Transport Malta - Manual of Contract Documents for Roadworks Series 900- Road Pavements - Bituminous Bound Mixes

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Transport Malta Specification Series 900

Road Pavements: Bituminous Bound Materials - Particular Requirements for Asphalt Concrete (High Modulus) and Stone Mastic Asphalt

1 General

i. The provisions in the Transport Malta (ADT) Specification Series 900 shall apply unless otherwise described hereunder in the particular provisions.

ii. The Overseeing Organisation will support and assist - as may be required and within the parameters imposed by regulations and legislation - bituminous mixture producers with regards to target input testing (laboratory testing.

iii. National Standards (BSI, ASTM, DIN) - The CEN equivalents shall apply subject to the approval and guidance of the Overseeing Organisation.

2 Particular Provisions - Modified Bitumen

The binder shall be a polymer-modified bitumen complying with EN 14023.

The following requirements shall apply:

Table A Modified Bitumen Requirements

Characteristic Unit Standard Value

Classification NA EN 14023 NA

Penetration dmm EN 1426 50-70

Ring & Ball Degrees Celsius EN 1427 70 to 90

Elastic recovery @

25 Deg. C,

50mm/min

% EN 13398 ≥ 80

Storage stability, 3

days @ 180 Deg. C,

Softening point

Degrees Celsius EN 13399 ≤ 3

FRAAS Break Point

Temp.

Degrees Celsius EN 12593 ≤ - 12

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Dynamic viscosity at

160 Deg. C, y =

100s-1

(Pa-sec) EN 13302 ≤ 0.40

After RTFOT (Rolling Thin Film)

Loss after heating @

163 Deg. C

% EN 12607-1 ≤ 0.8

Residual Penetration % EN 1426 ≤ 40

Increase in Softening

Point

Degrees Celsius EN 1427 ≤ 5

Note: The polymer modification shall be made on a “base bitumen”. The polymers shall be

SBS-L (linear elastomers) or SBS-R (radial elastomers) or both.

3 Particular Provisions - Gyratory Compactor

The gyratory compactor shall comply with EN 12697-31 and the following parameters shall apply:

Table B Gyratory Compactor Criteria

Characteristic Unit Value Notes

Vertical pressure kPa 600 ± 3

Rotation angle Degrees 1.25º ± 0.02

Rotation speed rpm 30

Specimen diameter mm 150 Base Courses

100 Binder and

Wearing Courses

4 Particular Provisions for Modified Bitumen AC Base, AC Binder

and SMA Wearing Courses

903 Asphalt Concrete (AC) for Base Courses (High Modulus) 903.1 Unless otherwise specified in Appendix 7/1, base course (high modulus) mixtures shall comply with EN 13108-1 and sub-clause 2 and 3 of this clause.

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The designation shall be AC32/base/50-70mod. The tolerances from the approved input target composition (laboratory mix design) during production and delivery for the evaluation of conformity shall be as described in EN 13108-21, Annex A, Table A.1.

Aggregate 903.2 The grading of total aggregate shall comply with Table C. The content of aggregate between 19mm and 25mm shall be at least 10%. The sieves shall be as described in EN 13108-1 from the basic sieve set plus set 2. Table C AC Base Course (High Modulus) Grading

Sieve Size (mm) Passing (%) Notes

Same as for AC Base Course using Non-Modified Bitumen

Binder 903.3

The binder shall be modified bitumen complying with Table A. The bitumen content by weight of total mixture shall be within the limits of 3.8% to 5.2%. IMPORTANT: The target (informative) percentage voids filled with bitumen (VFB) are in the range of 65% to 78%. VFB values shall be evaluated as part of the mix acceptance criteria (laboratory and production validation). Mixes exhibiting abnormal VFB values considered detrimental to durability shall be rejected. Technological Properties 903.4 The technological properties of the bituminous mixture compacted using the Marshall method shall be as follows: Table D Marshall Requirements

Characteristic Unit Value Notes

Specimen compaction

temperature

Degrees C As

recommended

by the bitumen

producer

To be declared

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Characteristic Unit Value Notes

Blows No. 75 Each side

Stability @ 60 Deg. C kN 10 to 15.5

Marshall rigidity kN/mm 2.5 to 4.5 Conditions shall

apply for high

rigidity

Void content % 3 to 7

IMPORTANT: Marshall rigidity: Abnormally rigid mixes with stability / flow values (both laboratory and production validation) detrimental to durability shall be rejected irrespective of the stability and flow values achieved. Additionally, the mixture shall be tested in accordance with EN 12697-31 using a gyratory compactor. The parameters in Table B shall apply. The specimens shall be compacted as follows: Table E Gyrations and Voids Criteria

Characteristic % Voids EN 12697-8 Notes

Number of revolutions

N1 - 10 11-15

N2 - 120 3-6 Project reference density

for compaction control

N3 - 200 ≥ 2

The density at N2-120 revolutions shall be the project reference density for compaction control (compaction degree) when compared to the extracted cores from the laid and compacted material in situ. In accordance with EN 12697-23 - Indirect tensile strength the following criteria shall apply: Table F Indirect Tensile Strength Criteria @ 25ºC

Characteristic Unit Value Notes

Test temperature Degrees C. 25

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Resistance N/mm2 0.95 to 1.70 GPa x 10-3

Coefficient N/mm2 ≥ 80 GPa x 10-3

Table G Indirect Tensile Strength Criteria @ 40ºC

Characteristic Unit Value Notes

Test temperature Degrees C. 40

Resistance N/mm2 0.30 to 0.80 GPa x 10-3

Coefficient N/mm2 ≥ 40 GPa x 10-3

In accordance with EN 12697-26 - Stiffness the following criteria shall apply: Table H Stiffness Criteria

Characteristic Unit Value Notes

Test temperature Degrees C. 20

Stiffness of test

specimen at N2-120

MPa ≥ 4000 IT-CY (Annex C),

20ºC, 10Hz - Project

reference stiffness

The stiffness (MPa) at N2-120 revolutions shall be the project reference stiffness for acceptance. 904 Asphalt Concrete (AC) for Binder Courses (High Modulus) 904.1 Unless otherwise specified in Appendix 7/1, binder course (high modulus) mixtures shall comply with EN 13108-1 and sub-clause 2 and 3 of this clause. The designation shall be AC20/bin/50-70mod The tolerances from the approved input target composition (laboratory mix design) during production and delivery for the evaluation of conformity shall be as described in EN 13108-21, Annex A, Table A.1.

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Aggregate 904.2 The grading of total aggregate shall comply with Table I. Table I AC Binder Course (High Modulus) Grading

Sieve Size (mm) Passing (%) Notes

Same as for AC Binder Course using Non-Modified Bitumen

Binder 904.3 The binder shall be a polymer-modified bitumen complying with EN 14023. The following requirements shall apply: Table J Modified Bitumen Requirements

Characteristic Unit Standard Value

Same as for AC Base Course (High Modulus) in this specification.

The bitumen content by weight of total mixture shall be within the limits of 4.1% to 5.5%. IMPORTANT: The target (informative) percentage voids filled with bitumen (VFB) are in the range of 65% to 78%. VFB values shall be evaluated as part of the mix acceptance criteria (laboratory and production validation). Mixes exhibiting abnormal VFB values considered detrimental to durability shall be rejected.

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Technological Properties 904.4 The technological properties of the bituminous mixture compacted using the Marshall method shall be as follows: Table K Marshall Requirements

Characteristic Unit Value Notes

Specimen compaction

temperature

Degrees C As

recommended

by the bitumen

producer

To be declared

Blows No. 75 Each side

Stability @ 60 Deg. C kN 12.0 to 16.0

Marshall rigidity kN/mm 3.0 to 5.0 Conditions shall

apply for high

rigidity

Void content % 4 to 6

IMPORTANT: Marshall rigidity: Abnormally rigid mixes with stability / flow values (both laboratory and production validation) detrimental to durability shall be rejected irrespective of the stability and flow values achieved. Additionally, the mixture shall be tested in accordance with EN 12697-31 using a gyratory compactor. The parameters in Table B shall apply. The specimens shall be compacted as follows: Table L Gyrations and Voids Criteria

Characteristic % Voids EN 12697-8 Notes

Number of revolutions

N1 - 10 11-15

N2 - 120 3-6 Project reference density

for compaction control

N3 - 200 ≥ 2

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The density at N2-120 revolutions shall be the project reference density for compaction control (compaction degree) when compared to the extracted cores from the laid and compacted material in situ. In accordance with EN 12697-23 - Indirect tensile strength. The following criteria shall apply: Table M Indirect Tensile Strength Criteria @ 25ºC

Characteristic Unit Value Notes

Test temperature Degrees C. 25

Resistance N/mm2 0.95 to 1.70 GPa x 10-3

Coefficient N/mm2 ≥ 80 GPa x 10-3

Table N Indirect Tensile Strength Criteria @ 40ºC

Characteristic Unit Value Notes

Test temperature Degrees C. 40

Resistance N/mm2 0.30 to 0.90 GPa x 10-3

Coefficient N/mm2 ≥ 45 GPa x 10-3

In accordance with EN 12697-26 - Stiffness. The following criteria shall apply: Table O Stiffness Criteria

Characteristic Unit Value Notes

Test temperature Degrees C. 20

Stiffness of test

specimen at N2-120

MPa ≥ 4000 IT-CY (Annex C),

20ºC, 10Hz - Project

reference stiffness

The stiffness (MPa) at N2-120 revolutions shall be the project reference stiffness for acceptance.

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906 Stone Mastic Asphalt (SMA) for Wearing Courses (High Modulus) 906.1

Unless otherwise specified in Appendix 7/1, stone mastic asphalt wearing course (high modulus) mixtures shall comply with EN 13108-5 and sub-clause 2 and 3 of this clause. The designation shall be SMA10/50-70mod. The tolerances from the approved input target composition (laboratory mix design) during production and delivery for the evaluation of conformity shall be as described in EN 13108-21, Annex A, Table A.1.

Aggregate 906.2 The grading of total aggregate shall comply with Table P. The sieves shall be as described in EN 13108-1 from the basic sieve set plus set 2. Table P SMA Wearing Course Grading

Sieve Size (mm) Passing (%) Notes

12.5 100 ≈ 1.4D

10 81 100 D (10mm)

8 60 88

6.3 ----- -----

4 30 52

2 22 34

1 16 26

0.500 11 21

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0.250 10 18

0.063 8 14

Binder 906.3 The binder shall be a polymer-modified bitumen complying with EN 14023. The bitumen content by weight of total mixture shall be within the limits of 5.5% to 7.5%. The following requirements shall apply: Table Q Modified Bitumen Requirements

Characteristic Unit Standard Value

Same as for AC Base Course (High Modulus)

The average binder drainage category of a set of specimens tested in accordance with EN 12697-18 (Schellenberg method) shall be D0.3. The air voids content of the mixture at input target composition (laboratory compacted specimens) prepared and tested as detailed in EN 13108-20 shall be between 2% and 4%. The air voids filled with bitumen of the mixture at input target composition (laboratory compacted specimens) prepared and tested as detailed in EN 13108-20 shall be between 77% and 86%. IMPORTANT: The VFB values shall be evaluated as part of the mix acceptance criteria (laboratory and production validation). Mixes exhibiting abnormal VFB values considered detrimental to durability shall be rejected. The air voids content of the mixture at output target composition (laid and compacted plant mix material extracted as core specimens in situ ) shall be between 2% and 5%. The texture depth of the laid and compacted surface shall be determined in accordance with EN 13036-1. Ten (10) locations shall be randomly selected over 1000m long sections and three (3) points measured. The average texture depth for each 1000m length of paving, or for the complete length where this is less than 1000m, and the individual test measurements shall be as follows:

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Table R Texture Depth Values

Characteristic 1000m Mean Individual Result

SMA10 ≥ 1.1 ≥ 1.1

Technological Properties 906.4 The technological properties of the bituminous mixture compacted using the Marshall method shall be as follows: Table S Marshall Requirements

Characteristic Unit Value Notes

Specimen compaction

temperature

Degrees C As

recommended

by the bitumen

producer

To be declared

Blows No. 75 Each side

Stability @ 60 Deg. C kN 10 to 16.0

Marshall rigidity kN/mm 3.5 to 5.0 Conditions shall

apply for high

rigidity

Void content % 2 to 4

IMPORTANT: Abnormally rigid mixes with stability / flow values (laboratory and production validation) detrimental to durability shall be rejected irrespective of the stability values achieved. Additionally, the mixture shall be tested in accordance with EN 12697-31 using a gyratory compactor. The parameters in Table B shall apply. The specimens shall be compacted as follows: Table T Gyrations and Voids Criteria

Characteristic % Voids EN 12697-8 Notes

Number of revolutions

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N1 - 10 10-12

N2 - 150 1-4 project reference density

for compaction control

N3 - 240 ≥ 1

The density at N2-150 revolutions shall be the project reference density for compaction control (compaction degree) when compared to the extracted cores from the laid and compacted material in situ. In accordance with EN 12697-23 - Indirect tensile strength. The following criteria shall apply: Table U Indirect Tensile Strength Criteria @ 25ºC

Characteristic Unit Value Notes

Test temperature Degrees C. 25

Resistance N/mm2 0.95 to 1.70 GPa x 10-3

Coefficient N/mm2 ≥ 80 GPa x 10-3

Table V Indirect Tensile Strength Criteria @ 40ºC

Characteristic Unit Value Notes

Test temperature Degrees C. 40

Resistance N/mm2 0.3 to 0.6 GPa x 10-3

Coefficient N/mm2 ≥ 30 GPa x 10-3

In accordance with EN 12697-26 - Stiffness. The following criteria shall apply: Table W Stiffness Criteria

Characteristic Unit Value Notes

Test temperature Degrees C. 20

Stiffness of test

specimen at N2-150

MPa ≥ 4000 IT-CY (Annex C),

20ºC, 10Hz - Project

reference stiffness;

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project reference

stiffness

The stiffness (MPa) at N2-150 revolutions shall be the project reference stiffness for acceptance. 911 Mix Design for Asphalt Concrete 911.1 Asphalt concrete mixes shall be designed mixes. The Contractor shall be responsible for the design of the mixes in accordance with the requirements in EN 13108-20: Type Testing. The following definitions shall apply:

i. Mix formulation EN 13108-20, clause 3.2 ii. Input target composition EN 13108-20, clause 3.3 iii. Output target composition EN 13108-20, clause 3.4

Initial input target composition (laboratory mix design) shall be performed using the Marshall method. The additional requirements in accordance with EN 12697-23 and EN 12697-26 shall then be applied as described in this Specification. The type testing validation shall be any one from the models a) or b) as described in clause 6.2. The model selected shall be declared by the Contractor. The selected laboratory or production validation shall be approved by the Overseeing Organisation. Verification 911.4 Additionally, whenever model a) as described in clause 6.2 is selected as the validation model the Contractor shall be required to comply with the requirements of clause 6.5.3 and using materials obtained from the plant. The Contractor shall use any one from the procedures a) or b) as described in clause 6.5.3. The procedure selected shall be declared by the Contractor. The technological properties shall be determined at the proposed target binder content approved by the Overseeing Organisation.

The evaluation of conformity of production tolerances as described in EN 13108-21, Annex A, Table A.1 shall apply.

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Composition 911.5 When determined in accordance with the test methods in EN 13108-20, Annex A, Table A.1 the constituent materials shall comply with the specified requirements. When determined in accordance with the test methods in EN 13108-20, Annex B, Table B.1 the bituminous mixtures shall comply with the specified technological properties. The nature and source of the coarse and fine aggregate may be changed only if the mix is re-designed and approved by the Overseeing organisation prior to its incorporation in the permanent Works. The source of the filler may be changed provided its characteristics remain essentially the same and subject to the approval of the Overseeing Organisation. 925 Testing of Bituminous Mixtures and their Component Materials 925.1 The sampling, testing and analysis of bituminous mixtures shall comply with EN 13108-21 except where specified otherwise in this Series. 925.2

Output target composition (plant production) by factory production control shall be carried out by the Contractor in accordance with EN 13108-21. The additional requirements in accordance with EN 12697-26 shall be applied as described in this Specification. The frequency of testing shall be as described in shown EN 13108-21 Tables 3, 4, 5, 6 (where applicable), 7 (where applicable) and 8 (delivered product). Whenever production is less than that provided for in the above the frequency shall be that of one (1) test per production day. The test results have to be presented to the Overseeing Organization on request. Non-conformities from the specified requirements have to be reported to the Overseeing Organization immediately and shall be rectified without delay. 927 Compaction Degree AC Base and AC Binder Courses The density at N2-120 revolutions shall be the project reference density for compaction control (compaction degree) when compared to the extracted cores from the laid and compacted material in situ.

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SMA Wearing Courses The density at N2-150 revolutions shall be the project reference density for compaction control (compaction degree) when compared to the extracted cores from the laid and compacted material in situ. Other Requirements Temperatures i. The maximum temperature of the bitumen at any stage shall not exceed that

recommended by the producer and must be declared by the Contractor.

ii. The mixing, rolling and compaction temperature ranges shall be those recommended by the bitumen producer and must be declared by the Contractor.

Contractor’s Responsibility Nothing in this specification shall be construed as relieving the Contractor from his responsibility and obligation of delivering a quality product that is: i. fit for purpose; ii. performing to the current state of technological advancement; iii. compliant with the current European product classification and test standards iv. serviceable and durable for its intended use.

END