highways capable of placing the prescribed
number of lines at a single pass as solid lines, intermittent lines, or a combination of solid
and intermittent lines using a maximum of three different colors of paint as specified. The
equipment for applying the paint for airfield pavements shall be a self-propelled or mobile-
drawn pneumatic spraying machine with an arrangement of atomizing nozzles capable of
applying a width of line at any one time in multiples of 50 mm, from 50 to 500 mm, except
120 mm line. . Provide paint applicator with paint reservoirs or tanks of sufficient capacity
and suitable gages to apply paint in accordance with requirements specified. Equip tanks
with suitable air-driven mechanical agitators. Equip spray mechanism with quick-action
valves conveniently located, and include necessary pressure regulators and gages in full
view and reach of the operator. Install paint strainers in paint supply lines to ensure freedom
from residue and foreign matter that may cause malfunction of the spray guns. The paint
applicator shall be readily adaptable for attachment of an air-actuated dispenser for the
reflective media approved for use. Provide pneumatic spray guns for hand application of
paint in areas where the mobile paint applicator cannot be used. Applicator for water-based
markings shall be equipped with non-stick coated hoses; metal parts in contact with the
paint material shall be constructed of grade 302, 304, 316, or equal stainless steel.
1.5.3 Thermoplastic Application Equipment
1.5.3.1 Thermoplastic Material
Thermoplastic material shall be applied to the primed pavement surface by spray techniques
or by the extrusion method, wherein one side of the shaping die is the pavement and the
other three sides are contained by, or are part of, suitable equipment for heating and
controlling the flow of material. By either method, the markings shall be applied with
equipment that is capable of providing continuous uniformity in the dimensions of the stripe.
1.5.3.2 Application Equipment
a. Application equipment shall provide continuous mixing and agitation of the material.
Conveying parts of the equipment between the main material reservoir and the
extrusion shoe or spray gun shall prevent accumulation and clogging. All parts of the
equipment which come into contact with the material shall be easily accessible and
exposable for cleaning and maintenance. All mixing and conveying parts up to and
including the extrusion shoes and spray guns shall maintain the material at the
required temperature with heat-transfer oil or electrical-element-controlled heat.
b. The application equipment shall be constructed to ensure continuous uniformity in the

dimensions of the stripe. The applicator shall provide a means for cleanly cutting off
stripe ends squarely and shall provide a method of applying "skiplines". The
equipment shall be capable of applying varying widths of traffic markings.

c. The applicator shall be equipped with a drop-on type bead dispenser capable of
uniformly dispensing reflective glass spheres at controlled rates of flow. The bead
dispenser shall be automatically operated and shall begin flow prior to the flow of
composition to assure that the strip is fully reflectorized.
1.5.3.3 Mobile and Maneuverable
Application equipment shall be mobile and maneuverable to the extent that straight lines can
be followed and normal curves can be made in a true arc. The equipment used for the
placement of thermoplastic pavement markings shall be of two general types: mobile
applicator and portable applicator.
1.5.3.4 Mobile Application Equipment

The mobile applicator shall be defined as a truck-mounted, self-contained pavement marking
machine that is capable of hot applying thermoplastic by either the extrusion or spray
method. The unit shall be equipped to apply the thermoplastic marking material at
temperatures exceeding 190 degrees C , at widths varying from 75 to 300 mm and in
thicknesses varying from 1.0 to 5.0 mm and shall have an automatic drop-on bead system.
The mobile unit shall be capable of operating continuously and of installing a minimum of 6
km of longitudinal markings in an 8-hour day.
The mobile unit shall be equipped with a melting kettle which holds a minimum of 2.7 metric
tons of molten thermoplastic material. The kettle shall be capable of heating the
thermoplastic composition to temperatures of 190 to 218 degrees C . A thermostatically
controlled heat transfer liquid shall be used. Heating of the composition by direct flame shall
not be allowed. Oil and material temperature gauges shall be visible at both ends of the
kettle. The mobile unit shall be equipped with a spray gun system. The spray system shall
consist of a minimum of four spray guns, located two on each side of the truck, and shall be
capable of marking simultaneous edgeline and centerline stripes. The spray system shall be
surrounded (jacketed) with heating oil to maintain the molten thermoplastic at a temperature
of 190 to 218 degrees C ; and shall be capable of spraying a stripe of 75 to 300 mm in
width, and in thicknesses varying from 1.5 mm to 2.5 mm , and of generally uniform cross
section.
The mobile unit shall be equipped with an electronic programmable line pattern control
system. The control system shall be capable of applying skip or solid lines in any sequence,
through any and all of the extrusion shoes, or the spray guns, and in programmable cycle
lengths. In addition, the mobile unit shall be equipped with an automatic counting
mechanism capable of recording the number of lineal meters of thermoplastic markings
applied to the pavement surface with an accuracy of 0.5 percent.
1.5.3.5 Portable Application Equipment
The portable applicator shall be defined as hand-operated equipment, specifically designed

for placing special markings such as crosswalks, stopbars, legends, arrows, and short
lengths of lane, edge and centerlines. The portable applicator shall be capable of applying
thermoplastic pavement markings by the extrusion method. The portable applicator shall be
loaded with hot thermoplastic composition from the melting kettles on the mobile applicator.
The portable applicator shall be equipped with all the necessary components, including a

materials storage reservoir, bead dispenser, extrusion shoe, and heating accessories, so as
to be capable of holding the molten thermoplastic at a temperature of 190 to 218 degrees C,
of extruding a line of 75 to 300 mm in width, and in thickness of not less than 3 mm nor
more than 5 mm and of generally uniform cross section.
1.5.4 Reflective Media Dispenser
The dispenser for applying the reflective media shall be attached to the paint dispenser and
shall operate automatically and simultaneously with the applicator through the same control
mechanism. The dispenser shall be capable of adjustment and designed to provide uniform
flow of reflective media over the full length and width of the stripe at the rate of coverage
specified in paragraph APPLICATION, at all operating speeds of the applicator to which it is
attached.
1.5.5 Preformed Tape Application Equipment
Mechanical application equipment shall be used for the placement of preformed marking
tape. Mechanical application equipment shall be defined as a mobile pavement marking
machine specifically designed for use in applying precoated, pressure-sensitive pavement
marking tape of varying widths, up to 300 mm . The applicator shall be equipped with
rollers, or other suitable compactive device, to provide initial adhesion of the preformed,
pressure-sensitive marking tape with the pavement surface. Additional hand-operated rollers
shall be used as required to properly seat the thermoplastic tape.
1.5.6 Surface Preparation Equipment
1.5.6.1 Sandblasting Equipment
Sandblasting equipment shall include an air compressor, hoses, and nozzles of proper size
and capacity as required for cleaning surfaces to be painted. The compressor shall be
capable of furnishing not less than 70.8 L/sec of air at a pressure of not less than 620 kPa at
each nozzle used, and shall be equipped with traps that will maintain the compressed air
free of oil and water.
1.5.6.2 Waterblast Equipment
The water pressure shall be specified at 17.9 MPa at 60 degrees C in order to adequately
clean the surfaces to be marked.
1.5.7 Marking Removal Equipment
Equipment shall be mounted on rubber tires and shall be capable of removing markings from
the pavement without damaging the pavement surface or joint sealant. Waterblasting
equipment shall be capable of producing an adjustable, pressurized stream of water.
Sandblasting equipment shall include an air compressor, hoses, and nozzles. The compressor
shall be equipped with traps to maintain the air free of oil and water.

1.5.7.1 Shotblasting Equipment
Shotblasting equipment shall be capable of producing an adjustable depth of removal of

marking and pavement. Each unit shall be self-cleaning and self-contained, shall be able to
confine dust and debris from the operation, and shall be capable of recycling the abrasive
for reuse.
1.5.7.2 Chemical Equipment
Chemical equipment shall be capable of application and removal of chemicals from the
pavement surface, and shall leave only non-toxic biodegradeable residue.
1.5.8 Traffic Controls
Suitable warning signs shall be placed near the beginning of the worksite and well ahead of
the worksite for alerting approaching traffic from both directions. Small markers shall be
placed along newly painted lines or freshly placed raised markers to control traffic and
prevent damage to newly painted surfaces or displacement of raised pavement markers.
Painting equipment shall be marked with large warning signs indicating slow-moving painting
equipment in operation.
1.6 MAINTENANCE OF TRAFFIC
1.6.1 Airfield
The performance of work in the controlled zones of airfields shall be coordinated with the
Contracting Officer and with the Flight Operations Officer. Verbal communications shall be
maintained with the control tower before and during work in the controlled zones of the
airfield. The control tower shall be advised when the work is completed. A radio for this
purpose shall be provided by the Contractor and approved by the Contracting Officer.
1.6.2 Lighting
When night operations are necessary, all necessary lighting and equipment shall be
provided. Lighting shall be directed or shaded to prevent interference with aircraft, the air
traffic control tower, and other base operations. All lighting and related equipment shall be
capable of being removed from the runway within 15 minutes of notification of an
emergency. Night work must be coordinated with the Airfield Manager and approved in
advance by the Contracting Officer or authorized representative. The Employer reserves the
right to accept or reject night work on the day following night activities by the Contractor.
1.6.3 Roads, Streets, and Parking Areas
When traffic must be rerouted or controlled to accomplish the work, the necessary warning
signs, flagpersons, and related equipment for the safe passage of vehicles shall be provided.
1.7 WEATHER LIMITATIONS FOR REMOVAL
Pavement surface shall be free of snow, ice, or slush. Surface temperature shall be at least 5
degrees C and rising at the beginning of operations, except those involving shot or sand

blasting. Operation shall cease during thunderstorms. Operation shall cease during rainfall,
except for waterblasting and removal of previously applied chemicals. Waterblasting shall
cease where surface water accumulation alters the effectiveness of material removal.
1.8 QUALIFICATIONS
The Contractor shall submit documentation certifying that pertinent personnel are qualified
for equipment operation and handling of chemicals.
1.9 WARRANTY
be signed.
PART 2 PRODUCTS
2.1 MATERIALS
Provide materials conforming to the requirements specified herein.

2.1.1 Paints for Airfields
FS A-A-2886 FS TT-P-1952, color as indicated.
2.1.2 Paints for Roads and Streets
FS A-A-2886 FS TT-P-1952 High Build Acrylic Coating (HBAC) indicated.
2.1.3 Reflective Media for Airfields
FS TT-B-1325, Type I, Gradation A.
2.1.4 Reflective Media for Roads and Streets
FS TT-B-1325, Type I, Gradation A.

2.1.5 Thermoplastic Compound
The thermoplastic reflectorized pavement marking compound shall be extruded or sprayed

in a molten state onto a primed pavement surface. Following a surface application of glass
beads and upon cooling to normal pavement temperatures, the marking shall be an
adherent reflectorized strip of the specified thickness and width that is capable of resisting
deformation by traffic.
2.1.5.1 Composition Requirements
The binder component shall be formulated as a hydrocarbon resin. The pigment, beads and
filler shall be uniformly dispersed in the binder resin. The thermoplastic composition shall be
free from all skins, dirt, and foreign objects and shall comply with the following
requirements:
Percent by Weight
Component White Yellow
Binder 17 min 17 min
Titanium dioxide 10 min -
Glass beads 20 min 20 min
Calcium carbonate and inert fillers 49 min *
Yellow pigments - *
*Amount and type of yellow pigment, calcium carbonate and inert fillers shall be at the option of the
manufacturer, providing the other composition requirements of this specification are met.
2.1.5.2. Physical Properties
a. Drying time: When installed at 21 degrees C and in thicknesses between 3 and 5 mm,
the composition shall be completely solid and shall show no damaging effect from
traffic after curing 15 minutes.
b. Softening point: The composition shall have a softening point of not less than 90
degrees C when tested in accordance with ASTM E 28.
c. Specific gravity: The specific gravity of the composition shall be between 1.9 and 2.2
as determined in accordance with ASTM D 792.
2.1.5.3. Primer
a. Asphalt concrete primer: The primer for asphalt concrete pavements shall be a
thermosetting adhesive with a solids content of pigment reinforced synthetic rubber
and synthetic plastic resin dissolved or dispersed in a volatile organic solvent. The
solids content shall not be less than 10 percent by weight at 21 degrees C and 60
percent relative humidity. A wet film thickness of 0.13 mm, plus or minus 0.03 mm,
shall dry to a tack-free condition in less than 5 minutes.

b. Portland cement concrete primer: The primer for portland cement concrete pavements
shall be an epoxy resin primer. The primer shall be of the type recommended by the
manufacturer of the thermoplastic composition.
2.1.6 PREFORMED TAPE
The preformed tape shall be an adherent reflectorized strip in accordance with ASTM D 4505
Type I or IV, Class optional.
2.1.7 Raised Pavement Markers
Either metallic or nonmetallic markers of the button or prismatic reflector type may be used.
Markers shall be of permanent colors as specified for pavement marking, and shall retain the
color and brightness under the action of traffic. Button markers shall have a diameter of not
less than 100 mm, and shall be spaced not more than 12 meters apart on solid longitudinal
lines. Broken centerline marker spacings shall be in segments indicated with gaps [indicated
between segments. Button markers shall have rounded surfaces presenting a smooth
contour to traffic and shall not project more than 3/4 inch above level of pavement.
Pavement markers and adhesive epoxy shall conform to ASTM D 4280
2.1.8 High Build Acrylic Coating (HBAC)
Formulate High Build Acrylic Coating (HBAC) to meet the requirements of Table I.
2.1.8.1 Preapproved HBAC Vendors and Materials
Table II presents a partial list of HBAC vendors and materials. Up to specifications's date of
issue, preapproved materials met specification requirements. It is the user's responsibility to
confirm preapproved material formulations have not changed and specification requirements
will be met. Other products may meet HBAC requirements.
PART 3 EXECUTION
3.1 SURFACE PREPARATION
Allow new pavement surfaces to cure for a period of not less than 20 days before application
of marking materials. Thoroughly clean surfaces to be marked before application of the
paint. Remove dust, dirt, and other granular surface deposits by sweeping, blowing with
compressed air, rinsing with water, or a combination of these methods as required. Remove
residual curing compounds, and other coatings adhering to the pavement by water blasting.
For Portland Cement Concrete pavement, grinding, light shot blasting, and light scarification,
to a resulting profile equal to ICRI 03732 CSP 2, CSP 3, and CSP 4, respectively, can be used
in addition to water blasting, to either remove existing coatings or for surface preparation on
most pavements: shot blasting shall not be used on airfield pavements due to the potential
of Foreign Object Damage (FOD) to aircraft. Scrub affected areas, where oil or grease is
present on old pavements to be marked, with several applications of trisodium phosphate
solution or other approved detergent or degreaser and rinse thoroughly after each
application. After cleaning oil-soaked areas, seal with shellac or primer recommended by the

manufacturer to prevent bleeding through the new paint. Do not commence painting in any
area until pavement surfaces are dry and clean.
3.1.2 Early Painting of Asphalt Pavements
For asphalt pavement systems requiring painting application at less than 30 days, apply the
paint and beads at half the normal application rate, followed by a second application at the
normal rate after 30 days.
3.2 APPLICATION
3.2.1 Testing for Moisture
Apply pavement markings to dry pavement only. The Contractor shall test the pavement
surface for moisture before beginning work after each period of rainfall, fog, high humidity,
or cleaning, or when the ambient temperature has fallen below the dew point. Do not
commence marking until the pavement is sufficiently dry and the pavement condition has
been approved by the CO or authorized representative. Employ the "plastic wrap method" to
test the pavement for moisture as follows: Cover the pavement with a 300 mm by 300 mm
(12 inch by 12 inch) section of clear plastic wrap and seal the edges with tape. After 15
minutes, examine the plastic wrap for any visible moisture accumulation inside the plastic.
Do not begin marking operations until the test can be performed with no visible moisture
accumulation inside the plastic wrap.
3.2.2 Rate of Application
3.2.2.1 Reflective Markings
Apply paint evenly to the pavement area to be coated at a rate of 2.5 plus or minus 0.10
square meter per liter. Apply High Build Acrylic Coating (HBAC) at a rate of 1.3 square
meters per liter . Apply glass spheres uniformly to the wet paint on road and street pavement
at a rate of (719) plus or minus (60) g of glass spheres per liter. Collect and record readings
for white and yellow retroreflective markings at the rate of one reading per 300 linear
meters. The minimum acceptable average for white markings is 200 millicandelas per square
meter per lux (mcd/m2/lx) (measured with Mirolux 12 Retroreflectometer or similar
instrument as agreed). The minimum acceptable average for yellow markings is 175
millicandelas per square meter per lux (mcd/m2/lx). Readings shall be computed by
averaging a minimum of 10 readings taken within the area at random locations. Areas not
meeting the retroreflective requirements stated above shall be re-marked.
3.2.2.2 Nonreflective Markings
Apply paint evenly to the pavement surface to be coated at a rate of 2.5 plus or minus 0.10
square meter per liter.
3.2.2.3 Thermoplastic Compound
After surface preparation has been completed, prime the asphalt or concrete pavement
surface with spray equipment. Allow primer materials to "set-up" prior to applying the

thermoplastic composition. Allow the asphalt concrete primer to dry to a tack-free condition,
usually occurring in less than 10 minutes. Apply asphalt concrete primer to all asphalt
concrete pavements at a wet film thickness of 0.13 mm, plus or minus 0.03 mm 6.5 to 10.0
square meters per liter. After the primer has "set-up", apply the thermoplastic at
temperatures no lower than 191 degrees C nor higher than 218 degrees C at the point of
deposition. Immediately after installation of the marking, apply drop-on reflective glass
spheres mechanically at the rate of 0.24 kg per square meter such that the spheres are held
by and imbedded in the surface of the molten material. Apply all extruded thermoplastic
markings at the specified width and at a thickness of not less than 3 mm nor more than 5
mm. Apply all sprayed thermoplastic markings at the specified width and the thickness
designated in the contract plans. If the plans do not specify a thickness, apply centerline
markings at a wet thickness of 2.3 mm, plus or minus 0.13 mm, and edgeline markings at a
wet thickness of 1.5 mm, plus or minus 0.13 mm.
3.2.3 Painting
Apply paint pneumatically with approved equipment at rate of coverage specified herein.
Provide guidelines and templates as necessary to control paint application. Take special
precautions in marking numbers, letters, and symbols. Manually paint numbers, letters, and
symbols. Sharply outline all edges of markings. The maximum drying time requirements of
the paint specifications will be strictly enforced, to prevent undue softening of bitumen, and
pickup, displacement, or discoloration by tires of traffic. Discontinue painting operations if
there is a deficiency in drying of the markings until cause of the slow drying is determined
and corrected.
3.2.4 Reflective Media
Application of reflective media shall immediately follow the application of paint. Accomplish
drop-on application of the glass spheres to ensure even distribution at the specified rate of
coverage. Should there be malfunction of either paint applicator or reflective media
dispenser, discontinue operations until deficiency is corrected.
3.2.5 Thermoplastic Compound
Place thermoplastic pavement markings upon dry pavement. At the time of installation the
pavement surface temperature shall be a minimum of 5 degrees C and rising.
Thermoplastics, as placed, shall be free from dirt or tint. Apply all centerline, skipline,
edgeline, and other longitudinal type markings with a mobile applicator. Place all special
markings, crosswalks, stop bars, legends, arrows, and similar patterns with a portable
applicator, using the extrusion method.
3.2.6 Raised Pavement Markers
Prefabricated markers shall be aligned carefully at the required spacing or as directed and
permanently fixed in place by means of epoxy adhesives. To ensure good bond, areas where
markers will be set shall be thoroughly cleaned by water blasting and use of compressed air
prior to applying adhesive.

3.3 FIELD TESTING, INSPECTION, AND DEMONSTRATIONS
3.3.1 Sampling and Testing
As soon as the paint and reflective materials are available for sampling, obtain by random
selection from the sealed containers, two quart samples of each batch in the presence of the
Contracting Officer. Accomplish adequate mixing prior to sampling to ensure a uniform,
representative sample. A batch is defined as that quantity of material processed by the
manufacturer at one time and identified by number on the label. Clearly identify samples by
designated name, specification number, batch number, project contract number, intended
use, and quantity involved. Test samples by an approved laboratory. If a sample fails to
meet specification, replace the material in the area represented by the samples and retest
the replacement material as specified above. Submit copy of the test results to the
Contracting Officer. Include in the report of test results a listing of any specification
requirements not verified by the test laboratory.
3.3.2 Inspection
Examine material at the job site to determine that it is the material referenced in the report
of test results or certificate of compliance. A certificate of compliance shall be accompanied
by test results substantiating conformance to the specified requirements.
3.3.3 Surface Preparations and Application Procedures
Surface preparations and application procedures will be examined by the Contracting Officer
to determine conformance with the requirements specified. Approve each separate operation
prior to initiation of subsequent operations.
3.3.3.1 Surface Preparation Demonstration
Prior to surface preparation, demonstrate surface preparation using the proposed

materials,methods and equipment. Prepare areas large enough to determine adhesion of
remaining coating and rate of cleaning.
3.3.3.2 Test Stripe Demonstration
Prior to paint application, demonstrate test stripe application within the work area using the
proposed materials and equipment. Apply separate test stripes in each of the line widths and
configurations required herein using the proposed equipment. The test stripes shall be long
enough to determine the proper speed and operating pressures for the vehicle(s) and
machinery, but not less than 15 meters long.
3.3.3.3 Application Rate Demonstration
During the Test Stripe Demonstration, demonstrate compliance with the application rates
specified herein. Document the equipment speed and operating pressures required to meet
the specified rates in each configuration of the equipment and provide a copy of the
documentation to the Contracting Officer or authorized representative prior to proceeding
with the work.

3.3.3.4 Retroreflective Value Demonstration
After the test stripes have cured to a "no-track" condition, demonstrate compliance with the
average retroreflective values specified herein. Take a minimum of ten readings on each test
stripe with a Mirolux 12 Retroreflectometer, or similar instrument with the same measuring
geometry and direct readout in millicandelas per square meter per lux (mcd/m2/lx).
3.3.3.5 Level of Performance Demonstration
The Contracting Officer or authorized representative will be present the application

demonstrations to observe the results obtained and to validate the operating parameters of
the vehicle(s) and equipment. If accepted by the Contracting Officer or authorized
representative, the test stripe shall be the measure of performance required for this project.
Work shall not proceed until the demonstration results are satisfactory to the Contracting
Officer or authorized representative.
3.4 TRAFFIC CONTROL AND PROTECTION
Place warning signs near the beginning of the work site and well ahead of the work site for
alerting approaching traffic from both directions. Place small markers along newly painted
lines to control traffic and prevent damage to newly painted surfaces. Mark painting
equipment with large warning signs indicating slow-moving painting equipment in operation.
Do not use foil-backed material for temporary pavement marking because of its potential to
conduct electricity during accidents involving downed power lines.
Demonstrate success of bond of reflective media, new paint marking and the pavement
surface, vacuum cured surface of new marking after a seven (7) day dry time. Inspect newly
applied markings for signs of bond failure based on visual inspection and comparison to
results from Test Stripe Demonstration paragraph.
3.5.1 Reflective Media and Coating Bond Verification
Within seven (7) days after pavement marking application, use industrial vacuum to sweep
new markings. Visually inspect the pavement markings and the material captured by the
vacuum. Verify that no significant loss of reflective media has occured to the pavement
marking due to the vacuum cleaning.
3.5.2 Reflective Media and Coating Application Verification
Use a wet film thickness guage to masure the application of wet paint.
Use a microscope or magnifying glass to evaluate the embedment of glass beads in the paint.
Verify the glass bead embedment with approximately 50% of the beads embedded and 50%
of the beads exposed.

TABLE I
REQUIREMENTS FOR HIGH BUILD ACRYLIC COATINGS (HBAC)
Test Minimum Requirement
(and Maximum where indicated)
Resin System (ASTM D 2621) Waterborne 100% Acrylic
Percent Volume Solids (ASTM D 2697) 58%
Volatile Organic Compound, max. (ASTM D 3960) 150 g/l
White (FED-STD-595) 37925
Yellow (FED-STD-595) 33538
Shore D Hardness (ASTM D 2240) 45
1/8 inch Mandrel Bend @ 5 mils No visual defects at bend
Dry Film Thickness (DFT, one-week (Conditions @ ASTM D 3924)
Cure) (ASTM D 522, Method B)
Adhesion to Concrete and Asphaltic 0.97 MPa or 100%
Pavements (ASTM D 4541) cohesive failure in pavement
Accelerated Weathering, Yellow, Max. Color loss to 33655
2500 Hours UV Exposure (ASTM G 53: see note 1) (FED-STD-595)
Water Absorption@168 Hours 9.0% max. weight increase
Immersion Tap Water (ASTM D 471) (conditions@ASTM D 3924)
Application@1650 microns No visual cracking or curling
Wet, One Coat, One-week Cure (see note 2) (conditions@ASTM D 3924)
No Pick-Up@630 microns (ASTM D 711) Wet 10 minutes max.
Lead (ASTM D 3335) 0.06% max.
Cadmium (ASTM D 3335) 0.06% max.
Chromium (ASTM D 3718) 0.00%
Notes:
(1) Properly mix and apply yellow paint at 250 microns +/- 50 microns DFT over a suitably
sized, clean al cure for aluminum substrate (ASTM D 823), and cure for a minimum of 48
hours: four individual yellow sample shall be prepared. Expose three samples to continuous
Ultraviolet (UV) light for 2500 hours, without cycles condensation, in accordance to ASTM G
53: UVA-340 lamps shall be used in the testing apparatus. Following exposure, compare the
three exposed samples to FED-STD-595 colors 33538 and 33655 as visual references:
evaluate exposed samples for degree of visual color loss. Yellow paint shall receive a passing
rating if each exposed sample appears equivalent to the non-exposed sample, and in
addition, display color loss no greater than FED-STD-595 color 33655.
(2) Using double-stick, foam mounting tape (or equal) with a nominal thickness of 1625
microns , apply a rectangular mold with inner dimensions of 7.6 cm by 25.5 cm to a clean
aluminum sample approximately sized at 15 cm by 30 cm by 0.30 cm . Do not remove the

tape's plastic backing. Mix and apply excess paint into mold. Remove excess paint, by
squeegee or other appropriate draw down technique, to a uniform thickness equal to the
tape's height. Paint application and draw down shall be performed within a period of no more
than 60 seconds. Approximately one to two minutes following the draw down, remove tape
from sample and allow coating to cure for a minimum period of one week ASTM D 3924.
Using a micrometer or other appropriate device, measure cured coating thickness (less
sample thickness) to confirm resulting coating application was at or above 950 microns DFT.
Inspect coating for visual signs of cracking and curling. Following a one week cure, coating
shall receive a passing rating if applied greater than 950 microns DFT and visually free of
both cracking and curling.

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DIVISION 32 00 00 EXTERIOR IMPROVEMENTS

SECTION 32 01 16 FLEXIBLE PAVING REHABILITATION

SUB-SECTION 32 01 16.71 COLD MILLING ASPHALT PAVING

ASTM INTERNATIONAL (ASTM)

ASTM C 136 (2006) Standard Test Method for Sieve Analysis

1.2 SYSTEM DESCRIPTION

1.2.1 Cold-Milling Machine

Provide a cold-milling machine which is self-propelled, capable of milling the pavement to a

1.2.2 Cleaning Equipment

Final Terminal Building Design- Airfield SSH-TBL-FAD-SPE_02 -Page 1

1.3.2 Surface Smoothness

1.3.3 Traffic Control

Provide all necessary traffic controls during milling operations.

1.4 ENVIRONMENTAL REQUIREMENTS

Two plus one years, as follows:

Final Terminal Building Design- Airfield SSH-TBL-FAD-SPE_02 -Page 2

3.1 PREPARATION OF SURFACE

3.2 MILLING OPERATION

3.3 GRADE AND SURFACE-SMOOTHNESS TESTING

3.3.1 Grade-Conformance Tests

3.3.2 Surface-Smoothness Tests

3.4 REMOVAL OF MILLED MATERIAL

Material that is removed shall be placed in the disposal area as specified.

END OF SUB-SECTION 32 01 16.71

Final Terminal Building Design- Airfield SSH-TBL-FAD-SPE_02 -Page 3

ASTM INTERNATIONAL (ASTM)

ASTM C 509 (2006) Elastomeric Cellular Preformed Gasket

ASTM D 6690 (2007) Standard Specification for Joint and Crack

ASTM D 789 (2007) Determination of Relative Viscosity and

1.2 SYSTEM DESCRIPTION

1.2.1 Routing Equipment

1.2.2. Concrete Saw

1.2.3. Sandblasting Equipment

Development of Sharm El Sheikh International Airport 32 01 17 FLEXIBLE PAVING REPAIR

Final Terminal Building Design- Airfield SSH-TBL-FAD-SPE_02 -Page 1

1.2.4. Waterblasting Equipment

1.2.5. Hand Tools

1.2.6 Crack Sealing Equipment

Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-03 Product Data

until it has been approved.

Development of Sharm El Sheikh International Airport 32 01 17 FLEXIBLE PAVING REPAIR

Final Terminal Building Design- Airfield SSH-TBL-FAD-SPE_02 -Page 2

Reports of all tests. Perform testing of the materials in an approved, independent

1.4 QUALITY ASSURANCE

1.5 DELIVERY, STORAGE, AND HANDLING

1.6 ENVIRONMENTAL REQUIREMENTS

Two plus one years, as follows:

Development of Sharm El Sheikh International Airport 32 01 17 FLEXIBLE PAVING REPAIR

Final Terminal Building Design- Airfield SSH-TBL-FAD-SPE_02 -Page 3

Provide sealants conforming to ASTM D 6690, Type II or ASTM D 6690, Type I.

2.2 BACKUP MATERIALS

Provide backup material that is a compressible, nonshrinking, nonstaining, nonabsorptive

3.1 PREPARATION OF CRACKS

Cracks that are less than 6 mm wide do not need to be sealed.

Cracks that are 6 to 20 mm wide shall be routed to a nominal width 3 mm greater

3.1.1.3 Medium Cracks

3.1.1.4 Large Cracks

Development of Sharm El Sheikh International Airport 32 01 17 FLEXIBLE PAVING REPAIR

Final Terminal Building Design- Airfield SSH-TBL-FAD-SPE_02 -Page 4

3.1.6 Backup Material

3.1.7 Rate of Progress of Crack Preparation