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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, asphaltconcrete paving, sampling and testing for the parking and play area pavement orpavement widening and patching as shown on the Construction Drawings and asrequired to complete the WORK acceptable to Company Representative.

1.02 REFERENCES CODES AND STANDARDS: Comply with applicable SAUDI ARAMCOStandards, 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 roadsand parking areas. Coarse material shall be crushed rock or crushed gravel. Finematerial shall be quarry screening or natural material and of suitable bindingquality. The material shall be free from foreign or organic matter, dirt, shale, clay,clay lump or other deleterious matter. Aggregate base course shall meet thefollowing requirements:

1. Physical requirements:

a. Soundness test using magnesium sulfate. (ASTM C-88):18% maximum for coarse aggregate

20% maximum for fine aggregate

b. Loss by abrasion (ASTM C-131 and ASTM C-535) 40% maximum

c. Thin and elongated pieces, by weight, larger than 25mm, thicknessless than 1/5 length (CRD-C-119)5% maximum

d. Friable particles (ASTM C-142)0.25% maximum

e. Plasticity index (ASTM D-4318) : 4-6

f. Sand equivalent (ASTM D-2419)30% minimum

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2. G radation:

The combined materials shall consist of a mixture of all aggregateuniformly graded from coarse to fine to conform to the following gradationrequirements:

Sieve Size Percent Passing

2-1/2 inch 1002-inch 90 - 1001-1/2 inch 60 - 901-inch 42 - 773/4 inch 35 - 701/2 inch 25 - 60No. 4 15 - 40No. 10 10 - 26No. 40 5 - 15No. 200 2 - 9

B. Marl Base: Marl base shall be used as base course for play area. The marl basematerials shall have the same properties as the Select Fill materials as definedin 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 (RasTanura Refinery) Standard A-971 or RC-800, conforming to SAUDI ARAMCO Standard

A-972.

2.04 BITUMINOUS PAVING MIXTURE

A. Asphalt shall be petroleum asphalt cement, penetration Grade 60-70, conformingto the requirements of SAUDI ARAMCO (Ras Tanura Refinery) Standard A-970.

B. Mineral Aggregate:

1. Gradation: When tested according to ASTM C-117 and ASTM C-136, thecombined mineral aggregate shall conform to the following grading.

Hot Asphalt Binder Course Hot Asphalt Surface CourseClass A Class A

Sieve Size % Passing Sieve Size % Passing

1-1/2" - 1-1/2 -1" 100 1 100

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3/4" 80 - 100 3/4 100

1/2" - 1/2 80 - 953/8" 60 - 80 3/8 -#4 45 - 65 #4 48 - 62#10 30 - 50 #10 32 - 45

#40 15 - 32 #40 16 - 26#80 - #80 8 - 18#200 3 - 10 #200 4 - 8

2. Physical requirement: The combined mineral aggregates for bindercourse and asphalt surface shall conform to the following physicalrequirements:

a. Sand Equivalent 45 minimum(ASTM D-2419)

b. Plasticity Index

(ASTM D-4318) 6 maximum(Binder Course)3 maximum(Surface Course)

c. Loss by Abrasion % 40% maximum(ASTM C-131)

d. Loss by Magnesium SulfateSoundness for:

Coarse Aggregate 18% maximum Fine Aggregate 20% maximum

(ASTM C-88)

e. Thin and elongated pieces, by weightlarger than 25mm, thickness less than1/5 length per CRD-C-119 5% maximum

C. Job Mix

1. The job mix formula shall be approved by Company Representative andshall combine the mineral aggregates and asphalt in such proportion as toproduce a mixture conforming to the following composition limits by weight:

Percent

a. Total Mineral Aggregates 96 - 93

b. Asphalt Cement 4 - 7

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

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Binder SurfaceCourse Course

a. Stability (Kg.) 700 min. 700 min.

b. Flow (mm) 2.4-5.0 2.4-4.0

Loss of Marshall stability bysubmerging specimens in water @60 deg. C for24 hrs. as compared tostability measured after submersion in water @ 60deg. C for 20 minutes

a. (ASTM D-1559) 25% max. 25% max.

b. Voids in total mix 3.0-7.0% 3.0-5.0%

c. Voids filled with Bitumen 60-75% 70-80%

d. Voids in mineral aggregate

(VMA) ASTM D-2041 13% min. 14% min.

2. Maximum Variation: Upon receiving the job-mix formula, approved by theCompany Representative, CONTRACTOR shall adjust his plant to proportion theindividual aggregates, mineral filler and asphalt to produce a final mix that whencompared to the job-mix formula, shall be within the following limits:

Tolerance

a. Aggregate Sieve size No. 4 and Larger +/- 5 percent

b. Aggregate Sieve size No. 10 and

c retained on the No. 200 +/- 5 percent

d. Aggregate Sieve size No. 200 & smaller +/- 1.5 percent

e. Asphalt Content +/- 0.3 percent

Submit asphalt mix design to Company Representative for review and approval atleast 30 days prior to use. The asphalt concrete graded from a SAUDI ARAMCOapproved batch plant.

3. Temperature: The mixture shall have a temperature between 139 Deg. C and 163Deg. 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, previouslycleaned of all foreign materials. The mixture shall be delivered on the surface tobe 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 todelivery of materials for the base course, prepare the subgrade surface by

sprinkling, blading, rolling and lightly scarifying where necessary, until the propercrown is obtained. When compacted and ready for base course construction, thesubgrade shall be well compacted, smooth, hard and uniform, all irregularitieshaving been bladed out and rolled smooth.

B. Compaction: Subgrade shall be compacted to not less than 95 percent of themaximum dry density per ASTM D-1557, Method D, or AASHTO T-180, MethodD, or to 85 percent relative density determined by ASTM D-4253 and D-4254.

C. Maintenance of Subgrade: The finished subgrade shall be maintained in asmooth and compacted condition until the base course and surface course are inplaced.

3.02 BASE COURSE PLACING AND COMPACTION

A. Construction: Do not construct base course until the subgrade is approved byCompany Representative.

B. Placing: Granular base material shall be placed in layers of uniform thicknesswith approved spreaders. Layer thickness generally shall not exceed 150 mmafter compaction. When the base or subbase course is constructed in more thanone layer, the previously constructed layers shall be cleaned of loose and foreignmatter. The water content of the material shall be maintained during compactionat the optimum percentage (+/- 1-1/2%) as determined by ASTM D-1557 or

AASHTO T-180.

C. Compaction: While at optimum moisture (+/- 1-1/2%) the subbase or basematerial shall be compacted with equipment capable of obtaining the desireddensity to the full depth of the respective layer. The rolling shall continue until thebase and subbase are compacted to not less than (100 percent for the base or95 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 measuredby ASTM D-2922 or other approved methods.

D. Finishing : The surface of the compacted material shall be finished by blading orwith automated equipment especially designed for this purpose and rolled with asteel-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 surfaceof the completed base shall not show any deviation in excess of 6mm whentested with a 3 meter straightedge. The completed thickness of the base shall bewithin +/- 6mm of the thickness shown on the Construction Drawings, and theaverage thickness shall not be less than the design thickness.

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E. CBR Value: For Aggregate Base Course, the laboratory compacted CaliforniaBearing Ratio, per ASTM D-1883 shall not be less than 50 after four dayssoaking.

3.03 PRIME COAT APPLICATION

A prime coat consists of the initial application of liquid asphalt onto the surface of a non-asphalt base course.

A. Cleaning Surface: Prior to the application of the prime coat the surface shall becleaned of all loose dirt and other objectionable materials by means of approvedmechanical sweepers or blower and or hand broom.

B. Application: Prior to application, the surface shall be cleaned of all loose dirt andother objectionable materials by means of mechanical sweepers, blower and/orhand broom. Prime coat shall be applied by means of a pressure distributor at arate between 0.65 and 1.75 liters per square meter and at a temperature between50 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 betreated is dry and when the weather is not foggy or rainy and the temperature inthe shade is 8 degrees C and rising.

C. Curing: The prime coat shall be permitted to cure until the penetration intounderlying surface has been approved by Company Representative, but in notime shall the curing period be less than 24 hours. The prime coat shall be fullyset and cured before placing an asphalt mixtures on the base.

3.04 APPLICATION OF TACK COAT

A. Concrete Surfaces: Tack coat shall be applied to all concrete surfaces that willbe in contact with the asphalt pavement. Tack coat applications shall take placeprior to the paving operations and will include surfaces of concrete curbs andother drainage structures.

B. Binder Course: Tack coat shall be applied between the binder course and thesurface course. If applications of the surface course is delayed by more than 3days, or if dirt, sand or other impurities have contaminated the tack coat, then atack coat shall be applied after the original one has been swept clean.

C. Application: The tack coat shall be uniformly applied over the entire surface ofthe area to be covered by means of a bituminous distributor at a rate of 0.25 litersper square meter or as directed by the Company Representative. A hand broomshall 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 whenthe surface to be paved is not free from moisture.

3.05 PLACEMENT OF ASPHALT CONCRETE

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A. Receipt of Materials: Do not accept asphalt concrete materials unless it iscovered with tarpaulins until unloaded, and unless it has a temperature within thelimits 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 notmore than 90 meters in length. The bituminous mixture shall be spread, shapedand finished with the power machine. The asphalt concrete shall be placed onlywhen the atmosphere temperature is 4 Deg. C, or above, and when the weatheris not foggy or rainy and when the existing surface is free from moisture.

C. Spreading: Bituminous mixture shall be spread in placement thickness so thatafter rolling, the nominal thickness of the compacted bituminous materials shallnot be more than 80mm per layer and not less then 50mm per layer.

D. 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 progresstoward the center. Rolling shall continue until the surface is of uniform textureand degree of compaction, and is true to grade and cross section. Under nocircumstances shall the center of the surface course be rolled first.

E. Compaction Density: The requirement shall be equal to or greater than 96% ofthe Marshall density per ASTM D-1559 of each days production.

F. Protection of WORK: Protect those portions of curbs, manholes, valve boxesand other structures, that will be visible upon completion of the project, frombituminous material. Remove any bituminous material from asphalt fouledsurfaces and clean these surfaces to the satisfaction of CompanyRepresentative.

3.06 COMPACTION, SAMPLING AND TESTING

A. Quality Control: See SAUDI ARAMCO Engineering Standards, SAES-Q-006,Paragraph 5.4.4.

B. Compaction Sampling and Testing: The field Mold Density shall be determined inaccordance with AASHTO T 166 taken from samples of freshly-mixed bituminousmixture at the plant. Reheating of the mixture will not be permitted. The densityof the mixture as placed and compacted shall be determined from samples cutfrom the compacted courses at locations specified by Company Representative.Samples shall be obtained in sets of two (2), cut from the same specifiedlocation. The frequency of testing shall be be as directed by CompanyRepresentative.

Cores extracted for thickness measurement shall not be used for densitydetermination and density samples shall not be used for thicknessmeasurements.

The CONTRACTOR shall, when necessary, furnish and apply cold water, ice, orother cooling substance to the surface of the pavement to prevent the samplesfrom shattering or disintegrating. The CONTRACTOR shall cut all samples, filland compact all test holes at his own expense. Sample holes shall be filled withconcrete in traffic areas, and with asphalt in play court areas.

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C. Tolerance in Thickness: The total depth of base courses and surface coursesshall 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 byCompany Representative. Measurement of any core shall not be deficient bymore 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. Thevariation 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 tothe center line or three (3) mm when placed perpendicular to the center line of theroadway or three (3) mm in any direction for athletic areas. A water ponding test shall beapplied over entire surface of rectangular athletic areas. All humps and depressionsexceeding the specified tolerance shall be corrected by removing the defective WORKand replacing it with new material as directed by Company Representative at noadditional cost to SAUDI ARAMCO.

END OF SECTION

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