TNZ P/23: 2005

PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING

1.

SCOPE This specification sets out the performance requirements for the following types of asphalt as wearing courses: The supply and laying of Open Graded Porous Asphalt (OGPA); The supply and laying of Textured High Stress Resistant type asphalts, such as Stone Mastic Asphalt; and The supply and laying of Dense Graded Asphaltic Concrete (DGAC).

2.

DEFINITIONS 2.1 Hot Mix Asphalt

Hot Mix Asphalt (HMA) is a mixture of bituminous binder and aggregate, with or without added mineral filler, produced in a mixing plant. It is delivered spread and compacted while hot. 2.2 Coarse Aggregate

The Coarse Aggregate is the fraction of the aggregate components retained on a 4.75mm test sieve. 2.3 Fine Aggregate

Fine aggregate is the fraction of the aggregate components passing the 4.75mm test sieve, excluding added mineral fillers. 2.4 Mineral Filler

Mineral Filler is finely ground particles of limestone, hydrated lime, Portland cement or other non-plastic mineral matter, predominantly finer than 0.075mm. that is added to the mix. 2.5 Binder

Unless specified in the specific contract requirements binder is penetration grade bitumen complying with TNZ M/1 specification. 2.6 Job Mix Formula

SP/SP23:051014

PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING

Page 1 of 18

TNZ P/23: 2005

The Job Mix Formula (JMF) is the combined aggregate particle size distribution and total binder content that is chosen by the Contractor and produces a HMA that complies with the criteria specified in Table 2. 2.7 Mix Control Envelope

The Mix Control Envelope (MCE) is the range of allowable variation from the JMF allowed during production. The MCE may include some or all of the sieves required to produce the particle size distribution. 2.8 Voids in the Mineral Aggregate

The Voids in the Mineral Aggregate (VMA) is the volume of intergranular void space between the aggregate particles of a compacted mixture that includes the air voids and the effective binder content, expressed as a percentage of the total volume of the sample. 2.9 Wearing Mix

A mix applied as the uppermost layer in a pavement subjected to the wearing action of traffic. 2.10 Reclaimed Asphalt Pavement (RAP)

Reclaimed asphalt Pavement (RAP) is material comprising old asphalt that has been processed by crushing and/or screening to produce a free flowing and consistent product. 2.11 Maximum size

The maximum size of a mix is the smallest sieve size at which 100% of the aggregate passes. 2.12 Nominal Size

The nominal size of a mix is the smallest sieve size at which more than 90% of the aggregate passes. 2.13 Refusal Density

The density of a laboratory compacted specimen, compacted in accordance with AS2891.2.2 using the ServopacTM using compaction 250 cycles. 2.14 Theoretical Maximum Specific Gravity

Theoretical Maximum Specific Gravity (MSG) is a theoretical relative density of the asphalt with no air voids (see ASTM D 2041)

SP/SP23:051014

PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING

Page 2 of 18

TNZ P/23: 2005

2.15

Lot Definitions

A Manufacturing Lot shall be deemed to be the quantity of a specified mix manufactured at a specific facility under essentially uniform process conditions with consistent ingredients resulting in a homogeneous product. A Production Lot shall be made up of manufactured material (within a manufacturing lot) which has been handled to regulate and conserve characteristics of homogeneity and workability in suitable manner. A Field Lot shall be representative of production mix (within a production lot) which has been continuously laid under essentially constant conditions to achieve an end product homogeneous in appearance.

PERFORMANCE REQUIREMENTS The specified performance requirements for the HMA controlled by this specification are given in Table 1, Table 2 and Table 3. The specific contract requirements given in Schedule A, specify design values for layer thickness, binder type, aggregate polished stone value (PSV), texture depth, mix designation and any other requirements. 3.1 Polished Stone Value Requirements.

At least 85 % of the coarse aggregate shall be obtained from an aggregate source(s) of the required Polished Stone Value (PSV). Blending of coarse aggregates from different sources with different PSVs, including PSVs lower than that required, to theoretically achieve the specified value is prohibited.

CONTRACT QUALITY PLAN The Contractor shall submit to the Engineer a Contract Quality Plan (CQP) detailing the procedures to be followed to ensure compliance with the specified performance requirements and specific criteria detailed in this specification. The Engineer and Contractor will mutually agree to its content and appropriateness. The quality plan shall define the MCE, which shall have allowable variations reflecting current industry best practice.

SP/SP23:051014

PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING

Page 3 of 18

TNZ P/23: 2005

TABLE 1 HMA Raw Material Properties Table 1a Binder Properties Test Property Test Method Requirements Penetration Grade Bitumen Compliance with M/1 Modified Binder Softening AGPT/T157 Report Value Point or ASTM D36 Modified Binder Torsional AGPT/T154 Report Value Recovery Modified Binder Viscosity AGPT/T132 Report Value or ASTM D4402

Frequency

Comments

One representative test per production batch of modified binder.

Requirements to be included in Schedule A

SP/SP23:051014

PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING

Page 4 of 18

TNZ P/23: 2005

TABLE 1 HMA Raw Material Properties Table 1b Aggregate Properties Test Property Crushing Resistance Dense Graded Asphalt (Table 2c) Other Types of HMA (Table 2a and 2b) Weathering Resistance Polished Stone Value Los Angeles Abrasion Loss Wet/Dry Strength Variation Water Absorption Test Method NZS 4407 Test 3.10 Requirements Frequency Coarse Aggregate Properties As per BCA 9805 Quality 200 kN min Assurance of Aggregates for Chipseals and Bituminous Mixes 230 kN min AA or BA As per Specific Contract Requirements and T/10 Report Value Report Value Report Value Comments Current requirements for TNZ M/10

NZS 4407 Test 3.11 BS EN 1097 Part 8 AS 1141.23 or NZS 4407 Test 3.12 AS 1141.22 AS 1141.8 or ASTM C127 NZS 4407 Test 3.10 NZS 4407 Test 3.6 NZS 4407 Test 3.5 AS 1141.5 or ASTM C128 AS 1141.25.3

Representative test values of the aggregate(s) to be used in the contract

A number of new tests have been introduced in order to explore alternative means of assessing aggregate quality for use in HMA. Current requirements for TNZ M/10

Crushing Resistance Sand Equivalent, or Clay Index (<0.075mm) Water Absorption

Fine Aggregate Properties 200kN min (parent rock) As per BCA 9805 Quality Assurance of Aggregates for 35 min, or Chipseals and Bituminous 3 max Mixes Report Value Representative test result of the aggregate(s) to be used in contract Report Value

Degradation Factor

A number of new tests have been introduced in order to explore alternative means of assessing aggregate quality for use in HMA.

SP/SP23: 051014

PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING

Page 5 of 18

TNZ P/23: 2005

TABLE 2 Wearing Course Asphalt Performance Criteria 2(a): Open Graded Porous HMA Performance Requirement 1. Field Criteria Surface ride Test/Reference Method Test Value Comments

NAASRA roughness Deviation under 3m straight 5 max edge (mm) Field Permeability (sec) TNZ Test Method, refer 12 max Notes Appendix

To be specified in Schedule A At construction joints, and any localised defect. At time of laying, not applicable to high strength OGPA, similar to P/11 PA 14 HS.. Data gathering only not contractually binding

Permeability

Permeability

2. Mix Design Properties

Relative Hydraulic Conductivity (Reciprocal seconds) Binder Drain-down (%)

BS DD 229

Report Value

AGPT / T 235 (flask) or BS 0.3 max at 8C above DD 232 (basket) nominated mixing temp AGPT / T 236 Unconditioned Heavy/Very Heavy Traffic Medium traffic

Asphalt Particle Loss (%) 15 max 20 max Report Value Moisture Conditioned Retained Tensile Strength ASTM D4867 as modified (%) by TNZ P/11 80 min

SP/SP23: 051014

PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING

Page 6 of 18

TNZ P/23: 2005

Performance Requirement 3. Production Testing

Test/Reference Process Control Monitoring of mix consistency of design JMF MSG

Method Plot variation from JMF, (individual and rolling average) refer Clause 6.7 ASTM D2041

Test Value MCE from Quality Plan.

Comments Minimum acceptable process control testing shall be one test per 300 Tonne of a production not Lot or part thereof.

Report Values, contractually binding. 0.3 max at 8C above nominated mixing temp

Binder Drain-down (%)

AGPT / T 235 or BS DD 232

Minimum frequency once per site

Asphalt Particle Loss (%)

AGPT / T 236 Unconditioned 15 max 20 max Moisture Conditioned Report Value

Minimum frequency once per site Heavy / Very Heavy Traffic Medium Traffic

SP/SP23: 051014

PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING

Page 7 of 18

TNZ P/23: 2005

TABLE 2 Wearing Course Asphalt Performance Criteria 2(b): Textured High Stress Resistant HMA Performance Requirement 1.Field Criteria Surface ride Test/Reference Method Test Value Comments

NAASRA roughness Deviation under 3m straight edge (mm) Relative BS DD 229 Hydraulic Conductivity (Reciprocal seconds) Air voids from Cores (%) ASTM D3203 and ASTM D2726 See clause 6.8. 5 max Report Value

To be specified in Schedule A At construction joints, and any localised defect. Values to be set at laydown trial. Refer Notes.

Permeability

Safety Pavement

Texture depth MPD (mm) Posted Speed limit 60km/hr 70km/hr

Agreed Range At laydown trial. established in CQP. Final acceptance shall be against the criteria in section 0.70 6.8. 0.90

2.Mix Design Properties

Binder Drain-down (%)

AGPT / T 235 or BS DD 0.3 max at 8C above 232 nominated mixing temp

Asphalt Particle Loss (%)

AGPT / T236 Unconditioned Moisture Conditioned

15 max Report value

SP/SP23: 051014

PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING

Page 8 of 18

TNZ P/23: 2005

Performance Test/Reference Method Requirement 2.Mix Design Retained Tensile Strength ASTM D 4867 (%) Properties (cont) Voids in Mineral Aggregate MS-2 (%) Wheel Tracking Test AGPT / T 231

Test Value 80 min

Comments

Refer Table 3

Report Value

Data gathering only not contractually binding Test to be carried out on design mix and cores from pavement at laydown trial

3. Production Testing

Process Control Monitoring Plot variation from JMF, MCE from Quality Plan. of mix consistency of design (individual and rolling JMF average) Refer Clause 6.7 MSG ASTM D2041 Report Values, not contractually binding.

Minimum acceptable process control testing shall be one test per 300 Tonne of a production Lot or part thereof.

Binder Drain-down (%)

AGPT / T 235 or BS 0.3 max at 8C above Minimum frequency once per DD 232 site nominated mixing temp

SP/SP23: 051014

PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING

Page 9 of 18

TNZ P/23: 2005

TABLE 2 Wearing Course Asphalt Performance Criteria 2(c): Dense Graded Asphaltic Concrete Performance Requirement 1.Field Criteria Surface ride Test/Reference Method Test Value Comments

NAASRA roughness 5 max Report value

To be specified in Schedule A At construction joints, and any localised defect. Values yet to be set at laydown trial

Permeability

2.Mix Properties

Deviation under 3m straight edge (mm) Relative BS DD 229 Hydraulic Conductivity (Reciprocal seconds) Air voids from Cores (%) ASTM D3203 and ASTM D2726 Design Retained Tensile Strength ASTM D4867 (%) Voids in Mineral Aggregate MS-2 (%) Wheel Tracking Test AGPT / T231

Agreed Range At Laydown trial established in CQP. 80 min

Refer Table 3

Report Value

Requirement Site Dependant. Data gathering only not contractually binding

Refusal Air Voids (%)

ASTM D2726 & ASTM 2 min unless otherwise Heavy / Very Heavy Traffic D3203 agreed by Engineer. Traffic AGPT / T237 7.5 min

Binder Film Index (m)

SP/SP23: 051014

PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING

Page 10 of 18

TNZ P/23: 2005

Performance Requirement 3. Production Testing

Test/Reference Process Control Monitoring of mix consistency of design JMF MSG

Method Plot variation from JMF, (individual and rolling average) Refer Clause 6.7 ASTM D2041

Test Value MCE from Quality Plan.

Comments Minimum acceptable process control testing shall be one test per 300 Tonne of a production not Lot or part thereof.

Report Values, contractually binding.

SP/SP23: 051014

PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING

Page 11 of 18

TNZ P/23: 2005

Mix Nominal Size 7 10 14

Table 3 Minimum VMA Requirements (%) Dense Graded Asphaltic Concrete (DGAC) Stone Mastic Asphalt (SMA)see Note below Heavy / Very Heavy Other Traffic Heavy / Very Heavy Other Traffic Traffic Conditions Traffic Conditions 16 19 16 15 17 18 15 14 16 17
Note the minimum values given above for DGAC for other traffic conditions are derived from the Asphalt Institute MS-2 publication for a 4 % air void design. Values for SMA are derived from BCA 9808 (50 cycles, other traffic conditions) and AAPA National Asphalt Specification version 2 (120 cycles, heavy/very heavy traffic conditions). These VMA criteria are design criteria only and may not be appropriate for other types of textured stress resistant HMA.

SITE ACCEPTANCE The treatment selection of each site shall be specified in Schedule A. The Engineer will confirm that the underlying pavement is fit for resurfacing. The Contractor shall inspect each site and consider whether the treatment specified is appropriate for the site and whether any repairs are required or have been satisfactorily completed. Where the construction of the layer on which the paving is to be laid is not part of the contract, the road shall be handed over in a condition ready to be prepared for paving unless specified otherwise in the job specification. Where a correction layer is identified in the job specification it shall become a function of the Contractors treatment solution.

ACCEPTANCE TESTING 6.1 Accreditation

All sampling and testing shall be performed by a laboratory which holds either accreditation by International Accreditation New Zealand (IANZ), or alternative accreditation as accepted by the Engineer. 6.2 Aggregate Properties

The Contractor shall demonstrate, through quality records, that the aggregate properties comply with this specification. It is expected that the testing frequency shall be in accordance with the New Zealand Pavement and Bitumen Contractors' Association Guidelines "Quality Assurance of Aggregates for Chipseals and Bituminous Mixes" BCA 9805. 6.3 Binder Properties

Penetration grade bitumen used shall comply with TNZ M/1 Specification.
SP/SP23: 051014 PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING Page 12 of 18

TNZ P/23: 2005

The bitumen may be modified as specified in Schedule A. The performance criteria of the modified binder shall be specified in Schedule A. The Contractor shall demonstrate, through quality records, that the binder properties comply with the specified requirements. 6.4 Hot Mix Asphalt Properties

The design and selection of aggregates, filler and binder proportions shall be the responsibility of the Contractor. The Contractor shall identify the mix design procedure(s) utilised, in the CQP. The Contractor shall demonstrate, through quality records, that HMA properties comply with this specification. The testing frequency shall be as outlined below, or as detailed in the CQP. 6.5 OGPA Binder Content Optimisation

The mix design for OGPA shall be optimised to provide the maximum binder content that is feasible within the limits imposed by the binder drain down criteria. This process is explained in the Notes. 6.6 Testing Frequency

The minimum testing frequencies for the various materials and mix types are scheduled in Table 1 and 2. 6.7 Allowable Variability Of Production

The allowable variations from the design values approved by the Engineer are either given in Table 2 or included in the CQP. Process control charts shall be produced by the Contractor monitoring critical sieve sizes for the mix under production, as well as binder content and Maximum Theoretical Specific Gravity (MSG). This process shall be described fully in the CQP. 6.8 Macrotexture

Macrotexture requirements are scheduled in Table 2 for Textured High Stress Resistant HMA. For macrotexture assessment: Divide the area into lots not exceeding 500 m2. For laser-based equipment: 1. If there is any doubt as to the accuracy of the laser-based equipment then calibration and verification of the equipment according to the current
SP/SP23: 051014 PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING Page 13 of 18

TNZ P/23: 2005

requirements of the Transit New Zealand Annual High Speed Data Collection Survey Contract shall be undertaken. 2. Texture shall be measured along the full length of the lot in the estimated location of the wheelpaths. 3. The continuous texture data for each lot shall be reported as average per 10m length, and for each lot shall meet the following requirements: x 2.35 s > m Where x = mean of the lot s = standard deviation of the lot m = minimum macrotexture, either 0.7 or 0.9 MPD 4. No average over a longitudinal 10m section shall be more than 0.1 MPD below the minimum macrotexture. 5. Where the texture appears to vary transversely across the lane, measurements shall be taken along a longitudinal line through the lowest texture area. For sand circle: Where laser based equipment is not available the average texture depth shall be measured in accordance with the TNZ T/3 Specification. The measured texture shall be converted to Mean Profile Depth (MPD) using the following equation: MPD = 0.59 x TDsc + 0.27 Where TDsc is the average texture depth in mm derived from the sand circle test, TNZ T/3. The procedure shall be: 1. Visually inspect the lot. 2. Identify consecutive 10 m sections that appear to have the lowest texture. 3. Take 6 sand circles readings uniformly spaced along each wheel track (12 results). 4. No single sand circle reading may fall more than 0.2 MPD below the minimum macrotexture specified in Table 2 and the average for any 10 m section of wheelpath shall not be below the minimum macrotexture specified in Table 2. Remedial Treatment: Where the lot does not meet the above macrotexture requirements, all of the noncomplying area shall be treated by a method accepted by the Engineer. The treatment shall leave the lots surface with a reasonably uniform appearance. Note: Highpressure water treatment with appropriate care may provide a satisfactory result. 6.9 Ravelling

Ravelling is the loss of particles from the surface of the wearing course. This shall be determined by assessing a 300 mm by 300 mm area for the extent of particle loss. The section shall be rejected if any three locations assessed has more than 2 % particle loss in trafficked areas and that has more than 5 % particle loss in any
PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING

SP/SP23: 051014

Page 14 of 18

TNZ P/23: 2005

untrafficked area. Accident damaged areas shall be excluded from assessment for particle loss. 6.10 Other Field Control Criteria Other field control tests and their limits are included in Table 2 and the CQP for the various mix types.

PRODUCTION AND CONSTRUCTION TRIAL If the mix has not been previously approved, the Contractor shall undertake a specific offsite laydown trial. Each trial must be successfully completed before the use of any new or previously unknown nominated mix on site. The Contractor may only proceed with a laydown trial once the Engineer has approved the initial mix design for trial. The Engineer will attend the full duration of each laydown trial and requires two working days prior notice of any planned laydown trial. A laydown trial shall consist of a minimum production lot of 20 tonnes. An offsite trial site shall be considered to be a pavement suitable to be covered by the proposed mix that is not owned by the Principal. Should the Contractor propose a trial site that requires a larger quantity than that specified as the minimum required for offsite trials, then the offsite trial shall be the first portion of mix laid on that site unless otherwise agreed by the Engineer. The handling, sampling, paving and rolling operations undertaken during the laydown trial shall simulate those proposed for on site operation. The trial can be used to assess the effects of different techniques. Payment for each required laydown trial shall be made under a scheduled item. 7.1 Laydown Trial Testing and Reporting Requirements The following sampling and testing regime shall be required for each laydown trial. The size of samples is to be nominated prior to the trial commencing. 1) The mix shall be tested to confirm compliance with this specification. 2) Compaction trials shall be carried out to obtain the optimum rolling pattern. 3) Field Permeabilities / hydraulic conductivity shall be tested at a minimum of three locations. 4) The texture depth of the finished trial surface shall be measured. 5) Air voids taken from 4 cores extracted from the trial section where applicable. 6) Other testing such as wheel tracking as specified in Schedule A. The following details are to be reported to the Engineer following each laydown trial: 1) Mix Design Report as required by Tables 1 and 2 2) Manufacturing Temperatures

SP/SP23: 051014

PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING

Page 15 of 18

TNZ P/23: 2005

3) Storage and Delivery time duration 4) Lot size, reported as tonnes produced, area covered, including a clear description of the trial location. 5) Target mat thickness and estimated compacted thickness 6) Results of the Contractors testing 7) Optimum rolling pattern 7.2 Additional Requirements for Textured High Skid Resistance Surfacing and Dense Graded Mix In addition to the requirements above, a section of the trial site for these mixes is to be laid at the depth this mix is expected to be laid in the field. Another section of the trial shall be constructed at a depth to enable the mat to be cored and the field air voids determined where the normal depth is not suitable for coring.

COMPLIANCE ASSESSMENT An assessment shall be undertaken of the wearing course layer by visual inspection immediately prior to the issue of the practical completion certificate to check for rutting, shoving flushing and ravelling. The maintenance inspection is to be carried out in the final month of the maintenance period. This shall require traffic control as the following properties are to be measured for compliance with the specification where applicable. Measurement should only be undertaken when one of the following properties is suspected to be non-compliant with this specification: Texture depth as required by Table 2 and clause 6.8. Surface shape Ravelling (Refer Clause 6.9)

Permeability of the surface shall also be measured however this property is not required to comply with the specified values. A further inspection of a portion of the works completed under this specification may be inspected again up to 24 months after the end of the maintenance period. This inspection shall be for information gathering only. If the Contractor is required to attend then this shall be stated and scheduled in the contract specification.

MAINTENANCE It is the Contractor's responsibility to maintain the wearing course in a safe condition and in compliance with the shape and surface integrity requirements of Section 8 for a period of twelve months from the completion of the contract. Acceptance of the finished surface shall be in finished surface lots. A finished surface lot is defined as 500m2 of the finished area.

SP/SP23: 051014

PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING

Page 16 of 18

TNZ P/23: 2005

If at any time during the maintenance period, repairs are required for greater than 10% over any 500m2 area of the site then the proposed repair technique and acceptance criteria shall be agreed with the Engineer. Any areas repaired more than nine months after construction will, at the discretion of the Engineer, be subjected to a further 12 months maintenance period. If the area of repairs at the end of 12 months are greater than 10% over any 500m2 of the site and a revised acceptance criteria has not been agreed with the Engineer, then the site will be subject to a further 12 month maintenance period.

SP/SP23: 051014

PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING

Page 17 of 18

TNZ P/23: 2005

SCHEDULE A EXAMPLE SCHEDULE OF SPECIFIC CONTRACT REQUIREMENTS FOR CONSTRUCTION OF HOT MIX ASPHALT PAVING

1. 2. 3. 4. 5. 6.

Location Number Location Name Location Reference (a) Length of Contract (m) (b) Width of Paving (m) Traffic Loading (AADT and % HCV) Details of Existing Pavement, including depth, known strength and layer materials. Layer Depth (mm) Mix Designation OPGA Standard/High Strength, High Textured Skid Resistant or Dense Graded Binder Type for Designated Mix, including additional criteria for modified binders.

7. 8.

9.

10. 11. 12.

Aggregate Polished Stone Value, min Correction Layer Quantity (Tonnes) Maximum Pavement Roughness

SP/SP23: 051014

PERFORMANCE BASED SPECIFICATION FOR HOTMIX ASPHALT WEARING COURSE SURFACING

Page 18 of 18