DIVISION 2 - SITE WORK SECTION 02513 - BASE COURSE & ASPHALT CONCRETE PAVING PART 1 - GENERAL 1.

01 DESCRIPTION This Section covers providing grading, base course, prime coat, tack coat, asphalt concrete paving, sampling and testing for the parking and play area pavement or pavement widening and patching as shown on the Construction Drawings and as required to complete the WORK acceptable to Company Representative. 1.02 REFERENCES CODES AND STANDARDS: Comply with applicable SAUDI ARAMCO Standards, and Codes and Standards as specified herein.

PART 2 - PRODUCTS 2.01 BASE COURSE A. Aggregate Base: Aggregate base, Class A, shall be used in asphalt paved roads and parking areas. Coarse material shall be crushed rock or crushed gravel. Fine material shall be quarry screening or natural material and of suitable binding quality. The material shall be free from foreign or organic matter, dirt, shale, clay, clay lump or other deleterious matter. Aggregate base course shall meet the following requirements: 1. Physical requirements: a. Soundness test using magnesium sulfate. (ASTM C-88): 18% maximum for coarse aggregate 20% maximum for fine aggregate Loss by abrasion (ASTM C-131 and ASTM C-535) 40% maximum Thin and elongated pieces, by weight, larger than 25mm, thickness less than 1/5 length (CRD-C-119) 5% maximum Friable particles (ASTM C-142) 0.25% maximum Plasticity index (ASTM D-4318) : 4-6 Sand equivalent (ASTM D-2419) 30% minimum

b. c.

d. e. f.

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2.

Gradation: The combined materials shall consist of a mixture of all aggregate uniformly graded from coarse to fine to conform to the following gradation requirements: Sieve Size 2-1/2 inch 2-inch 1-1/2 inch 1-inch 3/4 inch 1/2 inch No. 4 No. 10 No. 40 No. 200 Percent Passing 100 90 - 100 60 - 90 42 - 77 35 - 70 25 - 60 15 - 40 10 - 26 5 - 15 2-9

B.

Marl Base: Marl base shall be used as base course for play area. The marl base materials shall have the same properties as the Select Fill materials as defined in Section-02210, Earthwork.

2.02

BITUMINOUS PRIME COAT Prime Coat: Shall be MC-70 conforming to SAUDI ARAMCO (Ras Tanura Refinery) Standard A-973 or MC-250 conforming to SAUDI ARAMCO Standard A-974.

2.03

TACK COAT Liquid asphalt for tack coat: Shall be RC-250 conforming to SAUDI ARAMCO (Ras Tanura Refinery) Standard A-971 or RC-800, conforming to SAUDI ARAMCO Standard A-972.

2.04

BITUMINOUS PAVING MIXTURE A. B. Asphalt shall be petroleum asphalt cement, penetration Grade 60-70, conforming to the requirements of SAUDI ARAMCO (Ras Tanura Refinery) Standard A-970. Mineral Aggregate: 1. Gradation: When tested according to ASTM C-117 and ASTM C-136, the combined mineral aggregate shall conform to the following grading. Hot Asphalt Binder Course Class A Sieve Size 1-1/2" 1" % Passing 100 Hot Asphalt Surface Course Class A Sieve Size 1-1/2 1 % Passing 100 SECTION 02513

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3/4" 1/2" 3/8" #4 #10 #40 #80 #200 2.

80 - 100 60 - 80 45 - 65 30 - 50 15 - 32 3 - 10

3/4 1/2 3/8 #4 #10 #40 #80 #200

100 80 - 95 48 - 62 32 - 45 16 - 26 8 - 18 4-8

Physical requirement: The combined mineral aggregates for binder course and asphalt surface shall conform to the following physical requirements: a. b. Sand Equivalent (ASTM D-2419) Plasticity Index (ASTM D-4318) 45 minimum

6 maximum (Binder Course) 3 maximum (Surface Course) 40% maximum

c. d.

Loss by Abrasion % (ASTM C-131) Loss by Magnesium Sulfate Soundness for: Coarse Aggregate Fine Aggregate (ASTM C-88)

18% maximum 20% maximum

e.

Thin and elongated pieces, by weight larger than 25mm, thickness less than 1/5 length per CRD-C-119 5% maximum

C.

Job Mix 1. The job mix formula shall be approved by Company Representative and shall combine the mineral aggregates and asphalt in such proportion as to produce a mixture conforming to the following composition limits by weight: Percent a. Total Mineral Aggregates b. Asphalt Cement 96 - 93 4-7 SECTION 02513

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When tested according to the Marshall Method, the bituminous mixture shall conform to the following requirements:

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Binder Course a. b. Stability (Kg.) Flow (mm) 700 min. 2.4-5.0

Surface Course 700 min. 2.4-4.0

Loss of Marshall stability bysubmerging specimens in water @60 deg. C for 24 hrs. as compared tostability measured after submersion in water @ 60 deg. C for 20 minutes a. b. c. d. 2. (ASTM D-1559) Voids in total mix Voids filled with Bitumen Voids in mineral aggregate (VMA) ASTM D-2041 25% max. 3.0-7.0% 60-75% 13% min. 25% max. 3.0-5.0% 70-80% 14% min.

Maximum Variation: Upon receiving the job-mix formula, approved by the Company Representative, CONTRACTOR shall adjust his plant to proportion the individual aggregates, mineral filler and asphalt to produce a final mix that when compared to the job-mix formula, shall be within the following limits: Tolerance a. b. c d. e. Aggregate Sieve size No. 4 and Larger Aggregate Sieve size No. 10 and retained on the No. 200 Aggregate Sieve size No. 200 & smaller Asphalt Content +/- 5 percent +/- 1.5 percent +/- 0.3 percent +/- 5 percent

Submit asphalt mix design to Company Representative for review and approval at least 30 days prior to use. The asphalt concrete graded from a SAUDI ARAMCO approved batch plant. 3. Temperature: The mixture shall have a temperature between 139 Deg. C and 163 Deg. C when it leaves the plant and shall be transported from the mixing plant to the point of use in pneumatic tired vehicles having tight bodies, previously cleaned of all foreign materials. The mixture shall be delivered on the surface to be paved, between the temperature of 139 Deg. C and 163 Deg. C.

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PART 3 - EXECUTION 3.01 SUBGRADE PREPARATION AND MAINTENANCE A. Subgrade Preparation: CONTRACTOR shall, as a part of the WORK and prior to delivery of materials for the base course, prepare the subgrade surface by sprinkling, blading, rolling and lightly scarifying where necessary, until the proper crown is obtained. When compacted and ready for base course construction, the subgrade shall be well compacted, smooth, hard and uniform, all irregularities having been bladed out and rolled smooth. Compaction: Subgrade shall be compacted to not less than 95 percent of the maximum dry density per ASTM D-1557, Method D, or AASHTO T-180, Method D, or to 85 percent relative density determined by ASTM D-4253 and D-4254. Maintenance of Subgrade: The finished subgrade shall be maintained in a smooth and compacted condition until the base course and surface course are in placed.

B.

C.

3.02

BASE COURSE PLACING AND COMPACTION A. B. Construction: Do not construct base course until the subgrade is approved by Company Representative. Placing: Granular base material shall be placed in layers of uniform thickness with approved spreaders. Layer thickness generally shall not exceed 150 mm after compaction. When the base or subbase course is constructed in more than one layer, the previously constructed layers shall be cleaned of loose and foreign matter. The water content of the material shall be maintained during compaction at the optimum percentage (+/- 1-1/2%) as determined by ASTM D-1557 or AASHTO T-180. Compaction: While at optimum moisture (+/- 1-1/2%) the subbase or base material shall be compacted with equipment capable of obtaining the desired density to the full depth of the respective layer. The rolling shall continue until the base and subbase are compacted to not less than (100 percent for the base or 95 percent for the subbase) of the maximum laboratory density as determined by ASTM D 1557, Method D or AASHTO T-180. In-place density shall be measured by ASTM D-2922 or other approved methods. Finishing : The surface of the compacted material shall be finished by blading or with automated equipment especially designed for this purpose and rolled with a steel-wheeled roller. In no case shall thin layers of fine materials be added to the top layer of the base course in order to meet the required elevation. The surface of the completed base shall not show any deviation in excess of 6mm when tested with a 3 meter straightedge. The completed thickness of the base shall be within +/- 6mm of the thickness shown on the Construction Drawings, and the average thickness shall not be less than the design thickness. SECTION 02513

C.

D.

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E.

CBR Value: For Aggregate Base Course, the laboratory compacted California Bearing Ratio, per ASTM D-1883 shall not be less than 50 after four days soaking.

3.03

PRIME COAT APPLICATION A prime coat consists of the initial application of liquid asphalt onto the surface of a nonasphalt base course. A. Cleaning Surface: Prior to the application of the prime coat the surface shall be cleaned of all loose dirt and other objectionable materials by means of approved mechanical sweepers or blower and or hand broom. Application: Prior to application, the surface shall be cleaned of all loose dirt and other objectionable materials by means of mechanical sweepers, blower and/or hand broom. Prime coat shall be applied by means of a pressure distributor at a rate between 0.65 and 1.75 liters per square meter and at a temperature between 50 Deg. to 80 Deg. C. for MC-70 and at temperature between 65 deg. and 105 deg. C for MC-250. Prime coat shall be applied only when the surface to be treated is dry and when the weather is not foggy or rainy and the temperature in the shade is 8 degrees C and rising. Curing: The prime coat shall be permitted to cure until the penetration into underlying surface has been approved by Company Representative, but in no time shall the curing period be less than 24 hours. The prime coat shall be fully set and cured before placing an asphalt mixtures on the base.

B.

C.

3.04

APPLICATION OF TACK COAT A. Concrete Surfaces: Tack coat shall be applied to all concrete surfaces that will be in contact with the asphalt pavement. Tack coat applications shall take place prior to the paving operations and will include surfaces of concrete curbs and other drainage structures. Binder Course: Tack coat shall be applied between the binder course and the surface course. If applications of the surface course is delayed by more than 3 days, or if dirt, sand or other impurities have contaminated the tack coat, then a tack coat shall be applied after the original one has been swept clean. Application: The tack coat shall be uniformly applied over the entire surface of the area to be covered by means of a bituminous distributor at a rate of 0.25 liters per square meter or as directed by the Company Representative. A hand broom shall be used for application of the tack coat to concrete surfaces not covered by the bituminous distributor. Do not apply tack coat during rainy weather or when the surface to be paved is not free from moisture.

B.

C.

3.05

PLACEMENT OF ASPHALT CONCRETE SECTION 02513

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Receipt of Materials: Do not accept asphalt concrete materials unless it is covered with tarpaulins until unloaded, and unless it has a temperature within the limits described in Paragraph 2.04, C,3 of this Section.

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B.

Placing and Compaction of the bituminous mixture shall progress in sections not more than 90 meters in length. The bituminous mixture shall be spread, shaped and finished with the power machine. The asphalt concrete shall be placed only when the atmosphere temperature is 4 Deg. C, or above, and when the weather is not foggy or rainy and when the existing surface is free from moisture. Spreading: Bituminous mixture shall be spread in placement thickness so that after rolling, the nominal thickness of the compacted bituminous materials shall not be more than 80mm per layer and not less then 50mm per layer. Rolling: After a layer has been placed the full width, the surface shall be rolled. Rolling shall be longitudinal, and shall commence at the outer edge and progress toward the center. Rolling shall continue until the surface is of uniform texture and degree of compaction, and is true to grade and cross section. Under no circumstances shall the center of the surface course be rolled first. Compaction Density: The requirement shall be equal to or greater than 96% of the Marshall density per ASTM D-1559 of each days production. Protection of WORK: Protect those portions of curbs, manholes, valve boxes and other structures, that will be visible upon completion of the project, from bituminous material. Remove any bituminous material from asphalt fouled surfaces and clean these surfaces to the satisfaction of Company Representative.

C.

D.

E. F.

3.06

COMPACTION, SAMPLING AND TESTING A. B. Quality Control: See SAUDI ARAMCO Engineering Standards, SAES-Q-006, Paragraph 5.4.4. Compaction Sampling and Testing: The field Mold Density shall be determined in accordance with AASHTO T 166 taken from samples of freshly-mixed bituminous mixture at the plant. Reheating of the mixture will not be permitted. The density of the mixture as placed and compacted shall be determined from samples cut from the compacted courses at locations specified by Company Representative. Samples shall be obtained in sets of two (2), cut from the same specified location. The frequency of testing shall be be as directed by Company Representative. Cores extracted for thickness measurement shall not be used for density determination and density samples shall not be used for thickness measurements. The CONTRACTOR shall, when necessary, furnish and apply cold water, ice, or other cooling substance to the surface of the pavement to prevent the samples from shattering or disintegrating. The CONTRACTOR shall cut all samples, fill and compact all test holes at his own expense. Sample holes shall be filled with concrete in traffic areas, and with asphalt in play court areas. SECTION 02513

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C.

Tolerance in Thickness: The total depth of base courses and surface courses shall be measured in two (2) separate operations for each type of material. Thickness determination shall be made per layer and a minimum of two (2) locations per 500 meter or rectangular athletic area, at locations designated by Company Representative. Measurement of any core shall not be deficient by more than 10mm or 15% of the design thickness whichever is less.

3.07

TOLERANCE The surface will be tested with a four (4) meter straight edge at selected locations. The variation of the surface from the testing edge of the straight edge between any two (2) contacts with the surface shall at no point exceed four (4) mm when placed parallel to the center line or three (3) mm when placed perpendicular to the center line of the roadway or three (3) mm in any direction for athletic areas. A water ponding test shall be applied over entire surface of rectangular athletic areas. All humps and depressions exceeding the specified tolerance shall be corrected by removing the defective WORK and replacing it with new material as directed by Company Representative at no additional cost to SAUDI ARAMCO. END OF SECTION

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