(FAA)
PART 1.
GENERAL
1.01
SUMMARY
A.
This Section specifies requirements for plant mix macadam base course, bottom course,
top course, tack coat and overlay of existing pavement with asphalt concrete. This
Section conforms to the requirements, with FAA approved modifications, of FAA
Specification Item P-401, "Plant Mix Bituminous Pavements".
B.
Except as provided in 1.01 C. below, recycled asphalt concrete pavement (consisting of
reclaimed asphalt pavement blended with new materials) may be used to the maximum
percentages specified in 1.04 C.2.b.
C.
Recycled asphalt concrete pavement shall not be used in the top courses within the center
80 feet of runways and the center 50 feet of taxiways, nor in any mixes where modified
asphalts are used.
1.02
REFERENCES
The following is a listing of the publications referenced in this Section:
American Association of State Highway and Transportation Officials (AASHTO)
AASHTO M320
Performance Graded Asphalt Binder
AASHTO R28
Practice for Accelerated Aging of Asphalt Binder Using a Pressurized
Aging Vessel (PAV)
AASHTO T313
Test Method for Determining the Flexural Creep Stiffness of Asphalt
Binder Using the Bending Beam Rheometer (BBR)
AASHTO T315
Test Method for Determining the Rheological Properties of Asphalt
Binder Using a Dynamic Shear Rheometer (DSR)
AASHTO T48
Flash and Fire Points by Cleveland Open Cup
AASHTO T240
Effect of Heat and Air on a Moving Film of Asphalt (Rolling Thin Film
Oven Test)
American Society for Testing and Materials (ASTM)
ASTM C 88
Test Method For Soundness of Aggregates by Use of Sodium Sulfate or
Magnesium Sulfate
ASTM C 117
Test Method for Materials Finer than 75-micrometres (No. 200) Sieve
in Mineral Aggregates by Washing
02561 - 1 ASTM C 127
Test Method for Specific Gravity and Absorption of Coarse Aggregate
ASTM C 128
Test Method for Specific Gravity and Absorption of Fine Aggregate
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
Test Method for Sieve Analysis of Fine and Coarse Aggregates
ASTM C 566
Test Method for Total Moisture Content of Aggregate by Drying
ASTM C 1252
Test Methods for Uncompacted Void Content of Fine Aggregate (as
Influenced by Particle Shape, Surface Texture, and Grading)
ASTM D 75
Practice for Sampling Aggregates
ASTM D 242
Mineral Filler for Bituminous Paving Mixtures
ASTM D 692
Coarse Aggregate for Bituminous Paving Mixtures
ASTM D 979
Practice for Sampling Bituminous Paving Mixtures
ASTM D 995
Mixing Plants for Hot-Mixed, Hot-Laid Bituminous Paving Mixtures
ASTM D 1073
Fine Aggregate for Bituminous Paving Mixtures
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 Soils and Fine Aggregate
ASTM D 2726
Test Method for Bulk Specific Gravity and Density of Non-Absorptive
Compacted Bituminous Mixtures
ASTM D 3203
Test Method for Percent Air Voids in Compacted Dense and Open
Bituminous Paving Mixtures
ASTM D 3549
Test Method for Thickness or Height of Compacted Bituminous Paving
Mixture Specimens
ASTM D 3666
Minimum Requirements for Agencies Testing and Inspecting
Bituminous Paving Materials
ASTM D 4125
Test Method for Asphalt Content of Bituminous Mixtures by Nuclear
Method
ASTM D 4318
Test Method for Liquid Limit, Plastic Limit, and Plasticity Index of
Soils
ASTM D 4402
Test Method for Viscosity Determinations of Unfilled Asphalt Using
the Brookfield Thermosel Apparatus
ASTM D 4791
Test Method for Flat Particles, Elongated Particles, or Flat and
Elongated Particles in Coarse Aggregate
ASTM D 4867
Test Method for Effect of Moisture on Asphalt Concrete Paving
Mixtures
ASTM D 5444
Test Method for Mechanical Size Analysis of Extracted Aggregate
02561 - 2 ASTM D 5821
Test Method for Determining the Percentage of Fractured Particles in
Coarse Aggregate
ASTM D 5976
Type I Polymer Modified Asphalt Cement for Use in Pavement
Construction
ASTM D 6084
Method for Elastic Recovery of Bituminous Materials by Ductilometer
ASTM D 6307
Test Method for Asphalt Content of Hot-Mix Asphalt by Ignition
Method
ASTM D 6926
Test Method for Preparation of Bituminous Specimens Using Marshall
Appartus
ASTM D 6927
Test Method for Marshall Stability and Flow of Bituminous Mixtures
ASTM E 178
Practice for Dealing with Outlying Observations
ASTM E 950
Test Method for Measuring the Longitudinal Profile of Traveled
Surfaces with an Accelerometer Established Internal Profile Reference
ASTM E 1274
Test Method for Measuring Pavement Roughness Using a Profilograph
Asphalt Institute - Manual Series
MS - 2
Mix Design Methods for Asphalt Concrete, and Other Hot-Mix Types
MS -20
Asphalt Hot-Mix Recycling
Dept. of Transportation - Federal Aviation Administration (FAA)
Eastern Region Laboratory Procedures Manual (ERLPM) March, 1994
Standards for Specifying Construction of Airports
P-401
Plant Mix Bituminous Pavements
1.03
DESIGN AND PERFORMANCE REQUIREMENTS
A. Job
Conditions
1.
Apply tack coat only when the base surface is dry and the ambient temperature in the
shade has not been below 32 degrees F for 12 hours immediately prior to application,
unless otherwise approved by the Engineer.
2.
Do not place asphalt concrete upon a wet or frozen surface.
3.
The minimum laydown temperature shall be not less than 310
o
F, when the base
temperature is below 50
o
F and not less than 275
o
F when the base temperature is 50
o
F
or greater. The Engineer will measure the temperature of the asphalt concrete in the
truck at the paver.
4.
The minimum allowable base temperature for a lift thickness is shown in the
following table:

Nominal Lift thickness (inches)
Minimum Allowable Base
Temperature Degrees F)
2 or greater
32
1-1/2 or greater, but less than 2
40
Less than 1-1/2
50
02561 - 3 5.
If nominal lift thickness is two inches or greater and the base temperature is below
32
o
F, the Engineer may approve paving operations if the Contractor can demonstrate,
prior to commencing with paving, that density and mat texture uniformity can be
achieved. All other requirements apply.
6.
In case of sudden rain, the Engineer may at his sole discretion permit placing of
mixture already in transit from the plant, provided the surface to be paved is free
from pools of water and laydown temperatures conform to the above tabulation. Such
permission, however, shall not be interpreted as a waiver of any of the quality re-
quirements.
B.
Asphalt Concrete Mix Design
1.
Design asphalt concrete job mix formula based on the "Mix Design Table" specified
in 2.03 A and specimen compaction temperature specified in 1.04 E.3
2.
Design top and bottom courses to the following target values:




Bottom Course
Top Course
Design Properties
Mix 1
1
Mix 2
Mix 3
Marshall Stability, lbs.
@ 75 Blows (ASTM D 6927)
2150 min.
2150 min.
2150 min.
Flow Value, 0.01 inch
gradation (ASTM D 6927)
8 - 16
8 - 16
8 - 16
Air Voids, Percent
2
(ASTM D 3203)
3.8 - 5.2
3.3 - 4.7
3.3 - 4.7
Percent Voids Filled
With Bitumen
65 - 75
65 - 75
65 - 75
Voids in the Mineral Aggregate
(VMA) Minimum %
12 13 14
3.
Plant mix macadam base course shall be a mixture designed within the gradation
limits specified in 2.03 A.
4.
The design job mix formula shall indicate definite percentages passing for each sieve
fraction of aggregate and the asphalt content.
5.
Design new job mix formula for each asphalt plant used, whenever there is a change
in material or when field conditions dictate a need for redesign.
6.
When required by the Engineer, determine the tensile strength ratio of specimens of
the composite paving mixture by procedures specified in ASTM D 4867. The value
shall be not less than 80 percent.
C.
Plant Production Requirements

1

For asphalt concrete mixes with five percent of the aggregate or greater retained on the 1" sieve, the
Engineer may require the use of six inch molds to increase the repeatability of Marshall test results. For six
inch molds Marshall stability shall be 4800 lbs. minimum at 113 blows with 22.5 lb. hammer and 18 inch
drop and the flow value shall be within the 12 to 24 range.
2

Determine by comparing bulk specific gravity (ASTM D 2726) to maximum specific gravity (ASTM
D 2041).
02561 - 4 1.
The asphalt concrete mixture or its components shall not be heated to a temperature
outside the limits specified in 3.02 A.
2.
Plant production tolerance limits for Marshall Stability and flow value are as follows:
Marshall Stability at 75 blows (ASTM D 6927) - 1800 lbs. min.
3
Flow Value, 0.01inch gradation (ASTM D 6927) - 8 to 16.
3
Acceptance shall be on a lot basis as set forth in 1.04 E.3. The acceptance of each lot
shall be based on the Percent of Material Within Tolerance Limits (PWL), as set forth
in 4.03 B.5. If the PWL of the lot for either parameter is less than 90 percent, the
Contractor shall take corrective actions as set forth in 3.03 C.
3.
Modified Asphalt Performance Grade
Modified asphalt shall meet the performance grade requirements set forth in 2.02 B,
when tested in accordance with 1.04 E.12. When material fails to meet the
requirements, make corrections in accordance with 3.03 E.
4.
Marshall Air Voids
Targets for Marshall air voids are 4.5 percent for mix 1, an