FAA/10D NC

ITEM P-209 CRUSHED AGGREGATE BASE COURSE

DESCRIPTION

209-1.1 This item consists of a base course composed of crushed aggregates constructed on a prepared
course in accordance with these specifications and in conformity to the dimensions and typical cross
sections shown on the plans.

MATERIALS

209-2.1 AGGREGATE. Aggregates shall consist of clean, sound, durable particles of crushed stone, or
crushed gravel, or crushed slag and shall be free from coatings of clay, silt, vegetable matter, and other
objectionable materials and shall contain no clay balls. Fine aggregate passing the No. 4 (4.75 mm)
sieve shall consist of fines from the operation of crushing the coarse aggregate. If necessary, fine
aggregate may be added to produce the correct gradation. The fine aggregate shall be produced by
crushing stone, gravel, or slag that meet the requirements for wear and soundness specified for coarse
aggregate.

The crushed slag shall be an air-cooled, blast furnace slag and shall have a unit weight of not less than
70 pounds per cubic foot (1.12 Mg/cubic meter) when tested in accordance with ASTM C 29.

The coarse aggregate portion, defined as the material retained on the No. 4 (4.75 mm) sieve and larger,
shall contain not more than 15 percent, by weight, of flat or elongated pieces as defined in ASTM D 693
and shall have at least 90 percent by weight of particles with at least two fractured faces and 100 percent
with at least one fractured face. The area of each face shall be equal to at least 75 percent of the
smallest midsectional area of the piece. When two fractured faces are contiguous, the angle between the
planes of fractures shall be at least 30 to count as two fractured faces.

The percentage of wear shall not be greater than 45 percent when tested in accordance with ASTM C
131. The sodium sulfate soundness loss shall not exceed 12 percent, after 5 cycles, when tested in
accordance with ASTM C 88.

The fraction passing the No. 40 (0.42 mm) sieve shall have a liquid limit no greater than 25 and a
plasticity index of not more than 4 when tested in accordance with ASTM D 4318. The fine aggregate
shall have a minimum sand equivalent value of 35 when tested in accordance with ASTM D 2419.

a. Sampling and Testing. Aggregates for preliminary testing shall be furnished by the Contractor
prior to the start of production. All tests for initial aggregate submittals necessary to determine
compliance with the specification requirements will be made by the Contractor Engineer at no expense to
the Contractor.

Samples of aggregates shall be furnished by the Contractor at the start of production and at intervals
during production. The sampling points and intervals will be designated by the Engineer. The samples
will be the basis of approval of specific lots of aggregates from the standpoint of the quality requirements
of this section.

In lieu of testing, the Engineer may accept certified state DOT test results indicating that the aggregate
meets specification requirements. Certified test results shall be less than 6 months old.

Samples of aggregates to check gradation shall be taken by the Engineer at least two per lot. The lot will
be consistent with acceptable sampling for density. The samples shall be taken from the in-place,
compacted material. Sampling shall be in accordance with ASTM D 75, and testing shall be in
accordance with ASTM C 136 and ASTM C 117.

DULUTH AIRPORT AUTHORITY P-209-1 TECHNICAL SPECIFICATIONS

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b. Gradation Requirements. The gradation (job mix) of the final mixture shall fall within the design
range indicated in Table 1, when tested in accordance with ASTM C 117 and ASTM C 136. The final
gradation shall be continuously well graded from coarse to fine and shall not vary from the low limit on
one sieve to the high limit on an adjacent sieve or vice versa.

TABLE 1. REQUIREMENTS FOR GRADATION OF AGGREGATE \1\

Sieve Size Design Range Job Mix Tolerances

Percentage by Weight Percent
Percentage by Weight
2 in (50.0 mm) 100 0
1-1/2 (37.0 mm) 95-100 +/- 5
1 in (25.0 mm) 70-95 +/- 8
3/4 in (19.0 mm) 55-85 +/- 8
No. 4 (4.75 mm) 30-60 +/- 8
No. 30 (0.60 mm) 12-30 +/- 5
No. 200 (0.075 mm) 0-8 +/- 3

\1\ Where environmental conditions (temperature and availability of free moisture) indicate potential
damage due to frost action, the maximum percent of material, by weight, of particles smaller than 0.02
mm shall be 3 percent when tested in accordance with ASTM D 422. It also may be necessary to have a
lower percentage of material passing the No. 200 sieve to help control the percentage of particles smaller
than 0.02 mm (maximum limit of 5 percent is recommended).

The job mix tolerances in Table 1 shall be applied to the job mix gradation to establish a job control
grading band. The full tolerance still will apply if application of the tolerances results in a job control
grading band outside the design range.

The fraction of the final mixture that passes the No. 200 (0.075 mm) sieve shall not exceed 60 percent of
the fraction passing the No. 30 (0.60 mm) sieve.

CONSTRUCTION METHODS

209-3.1 PREPARING UNDERLYING COURSE. The underlying course shall be checked and accepted
by the Engineer before placing and spreading operations are started. Any ruts or soft yielding places
caused by improper drainage conditions, hauling, or any other cause shall be corrected at the
Contractor's expense before the base course is placed thereon. Material shall not be placed on frozen
subgrade.

209-3.2 MIXING. The aggregate shall be uniformly blended during crushing operations or mixed in a
plant. The plant shall blend and mix the materials to meet the specifications and to secure the proper
moisture content for compaction.

209-3.3 PLACING. The crushed aggregate base material shall be placed on the moistened subgrade in
layers of uniform thickness with a mechanical spreader.

The maximum depth of a compacted layer shall be 6-inches (150 mm). If the total depth of the
compacted material is more than 6-inches (150 mm), it shall be constructed in two or more layers. In
multi-layer construction, the base course shall be placed in approximately equal-depth layers.

The previously constructed layer should be cleaned of loose and foreign material prior to placing the next
layer. The surface of the compacted material shall be kept moist until covered with the next layer.

DULUTH AIRPORT AUTHORITY P-209-2 TECHNICAL SPECIFICATIONS

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209-3.4 COMPACTION. Immediately upon completion of the spreading operations, the crushed
aggregate shall be thoroughly compacted. The number, type, and weight of rollers shall be sufficient to
compact the material to the required density.
The moisture content of the material during placing operations shall not be below, nor more than 2
percentage points above, the optimum moisture content as determined by ASTM [ D1557 ].

209-3.5 ACCEPTANCE SAMPLING AND TESTING FOR DENSITY. Aggregate base course shall be
accepted for density on a lot basis. A lot will consist of one day's production where it is not expected to
exceed 2400 square yards (2000 square meters). A lot will consist of one-half day's production where a
day's production is expected to consist of between 2400 and 4800 square yards (2000 and 4000 square
meters).

Each lot shall be divided into two equal sublots. One test shall be made for each sublot. Sampling
locations will be determined by the Engineer on a random basis in accordance with statistical procedures
contained in ASTM D 3665.

Each lot will be accepted for density when the field density is at least 100 percent of the maximum density
of laboratory specimens prepared from samples of the base course material delivered to the job site. The
specimens shall be compacted and tested in accordance with ASTM [ D1557 ]. The in-place field
density shall be determined in accordance with ASTM D 1556 or D 2167. If the specified density is not
attained, the entire lot shall be reworked and/or recompacted and two additional random tests made.
This procedure shall be followed until the specified density is reached.

In lieu of the core method of field density determination, acceptance testing may be accomplished using a
nuclear gage in accordance with ASTM D 2922 and ASTM D 3017. The gage should be field calibrated
in accordance with paragraph 4 of ASTM D 2922. Calibration tests shall be conducted on the first lot of
material placed that meets the density requirements.

Use of ASTM D 2922 results in a wet unit weight, and when using this method, ASTM D 3017 shall be
used to determine the moisture content of the material. Calibration and Standardization shall be
conducted in accordance with ASTM standards.

If a nuclear gage is used for density determination, two random readings shall be made for each sublot.

209-3.6 FINISHING. The surface of the aggregate base course shall be finished by blading or with
automated equipment especially designed for this purpose.

In no case will the addition of thin layers of material be added to the top layer of base course to meet
grade. If the elevation of the top layer is 1/2-inch (12 mm) or more below grade, the top layer of base
shall be scarified to a depth of at least 3-inches (75 mm), new material added, and the layer shall be
blended and recompacted to bring it to grade. If the finished surface is above plan grade, it shall be cut
back to grade and rerolled.

209-3.7 SURFACE TOLERANCES. The finished surface shall not vary more than 3/8-inch (9 mm) when
tested with a 16-foot (4.8 m) straightedge applied parallel with or at right angles to the centerline. Any
deviation in excess of this amount shall be corrected by the Contractor at the Contractor's expense.

209-3.8 THICKNESS CONTROL. The completed thickness of the base course shall be within 1/2-inch
(12 mm) of the design thickness. Four determinations of thickness shall be made for each lot of material
placed. The lot size shall be consistent with that specified in paragraph 3.5. Each lot shall be divided into
four equal sublots. One test shall be made for each sublot. Sampling locations will be determined by the
Engineer on a random basis in accordance with procedures contained in ASTM D 3665. Where the
thickness is deficient by more than 1/2-inch (12 mm), the Contractor shall correct such areas at no
additional cost by excavating to the required depth and replacing with new material. Additional test holes
may be required to identify the limits of deficient areas.

DULUTH AIRPORT AUTHORITY P-209-3 TECHNICAL SPECIFICATIONS

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209-3.9 MAINTENANCE. The base course shall be maintained in a condition that will meet all
specification requirements until the work is accepted. Equipment used in the construction of an adjoining
section may be routed over completed portions of the base course, provided no damage results and
provided that the equipment is routed over the full width of the base course to avoid rutting or uneven
compaction.

The Contractor shall remove all survey and grade hubs from the base courses prior to placing any
bituminous surface course.

METHOD OF MEASUREMENT

209-4.1 The quantity of crushed aggregate base course to be paid for will be determined by
measurement of the number of [square yards (square meters)][cubic yards (cubic meters)] of
material actually constructed and accepted by the Engineer as complying with the plans and
specifications. [On individual depth measurements, thicknesses more than 1/2 inch (12 mm) in
excess of the design thickness shall be considered as the specified thickness, plus 1/2 inch (12
mm) in computing the number of cubic yards (cubic meters) for payment.] The Contractor shall be
paid for neat line quantities in place at the depth and width specified.

BASIS OF PAYMENT

209-5.1 Payment shall be made at the contract unit price per [square yard (square meter)][cubic yard
(cubic meter)] for crushed aggregate base course. This price shall be full compensation for furnishing all
materials, for preparing and placing these materials, and for all labor, equipment tools, and incidentals
necessary to complete the item.

Payment will be made under:

Item P-209-5.1 Crushed Aggregate Base Course -- Per [square yard (square
meter][Cubic Yard (Cubic Meter)]

TESTING REQUIREMENTS

ASTM C 29 Unit Weight of Aggregate

ASTM C 88 Soundness of Aggregates by Use of Sodium Sulfate or Magnesium

Sulfate

ASTM C 117 Materials Finer than 75μm (No. 200) Sieve in Mineral Aggregates by
Washing

ASTM C 131 Resistance to Degradation of Small-Size Coarse Aggregate by abrasion

and impact in the Los Angeles Machine

ASTM C 136 Sieve Analysis of Fine and Coarse Aggregates

ASTM D 75 Sampling Aggregate

ASTM D 422 Particle Size Analysis of Soils

ASTM D 693 Crushed Aggregate for Macadam Pavements

ASTM D 698 Moisture-Density Relations of Soils and Soil-Aggregate Mixtures Using

5.5-lb (2.49-kg) Rammer and 12-in (305mm) Drop

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ASTM D 1556 Density of Soil in Place by the Sand-Cone Method

ASTM D 1557 Test for Laboratory Compaction Characteristics of Soil Using Modified
Effort

ASTM D 2167 Density and Unit Weight of Soil in Place by the Rubber Ballon Method

ASTM D 2419 Sand Equivalent Value of Soils and Fine Aggregate

ASTM D 2922 Density of Soil and Soil-Aggregate in Place by Nuclear Methods

ASTM D 3017 Water Content of Soil and Rock in Place by Nuclear Methods

ASTM D 3665 Random Sampling of Construction Materials

ASTM D 4318 Liquid Limit, Plastic Limit, and Plasticity Index of Soils

ASTM D 6938 Moisture Content of Soil and Soil Aggregate in Place by Nuclear
Methods

END OF ITEM P-209

DULUTH AIRPORT AUTHORITY P-209-5 TECHNICAL SPECIFICATIONS

DULUTH INTERNATIONAL AIRPORT AUGUST 18, 2009
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