SECTION 02510

ASPHALT CONCRETE PAVING

PART 1 - GENERAL

1.1 SECTION INCLUDES

A. Providing asphalt concrete paving including placement and compaction as

shown on Drawings and as specified herein.

1.2 REFERENCES

A. MOT Ministry of Transportation, Kingdom of Saudi Arabia

General Specification of Road and Bridge Construction

B. SASO – Saudi Arabian Standards Organization

SASO 916 Sampling bituminous materials.

SASO 917 Penetration of asphaltic (Bituminous) materials.

SASO 918 Ductility of bituminous materials.

SASO 919 Solubility of bituminous materials in

trichloroethylene

SASO 920 Effect of heat and air on asphaltic materials

C. AASHTO - American Association of State Highway and Transportation

Officials

AASHTO M 145 Classification of Soils and Soil-Aggregate Mixtures

For Highway Construction Purposes

AASHTO M 147 Materials for Aggregate and Soil-Aggregate

Subbase, Base and Surface Courses

AASHTO T 11 Material Finer than 0.075 mm (No. 200) Sieve in

Aggregate

AASHTO T 27 Sieve Analysis of Fine and Coarse Aggregates

AASHTO T 44 Solubility Test for Bituminous Materials

AASHTO T 49 Penetration of Bituminous Materials

AASHTO T 51 Ductility of Bituminous Materials

AASHTO T 84 Specific Gravity and Absorption of Fine Aggregates

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 AASHTO T 85 Specific Gravity and Absorption of Coarse
Aggregates

AASHTO T 96 Resistance to Abrasion of Coarse Aggregate by Use

of the Los Angeles Machine

AASHTO T 104 Soundness of Aggregates by Use of Sodium Sulfate

of magnesium Sulfate

AASHTO T 112 Friable Particles in Aggregates

AASHTO T 176 Sand Equivalent Test

AASHTO T 180 Proctor Compaction Tests

AASHTO T 182 Coating and Stripping Test

AASHTO T 191 Field Density Determination

AASHTO T 193 California Bearing Ratio test

D. ASTM - American Society for Testing and Materials

ASTM C 88 Test Method for Soundness of Aggregates by Use of

Sodium Sulfate of Magnesium Sulfate

ASTM C 117 Test Method for Material Finer than 0.075 mm (No.
200) Sieve in Mineral Aggregates by Washing

ASTM C 127 Test Method for Specific Gravity and Absorption of

Coarse Aggregates by Washing

ASTM C 131 Test Method for Resistance to Degradation of

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

ASTM C 136 Method for Sieve Analysis of Fine and Coarse

Aggregates

ASTM C 535 Test Method for Resistance to Degradation of Large-

Size Coarse Aggregate by Abrasion and Impact in
the Los Angeles Machine

ASTM D 75 Practice for Aggregate Sampling

ASTM D 140 Practice for Bituminous Material Sampling

ASTM D 242 Specification for Mineral Filler for Bituminous Paving

Mixtures

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ASTM D 448 Classification for Sizes of Aggregate for Road and
Bridge Construction

ASTM D 946 Specification for Penetration-Graded Asphalt Cement

for Use in Pavement Construction

ASTM D 977 Specifications for Emulsified Asphalt

ASTM D 995 Requirements for Mixing Plants for Hot-Mixed,

Hot-Laid Bituminous Paving Mixtures

ASTM D 1188 Test Method for Bulk Specific Gravity and Density of
Compacted Bituminous Mixtures Using
Paraffin-Coated Specimens

ASTM D 1556 Test Method for Density of Soil in Place by the

Sand-Cone Method

ASTM D 1557 Test Method for Moisture-Density Relations of Soils,

and Soil-Aggregate Mixtures Using 10-lb (4.5-kg)
Rammer and 18-inch (457-mm) Drop

ASTM D 1559 Test Method for Resistance to Plastic Flow of

Bituminous Mixtures Using Marshall Apparatus

ASTM D 1664 Test Method for Coating and Stripping of

Bitumen-Aggregate Mixtures

ASTM D 1883 Test Method for CBR (California Bearing Ratio) of

Laboratory-Compacted Soils

ASTM D 2027 Specifications for Cutback Asphalt (Medium-Curing

Type)

ASTM D 2028 Specifications for Cutback Asphalt (Rapid-Curing

Type)

ASTM D 2041 Test Method for Theoretical Maximum Specific

Gravity and Density of Bituminous Paving Mixtures

ASTM D 2172 Test Methods for Quantitative Extraction of Bitumen

from Bituminous Paving Mixtures

ASTM D 2419 Test Method for Sand Equivalent Value of Soil and
Fine Aggregate

ASTM D 2726 Test Method for Bulk Specific Gravity of Compacted

Bituminous Mixtures Using Saturated Surface-Dry
Specimens

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 ASTM D 3515 Specifications for Hot-Mixed, Hot-Laid Bituminous
Paving Mixtures

ASTM D 3549 Test Method for Thickness or Height of Bituminous

Paving Mixture Specimens

E. CRD - U.S. Army, Corps of Engineers

CRD-C 119 Method of Testing for Flat and Elongated Particles in

Coarse Aggregates

F. AI - Asphalt Institute

AI-MS 2 Mix Design Methods for Asphalt Concrete and Other

Hot-Mix Types

1.3 SUBMITTALS

A. Samples: Materials and Bituminous Mixture.

B. Certificate of Compliance for Materials.

C. Test Reports.

D. In addition to the above, submit the following:

1. Job-Mix Formula.

2. Schedule

3. List of Plant and Equipment.

4. Detail and procedures of furnishing and delivering asphalt cement

from off-site plant.

1.4 QUALITY ASSURANCE

A. Tests specified herein and additional tests as may be necessary to

determine the quality of the work will be performed by the Contractor using
an independent testing laboratory nominated by the Contractor and
approved by the Engineer. Contractor shall restore areas where samples
have been taken so that such areas will conform to these specifications.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Sub-Grade:

1. Conform to the requirements specified in Section 02200 -

EARTHWORK.

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B. Granular Sub-Base (200 mm thick unless otherwise indicated on Drawings):

1. Conform to the requirements specified in Section 02200 -

EARTHWORK.

C. Aggregates for Bituminous Base Course and Wearing Course:

1. Aggregates shall consist of coarse aggregates and fine aggregates,

and filler material, if required, all conforming to MOC Specifications
and the requirements specified herein. Aggregates shall consist of
crushed rock or crushed gravel, clean, hard, tough, durable, uniform
quality, and free from organic material.

2. Aggregates shall be obtained from an approved quarry and shall

consist of a mixture of all aggregate uniformly graded from coarse to
fine.

3. Combined aggregates shall conform to the following gradation

requirements when tested in accordance with AASHTO T 27 or
ASTM C 117 and ASTM C 136:

Percent Passing by Weight

Sieve Size Base Course Wearing Course

3/4" (19.05 mm) 100 None
1/2" (13 mm) 80 - 90 100
3/8" (9.5 mm) None 80 - 100
No.4 (4.75 mm) 48 - 62 55 - 75
No.10 (2 mm) 32 - 45 32 - 47
No.40 (0.425 mm) 16 - 26 16 - 26
No.80 (0.25 mm) 8 - 18 10 - 18
No.200 (0.075 mm) 4-8 4 - 10

Grading limits specified here are based on materials of uniform

specific gravity and shall be adjusted by the Engineer to compensate
for any variation in specific gravity of the individual sizes. The
grading may be varied by the Engineer of Marshall Tests to obtain
optimum stability and life of completed wearing course mix.

a. Processed aggregates shall consist of 100 percent crushed

stone of hard durable particles having two or more broken
faces, free from dirt and other objectionable matter, and
meeting the following physical requirements when tested in
accordance with ASTM C 117 and ASTM C 136:

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 b. Plasticity Index: 3 Percent maximum as per AASHTO T 90 or
ASTM D 424

c. Sand Equivalent: 45 percent minimum as per AASHTO T

176

d. Loss of Sodium Sulfate (Soundness Test): 10 percent

maximum as per AASHTO T 104 or ASTM C 88

e. Loss of Magnesium Sulfate (Soundness Test): 12 percent

maximum as per AASHTO T 104 or ASTM C 88

f. Loss by Abrasion Test: 40 percent maximum as per

AASHTO T 96 or ASTM C 131 or ASTM C 535

g. Flat and Elongated Particles: 5 percent maximum as per

CRD-C119

h. Friable Particles: 0.25 percent maximum as per AASHTO T

112

D. Asphalt Cement: Petroleum asphalt cement, Grade 60 - 70 penetration,

conforming to AASHTO M 20 or ASTM D 946.

E. Liquid Asphalt:

1. Prime Coat: Medium-curing cutback asphalt conforming to

AASHTO M 82, Grade MC-1 or ASTM D 2027, Grade MC-70.

2. Tack Coat: Rapid curing cutback asphalt conforming to AASHTO T

49, Grade RC-2 as well as ASTM D 2028, Grade RC-70.

F. Mineral Filler: Rock or slag dust, hydraulic cement, or other inert material
complying with AASHTO M 17 or ASTM D 242.
2.2 BITUMINOUS PLANT MIX

A. Job Mix:

1. A satisfactory job-mix formula shall be established for each mixture

used. Formula shall establish a single percentage of aggregate
passing each sieve size, a single percentage of bituminous material
to be added, and a single temperature at which the mixture is to be
delivered at the point of discharge. Procedures shall conform to
ASTM D 1559.

2. Combined mineral aggregates and asphalt shall conform to the

following composition limits by weight.

a. Total Mineral Aggregates (percent) : 92 - 96

b. Asphaltic Binder (percent) :4-8

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 3. When tested according to ASTM D 1559 (75 blows each face) the
bituminous mixture shall conform to the following requirements.
Bituminous mixture properties shall be determined in accordance
with procedures contained in AI MS-2.

a. Stability (Marshall):

1) Base Course: 500 kg minimum

2) Wearing Course: 700 Kg minimum

b. Flow (millimeters):

1) Base Course: 2-5

2) Wearing Course: 2-4

c. Voids in total mix (percent):

1) Base Course: 3-7

2) Wearing Course: 3-5

d. Voids filled with Asphalt (percent):

1) Base Course: 60 - 75
2) Wearing Course: 70 - 80

e. Voids in mineral aggregate (percent):

1) Minimum 14 percent

f. Loss of Marshall stability by submerging specimens in water

at 60°C for 24 hours as compared to stability measured after
submersion in water at 60°C for 20 minutes in accordance
with MIL-STD-620A, Method 104:

1) Maximum of 25 percent

g. Aggregates shall not show evidence of stripping when tested

in accordance with ASTM D 1664. Coated area shall be
greater than 95 percent. Hydrated lime, Portland Cement or
an approved anti-stripping agent shall be used to reduce
asphalt stripping and loss of stability. Determine the most
effective additive which shall be approved by the Engineer
prior to use.

h. Dune sand added to the mixture shall not exceed 10 percent

of the total weight of the blended aggregate.

4. When tested in accordance with ASTM D 1560 the bituminous

mixture shall have a Stability of 37 or more.

B. Variations From Job Mix Based on the Results of Single Test: Variation from
the approved job mix shall not exceed the following:

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 1. Aggregates Passing 4.75 mm (No. 4) and Larger: Plus or minus 7
percent

2. Aggregates Passing 2 mm (No. 10), & 0.425 mm (No. 40): Plus

or minus 4 percent

3. Aggregates Passing 0.25 mm (No. 80) and 0.075 mm (No. 200):

Plus or minus 2 percent

4. Asphalt Content: Plus or minus 0.4 percent

5. Temperature Range: Plus or minus 11°C

C. Select asphalt content so that the air voids will not fall below three percent
after allowance is made for job tolerance of plus or minus 0.4 percent.

PART 3 - EXECUTION

3.1 SUB-GRADE PREPARATION

A. Conform to Section 02200 - EARTHWORK.

3.2 GRANULAR SUB-BASE

A. Conform to Section 02200 - EARTHWORK.

3.3 BATCHING AND MIXING OF BITUMINOUS CONCRETE

A. Batching and Mixing: Mixing plants shall conform to ASTM D 995. Truck
scales shall be provided by Contractor.

1. Preparation of Asphalt Cement: Heat asphalt cement within a

temperature range of 135°C to 163°C at the time of mixing. All
material heated above 204°C shall be rejected.

2. Preparation of Mineral Aggregate:

a. Heat and dry aggregates to a temperature after screening of

not more than 163°C. If the aggregates contain sufficient
moisture to cause foaming in the mixture, or if their
temperature is in excess of 163°C, they shall be rejected and
removed from the bins.

b. Immediately after heating, screen aggregates into at least

three sizes and convey into separate bins ready for batching
and mixing. Screening operation shall produce gradations of
heated and dried aggregates which are reasonably uniform
and result in the production of a mixture as specified.

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 3. Preparation of Bituminous Mixture:

a. Introduce aggregates and asphalt cement into the mixture in

proportionate amount according to the job-mix formula. The
combined aggregate shall not contain more than one percent
moisture. The temperature of the asphalt shall be not less
than 32°C below the temperature of aggregate at the time
the materials enter the mixer or pug mill.

b. Use the shortest mixing time that will produce a satisfactory

mixture. Use the procedure for determining the percentage
of coated particles described in ASTM D 2489. The mixing
times shall be set to achieve 95 percent of coated particles
for all mixtures.

c. For batch plants, dry mixing time, if necessary, shall not

exceed 10 seconds. Wet mixing time shall not exceed 50
seconds. For batch plants, wet mix timing shall begin at the
start of the asphalt introduction into the pug mill.

3.4 PREPARATION OF SURFACE

A. Proof roll prepared subbase surface to check for unstable areas and areas
requiring additional compaction.

B. Notify the Engineer of unsatisfactory conditions, if any. Do not start paving

work until deficient subbase areas have been corrected and are ready to
receive paving.

C. Prior to application of bituminous material, remove loose materials from the

underlying surface and clean such surface using approved mechanical
sweepers, blowers, and hand brooms.

3.5 PRIME COATS

A. General:

1. Prime Coat (MC-1): Apply liquid asphalt on previously constructed

subgrade, subbase, or base course at a rate from 0.65 l/m² to 1.75
l/m² as approved. Apply prime coat up to a line 200 mm outside the
edge of the pavement line.

2. Tack Coat (RC-2): Apply liquid asphalt on previously constructed

bituminous concrete surfaces (between layers) at a rate from 0.10 –
0.35 l/m2 as approved.

3. Temperature: Apply liquid asphalt at temperatures within the range

of 50°C to 70°C. Reject materials heated to temperatures above
108°C until the material can be re-sampled and retested.

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 B. Application:
1. Apply by approved pressure distributors. Spray nozzles and spray
bar shall be adjusted and frequently checked to ensure uniform
distribution. Stop spraying upon clogging or interference of any
nozzle, and take corrective measures before resuming.

2. Hand sprays will be approved only for priming small patches or

areas that cannot be primed by normal operation of the distributor.

3. Application at the junction of spreads shall not be in excess of the

specified amount. Squeegee excess from the surface and correct
skipped and deficient areas by means of approved hand sprayers.

4. Following application, the primed surface shall be allowed to cure not

less than 48 hours prior to placement of bituminous concrete mix.

5. Prior to application of tack coat, the surface shall be clean, free of

dust, dirt and other loose material. Tack coat shall be placed not
more than 4 hours prior to placement of next layer.

3.6 PLACING OF BITUMINOUS CONCRETE

A. Underlying course shall be cleaned of loose and deleterious material using a

power sweeper and/or hand brooms. The mixture shall be laid only upon an
approved underlying course which is dry and in suitable condition, and when
weather conditions are determined to be favorable. A mixture shall not be
placed when the air temperature in the shade and away from artificial heat is
4°C or lower, unless required by the Engineer. The Engineer may permit
work to continue during inclement weather only to provide for laying that
material which is in transit from the plant, provided the mixture is within the
temperature limits specified.

B. Deliver bituminous concrete to the paver at a temperature between 139°C

and 163°C. Do not use mixtures delivered to the paver at temperatures
outside this range.

C. Upon arrival, the mixture shall be dumped into an approved bituminous

paver and immediately spread to the width required. 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 will conform to the grade and surface contour
required. Dumping material in a windrow and then placing the material in the
paver with loading equipment will not be permitted. Regulate the speed of
the paver to eliminate pulling and tearing of the bituminous mat.

D. Place the mixture in consecutive, adjacent strips with a minimum width of 3

m except where edge lanes require strips of lesser width. Unless otherwise
directed, begin placing along the centerline of crowned sections or on the
high side of areas with a one-way slope. After the first strip or width has
been compacted, the second width shall be placed, finished, and compacted
in the same manner as the first width. After the second strip has been
placed and rolled, a 5 m straightedge shall be placed across the longitudinal

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 joint to determine if the surface conforms to grade and contour
requirements. If the grade and contour requirements are not as specified,
the strip shall be removed and replaced with satisfactory material in
sufficient quantity to meet the grade and contour requirements at the end of
rolling.

E. Place bituminous concrete so that after rolling the nominal thickness of each
layer will not exceed 100 mm. The top layer shall not exceed 50 mm in
thickness.

F. In areas where because of irregularities or unavoidable obstacles, the use of

mechanical spreading and finishing equipment is impractical, the mixture
may be hand spread as approved by the Engineer.

G. Joint: Make joints between old and new pavements, or between successive
days work, to ensure continuous bond between adjoining work. Construct
joints to have same texture, density and contact surfaces and apply tack
coat.

3.7 ROLLING

A. After spreading, compact mixture thoroughly and uniformly by rolling the

surface when the mixture has attained sufficient stability so that rolling does
not cause undue displacement, cracking, or shoving. The speed of the roller
shall, at all times, be slow enough to avoid displacement of the hot mixture.
Displacement occurring as a result of reversing the direction of the roller, or
from any other cause, shall be corrected at once.

B. Begin initial or breakdown rolling as soon as the bituminous concrete will

bear the roller without undue displacement. Roll longitudinally on the first
strip laid, rolling shall start in the center and continue toward either edge.
On subsequent strips, rolling shall start on the edge adjacent to previously
laid material and continue toward the opposite edge. Overlap successive
trips by at least one half the drum width. Alternate trips of the roller shall be
of different lengths.

C. To prevent adhesion of the mixture, moisten the roller drums with water; an
excess of water will not be permitted.

D. Follow initial or breakdown rolling by rolling with a pneumatic-tired roller.

Perform finish rolling with a tandem roller. Number and size of rollers shall
be selected to obtain the specified density.

E. Operate rollers continuously so that all areas of the pavement will receive
substantially equal compaction. Placing will be ordered to stop at any time
that proper rolling is not being performed.

F. Make surface tests to check conformity with the specified crown and grade
immediately after initial rolling. Correct any variation by the removal or
addition of materials and by continuous rolling. The finished surface shall not
vary by more than the specified tolerances. After the completion of final
rolling, retest the smoothness of the course. Immediately correct all humps

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 or depressions exceeding the specified tolerances, as approved. Replace
the pavement where holes are made for test purposes.

G. In areas not accessible to the roller, the mixture shall be thoroughly

compacted with hot hand tampers. Any mixture which becomes loose and
broken, mixed with dirt, or in any way defective shall be removed and
replaced with fresh hot mixture and immediately compacted to conform to
the surrounding area. Skin patching will not be permitted.

H. Patching: Remove and replace paving areas mixed with foreign materials
and defective areas. Cut-out such areas and fill with fresh, hot asphalt
concrete. Compact by rolling to maximum surface density and smoothness.

I. Protection: After final rolling, do not permit vehicular traffic on pavement until
it has cooled and hardened. Erect barricades to protect paving from traffic
until mixture has cooled enough not to become marked.

3.8 FIELD QUALITY CONTROL

A. Dimensional Tolerances:

1. Surfaces: Variation of the surface when tested with a 5 m

straightedge shall not exceed 6 mm when a straightedge is placed
parallel or at right angles to the centerline.

2. Elevations: Variations from grade line, elevations and cross sections

shall not exceed 13 mm above or 6 mm below the elevations shown.

3. Thickness: Variations in thickness shall not exceed a tolerance of

plus or minus 13 mm.

B. Test Sampling: For every 500 metric tones of asphaltic material produced,
the following tests will be performed by the Contractor through independent
testing laboratory.

1. For Plant Control:

a. Two hot bin gradations of aggregate sampled in accordance

with ASTM D 75.

b. Two sets of Marshall specimens prepared from hot asphaltic

mixture taken from truck.

c. Two asphalt content from hot asphaltic mixture taken from

truck.

d. Two sets of Hveem Stability specimens prepared from hot

asphaltic mixture taken from the truck.

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 2. For Density and Thickness Control:

a. Four samples taken from in-place pavement and

representing 500 metric tones, except that no more than 24
samples shall be taken in any one day.

b. Samples for determining density and thickness may be taken

with either a coring machine or by cutting out a section with a
concrete saw. Core bored or cut holes shall be filled with
approved material and compacted to the required density.

c. Sampling frequency may be varied at the discretion of the

Engineer.

3. Additional tests, if required by the Engineer, additional tests shall be

carried out by the Contractor without any extra cost to the Owner.

C. Minimum Test Requirements: In case the work involves production of less

than 500 metric tones of asphaltic material per day, the following tests will
be performed by the Contractor through an independent testing laboratory.

1. For Plant Control:

a. One hot bin gradations of aggregate sampled in accordance

with ASTM D 75.

b. One sets of Marshall specimens prepared from hot asphaltic

mixture taken from truck.

c. One asphalt content from hot asphaltic mixture taken from

truck.

d. One sets of Hveem Stability specimens prepared from hot

asphaltic mixture taken from truck.

2. For Density and Thickness Control:

a. Four samples taken from in-place pavement each day.

Samples for determining density and thickness may be taken
with either a coring machine or by cutting out a section with a
concrete saw. Core bored or cut holes shall be filled with
approved material and compacted to the required density.

b. Sampling frequency may be varied at the discretion of the

Engineer.

3. Additional tests, if required by the Engineer, additional tests shall be

carried out by the Contractor without any extra cost to the Owner.

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D. Testing: Tests shall be performed in accordance with the requirements of
the following:

1. Mechanical Analysis of Extracted Aggregate: AASHTO T 30.

2. Resistance to Plastic Flow of Bituminous Mixture: ASTM D 1559.

3. Extraction of Bitumen from Bituminous Paving Mixtures: ASTM D

2172, Method A or B, as required.

4. Bulk Specific Gravity of Compacted Bituminous Mixtures: ASTM D

2726.

5. Thickness of In-Place Pavement: Determined by average caliper

measurement of samples in accordance with ASTM D 3459.

6. Theoretical Maximum Specific Gravity of bituminous Paving

Mixtures: ASTM D 2041.

E. Acceptance:

1. A lot is defined as one-half day's production. Maximum size of a lot

will be about 500 metric tone.

2. Acceptance of the compacted pavement with respect to density shall

be based on the average of four laboratory density determinations
for each lot. Cores drilled from the pavement shall be used to test
the density of the layer by either ASTM D 1188 or ASTM D 2726, as
applicable. Each lot of the compacted pavement shall be accepted
when average density determinations are equal to or greater than 97
percent of the average density of the four laboratory-prepared
specimens with no single value less than 95 percent.

3. The location of sampling sites within a lot's placement area shall be

chosen on a random basis. At least 25 percent of the core samples
shall be obtained from joints. The same cores used to test the
density shall be used to measure the thickness of the pavement.

END OF SECTION

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