SECTION 02066

ASPHALTIC CONCRETE

1 PART 1 – GENERAL

1.1 SCOPE

A. The work covered by this section includes asphaltic concrete courses, and bitumen
coatings of the flexible pavements as indicated on the Drawings or as specified herein.

B. Where constructions of culverts, pipelines or other works are below existing roadways
complete reinstatement of the roadway is required to the original construction and
condition unless specified otherwise.

1.2 RELATED WORK SPECIFIED ELSEWHERE

1.3 APPLICABLE CODES AND STANDARDS

A. Reference Codes and Standards:

Kingdom of Saudi Arabia, Ministry of Transportation (MOT):

General Specifications for Road and Bridge Construction.

Kingdom of Saudi Arabia, Ministry of Transportation (MOT):

Design of Roadways Volumes 1 and 2

Department of the Environment: Specification for Highway Works.

American Society for Testing and Materials (ASTM): ASTM D 6114 and as
appropriate.

American Association of the Highway and Transportation Officials (AASHTO):

AASHTO M 320 and as appropriate.

Marshall Tests and Procedure.

TECHNICAL SPECIFICATIONS
1.4 QUALITY CONTROL

A. Complete details of the Contractor's procedures and manpower for inspection, testing
and measurement of all the work as specified herein shall be incorporated in the
approved Quality Control Program, given with the Method Statement to be submitted at
least 30 days before start of pavement construction work.

B. Previously laid pavement layers shall be approved by the Owner before such layers are
overspread. The approval shall be withheld until the Contractor's quality control reports
substantiate compliance by conclusive inspection reports, test results, survey records
and recommendations which are acceptable to the Owner.

C. The Quality Control Program shall commit the Contractor to effective control of
suppliers (vendors) by the actions taken on its inspection and reporting and from its
testing and charting the results. The only testing acceptable as part of the Contractor's
Quality Control Program shall be that conducted on its behalf by its approved materials
testing laboratory or as otherwise approved by the Owner.

D. The delivery and Contractor's acceptance of materials shall require fulltime attendance
on site of an approved Inspector from the Contractor's Quality Control Team. The
Contractor shall maintain records of each delivery of mixed material relating time,
temperature and location of placement within the area being constructed.

E. The laying and rolling operations shall be attended by the same Inspectors who are
responsible for the Contractor's acceptance of material at the site. The inspection team
shall also include the Contractor's surveyors who shall make frequent checks on vertical
control performance, which shall be made in time to modify screed control and
compaction techniques. This is particularly important where a pavement layer is
proposed for use as a datum from which to operate an "automatic levelling device" to
span hollows and lengthen humps by ramp action.

F. The survey record shall show deviations in millimetres from the required grade at 10
metre intervals longitudinally and 2 metre intervals transversely. For junctions and
intersections and non-road paved areas, the survey grid pattern shall be at 5 metre
centres in both directions. The survey shall be representative and shall be cover at least
5% of the area to be paved and as proposed by the Contractor, to attain the specified
requirements for ride quality and to provide the specified surface drainage.

TECHNICAL SPECIFICATIONS
 G. Compaction control by the Contractor shall include inspection of the compaction
equipment and its operation, measurement and recording of laying temperatures and
the study of voids from cores taken from each asphalt layer between 24 and 48 hours
after completion of finish rolling. All inspection reports and analysis of test results shall
be included in the regular weekly quality control reports as prepared by the Contractor
and submitted to the Owner.

H. The frequency of sampling and testing shall be in accordance with the approved Quality
Control Program and as additionally deemed necessary by the Owner as the work
progresses. The area of asphalt layer or volume of material represented by each
sample shall be as stated in the Quality Control Program and as further determined at
the time of sampling. The entire volume of work as measured for payment shall be
represented by inspection reports, temperature records, mix analysis and field
density/voids/thickness determination shall be submitted, after being evaluated by the
Contractor, to the Owner.

1.5 SUBMITTALS

A. All submittals shall be summarised by the Contractor, on a cover sheet which shall
compare what is being proposed or has been achieved, directly with the specified
requirements such that compliance or exceptions are clearly stated.

B. At least 30 days prior to commencing any of the operations, involved for laying the
asphaltic concrete surface courses, the Contractor shall submit for the Owner's
information and approval the items described in the following clauses:

1. Method Statement:
a. This will include the Contractors proposals for execution of the works to
meet the requirements given on the Drawings and/or in the Specification.
b. A Program showing the sequence of operations and areas of works.
c. Level of supervision to be exercised.
d. Full details of the plant and equipment to be used in each phase of the
works.
e. Record sheets defining the areas of the works, with the sequence of
operation, confirmation of compliance with Specification of each stage of
the Permanent Works with its acceptance by the Owner.

TECHNICAL SPECIFICATIONS
 2. The Quality Control Program as described in 1.04 above

3. Materials Report: The materials report shall include but not be limited to:
a. Details of the proposed suppliers and or sources of all ingredients for
making the asphalt mixtures
b. Details of the suppliers independent testing Program and evidence of
consistency in the quality of the products to be supplied.
c. Testing Laboratory Reports: Submit two (2) copies of laboratory test reports
for tests performed in the process of mix design and of core samples taken
after laying.
4. Proposals and permits and I or approvals from the Owner and the relevant
authorities for diversion and control of traffic.

2 PART 2 – PRODUCTS

2.1 MATERIALS

A. Binder: Bituminous 60/70 Penetration Grade.

The following ASTM tests shall be made for compliance on each consignment:

Property
Test Unit
Requirement

D36 0.1 mm
• Penetration
60/70

D92 ºC
• Flash point, minimum
232

D2398 ºC
• Softening point (ring & ball)
46/56

D113 cm
• Ductility, minimum, 250C
100

D2042 %
• Solubility (trichloroethylene)
99

TECHNICAL SPECIFICATIONS
 D2415 %
• Ash content by wt maximum
1.0

D1754 %
• Thin film oven test loss on
heating
0.8

D36 %
• Penetration of residue
of 1 above 50

D113 Cm
• Ductility of residue, 25 deg. C.
60

T102 %
• Spot test ASSHTO
35

n-heptane - xylene equivalent

B. Prime Coats: Cut-Back Bitumen.

Each consignment shall be tested for compliance by ASTM tests.

Property
Test Unit
Requirement

• Grade D2027 -
MC70

• Flash point, minimum D3143 ºC

38

• Viscosity-Kinematic at 60°C D2170 cSt

70-140

• Distillate at 225°C D402 % by vol

10-50

• Distillate at 260°C D402 % by vol

40-80

TECHNICAL SPECIFICATIONS
 • Distillate at 316°C D402 % by vol
80-95

• Minimum residue from D402 %by vol

55

one distillation at 360°C

• Water content D95 %

0.2

• Penetration of residue at 60°C D36 0.1 mm

120-250

• Viscosity of residue at 60°C D2171 Pas

300-1200

• Solubility of residue D2042 %

99

• Ductility of residue at 25°C D113 cm

100

• Max temp. at distributor - 0C

90

• Rate of application - l/m2

1.00-1.65

C. Tack Coats: Cut-Back Bitumen

1. Each consignment shall be tested to ASTM producers for compliance

Property
Test Unit
Requirement
Property
Test Unit
Requirement

• Grade D2027 -

TECHNICAL SPECIFICATIONS
MC250

• Flash point, minimum D3143 ºC

66

• Viscosity-Kinematic at 60ºC D2170 cSt

250-500

• Distillate at 225DC D402 min% by vol

35

• Distillate at 260DC D402 min % by vol

60

• Distillate at 316DC D402 min % by vol

80

• Minimum residue from D402 %

65

distillation at 360ºC

• Water content D95 %

0.2

• Penetration of residue at 60DC D36 0.1 mm

120-250

• Viscosity of residue at 60ºC D2171 Pa.s

300-1200

• Solubility of residue D2042 %

99

• Ductility of residue at 250ºC D113 cm

100

• Max temp. at distributor - ºC

110

TECHNICAL SPECIFICATIONS
 • Rate of application - l/m2
0.25-0.45

D. Aggregate for Base Course and Wearing Course

Aggregates shall be sound angular crushed stone, crushed gravel, and sharp-edged
natural sand, which shall be tested weekly for compliance with the following
requirements.

Property
Test Unit
Requirement

• Max percentage of soft ASTM %

2 C 142
particles by wt

• Los Angeles abrasion test ASTM %

C131
35

• Soundness in Magnesium % loss

18

sulphate (coarse fraction)

• Flakiness Index (coarse BS 812 Index

fraction)
30

• Water absorption mass BS 812 % of dry mass

1

• Stripping (bitumen retained) %

75-100

E. The grading of the aggregates shall be within and approximately parallel to the following
envelopes:

BS Sieve Percentage Passing Percentage Passing

TECHNICAL SPECIFICATIONS
 (mm) Base Course Wearing Course

37.5 - -
28 100 -

20 75-90 -

14 65-80 100

10 55-70 75-90

5 39-50 54-64

2.36 25-35 35-45

0.60 10-18 15-25

0.30 6-10 8-13

0.075 3-6 6-10

F. Filler shall be material smaller than 0.075 mm derived from the coarse and fine
aggregates, or milled limestone smaller than 0.075 mm, hydrated lime (max 2% ), or
Portland cement or a mixture of these materials. If a mixture of fine material from the
aggregates and either cement or milled limestone is used, the proportions shall be such
that the bulk density in toluene of the filler is between 0.5 and 0.9 grams per millilitre
when measured as described in BS 812. Control testing shall be made daily. The
grading of the combined aggregates and filler shall be within the limits stated in the
previous paragraph.

G. Herbicide Treatment: Commercial chemical for weed control, registered by

Environmental Protection Agency. Provide granular, liquid, or wettable powder subject
to approval of the Owner.

H. Asphalt-Rubber binder
Shall be a blend of asphalt cement, granulated reclaimed tire rubber and additives, with
a minimum rubber proportion of 20% by weight of the total blend, leading to an increase
viscosity and a higher resistance under hot desert environment, as defined by ASTM
D8.

The rubber required to produce Asphalt-Rubber should have the following

characteristics:

TECHNICAL SPECIFICATIONS
 • Specific gravity of 1.15 ± 0.05.
• No visible nonferrous metal particles.
• Less than 0.75% moisture and free flowing.
• No more than 0.01% ferrous metal particles by weight.
• For hot mix binder applications, fiber content shall not exceed 0.5% by weight.

Asphalt-rubber properties shall conform to the following:

Requirement Type
Property
1 2 3

Grade of base asphalt cement PG 64-16 PG 58-22 PG 52-28

Rotational Viscosity
1.5-4.0 1.5-4.0 1.5-4.0
177 °C, Pascal seconds
Penetration
4 °C, 200 g, 60 seconds (ASTM D5), 10 15 25
min

Requirement Type
Property
1 2 3

Softening Point
AASHTO t-53 or ASTM D36 57 54 52
(°C, min)

Resilence
25 °C (ASTM D5329) 30 25 15
(%, min)
Samples shall be tested for conformance with the mix design gradation in accordance
with the requirements of AASHTO T27 or C136.

The chemical composition of the ground tire rubber shall be determined in accordance
with ASTM D297 and shall meet the following requirements:
• Acetone Extract: Maximum 25%
• Rubber Hydrocarbon Content: 40 to 55%
• Ash Content: Maximum 8%
• Carbon Black Content: 20 to 40%
• Natural Rubber: 16 to 45%

The asphalt-rubber shall contain a minimum of 20 % ground rubber by weight of the

asphalt binder unless otherwise instructed by the Engineer.

TECHNICAL SPECIFICATIONS
2.2 MIX DESIGN

A. At least thirty (30) days prior to the date the Contractor intends to begin production of a
plant mix for Asphaltic Concrete; the Contractor shall make a written request for the
approval of his job-mix formula from the Owner.

B. The particle size grading of the combined aggregates and filler shall be a smooth curve
within and approximately parallel to the grading envelopes given in 2.01 D.

C. The job mixes for asphaltic concrete shall conform with the requirements for Marshal!
Stability and Flow and voids contents.

D. The Contractor shall carry out Marshal! Tests on laboratory mixes within the aggregate
grading given. Tests shall be carried out with at least 5 bitumen contents within the
following range:

Surfacing course: Specified bitumen content +/- 1.0 %

Base course: Specified bitumen content +/- 1 .5 %

The results shall be submitted to the Owner for acceptance with full details of the
proposed aggregate gradings and bitumen and filler contents to be used in the site
trials.

E. Properties of Mixed Materials

Test to be carried out in accordance with ASTM Specification D1559

Property Unit Base Course Surface Course

No. of blows per face No. 75 75
Marshall Stability (min) Kg 500 700
Marshall Flow mm 2-4 2.4 - 4
Voids in mixed aggregate % 14 - 18 16 - 19
Voids in total mix % 3-7 3–5
Percentage of voids in total
% 60 - 75 70 - 80
mix filled with bitumen
Bitumen Content Range % by weight of 5.0 - 7.5 6.0 - 7.5

TECHNICAL SPECIFICATIONS
 total mix

F. Full scale site trials shall be carried out using the plant and methods of construction and
the full range of aggregate gradings and layer thickness proposed for use in the Works
with the bitumen content agreed by the Owner after the laboratory tests.

G. The results of the tests on the trial areas shall be submitted to the Owner with proposals
for the Job Mix Formula which taking into account the tolerances allowed during the
mixing of the materials will ensure that Specification requirements are met. The Owner
will then either accept these proposals or give instructions for further tests which the
Contractor shall carry out. The aggregate grading envelopes and the bitumen contents
approved or instructed by the Owner shall constitute the Job Mix Formula for each
asphaltic concrete mix.

H. The Contractor shall determine a Job Mix density for each Job Mix Formula. The Job
Mix density shall be the average density of six Marshals! Specimens compacted by the
specified number of blows, in which none of the six results differs from the average by
more than 1.5%.

I. The mix design shall be controlled by the Marshal! Stability results of the tests as
scheduled below. If the mean of the results does not exceed the minimum given by a
margin of 2.33 times the standard deviation of the latest 30 stability results for a
particular mix the Contractor shall remove and replace the defective material.

2.3 CONTROL TESTING SCHEDULE

Material
Sampling Property Test Standard Unit Requirement
Point

Aggregates Grading BS 812

Mixing Plant Relaive BS 812
Densty
Moisture BS812 % 1
Content
Temperature - 150 - 170
ºC

Combined Density BS 812 g/ml 0.5 - 0.9

Storage bin

Filter in Toulene

TECHNICAL SPECIFICATIONS
Bitumen Temperature - ºC 150 – 170
On entry to
mixer

Asphaltic Aggregate BS 812 - -

From hopper

Concrete grading
of spreader

Bulk density BS 812 g/m 0.5 - 0.9

in Toluene
of recovered filler
Bitumen ASTM %l +0.2
Content D1272
Method A

Laboratory ASTM
Marshall test D1559

Temperature - ºC 145 - 165

Mixer
discharge
point

Temperature - ºC 135 - 165

at laying point in
spreader
hopper

Temperature - ºC 120
after laying
prior to
rolling

Asphaltic Aggregate BS 812 +0.2% of

Concrete Grading Specified
Bulk Bitumen ASTM D2172 pavement
Finished Sample content

Penetration of ASTM 0.1mm 54min

Recovered D1754
Bitumen
Density mg/m3 98% of
specified

Layer Thickness As
specified

Levels As
specified

TECHNICAL SPECIFICATIONS
3 PART 3 – EXECUTION

NOT USED

END OF SECTION

TECHNICAL SPECIFICATIONS