SS-01045
(Replaces SS-01039)

THE STANDARD SPECIFICATIONS, SERIES 2001, ARE AMENDED BY THE FOLLOWING MODIFICATIONS AND ADDITIONS. THESE ARE SUPPLEMENTAL SPECIFICATIONS AND THEY SHALL PREVAIL OVER THOSE PUBLISHED IN THE STANDARD SPECIFICATIONS.

This specification applies to projects on the Primary Road System only. It may apply to other projects when specifically identified in the contract documents.

Replace all of Article 2303.02, C with the following:

C. Recycled Asphalt Pavement.
RAP is salvaged asphalt pavement. RAP shall be from a source designated in the contract documents, a Classified RAP stockpile, or Unclassified RAP furnished by the Contractor. The designations Classified and Unclassified are exclusively for the use of RAP in HMA.

The Contractor shall identify each RAP stockpile and document Classified RAP stockpiles as directed in Appendix A. Information required for documentation of Classified RAP material in a stockpile for future use in HMA shall include identification of the project from which the material was removed; mix data from the original project including mixture type, aggregate classification, location and depth in the pavement structure; extracted gradation information, if available; and description of stockpile location and quantity. Additional material shall not be added to a Classified RAP stockpile without the approval of the District Materials Engineer.

The Engineer may reject a RAP stockpile for non-uniformity based on visual inspection. Stockpiles shall be worked in such a manner that the materials removed are representative of a cross section of the pile.

Stockpiles of RAP shall be placed on a base sufficient to prevent contamination as directed in Appendix A. RAP stockpiles containing concrete chunks, grass, dirt, wood, metal, coal tar, or other foreign or environmentally restricted materials shall not be used. RAP stockpiles may include PCC patches (not to exceed 10% of the stockpile pavement surface area) from patches or composite pavement that was milled as part of the asphalt pavement may be included in the stockpile.

When RAP is taken from a project, or is furnished by the Contracting Authority, the contract documents will indicate quantity of RAP expected to be available and test information, if known. The Contractor is responsible for salvaging this material. Unless otherwise specified in the contract documents, RAP not used in HMA shall become the property of the Contractor.

For HMA mix design purposes, the Contracting Authority will test samples of the RAP. The aggregate gradation and amount of asphalt binder in the RAP will be based on the Contract Authority’s extraction tests. When the amount of RAP binder exceeds 20% of the total asphalt binder, the asphalt binder grade shall be changed as directed in Materials I.M. 510.

1. Classified RAP.
Classified RAP is from a documented source with the aggregate meeting the appropriate quality requirements in Materials I.M. 510, and properly stockpiled.

Classified RAP may be used in the base, intermediate, and surface mixtures for which the RAP aggregate qualifies. The surface course may use up to 15% of Classified RAP. The Contractor may shall obtain the Engineer’s approval to use more than 15% of Classified RAP for the surface course when there is quality control sampling and testing of the RAP meeting the requirements in Appendix A. Not more than 30% of the total asphalt binder in the surface mix shall come from the RAP.

2. Unclassified RAP.
Any stockpiled RAP not meeting the requirements of Classified RAP or from an unknown source shall be designated as Unclassified RAP. For Interstate and Primary projects, up to 10% Unclassified RAP may be used in HMA base and shoulder mixtures. For Primary projects, up to 10% Unclassified RAP may be used for equal to or less than 1,000,000 ESAL intermediate mixtures. For all other projects, up to 10% Unclassified RAP may be used in HMA base, intermediate, and shoulder mixtures. There will be is no friction aggregate credit or aggregate crushed particles credit for Unclassified RAP.

When an Unclassified RAP stockpile is characterized by sampling and testing for mix design, no material can be added to the stockpile until the project is completed.

Replace all of Article 2303.05, C with the following:

C. Recycled Asphalt Pavement.
The quantity of asphalt binder in classified or unclassified RAP, which is incorporated into the mix, will be calculated in tons (megagrams) of asphalt binder in the RAP, based on the actual asphalt binder content determined for the mix design from the results of the Engineer’s extraction test.

The quantity of asphalt binder in classified or unclassified RAP, which is incorporated into the mix, will be included in the quantity of asphalt binder used.

Replace the second paragraph of Article 2303.06, B with the following:

Payment for asphalt binder will be for all new asphalt binder and the asphalt binder in the RAP which is incorporated in the mixture.

The quantity of asphalt binder in classified or unclassified RAP, which is incorporated into the mix, will be calculated in tons (megagrams) of asphalt binder in the RAP. This will be based on the actual asphalt binder content determined for the mix design from the results of the Engineer’s extraction test.

 

APPENDIX A – Instructions for RAP for HMA Mixtures (Supersedes Materials I.M. 505)

GENERAL
This Appendix describes requirements for processing, storing, documenting, and sampling & testing of RAP intended for use in HMA mixtures.

All notifications and documentation shall be submitted to the District Materials Engineer based on the District responsible for the location of the initial RAP stockpile.

PROCESSING
RAP suitable for HMA shall be processed by milling and/or crushing to a maximum particle size of 1.5 inches (37.5 mm). The Contractor shall notify the Engineer and District Materials Engineer 48 hours before processing begins.

Additional screening or blending may be done to achieve a more uniform stockpile. This processing may be done as the stockpile is built or as part of the HMA plant production. Additional actions that may improve the consistency of the RAP include further crushing to reduce top size, screening into coarse and fine fractions, or blending by proportioning through a two-bin cold feed.

STORAGE
Stockpiles shall be placed on a base with adequate drainage, constructed in layers to minimize RAP segregation and ensure a workable face.

To meet Classified RAP criteria, separate stockpiles shall be constructed for each source of RAP based on the quality of aggregate, type and quantity of asphalt binder, and size of processed material.

All RAP stockpiles shall be identified by maps of stockpile areas and signs placed in or near each stockpile.

DOCUMENTATION of CLASSIFIED RAP STOCKPILES
Stockpiled RAP material will only be considered Classified RAP when the following documentation requirements are met. No documentation is required when the RAP is used on the project it came from, or a tied project.

• Form 820009r (see Appendix B) is completed by the RAP owner and a copy is forwarded to the District Materials Engineer within 10 calendar days of completing the stockpile.
• Any special handling, treatment or conditions of the RAP or it’s use should be described on this form.
• Maps shall provide details that depict the stockpile site, including adjacent stockpiles of RAP or aggregates, permanent plant equipment, and landmarks.
• Maps and signs shall identify the stockpile by RAP Identification Number.

The District Materials Engineer will review Form 820009r for accuracy. Portions of the form including assigning the RAP identification number, aggregate quality type, crushed particle and friction type credit, average values for extracted aggregate gradation, aggregate bulk specific gravity, aggregate absorption and asphalt binder content will be completed by the District Materials Engineer.

Notify the District Materials Engineer at least 48 hours before relocating or reprocessing a classified RAP stockpile for future use (not intended for a specific project). The notification shall include the estimated quantity of RAP being relocated or reprocessed and the new location of the stockpile. Relocation of RAP shall be reported on Form 820009r and submitted to the District Materials Engineer within 10 calendar days of completing the relocation. Reprocessing a Classified RAP stockpile may require additional sampling, testing, and new Form 820009r with reassignment of a RAP Identification Number.

Before January 1st of each year, the cContractor shall update Form 820009r on the status of each Classified RAP stockpile. Report the estimated quantity of RAP removed for the construction season completed and the available RAP in each stockpile for future use.

SAMPLING AND TESTING
Mix Design
A certified Level I Aggregate Technician shall obtain the samples. Samples for mix design testing shall be obtained from at least 3 locations. Significant mixture differences in the pavement to be recycled may require separate stockpiles and samples. A sampling plan shall be developed by the Contractor and approved by the District Materials Engineer prior to sampling.

Samples for mix design obtained from the RAP stockpile are the most representative, but not always possible when the mix designs are performed. When stockpile samples are not available, RAP samples shall be obtained by milling a minimum of 50 feet (15 m) of project length at each sample location. Other methods of sampling for mix design, including coring or air-hammer patch areas, may only be used with the approval of the District Materials Engineer.

Obtain sufficient material for contractor mix design testing and owner agency RAP extraction testing as recommended in Materials I.M. 510. A representative 30 pound (15 kg) sample split from the total sample shall be delivered to the District Materials Laboratory for extraction testing. Results of the extraction test will be provided to the Contractor within 4 weeks of sample delivery.

Quality Control
When RAP quality control is required, the Contractor shall use one of the following quality control sampling programs. A certified Level I Aggregate Technician shall obtain the samples.

• Stockpiles – The Contractor shall obtain a representative sample of RAP from the stockpile for each 1000 tons of RAP placed in the stockpile.
• HMA Plant – The Contractor shall obtain a representative sample of RAP from the HMA plant RAP feed belt for each lot of HMA produced.

The Contractor shall use the ignition oven (Materials I.M. 338) or chemical extraction (AASHTO T 164) to extract the aggregate from the RAP sample. Calibration of the asphalt binder content from the ignition oven extraction is not required for the RAP quality control program. The gradation of the extracted RAP aggregate and the un-calibrated asphalt binder content shall be logged and charted within 24 hours of sampling.