New Jersey

Department of Transportation

Standard Specifications

for Road and Bridge Construction

2007


Division 1000 – Equipment
       
  Section 1001 – Traffic Control Equipment
    1001.01 Flashing Arrow Board
    1001.02 Portable Variable Message Sign
    1001.03 Traffic Control Truck with Mounted Crash Cushions
    1001.04 Portable Variable Message Sign with remote Communication
    1001.05 Portable Trailer mounted CCTV CAMERA Assembly
  Section 1002 – Compaction Equipment
    1002.01 Pneumatic-Tired Compactor
    1002.02 Dynamic Compactor
    1002.03 Steel-Wheel Roller
    1002.04 Padfoot Roller
  Section 1003 – HMA Site Equipment
    1003.01 Materials Transfer Vehicle (MTV)
    1003.02 HMA curb machine
    1003.03 HMA Paver
    1003.04 Ultra-Thin Lift Paver
    1003.05 HMA Compactor
    1003.06 Vibratory Drum Compactor
    1003.07 Bituminous Material Distributor
    1003.08 Sealer Application System
  Section 1004 – Pile Driving Equipment
    1004.01 Impact Hammer
    1004.02 Vibratory Hammer
    1004.03 Leads and Followers
  Section 1005 – Concrete Site Equipment
    1005.01 Pavement Forms
    1005.02 Spreading and Finishing Machine
    1005.03 Spreading and Finishing Machine for Concrete Bridge Decks
    1005.04 Vibrator
    1005.05 Slip-Form Paver
    1005.06 Slip-Form (Extrusion) Machine
    1005.07 Epoxy Resin Injection Equipment
  Section 1006 – Concrete Pavement Rehabilitation Equipment
    1006.01 Breaker
    1006.02 Seating Equipment
    1006.03 Grout Pumping Unit
    1006.04 Mixer
    1006.05 Injection Device
    1006.06 Lift Monitoring Equipment
    1006.07 Deflection Testing Equipment
    1006.08 Grinding Machine
    1006.09 Scarification Equipment
  Section 1007 – Traffic Striping Equipment
    1007.01 Epoxy Striping Unit
    1007.02 Thermoplastic Applicator
    1007.03 Traffic Stripe and Marking Removal Equipment
    1007.04 Rumble Strip Cutting Machine
  Section 1008 – Miscellaneous Equipment
    1008.01 Milling Machine
    1008.02 Straightedge
    1008.03 Mechanical Sweeper
    1008.04 Pavement Saw
    1008.05 Air Compressor
    1008.06 Hot-Air Lance
  Section 1009 – HMA Plant Equipment
    1009.01 HMA Plant
    1009.02 HMA Trucks
    1009.03 Asphalt-Rubber Binder Blending Equipment
  Section 1010 – Concrete Plant and Mixing Equipment
    1010.01 Batching Plant
    1010.02 Concrete Trucks
    1010.03 Mobile Mixer
    1010.04 Small-Batch Mixer
  Section 1011 – Precast and Prestressed Concrete Plant Equipment
    1011.01 Precast Plant
    1011.02 Prestressed Plant
    1011.03 ME’s Office

Division 1000 – Equipment

Section 1001 – Traffic Control Equipment


1001.01 Flashing Arrow Board   back to top

Provide Type A and Type C flashing arrow boards according to the MUTCD and the following requirements:

  1. Non-reflective, black boards equipped with battery-operated amber lights.
  2. A minimum peak luminous intensity of 8800 candelas and equipped with photocells that will automatically reduce the luminous intensity to 1500 candelas when the ambient light level drops to 5 foot-candles.
  3. A light on the rear face of the board to indicate that the lights are operating.
  4. Solid state controls with polarity and surge protection.
  5. Panel operation controls mounted in a lockable enclosure.

Ensure flashing arrow boards are equipped with a diesel charged battery system. Do not use gasoline powered systems. With RE approval, the Contractor may use flashing arrow boards equipped with solar charged battery systems in non-moving operations. The Department may require a solar charged battery system in noise sensitive areas.

Securely mount flashing arrow boards on a manufacturer-approved 2-wheeled towing trailer.

1001.02 Portable Variable Message Sign   back to top

Provide a portable variable message sign capable of displaying messages that are visible under ideal day and night conditions from a minimum distance of 1/2 mile and that are legible from a minimum distance of 900 feet with a viewing angle of at least 25 degrees. Ensure that the portable variable message sign is able to operate in ambient temperatures of −30 to 160 °F and is capable of withstanding wind gusts up to 80 miles per hour when positioned. Provide a portable variable message sign with the following:

  1. Sign Panel. Provide a sign panel capable of displaying 3 lines of a message, with each line capable of displaying up to 8 characters. Ensure that the characters have a minimum height of 18 inches, a minimum width of 12 inches, and are spaced at least 3 inches apart. Compose characters of a 5 wide by 7 high pixel matrix, with each pixel composed of between 4 and 6 LED lights. Ensure that the LED lights have a dominant wavelength between 585 and 595 nanometers and are set against a black background. Ensure that the LED lights provide a minimum daylight luminance of 1000 candelas per square meter. Ensure that the sign is equipped with a photocell to automatically reduce the LED lights’ luminance to between 30 to 100 candelas per square meter when the ambient light level drops to 5 foot-candles. Ensure that LED lights maintain constant luminance intensity with changes in battery voltage.

    Ensure that the sign panel is covered with an ultraviolet-resistant, clear polycarbonate.

  2. Controller. Ensure that the controller is unaffected by radio transmissions. Ensure that the controller is capable of displaying 3 messages sequentially. Ensure that controller has an adjustable display rate with a minimum of 3 seconds per phase. Ensure that the controller is capable of storing 100 user programmed messages in nonvolatile memory that will retain the programmed messages when power is interrupted. Provide a controller display screen that allows the operator to review messages before displaying on the message sign. Ensure that the controller display shows the operator all programming instructions. Ensure that the messages are able to be programmed at the sign with an integral or plug-in keyboard, and remotely with a cellular telephone.

    Secure panel controls in a lockable weatherproof enclosure. Prevent unauthorized access to the controller by requiring a password to the keyboard. Prevent unauthorized remote access by requiring a password. If the correct password is not entered within 60 seconds of initial phone contact, the phone call will terminate.

  3. Power Source. Equip portable variable message signs with either a diesel charged or a solar charged battery system. Ensure that the variable message sign is also capable of operating on 120-volt AC electrical service. The Department may require a solar charged battery system in noise sensitive areas. Provide the power with a battery back up system capable of providing continuous operation when the primary power source fails. Ensure that the power source meets the following requirements:

    1. Diesel. Ensure that the fuel tank is capable of operating the sign for a period of 72 hours without refueling. Equip with an exhaust muffler and a United States Department of Forestry approved spark arrester. Ensure that the engine is shock mounted to reduce vibration and locked in a ventilated enclosure.

    2. Solar. Provide solar panels capable of recharging the batteries at a rate of 4 hours of sun for 24 hours of sign usage. Ensure that the battery capacity is capable of operating the sign for a period of 18 days without sunlight.

  4. Structural Support System. Mount the variable message sign on a portable 2-wheeled trailer. Ensure that the sign panel is capable of being raised or lowered during sustained wind speeds of 30 miles per hour. Ensure that the sign panel is capable of being locked into position and is capable of being positioned at the proper height and orientation required for visibility according to the MUTCD.

1001.03 Traffic Control Truck with Mounted Crash Cushions   back to top

Provide a truck having a minimum gross weight of 10 tons, affixed with a bed-mounted, type C flashing arrow board, as specified in 1001.01, and a rear mounted crash cushion. The Contractor may use precast concrete ballast to meet the weight requirement. When using ballast, ensure that it is securely fastened to the truck. Provide crash cushions that conforms to the following requirements:

  1. Meets NCHRP 350 Level 3 crash-worthiness requirements.
  2. Designed to be attached to the rear of a truck.
  3. Equipped with a 90-degree hydraulic tilt system to raise and lower the crash cushion. The tilt system shall have a locking mechanism to secure the crash cushion when in the raised position.
  4. If equipped with energy absorbing modules, ensure that they are painted yellow.
  5. Displays alternating 6-inch wide black and yellow bands, composed of Type III-retroreflective sheeting, as specified in ASTM D 4956, in an inverted “V” chevron pattern on the surface of the rear module that faces traffic. When in the raised position, ensure that the surface of the rear facing module also displays the chevron pattern.
  6. Equipped with standard trailer lighting systems, including brake lights, taillights, and turn signals that are visible in the raised and lowered positions.

1001.04  PORTABLE VARIABLE MESSAGE SIGN W/REMOTE COMMUNICATION back to top

Provide a NTCIP compliant portable variable message sign as described under 1001.02 equipped with broadband cellular modem.

1001.05  Portable Trailer mounted CCTV CAMERA assembly back to top

Provide a Portable Trailer Mounted CCTV Camera Assembly (PTMCCA) with the following:

A.      Trailer Platform

    1. Maximum size, including tongue, 14 feet long by 7 feet wide by 8 feet high.

    2. NJDOT approved lighting package to include electrical brake and marker lights with wire connections.

    3. Primed and painted with powder coated orange color.

    4. Fitted with manual telescoping outriggers with adjustable jacks sized to counter full mast extension.

    5. Four 3500 pounds, drop leg, top wind screw jacks.

    6. All equipment secured to prevent theft or separation from platform.

    7. 24/7 operation in all weather conditions.

    8. One locking NEMA-4 equipment box for operational controls.

    9. Removable wheels (with wheel locks) when trailer is in deployed position.

    10. Operation manual with a copy placed in the storage bin.

B.      Mast

    1. 150 pounds payload capacity.

    2. 29 feet to 32 feet of extension with capability to mount antenna at 20 feet, 25 feet or at the top, 10 feet maximum nested length of mast - 3 to 9 sections.

    3. Un –guyed.

    4. Driven by galvanized steel cable.

    5. Spiral conduit for cables.

    6. Compactly retractable when nested into storage container at the bottom  & foldable for easy transport.

    7. Operated by a power winch with a safety brake.

    8. Capable of being raised or lowered during sustained wind speeds of 30 miles per hour.

C.      Power Source

    Equip the PTMCCA with either a diesel charged or a solar charged battery system.  Ensure that the PTMCCA is also capable of operating on 120-volt AC electrical service.  The Department may require a solar charged battery system in noise sensitive areas.  Provide the power with a battery back up system capable of providing continuous operation when the primary power source fails.  Ensure that the power source meets the following requirements:

    1. Diesel.  Ensure that the fuel tank is capable of operating the sign for a period of 72 hours without refueling.  Equip with an exhaust muffler and a United States Department of Forestry approved spark arrester.  Ensure that the engine is shock mounted to reduce vibration and locked in a ventilated enclosure.
    2. Solar.  Provide solar panels capable of recharging the batteries at a rate of 4 hours of sun for 24 hours of camera usage.  Ensure that the battery capacity is capable of operating the sign for a period of 18 days without sunlight.

D.      Electronics

    1. Cellular (CDMA), microwave, or 802.11 bandwidth option.

    2. Work lights in all cabinets.

    3. Remote trailer diagnostics (battery level, charging output, etc.).

E.      Camera and Software

Ensure that the camera has the following characteristics:

  1. Dome Camera in a heavy duty plastic dome or with a weather resistant case.

  2. Impact resistant viewing window.

  3. Minimum resolution of NTSC 704 (H) x 480 (V).

  4. Backlight compensation.

  5. Image stabilization.

  6. Light Sensitivity 0.02 lux NIR Mode.

  7. Auto Focus with Manual Focus capability.

  8. Auto White Balance with Manual White Balance capability.

  9. Motorized Zoom up to 16x optical, 10x digital.

  10. Motorized Pan-Tilt, pan 360°, tilt 180°.

  11. Thermostatically controlled heater and defroster -50° to 140°F operating range.

  12. Windshield wiper.

  13. 24/7 operation in all weather conditions.

  14. Time and date stamp.

Ensure the software provides the following functionality:

  1. Remote control of pan, tilt and zoom.

  2. Display of streaming video in MPEG format, motion-JPEG, and single snapshot JPEG images, remotely interchangeable by using central software.

  3. Preset controls of pan/tilt/zoom combinations.  Ensure all presets are accessible from a drop-down menu with descriptive name of preset.  Set first 8 presets with quick- launch icons with graphical representation of the preset views.

  4. Display of all the project’s web cams in a single view screen.

  5. Display of local time and weather conditions including temperature and humidity.

  6. Saving images and sending e-mail images.

  7. Viewing archived images via a graphical calendar control and storing archived images at least every five minutes.

  8. Three levels of password protection: administrator, user, and guest, individual user accounts.

  9. Monitoring and controlling the cameras using web access.

Section 1002 – Compaction Equipment


1002.01 Pneumatic-Tired Compactor   back to top

Provide a self-propelled, 2-axle, pneumatic-tired compactor equipped with pneumatic tires mounted to completely cover the area to be compacted in a single pass. Provide compactors with a minimum width of 5 feet. Ensure that the wheels on at least 1 axle oscillate vertically, either independently or in pairs. Equip wheels with smooth, wide-tread compactor tires of equal size and diameter. Ensure that the compactor is capable of producing a uniform, ground contact pressure on a level, unyielding surface through a range of 60 to 95 pounds per square inch on all wheels.

Uniformly inflate all tires. Ensure that tire pressures do not vary by more than 5 pounds per square inch. Provide charts and tabulations showing the contact areas and contact pressures for the full range of tire inflation pressures and for the full range of loadings for the tires used. Maintain operating tire contact pressure using ballast, and do not allow tire inflation pressure combinations to exceed the recommendations of the Tire and Rim Association Incorporated for the applicable tire size and ply rating. Do not provide wobble-wheeled compactors.

1002.02 Dynamic Compactor   back to top

Provide a vibratory roller or vibratory pad-type compactor capable of operating at the optimum frequency of vibration required for the size and type of compactor used and for the type of material being compacted. Mount on the vibratory roller a readily visible instruction plate containing the manufacturer’s recommended operating frequency, amplitude, and roller speed.

Provide vibratory pad type compactors when access with a vibratory roller is not practical.

1002.03 Steel-Wheel Roller   back to top

Provide a power-driven, 2-axle tandem roller with a load of at least 250 pounds per inch of width of tread of drive roll and a total ballasted weight of at least 8 tons.

1002.04 Padfoot Roller   back to top

Provide a tamping type or padfoot roller, with 1 or more cylinders, having pads of not less than 6-1/2 inches in length and capable of developing a pressure of not less than 200 pounds per square inch of bearing surface when a complete row of pads is in contact with a level surface.

Section 1003 – HMA Site Equipment


1003.01 Materials Transfer Vehicle (MTV)   back to top

Ensure that the MTV is capable of independently delivering HMA from the hauling equipment to the paving equipment. Ensure that the MTV is equipped with a high-capacity truck unloading system to receive mixtures; a storage system capable of holding at least 15 tons of HMA; and a discharge conveyor capable of swiveling to either side to deliver HMA to the paving spreader while allowing the MTV to operate from an adjacent lane. Ensure that the MTV is equipped with an automatic audible warning signal when operating in reverse.

Provide a paver hopper insert with a minimum capacity of 14 tons in the hopper of conventional paving equipment.

Provide a remixing system to continuously blend the HMA before placement. Remixing may occur within the MTV or in the paver hopper.

1003.02 hma curb machine   back to top

Provide a self-propelled, automatic HMA curb machine specifically designed to produce HMA curb, or a paver with attachments that produces curb of uniform texture, shape, and density.

1003.03 HMA Paver   back to top

For paving widths of 8 feet or more, provide a self-propelled HMA paver with an activated screed or strike-off assembly capable of spreading and finishing HMA in the lane widths and thicknesses required. Ensure that the paver is capable of being operated at forward speeds consistent with satisfactory laying of the mixture. Ensure that the paver is equipped with an automatic audible warning signal when operating in reverse.

Ensure that the paver is also equipped with the following:

  1. Receiving Hopper and Distribution System. Ensure that the receiving hopper is equipped with a distribution system capable of placing the HMA uniformly in front of the screed.

  2. Screed or Strike-off Assembly. Ensure that the screed or strike-off assembly produces finished surface of the required evenness and texture without tearing, shoving, or gouging the HMA. Ensure that the screed or strike-off assembly compacts the full width of the course being laid.

  3. Screed Heater. Ensure that the paver is equipped with a system for heating the screed or strike-off assembly.

  4. Sloped Plate. When constructing longitudinal wedge joints, ensure that the paver is equipped with a sloped plate. Ensure that the sloped plate is attached to the paver screed extension and is capable of producing a wedge edge having a face slope of 3H:1V. Ensure that the plate can accommodate compacted layer thicknesses from 1-1/2 to 4 inches. Mount the bottom of the sloped plate 3/8 to 1/2 inch above the existing surface. Ensure that the sloped plate is interchangeable for use on either side of the screed.

  5. Automatic Slope Controls. Ensure that the automatic slope control system maintains the screed or strike-off assembly in a constant position relative to profile and cross-slope references. Use references to ensure that control of the screed or strike-off position is independent of irregularities in the underlying surface and spreader operation. When paving in widths that exceed the manufacturer’s recommendations for use of the automatic slope control, use an RE approved grade reference system on both sides of the paver. If the RE determines that the automatic controls are ineffective, the Contractor may use other RE approved methods.

  6. Automatic Profile Control. For the first lift of paving, use a stringline or an RE approved electronic grade reference system for longitudinal grade control. For a stringline reference system, provide a line supported by devices compatible with the type of automatic paver control system used. Use stringline and supports capable of maintaining line and grade at the point of support while withstanding the tensioning necessary to prevent sag in excess of 1/4 inch between supports spaced 50 feet apart. Install additional supports spaced 25 feet or less apart to remove any apparent deviation of the stringline from the specified grade. The RE may require spacings of 25 feet at the crest and bottom of vertical curves. If the first lift of paving is placed on or adjacent to a surface that has been placed to the specified line, grade, and cross-section and has been approved by the RE, the Contractor may use a ski-type reference system.

    For subsequent lifts of paving, use a ski-type grade reference system. The RE may allow the use of a joint-matching shoe instead of the ski during paving.

  7. Manual Override System. Ensure that the paver is capable of manual override of the automatic controls while the paver is in automatic operation.

For paving widths of less than 8 feet, provide a paver that is capable of spreading and finishing HMA to the shown widths and thicknesses.

1003.04 Ultra-Thin Lift Paver   back to top

Provide a self-propelled paver specifically designed for applying ultra-thin friction course. Provide a single unit capable of spraying the modified asphalt tack/seal coat and spreading the mixture. Ensure that the paver is capable of spreading, without tearing, shoving, or gouging the mixture, to produce a smooth surface. Use a paver that is heated and capable of spreading and finishing the modified asphalt tack/seal coat and the ultra-thin HMA material to the widths and application rates shown. Provide pavers capable of operation at forward speeds of 70 to 100 feet per minute. Do not operate pavers at speeds less than 30 feet per minute. Ensure that the paver is equipped with an automatic reverse signal alarm that is audible above the surrounding noise.

1003.05 HMA Compactor   back to top

Provide to the RE the manufacturer’s technical data sheets, including the weight and dimensions of the rollers to be used.

Ensure that the roller is equipped with adjustable scrapers to keep wheels clean and with a system to keep wheels moist to prevent HMA from sticking to the wheels. Use wheels free of flat areas, openings, or projections that may mar the surface.

Ensure that the roller is equipped with an automatic audible warning signal when operating in reverse. Use rollers capable of reversing direction without backlash and that conform to the following:

  1. Steel-Wheel Roller. Provide a power-driven, 2-axle tandem roller with a load of at least 250 pounds per inch of width of tread of drive roll and a total ballast weight of at least 8 tons.

  2. HMA Vibratory Roller. Provide a self-propelled vibratory roller with at least 2 smooth steel drums. Use a vibratory roller having a static weight of at least 6-1/2 tons and that is capable of maintaining the frequency and amplitude of vibration specified by the manufacturer. Ensure that the vibratory roller is also equipped with the following:

    1. One light on each fender, or alternatively, 1 light above the roller, visible from a distance of 200 feet. Ensure that the light blinks when the vibratory system is in operation.
    2. Provide a speed indicator in feet per minute or tenths of a mile per hour and a frequency indicator to allow the operator to closely control the rolling speed.
    3. Equip rollers with an automatic vibration disconnect system that automatically shuts off the vibration when the roller is in a stationary position. Provide a mechanical override system in the event of temporary failure of the automatic system that shuts off the vibration when the roller is in a stationary position.

Provide instruction sheets for each vibratory roller used indicating operational instructions, recommended amplitude, vibrations per minute, and speed settings.

1003.06 Vibratory Drum Compactor   back to top

Provide a self-propelled vibratory drum compactor, equipped with 1 or 2 smooth steel drums having a minimum centrifugal force of 177 pounds per inch of width of tread of drive roll. Ensure that the self-propelled vibratory drum compactor is capable of maintaining the frequency of vibration and amplitude specified by the manufacturers. For each vibratory roller used, provide the manufacturer’s recommendations indicating operational instructions, recommended amplitude, vibrations per minute, and speed settings.

1003.07 Bituminous Material Distributor   back to top

Provide a pressurized bituminous material distributor capable of maintaining bituminous material within the specified temperature range and applying the material uniformly over variable surface widths of up to 15 feet. Ensure that the bituminous material distributor is equipped with the following:

  1. Temperature gauge on the truck body to indicate the temperature of the contained bituminous material.
  2. A separate power unit for the pump.
  3. Full circulation spray bars that are adjustable laterally and vertically.
  4. An analog or digital readout meter calibrated in English units.

1003.08 Sealer Application System   back to top

Provide sealing equipment for sealing joints or cracks that consists of a kettle or melter and an applicator wand. Ensure that the melter is a double boiler, with the space between the inner and outer shells filled with oil or other heat transfer medium. Ensure that the melter includes positive temperature control, mechanical agitation, recirculation pumps, and thermometers for continuous reading of the temperature of both the sealing compound and the heat transfer medium. Use a heated or insulated applicator wand to maintain the pouring temperature of the sealant during the placing operation. Do not use pouring pots or similar devices to fill sawed joints or cracks.

Section 1004 – Pile Driving Equipment

1004.01 Impact Hammer   back to top

Ensure that air, hydraulic, and diesel hammers develop at least 6000 foot-pounds of energy per blow. Ensure that drop hammers have a ram weight of at least 2000 pounds and a maximum drop of 8 feet.

For steam or air hammers, ensure that the weight of the ram is at least 1/3 the weight of the pile. For diesel hammers, ensure that the weight of the ram is at least 1/4 the weight of the pile.

Provide diesel hammers equipped with gauges and charts for the determination of the actual driving energy produced under all driving conditions.

  1. Hammer Cushion. Ensure that impact pile driving equipment, except for gravity hammers, are equipped with a suitable thickness of hammer cushion material to prevent damage to the hammer and pile and to ensure uniform driving. Provide hammer cushions made of manufactured materials according to the hammer manufacturer’s guidelines.

    Do not use wood, rope, wire rope, hose, tires, or asbestos hammer cushions.

    As recommended by the hammer manufacturer, place a striker plate on the hammer cushion to ensure uniform compression of the cushion material. Inspect the hammer cushion in the presence of the RE when beginning pile driving at each structure or after each 100 hours of pile driving, whichever is less. Replace the hammer cushion when its thickness is less than 75 percent of the original thickness.

  2. Pile Cushion. Use pile cushions made of plywood to protect the heads of concrete piles. Ensure that the plywood thickness is at least 4 inches before driving. Ensure that the pile cushion dimensions match the cross-sectional area of the pile head.

    Provide a new pile cushion for each pile. Immediately replace the pile cushion if it splits, is compressed to half of its original thickness, begins to burn, or does not function as intended.

  3. Pile Drive Head. Equip piles driven with impact hammers with a pile drive head to distribute the hammer blow to the pile head. Ensure that the pile drive head is aligned axially with the hammer and the pile. Use leads to guide the pile drive head. Ensure that the pile drive head fits around the pile head and prevents the transfer of torsional forces during driving operations while maintaining the proper alignment of the hammer and the pile.

    For steel and timber piles, ensure that the pile heads are cut squarely and provide a pile drive head to hold the longitudinal axis of the pile in line with the hammer.

    For precast concrete and prestressed concrete piles, ensure that the pile head is plane and perpendicular to the longitudinal axis of the pile to prevent eccentric impacts to the pile head.

    For special types of piles, provide appropriate pile drive heads, mandrels, or other devices to ensure that the piles are driven without damage.

1004.02 Vibratory Hammer   back to top

Select the vibratory hammer that satisfies the equation in which driving amplitude equals 2 times the eccentric moment divided by the vibratory load, as shown below.

   Driving Amplitude  =  
2 x Eccentric Moment

Vibratory Load

Ensure that the solution of this equation is between 1/4 and 1/2 inch. The vibratory load is the sum of the weight of the pile and the weight of the vibrating mass of the vibrator, including the weight of the clamp, housing, and jaws. Obtain the Eccentric Moment from the manufacturer.

1004.03 Leads and Followers   back to top

Provide pile driving leads that are straight and support the vertical or battered pile and hammer in proper position throughout the driving operation. Use leads that allow the hammer to move freely and ensure concentric impact for each blow. Use leads that are of sufficient length so that followers are not required. Use either fixed or swinging leads.

Use guys or braces to hold fixed leads in position to ensure support of the pile during driving operations. When using swinging leads, fit with a pile gate at the bottom of the leads. When using swinging leads, the RE may require a horizontal brace for battered piles. To maintain alignment, ensure that swinging leads are embedded in the ground or that the pile is constrained in a structural frame, such as a template.

Except where piles are driven through water, do not use followers unless approved by the RE.

Section 1005 – Concrete Site Equipment

1005.01 Pavement Forms   back to top

Provide straight-sided, metal forms with a thickness of at least 1/4 inch and sections at least 10 feet in length. Ensure that forms have a depth at least equal to the thickness of the concrete without horizontal joint and a base width at least equal to the depth of the forms. Use flexible or curved forms of wood or metal with the proper radius for curves with a 100-foot radius or less. Provide forms with devices for secure setting to ensure that when in place, the forms will withstand, without visible deflection or settlement, the impact and vibration of the consolidating and finishing equipment. Ensure that flange braces extend outward on the base at least two-thirds the height of the form. Ensure that the top face of the form does not vary from a true plane by more than 1/8 inch in 10 feet, and that the face of the form does not vary more than 1/4 inch.

Ensure that the forms are capable of tightly locking ends of abutting sections for secure setting. Use metal pins of the required size and length to hold the forms rigidly and securely in place. Ensure that pins are at least 2 feet in length.

1005.02 Spreading and Finishing Machine   back to top

Provide a vibratory, power driven spreading and finishing machine capable of striking off, screeding, consolidating, and floating the concrete to the required cross-section and elevation. Ensure that the spreading and finishing machine has sufficient weight and strength to produce the necessary pressure and is capable of being adjusted to produce the cross-section and finish required. Ensure that the spreading and finishing machine is geared to operate consistently and smoothly and is equipped with at least 2 oscillating-type transverse screeds and a scraping device to keep the tops of the forms clean.

1005.03 Spreading and Finishing Machine for Concrete Bridge Decks   back to top

Provide a self-propelled, rotating cylinder type or oscillating type finishing machine. The Contractor may use longitudinal or transverse type finishing machines. Ensure that the finishing machine is capable of operating forward and backward to repeat passes to correct surface irregularities and to produce a surface that conforms to the required profile grade, cross-section, and surface tolerances. If using a longitudinal finishing machine, ensure that the machine is capable of finishing the full length of the span, or finishing the full length between designated or approved construction joints. If using a transverse finishing machine, ensure that the machine is of sufficient size to finish the full width of deck between curbs, or the full distance between longitudinal construction joints. Ensure that the machine is equipped to travel on steel rails, pipe, or other supported grade controls securely fastened in place to prevent any appreciable deflection between supports.

1005.04 Vibrator   back to top

Use spud vibrators for consolidating concrete. The Contractor may use hand operated vibrators or vibrators attached to the spreading and finishing machine, or mounted on a separate carriage. Ensure that vibrators have a minimum frequency of 5000 impulses per minute.

Except for hand-held vibrators, ensure that vibration operation is controlled by the forward movement of the spreading and finishing machine so that vibration automatically ceases when the forward movement of the spreader is stopped.

1005.05 Slip-Form Paver   back to top

Provide a self-propelled slip-form paver designed to spread, consolidate, screed, and float-finish the concrete for the full depth of the slab in 1 pass of the machine. Ensure that the slip-form paver is equipped with automatic alignment and grade controls consisting of a sensing device that continuously remains in contact with a sensing guide. Use a slip-form paver that is capable of vibrating the concrete for the full width and depth of the slab and that automatically ceases vibrating when the paver’s forward movement is stopped.

1005.06 Slip-Form (Extrusion) Machine   back to top

Provide a slip-form (extrusion) machine capable of placing concrete through a mold of proper cross-section to produce concrete of the specified shape, surface texture, and density. Ensure that the slip-form machine is capable of consolidating the freshly placed concrete in 1 pass of the machine. Ensure that the slip-form machine is equipped with internal vibrators for consolidating the concrete along the faces of forms and adjacent to joints to produce a homogenous parapet, free from voids and honeycombs, and requiring no further finishing other than that required for Class 1 finish.

Ensure that the forming section of the slip-form machine is adjustable vertically during the forward motion of the machine to conform to the predetermined grade line. Attach a grade line gauge or pointer to the machine to ensure that continual comparison between the barrier being placed and the established grade line, as shown by the offset guide line, can be made.

Ensure that the slip-form machine is equipped with an automatic reverse signal alarm that is audible above the surrounding noise.

1005.07 Epoxy Resin Injection Equipment   back to top

Provide a positive-placement, fixed-ratio type pump for injecting epoxy resin adhesive into concrete cracks. Ensure that the equipment is capable of automatically mixing 2 components at the nozzle. Also ensure that the equipment is equipped with a rubber nozzle arrangement that will allow injection of adhesive, without air entrapment, at pressures of up to 300 pounds per square inch to ensure complete penetration of cracks. Also ensure that the machine is equipped with a pressure gauge at or near the nozzle to verify the working pressure.

Section 1006 – Concrete Pavement Rehabilitation Equipment


1006.01 Breaker   back to top

  1. Resonant Breaker. Provide a self-contained, self-propelled, resonant frequency breaker specifically designed for rubblizing concrete pavement. Ensure that the machine is capable of producing low-amplitude (1-1/2 inch maximum) blows with a 2000-pound force and delivering blows to the existing concrete surface at a rate of at least 44 cycles per second. Equip the resonant breaker with a screen to protect vehicles in adjacent lanes from flying chips during breaking.

  2. Multi-Head Breaker. Provide a self-contained, self-propelled, multi-head breaker specifically designed for rubblizing concrete pavement. Ensure that the multi-head breaker is capable of rubblizing the full lane width. Mount pavement breaking hammers so that there is continuous breakage from side to side. Ensure that the lift height of the hammers is independently adjustable. Equip the multi-head breaker with a screen to protect vehicles in adjacent lanes from flying chips during breaking.

1006.02 Seating Equipment   back to top

  1. Z-Grid Roller. Provide a vibratory roller fitted with a “Z” pattern grid on the drum face. Ensure that the roller has a gross weight of at least 10 tons and is capable of seating the rubblized pavement.

  2. Vibratory Roller. Provide a vibratory roller fitted with a smooth steel drum. Ensure that the roller has a gross weight of at least 10 tons and is capable of seating the rubblized pavement and providing an even surface for the HMA overlay.

1006.03 Grout Pumping Unit   back to top

  1. Positive-Displacement Injection or Non-Pulsating Progressive-Cavity Pump. Use either positive-displacement injection or non-pulsing progressive-cavity pumps. Ensure that the injection pump produces a maximum pressure of 200 pounds per square inch when pumping grout, and that meets the 12-second flow cone time. Ensure that the pump is capable of sustaining continuous pumping at rates as low as 1-1/2 gallons per minute. If the pump fails to meet this requirement, modify the system by adding a recirculating hose and valve at the discharge of the pump.

  2. Truck-Mounted Pumping Unit. Provide a truck-mounted pumping unit capable of injecting high-density polyurethane at a controlled rate directly beneath the concrete pavement. Ensure that the pumping unit is equipped with a manufacturer’s certified meter to measure the amount of high-density polyurethane injected at each location. Ensure that the system is capable of immediate control of the material flow to avoid excessive lifting of the pavement slabs.

    Ensure that each pumping unit is equipped with a digital output device capable of recording pump strokes. Convert the pump strokes to pounds using a calibration chart obtained from the pump manufacturer. Ensure that each digital output device is equipped with a manual reset button.

1006.04 Mixer   back to top

Provide a high-speed centrifugal pump mixer or high-speed shear-blade mixer. Ensure that the centrifugal pump mixer is capable of pulling the grout through a mixing chamber at high pressure and high velocity. Operate the shear-blade mixer between 800 and 2000 rotations per minute, creating a high shearing action and subsequent pressure release to make the mixture homogenous.

1006.05 Injection Device   back to top

Provide grout hole packers, of either the drive packer or expanding rubber type, to hold the injection pipe and discharge nozzle tightly in place while grout is being pumped. Ensure that hoses used for transporting grout from the pump to the packer are 3/4 to 1-1/2 inches in diameter.

1006.06 Lift Monitoring Equipment   back to top

Provide dial gauges and a laser leveling unit, capable of measuring vertical uplift or deflection to 0.001 inch, to detect slab movement with respect to a stable reference point. Ensure that the equipment is capable of detecting the movement of the pavement edge or any 2 outside slab corners adjacent to a joint and the adjoining shoulder. Obtain RE approval of the devices before using.

1006.07 Deflection Testing Equipment   back to top

Provide a falling weight deflectometer capable of applying at least 12,000 pounds of force to test joints and cracks. Ensure that reference calibration of the falling weight deflectometer is performed annually at a Strategic Highway Research Program calibration center. Submit certification of reference calibration to the RE before beginning testing. Ensure that relative calibration is performed no more than 15 days before testing.

1006.08 Grinding Machine   back to top

Provide a self-propelled machine equipped with diamond blades designed for grinding and texturing concrete surface courses. Ensure that the machine is properly sized to grind a strip at least 3 feet in width without operating in adjacent traffic lanes. Ensure that the grinding machine will not damage or cause strain to the underlying concrete surface course, or cause excessive ravels, aggregate fractures, spalls, or disturbance of transverse or longitudinal joints.

Ensure that the grinding machine is capable of immediately collecting the slurry produced from the operations. The Contractor may use a grinding machine that does not collect slurry if the RE approves an alternate slurry collection method.

1006.09 Scarification Equipment   back to top

Provide self-propelled scarification equipment that is capable of scarifying across the cutting path in 1 pass to a minimum depth of 1/4 inch. Use equipment capable of establishing profile grades by referencing from existing grades and capable of controlling cross slopes. Use equipment capable of removing milled material from the surface and preventing dust and other materials from escaping into the air. Use equipment with a floating type head that allows for deeper cutting in areas of deteriorated concrete and that is capable of locking out the head float.

Section 1007 – Traffic Striping Equipment


1007.01 Epoxy Striping Unit   back to top

Provide epoxy striping equipment designed to apply long-life material in variable widths at a consistent temperature. Ensure that the epoxy striping equipment is capable of continuously mixing and agitating the material and is equipped with the following:

  1. Epoxy Striping Units. Provide the following with each epoxy striping unit:

    1. A calibration sheet, certified by the manufacturer or testing agency, that shows the number of the truck, the capacity, and an outage table in increments of not over 1/2 inch.
    2. A metal rod for each holding vessel, with accurate divisions marked and consecutively numbered starting at the bottom. Do not use a rod less than 1 foot longer than the depth of the vessel.
    3. Slip-proof steps with handrails to ground level and a slip-proof catwalk with handrail running along the top of the vessel.

  2. Epoxy Striping Applicator. Ensure that the epoxy striping applicator is equipped with the following:

    1. A tachometer and a pressure gauge.
    2. A calibrated holding vessel for each long-life material component. Ensure that the holding vessels for the epoxy pigments and hardener have thermometers for measuring the temperature of vessel contents.
    3. A separate power unit for the pumps used to mix and distribute the components.
    4. Mixing and conveying parts and the shaping dies or spray gun that is capable of maintaining the material at optimum plastic temperature.
    5. A mechanical glass bead dispenser that automatically dispense beads uniformly on wet stripes or markings at the rates specified.

1007.02 Thermoplastic Applicator   back to top

Provide a thermoplastic applicator designed to apply thermoplastic in multiple widths between 4 to 12 inches and multiple thickness settings to achieve above the pavement thickness of 90 to 120 mils. Ensure that the thermoplastic applicator is equipped with the following:

  1. An oil-jacketed or air-jacketed pre-melting kettle equipped with an automatic thermostat control device to provide positive temperature control and continuous mixing and agitation of the thermoplastic material.
  2. An applicator storage kettle with an automatic thermostat control device to maintain the thermoplastic material at the application temperature and provide continuous mixing and agitation of the thermoplastic material during installation.

Ensure that the thermoplastic applicator has a capacity for containing a minimum of 1500 pounds of molten thermoplastic.

The Department may require special thickness equipment for in lane or shoulder transverse rumble strip pavement markings.

1007.03 Traffic Stripe and Marking Removal Equipment   back to top

For removing traffic stripes and traffic markings, provide equipment containing a vacuum system to remove all millings from the pavement surface and prevent residue from becoming airborne.

1007.04 Rumble Strip Cutting Machine   back to top

Provide a rumble strip cutting machine equipped with an acceptable guide that extends in front of the machine and is clearly visible to the operator to maintain alignment.

Section 1008 – Miscellaneous Equipment


1008.01 Milling Machine   back to top

Provide a self-propelled planing, grinding, or cutting milling machine with variable operating speeds that is capable of removing HMA or concrete without the use of heat. Ensure that the milling machine is equipped with automatic grade controls. Use either a stringline or ski type reference system. If a ski type reference system is used, ensure that the ski has a minimum length of 20 feet. Ensure that the milling machine is equipped with an automatic audible warning signal when operating in reverse. The RE may not require use of the automatic grade controls at intersections and other locations.

Immediately replace teeth in the milling drum that become dislodged, broken, or unevenly worn with teeth of the same length as the remaining teeth in that row.

1008.02 Straightedge   back to top

Provide an aluminum straightedge at least 10 feet in length. Provide up to a 16-foot straightedge if requested by the RE. Ensure that straightedges are kept clean and straight.

1008.03 Mechanical Sweeper   back to top

Provide a self-propelled vacuum or vacuum assisted sweeper that is capable of collecting and containing debris. Do not use steel bristles. Ensure that the sweeper is equipped with an automatic audible warning signal when operating in reverse.

1008.04 Pavement Saw   back to top

Provide a power-driven pavement saw capable of sawing to the required dimensions in 1 pass without causing uncontrolled cracking. Equip the pavement saw with water-cooled, circular, diamond-edge blades or abrasive wheels, and alignment guides. Ensure that the pavement saw is capable of immediately collecting the slurry produced from the operations. The Contractor may use a pavement saw that does not collect slurry if the RE approves an alternate slurry collection method.

When sawcutting grooves, use a multi-bladed saw with an adequate number of blades and alignment wheels.

Provide within the Project Limits spare saw blades and at least 1 standby saw that meets the above requirements.

1008.05 Air Compressor   back to top

Provide compressors for air blowing that filter moisture and oil from the air, deliver air at a minimum of 125 cubic feet per minute, and develop a nozzle pressure of at least 87 pounds per square inch.

1008.06 Hot-Air Lance   back to top

Provide a compressed air system designed for generating hot air at a temperature of at least 2000 °F. Ensure that the hot-air lance is capable of delivering air at the minimum rate of 80 cubic feet per minute at 100 pounds per square inch.

Section 1009 – HMA Plant Equipment


1009.01 HMA Plant   back to top

  1. Requirements for HMA Mixing Plants. Use fully automated batch type or drum mixing type plants for the preparation of HMA mixtures. Ensure that the HMA plant is designed, equipped, calibrated, and operated to deliver well-coated, homogeneous HMA mixtures conforming to the job mix formula. Immediately correct defects that adversely affect the functioning of a plant or plant unit, or the quality of the mixture.

    Ensure that all plant, laboratory, and truck scales are inspected and certified by an independent scale company accredited according to International Organization of Standards / International Electrotechnical Commission 17025, or a State or county Office of Weights and Measures. Ensure that certification is performed annually, or every 6 months if directed by the ME.

    The HMA producer is required to have a quality control (QC) program plan approved annually by the ME as per Materials Approval Procedure MAP-102. The HMA producer is required to ensure that the QC plan conforms to the requirements outlined in the report entitled “Hot Mix Asphalt Quality Control Program Plan” prepared by the Department of Transportation and New Jersey Asphalt Paving Association. Failure to follow these requirements will result in rejection of HMA materials supplied by the HMA producer and removal of the HMA supplier from the QPL.

    Ensure that the HMA plant is equipped with the following:

    1. Plant Laboratory. Provide and maintain a plant laboratory at each plant site for the ME’s use for sampling and acceptance testing, and for the producer’s use for quality control testing during periods of production. Ensure that the plant laboratory has an unobstructed view of the trucks as they are loaded. Ensure that, excluding the sanitary facilities, the plant laboratory has a floor area of at least 350 square feet, a ceiling height of at least 7-1/2 feet, adequate ventilation, and artificial lighting. Provide sanitary facilities located within the same building. Ensure that the plant laboratory is weather-tight, heated, air-conditioned, and can maintain a temperature of between 68 and 80 °F. For plants producing more than 3000 tons of HMA mixture per day, obtain the ME’s approval of the laboratory size and available facilities.

      Ensure that the plant laboratory is equipped with the following:

      1. General Equipment. Provide the following:

        1. An office for the exclusive use of the ME with a floor area of at least 100 square feet.
        2. Work benches, totaling at least 3 x 15 feet.
        3. Two desks, 1 table, and at least 3 armed desk chairs.
        4. Four-drawer, legal-size file cabinet with lock and 2 keys.
        5. Shelves and supply cabinets.
        6. Water cooler capable of dispensing hot and cold water, or a refrigerator supplied with bottled water.
        7. Telephone, with a direct, private line with no monitoring or recording devices attached.
        8. Class ABC fire extinguisher, meeting fire underwriters’ approval.
        9. A stocked, 5-person first-aid box according to ANSI standards.
        10. Electrical outlets sufficient in number and capacity for operating equipment.
        11. Approximately 4 x 4 feet of cork board or other mounting surface hung on a wall for the exclusive use of the ME.
        12. Mechanical shakers, screens, and sieves according to AASHTO M 92. Install and bolt down the mechanical shaker in a sound-dampening and dustproof enclosure. Provide at least a 12-inch diameter exhaust fan in the enclosure.
        13. Sink with hot and cold running water having adequate pressure, drainboard, and drain capable of handling elutriable material.
        14. Stand that holds and elevates sieves to allow material to properly drain.
        15. Two-element hot plate or electric range having dial-type thermostatic controls to adjust the heat for drying aggregates. Include a 12-inch fan capable of exhausting dust and fumes.
        16. Small hand tools required for sampling and testing.
        17. Computer and work station requirements as specified in 156.03.01.4.d. The ME may reduce or eliminate the requirement for the computer based upon operational needs.

      2. Testing Equipment. Provide the following testing equipment:

        1. Hood enclosed on 3 sides, top, and bottom, and of such size to enclose the operations of drying and weighing in which a vapor or gas is emitted. Ensure that the hood is designed and constructed so that any operation involving testing within the hood does not require the insertion of any portion of the tester’s body, other than hands and arms. Ensure that the hood contains an exhaust system capable of exhausting air to the outside at 33 yards per minute, linear velocity, based upon an interior hood opening measuring 3 × 3 feet, with an exhaust fan rated at 80 to 118 cubic feet per minute.
        2. When acceptance procedures for fully automated batch plants using hot bin samples according to NJDOT B-5 are used, an 8-inch shaker and a larger shaker are required.
        3. Apparatus to perform testing according to AASHTO T 308, AASHTO T 166, AASHTO T 245, and AASHTO T 209.
        4. Apparatus to perform testing according to AASHTO T 312. Calibrate the gyratory compactor using the internal angle.

    2. Aggregate Storage. Provide storage space for each size and source of aggregate. Keep different aggregates separate until they have been delivered to the cold-feed belt or elevator. Maintain the aggregate storage area, and stockpile the separate materials as specified in 901.02.

    3. Aggregate Bins. Ensure that the plant has cold-feed aggregate storage bins of sufficient number and capacity to store the amount of aggregate required to keep the plant in continuous operation. Ensure that the bins are designed to prevent overflow of material from each bin compartment to another. Provide at least 1 cold-feed aggregate bin for each stockpile of material to be used. Provide an indicator on each bin to show the gate opening.

    4. Equipment for Preparation of Asphalt Binder. Ensure that the tanks for storage of asphalt binder are equipped to uniformly heat the material to the required temperature under effective and positive control at all times. Ensure that heating is accomplished so that no flame comes in contact with the heating tank.

      Provide a circulating system of sufficient capacity for the binder to ensure continuous circulation between the storage tank and proportioning units during the entire operating period. Ensure that the discharge end of the binder circulating pipe is maintained below the surface of the binder in the storage tank to prevent discharge of hot binder into the open air.

      Ensure that pipe lines and fittings are steam or oil jacketed, electrically or otherwise heated, and insulated to prevent heat loss.

      Provide valves according to AASHTO T 40, except ensure that a sampling valve is also located in the lowest third of each storage tank.

    5. Feeder for Dryer. Provide separate feeders for each size and source of aggregate. Feed each size onto the belt going to the dryer by mechanical feeders with separate adjustable gates. Use adjustable feeders capable of delivering the separate aggregates onto the belt in proper proportions to ensure a constant and uniform flow of material from each bin.

    6. Thermometric Equipment. Affix an armored thermometer or dial thermometer of adequate range in the asphalt binder feed line near the charging valve at the mixer unit.

      Also ensure that plant is equipped with a recording thermometer, pyrometer, or other thermometric instrument positioned at the discharge chute of the dryer to indicate and automatically record the temperature of the heated aggregates.

    7. Dust Collector. Ensure that the plant is equipped with a dust collector capable of wasting or uniformly returning to the plant all or any part of the material collected as directed. Install and operate dust collecting systems according to N.J.A.C 7:27-6.1 et seq.

    8. Safety. Provide adequate and safe stairways to the mixer platform and sampling points. Place guarded ladders to other plant units at all points where accessibility to plant operations is required. Provide overhead protection at necessary locations. Provide ample and unobstructed space on the mixing platform. Maintain a clear and unobstructed passage at all times in and around the truck loading area. Keep this area free from drippings from the mixing platform.

      Provide accessibility to the top of truck bodies using 2 platforms located away from the mixing plant to enable samples and temperature data to be obtained from each side of loaded trucks. The Department will allow one platform if the truck has room to turn around and return to the platform.

      When plant production occurs during nighttime hours, provide permanently fixed lighting throughout the plant operations, plant laboratory, and truck scale areas to ensure a clear view of the operations. Also provide permanently mounted lighting at the sampling platforms to sufficiently illuminate the bed of the truck for inspection and sampling operations.

    9. Truck Scales. Use direct-reading, cabinet dial type or an electronic load cell platform truck scales with a visual indicating device capable of automatically printing both gross and tare weights and time and date on the delivery ticket. Equip scales with a motion detection device or a time delay relay that prevents printing the weight on the delivery ticket until the scale is fully at rest. Remove or permanently lock tare beams in place.

      Ensure that the scale has a manufacturer’s rating equal to or greater than the maximum gross load being weighed.

      Ensure that the approaches to the scale at both ends are at a level grade at the same elevation as the platform. House the scale cabinet and dial and the mechanical weight recorder in a suitable shelter with adequate heat and light.

    10. Automated Release Agent System. Install and use a system that automatically sprays the truck bed with a release agent to prevent the build up of HMA in the bed. Ensure that the equipment sprays a thin, even coat of release agent over the entire interior surface. Supply a non-petroleum based release agent to the system.

    11. Surge and Storage Bins. A plant may store HMA in a surge or storage bin if the supplier has obtained Department approval.

      Ensure that each bin is equipped with a signaling device that automatically provides a visible or audible signal when the material in the bin reaches the 25 ± 5 ton level. Ensure that the signal device is visible or audible from within the batch room, and remains in operation until the bin level exceeds the specified minimum.

      The supplier may store the HMA in a surge or storage bin for up to 8 hours. In extreme circumstances, the ME may approve the storage of HMA in a surge or storage bin for up to 12 hours.

      If the surge or storage system is changed or altered, notify the Department of the modification. The Department may require reevaluation to continue operations.

  2. Requirements for Fully Automated Batch Type Plants. Use fully automated batch type plants only for mixtures containing up to 25 percent RAP. Perform daily checks to ensure that hoppers are discharging completely and that the balance returns to zero tare whenever the hoppers are emptied. When directed, make checks to verify the accuracy of the batch scales within the normal weighing range, and to ensure that the interlocking devices and automatic recording equipment are functioning properly. When the accuracy of the batch scales is not within the required weighing tolerances, the Department may require weighing of all trucks on an approved truck scale.

    Ensure that the batch plant is equipped with controls for proportioning the RAP into the mixture without damaging the asphalt binder in the reclaimed material. If the RAP is introduced into the system before the hot bins, ensure that the proportioning controls include weigh belts or belt scales. Ensure that these items electronically interlock the new aggregate feed with the RAP feed and vary the feed rates, as required, to maintain the required ratio of new aggregate to RAP.

    Prepare the recycled HMA mixtures by the heat transfer method of recycling. Ensure that the RAP does not come in direct contact with the flame in the dryer. Adjust the temperature of new aggregate leaving the dryer and the time interval of the dry and wet mixing cycles as needed.

    Before combining with the heated new aggregate, ensure that the RAP passes through a 2-1/2-inch vibrating scalping screen.

    Ensure that fully automated batch type plants are also equipped with the following:

    1. Dryer. Provide a dryer or dryers that continuously agitate the aggregate during the heating and drying process. Use a dryer capable of drying and heating the aggregate to the specified moisture and temperature requirements without leaving any visible unburned oil or carbon residue on the aggregate when discharged.

    2. Screens. Use plant screens that are capable of screening aggregates to the specified sizes and proportions, and have capacities greater than the capacity of the mixer.

    3. Aggregate Hot Bins. Ensure that the plant is equipped with at least 4 aggregate storage bins of sufficient capacity to supply the mixer when it is operating at full capacity. Arrange the bins to ensure separate and adequate storage of appropriate fractions of the mineral aggregates. Provide separate dry storage when using mineral filler or hydrated lime, and ensure that the plant is equipped to feed such material into the mixer accurately and uniformly. Provide each bin with properly sized and located overflow pipes to prevent the material from backing up into other compartments or bins. Ensure that each compartment is provided with an individual outlet gate that is leak-free when closed and that will cut off flow quickly and completely. Provide bins with means to obtain representative samples. Ensure that each bin is equipped with a signaling device that automatically provides a visible or audible signal when the level of aggregate reaches the lowest 25 percent level, and remains in operation until the bin level exceeds the specified minimum.

    4. Plant Scales. Use springless dial type or electronic load cell type plant scales with a readout accurate to within the tolerances allowed by the New Jersey Department of Law and Public Safety, Office of Weights and Measures.

      Locate scales so that they are plainly visible to the plant operator at all times.

      For aggregate amounts less than 5000 pounds, ensure that the graduation of scales used in weighing is not greater than 5 pounds. For aggregate amounts from 5000 to 10,000 pounds, ensure that the graduation of scales used in the weighing is not greater than 10 pounds. For aggregate amounts more than 10,000 pounds, ensure that the graduation of scales used in the weighing is not greater than 0.1 percent of the capacity of the scales.

      For weighting asphalt binder, use scales that conform to the requirements for aggregate scales, except that they shall read to the nearest pound and they shall have a capacity of not more than 250 percent of the normal amount of asphalt binder required.

      Ensure that plants are capable of continuously weighing the various components of the mixture for the full range of batch sizes within the tolerances specified in Table 1009.01-1. These tolerances are based on the total batch weight of the HMA mixture.


    5. Table 1009.01-1 Weighing Tolerances

      Mixture Component

      Tolerance

      Each Aggregate Component

      ±1.5 percent

      Mineral Filler

      ±0.5 percent

      Asphalt Binder

      ±0.1 percent

      Zero Return (Aggregates)

      +0.5 percent

      Zero Return (Asphalt Binder)

      +0.1 percent


      If mineral filler is used in a batch cycle, ensure that the allowable tolerance for the aggregate component weighed just before the filler in a cumulative weighing system is ±0.5 percent.

    6. Weigh Box or Hopper. Ensure that the plant is equipped with the means for accurately weighing each size of aggregate in a weigh box or hopper suspended on scales that is sufficiently sized to prevent overflow to the pugmill.

      Ensure that no material can leak into the mixer while a batch is being weighed when the discharge gate is closed. Support the weigh box or hopper on fulcrums and knife edges that are not easily thrown out of alignment or adjustment.

    7. Asphalt Binder Control. When using an asphalt binder bucket, use a type recommended by the plant manufacturer. Ensure that the length of the discharge opening or spray bar is at least 3/4 the length of the mixer and that it discharges directly into the mixer. Ensure that the asphalt binder bucket discharge valve and spray are adequately heated. Ensure that the plant has an adequately heated, quick-acting, nondrip charging valve located directly over the asphalt binder bucket.

      When a volumetric meter is used, ensure that it automatically meters the asphalt binder into each batch. Ensure that the dial to indicate the amount of asphalt binder has the capacity to measure at least 10 percent more than the asphalt binder required in 1 batch. Ensure that the meter can be locked at any dial setting and automatically resets to this reading after the addition of asphalt binder to each batch. Locate the dial in full view of the mixer operator.

      Automatically control the flow of binder material to begin when the dry mixing period is finished. Ensure that all of the asphalt binder material required for 1 batch is discharged within 15 seconds after the flow has started. Ensure that the size and spacing of the spray bar openings provide uniform application of asphalt binder for the full length of the mixer.

    8. Mixer. Use a batch mixer capable of producing a uniform mixture within the job mix tolerances. If not enclosed, equip the mixer box with a dust hood.

      Ensure that the clearance of paddles does not exceed 1-1/2 inches from all fixed and moving parts.

    9. Control of Mixing Time. Ensure that the mixer is equipped with an accurate time lock to control the operations of a complete mixing cycle. It shall lock the weigh box gate after charging of the mixer until the closing of the mixer gate at the completion of the cycle. It shall lock the asphalt binder discharge throughout the dry mixing period and shall lock the mixer gate throughout the dry and wet mixing periods. The dry mixing period is defined as the interval of time between the opening of the weigh box gate and the start of introduction of asphalt binder. The wet mixing period is defined as the interval of time between the start of introduction of asphalt binder and the opening of the mixer gate.

      Ensure that timing control is adjustable and capable of being set at intervals of 5 seconds or less. As a part of the timing device, install a mechanical batch counter designed to register only completely mixed batches.

      Set time intervals in the presence of the ME to provide aggregate coating as specified in 903.02.

    10. Automated Batching and Mixing Control. Ensure that fully automated plants include an automatic batching and mixing control system, including an automatic printer system conforming to the following:

      1. Ensure that the recording equipment and batch scales are interlocked. Maintain the panels providing access to interlocking devices under sealed conditions.
      2. Ensure that the system contains auxiliary interlocking cut-off circuits to interrupt and stop the automatic cycling of the batching operations any time the weighing tolerances are exceeded, when any aggregate bin becomes empty, or when there is a malfunctioning of any portion of the control system. A platform truck scale is not required. However, if the automatic proportioning or recording devices becomes inoperative or inaccurate, then manually operate the plant to complete the day’s production with the approval of the RE. In this case, a platform truck scale is mandatory for manual operation.
      3. The Department will make independent checks on batch weights by weighing trucks before and after loading, and may request an inspection of the plant scales by the New Jersey Department of Law and Public Safety, Office of Weights and Measures for verification of the automatic printout tickets.

  3. Requirements for Drum Mixing Plants.  The Contractor may use drum mixing plants in the preparation of HMA paving mixtures. Heat, coat, and mix the HMA mixture in a parallel flow, counter flow, or other approved type of dryer-mixer.

    Ensure that the drum mixing plant includes the following:

    1. Aggregate Bins. Equip the fine aggregate bin compartments with a vibrator or other anti-bridging device that is automatically actuated when bridging of the material occurs. Ensure that this device automatically shuts off when continuous material flow is restored.

    2. Mineral Filler Bin. When adding mineral filler, use a bin and feeder that is separate from the aggregate cold bins. Ensure that the equipment is capable of feeding the mineral filler at adjustable rates. Ensure that the mineral filler feed rate in tons per hour is accurate to within 3 percent of the indicated rate throughout the range of the plant’s production capacity. Ensure that the feeder is interlocked to stop production if the flow of mineral filler is interrupted.

    3. Aggregate Feeder. Ensure that the plant is equipped with a mechanical system for uniformly and continuously feeding each aggregate in its proper proportion onto a collecting belt and then into the drum mixer.

      Ensure that the feeder system is designed so that the aggregates on the collector belt pass through a 2-inch scalping screen or other device to remove oversized material or debris before entering the mixer. Provide one feeder for each bin compartment. Ensure that each aggregate feeder is interlocked to stop production if flow of aggregate from any of the cold bins is interrupted.

      Use a variable speed system that provides for total and proportional control to regulate the quantity of aggregate fed to the drum mixer.

      Ensure that the individual bin feeder belts or the intermediate collecting belt that delivers the aggregate to the main feed for the drum mixer are equipped with belt type scales (load cells). Use belt type scales (load cells) that are capable of continuously displaying, at the operator’s station, the weight of aggregate flow in tons per hour or the corresponding percentage of total mix from each individual bin and the accumulated total from each bin in tons. Ensure that the aggregate feed rate in tons per hour from each bin is accurate to within 1 percent of the indicated rate throughout the range of the plant’s production capacity.

      Provide the means to conveniently divert the aggregate cold-feed delivery into trucks or other containers for checking the accuracy of the aggregate feed system. Provide the means to obtain representative samples of the composite aggregate from the main feed to the drum mixer at any time during production.

      For mixes containing RAP, the drum mix plant shall have a means for adding the RAP to the dryer-mixer in a manner that does not damage the asphalt binder in the reclaimed material. Provide control for proportioning the RAP into the mixture. Provide the means for compensating for the moisture in the RAP. Ensure that the RAP passes through a 2-1/2 inch vibrating scalping screen before being combined with the heated new aggregate.

    4. Asphalt Binder Metering System. Ensure that the plant is equipped with a metering system that introduces the proper amount of asphalt binder into the mix.

      Use a system that is capable of measuring the quantity and temperature of the asphalt binder introduced into the mix and transmitting that data to the operator’s station. Ensure that the metering system is interlocked to stop production if the flow is interrupted.

      Ensure that the metering system includes a temperature compensation device to correct the quantity of asphalt binder introduced into the mix to 60 °F. Ensure that the flow of asphalt binder to the drum mixer is continuously displayed at the operator’s station in units of tons per hour, corrected to 60 °F, or as the corresponding percentage of total mix. Ensure that the feed rate in tons per hour is accurate to within 1 percent of the indicated rate throughout the range of the plant’s production capacity. Ensure that the accumulated weight of asphalt binder fed to the mixer is totaled.

      Provide convenient means for diverting the asphalt binder into trucks or other containers for checking the accuracy of the metering system.

    5. Proportioning Controls. Ensure that the combined aggregates pass over a weigh belt or belt scale that is electronically interlocked with the asphalt binder metering system to automatically vary the asphalt binder feed rate, as required, to maintain the required asphalt binder content in the mixture.

      Make provisions for introducing the moisture content of the cold-feed aggregates into the composite aggregate weigh belt signal and correcting wet aggregate weight to dry aggregate weight. Continuously display, by electronic readout at the operator’s station, the dry weight of the composite aggregate flow in units of tons per hour and total. Ensure that the composite aggregate feed rate is accurate to within 1 percent of the indicated rate. Equip belt conveyors with scrapers or other suitable devices to prevent adherence or other loss of the weighed cold-feed aggregate.

      Before the start of production of Department mixes, ensure that plant controls are calibrated. Report to the ME any changes in or modifications to the equipment or operation occurring subsequent to the initial calibration. The ME may direct calibration checks or a new plant calibration. The ME may also direct recalibrating the plant if the finished mixture displays composition deficiencies. For each drum mix plant placed in operation, submit 2 complete sets of plant drawings, a plant operator’s manual, and a plan detailing the method of plant calibration. The ME will witness the calibration of the individual cold-feeders at several production rates throughout the range of the plant’s capacity. Submit a copy of the computations for the combined rate of flow, and a plot of calibration charts, indicating the rate of aggregate delivery in tons per hour from each cold-feeder for particular dial settings and gate openings. Determine calibration points by independently diverting each cold-feed into trucks (or running each feed through the plant) and determining the proper console dial setting corresponding to the measured rate of delivery. Determine calibration points in increments of approximately 100 tons per hour of total aggregate flow.

      The ME will witness a check on the mineral filler and asphalt binder feeds at several production rate increments throughout the range of the plant’s capacity. Divert the asphalt binder into trucks or other containers for weight or volumetric measurements to calibrate the asphalt binder metering system and subsequent checks. The method used to calibrate the mineral filler feeder system is subject to approval.

    6. Drum Mixer. Use a drum mixer that continually agitates the mixture of aggregate and asphalt binder during heating. The drum mixer should not adversely affect the aggregate or asphalt binder during drying and heating operations. Equip the mixer discharge with a pyrometer or thermometer probe to record the temperature of the mixture, with the data transmitted to the operator’s station.

      Ensure that the mixer is equipped to safely and conveniently obtain representative mixture samples before introduction into the surge bin.

      The ME may perform test comparisons between the consistency of the asphalt binder in its original form from plant tank samples and in processed form from mixture recovery samples obtained before the mixture’s introduction into the surge bin. The ME will use the results of the consistency tests to determine whether a processing improvement is necessary to eliminate excessive volatilization, oxidation, or other causes of premature hardening.

    7. Emission Control System. Ensure that the plant is equipped with an emission control system conforming to all applicable emission limitations.

    8. Control Console. Ensure that the following items are included in the control console at the operator’s station:

      1. Cold aggregate feed controls capable of both total and proportional control of the aggregates.
      2. Dryer burner controls that automatically control the temperature of the mix and record the mix temperature at the dryer discharge.
      3. Aggregate weigh belt readouts displaying the weight of material being proportioned from each aggregate bin in tons per hour or the corresponding percentage of total mix weight and the total flow over the main feeder to the drum mixer in tons per hour. Ensure that the accumulated weights in tons from each bin and the total feed to the mixer are separately totaled and are continuously displayed or are available on demand from a printout device.
      4. Mineral filler readouts displaying the weight of material being proportioned from the mineral filler bin in tons per hour or the corresponding percentage of total mix weight together with an accumulative total in tons.
      5. Asphalt binder metering system readouts indicating the quantity of asphalt binder, corrected to 60 °F, being proportioned into the mix together with an accumulative total in tons, and a recording pyrometer or thermometer that records the temperature of the asphalt binder at the pump.
      6. Proportioning controls that set the asphalt binder content as well as the aggregate moisture adjustment.

    9. Modifications. When producing mixes containing 26 to 50 percent of RAP, ensure that the mixing time allows thorough blending of new and reclaimed materials and complete coating all aggregate particles. If lumps of reclaimed material are observed in the mixture as it is discharged from the drum, adjust the mixing time in the drum or make other changes in the production process to correct this condition. Ensure that the temperature of the mixture at discharge from the plant or surge and storage bins is maintained at or above the temperature required to deliver the material to the work site and achieve optimum compaction.

1009.02 HMA Trucks   back to top

Transport the mixture from the mixing plant to the Project Limits in trucks equipped with tight, clean bodies. The Contractor may lightly coat the trucks with a fine aggregate, soap or lime solution, or other such non-petroleum-based release agent. Do not use a petroleum-based product as a release agent.

Permanently equip trucks with an airfoil that is capable, at any speed or under any weather conditions, to deflect air over the tarp and to prevent air from going under the tarp. Ensure that the airfoil is affixed no more than 2 feet in front of the tarp roll and be at least as high as the top of the tarp roll.

Provide a waterproof tarp that is capable of withstanding normal handling and placement temperatures of up to 400 °F without damaging the fabric, has a minimum weight of 18 ounces per square yard, and is properly sized to completely cover the load. Immediately cover each truckload after loading at the plant with the tarp to protect the mixture from the weather. Ensure that the tarp securely meets or overlaps the top of the tailgate and is securely held in place so as to prevent air from lifting the tarp during transportation.

Ensure that the truck body is heated or insulated as necessary to ensure delivery of the mixture at the specified temperature. Remove any truck from the work that does not have an airfoil or does not have an approved tarp until such conditions are corrected and the truck is presented for inspection to the RE. The RE or ME may require that the Contractor make available the vehicles used for transporting HMA mixture for inspection at the plant laboratory before shipping materials.

1009.03  Asphalt-Rubber Binder Blending Equipment

Provide equipment for preparation of Asphalt-Rubber Binder.  Ensure that the unit is equipped with a crumb rubber feed system capable of continuously supplying the asphalt cement feed system, and is capable of fully blending the individual crumb rubber particles with the asphalt cement.  Use an asphalt-rubber binder storage tank that is equipped with a heating system capable of maintaining the temperature of the binder between 325 and 375 °F during the reaction.  Ensure the asphalt-rubber binder storage tank is also equipped with an internal auger mixing device, oriented horizontally in the tank, capable of maintaining a uniform mixture of the asphalt-rubber binder.

Ensure that the tanks for storage of asphalt-rubber binder are equipped to uniformly heat the material to the required temperature under effective and positive control at all times.  Ensure that heating is accomplished so that no flame comes in contact with the heating tank.

Provide a circulating system of sufficient capacity for the binder to ensure continuous circulation between the storage tank and proportioning units during the entire operating period.  Ensure that the discharge end of the binder circulating pipe is maintained below the surface of the binder in the storage tank to prevent discharge of hot binder into the open air.

Ensure that pipe lines and fittings are steam or oil jacketed, electrically or otherwise heated, and insulated to prevent heat loss.

Provide valves according to AASHTO T 40, except ensure that a sampling valve is also located in the lowest third of each storage tank.

If the plant has been equipped with a water injection type asphalt foaming system, ensure that the system will allow the proper amount of asphalt rubber binder to be supplied continuously or provide a by-pass to ensure that the proper amount of asphalt rubber binder is supplied to the mix.

 

Section 1010 – Concrete Plant and Mixing Equipment


1010.01 Batching Plant   back to top

Ensure that plant, laboratory, and truck scales are inspected and certified by an independent scale company accredited according to International Organization of Standards / International Electrotechnical Commission 17025, or a State or county Office of Weights and Measures. Ensure that certification is performed annually, or every 6 months if directed by the ME.

Ensure that aggregate reserves at the batching plant are stockpiled as specified in 901.02.

Provide a batching plant with the specified site, layout, and equipment features capable of ensuring a continuous supply of concrete to the work. Ensure that the batching plant is equipped with the following:

  1. Plant Laboratory. Provide and maintain a plant laboratory at each plant site for the ME’s use for sampling and acceptance testing, and for the producer’s use for quality control testing during periods of production. Ensure that the plant laboratory has an unobstructed view of the trucks as they are loaded. Ensure that, excluding the sanitary facilities, the plant laboratory has a floor area of at least 350 square feet, a ceiling height of at least 7-1/2 feet, adequate ventilation, and artificial lighting. The ME may re-approve a previously approved concrete plant with a undersized laboratory if it functionally meets the needs for testing. Provide sanitary facilities located within the same building. Ensure that the plant laboratory is weather-tight, heated, air-conditioned, and can maintain a temperature of between 68 and 80 °F.

    Ensure that the plant laboratory is equipped with the following:

    1. General Equipment. Provide general equipment as specified in 1009.01.1.a.

    2. Testing Equipment. Provide the following testing equipment:

      1. Platform scale of 200 pounds minimum capacity with a beam or dial with significant graduations of 1/10 pound or less.
      2. Apparatus to perform testing according to AASHTO T 27, AASHTO T 248, AASHTO T 19, AASHTO T 119, AASHTO T 121, AASHTO T 196, AASHTO T 152, AASHTO T 84, and AASHTO T 85.
      3. Miscellaneous items including rubber hammer, mason’s trowels, pointed shovel, small and large sugar scoops, heavy galvanized pail (approximately 14-quart capacity), aggregate sample pans, brushes, flashlight, glassware, steel straightedge approximately 18 x 2 inches, and such expendable supplies necessary for the tests to be performed.

  2. Batch Counter. Ensure that the batching plant is equipped with a non-resettable batch counter that indicates the number of batches proportioned.

  3. Bins and Hoppers. Provide bins with separate compartments for fine aggregate, for each size of coarse aggregate, and for each brand and type of cement at the batching plant. Ensure that the weighing hoppers are sealed and vented to prevent dusting during operation. Use separate scales and hoppers for cement with a device to indicate the complete discharge of the batch of cement into the mixing drum. Ensure that the weighing hoppers and scales are of adequate size and capable of being locked. Ensure that the hopper discharge mechanism is interlocked against opening until the full batch is in the hopper and the scale is balanced, against opening while the hopper is being filled, against closing until the hopper is entirely discharged and the scale back in balance, and against opening if the batch in the hopper is either overweight or underweight by more than 1 percent of the amount specified. Ensure that the weighing hopper discharge gate operates in a manner that does not affect the scale balance. Ensure that the discharge chute, boot, or other such device is suspended from the encasement and not from the weighing hopper and is constructed so that cement does not lodge therein. Ensure that there is no loss of cement by air currents or otherwise. Ensure that there are means available to monitor the required cement content in each batch.

  4. Scales. Use beam scales, springless dial scales, or electronic load cell scales with a readout when weighing aggregates and cement. Use scales that are accurate to within 0.5 percent for cement and within 1 percent for aggregate throughout the range of use. When using beam type scales, provide a dial for indicating to the operator the required load in the weighing beams and for indicating critical position. Ensure that the weigh beam and device are in full view of the operator who shall have convenient access to all controls while charging the hopper. Ensure that poises are capable of being locked in any position to prevent unauthorized change.

  5. Water Measuring Equipment. Measure water by volume or by weight. Ensure that the range or error for water measuring equipment is less than 1 percent. Ensure that the measuring device automatically registers and stops the flow of water when the designated quantity has been delivered into the mixing drum. If measuring by volume, ensure that the water measuring device contains an auxiliary tank from which to fill the measuring tank. Ensure that the measuring tank is equipped with outside taps and valves, or equivalent means to accurately calibrate the tank, and to provide for the quick and accurate determination of the amount of water in the tank. Ensure that the volume of the auxiliary tank is at least equal to that of the measuring tank.

  6. Chemical Admixtures. Use an automatic displacement dispenser for adding each admixture. Ensure that the plant is equipped with a separate dispensing system with a visual sight gauge for each chemical admixture incorporated into the concrete. Provide a system capable of dispensing the total amount required to within ±3.0 percent or 1 ounce, whichever is greater. Provide convenient means to calibrate each system. Provide chemical admixture devices with each truck mixer approved for dispensing admixtures at the placement site.

  7. Mineral Admixtures. Ensure that mineral admixtures stored at the batching plant are located in a separate storage facility. Do not use a split silo to store mineral admixtures and cement, or 2 different mineral admixtures. Ensure that scales and batching tolerances are consistent with those specified for cement.

  8. Automatic Batching System. Ensure that batching plants equipped to proportion aggregates and bulk cement by means of automatic weighing and recording devices contain the following:

    1. Automatic Batching Controls. Ensure that batching equipment in the system for batching by weight is actuated by a single starting mechanism. The Department will allow a separate starting mechanism for volumetric batching of water or admixtures not batched at the time of initial weighing.

      Ensure that each automatic batcher returns to zero balance and each volumetric device resets to start or signal empty before it may be charged.

      Ensure that the discharge of any ingredient in the system does not start until all weighed ingredients have been batched, until all batching controls have been cleared of the previous batch with scale returning to zero balance, and until volumetric devices reset to start or signal empty.

      For cumulative batchers, provide interlocked sequential controls.

      Ensure that automatic batching controls start the weighing operation of each material and stop automatically when the designated weight of each material has been reached, interlocked in such a way that:

      1. The charging device cannot be actuated until the scale has returned to zero balance within ±0.3 percent of the scale capacity.
      2. The discharge device cannot be actuated until the required material is within the applicable tolerances.
      3. The discharge device cannot be actuated if the charging device or the discharge device is open.

    2. Recording Devices. Ensure that automatic batching plants are equipped with an accurate recorder or recorders that provide a permanent and continuous record of batching operations. Provide a maximum of 2 recording units in lockable enclosures with each plant. Provide batching records as directed by the ME. Ensure each recorder produces a digital record on tickets, providing the following information:

      1. The quantity or batched weights of each aggregate, cement, water, and admixture.
      2. The zero-balance condition of each scale after batches have been discharged, or before the start of the batching operation.
      3. A means of identifying each admixture batched.
      4. The time, date, and batch number of each batch delivered.
      5. Mix formula or concrete classification identification.

  9. Safety. Provide adequate and safe stairways at access points to plant operations. Provide overhead protection at locations where deemed necessary. Ensure that gears, pulleys, chains, sprockets, and other hazardous moving parts are guarded and protected.

1010.02 Concrete Trucks   back to top

Ensure that mixers have a fixed metal plate or plates on which the following information is plainly marked:

  1. The manufacturer’s capacity rating in terms of the gross drum volume;
  2. The capacity of the drum in terms of the volume of mixed concrete; and
  3. The manufacturer’s designated drum speed of rotation for both mixing and agitation.

The ME will inspect the mechanical condition of the truck mixer, the mixing and agitation rates, the accuracy of the water-measuring device, the sizes of the discharge opening and chutes, and the general condition and wear of the blades. The ME will not approve mixers if the pickup and throw-over blades are broken, missing, or excessively worn. Examine mixers on a daily basis for drum and blade cleanliness, leaks in the mixing water system, and the condition of the water-measuring device and revolution counter.

Ensure that the concrete supplier maintains, in a convenient location, a copy of the manufacturer’s design for each size and type of truck showing the dimensions and arrangements of the blades, the dimensions of the drum, the gross volume of the drum, the recommended rates of rotation for all types of operations, and any other pertinent information.

Ensure that the mixing water-measuring device is plainly visible to the truck operator when operating the mixing water and the drum controls, and to the ME while standing on the ground. Keep measuring indicators clean and in good condition.

Ensure that trucks for the delivery of central-mix concrete have a revolving, watertight drum that is capable of uniformly transporting and discharging the mixed concrete. Ensure that the speed of the drum conforms with the manufacturer’s stated agitating speed.

Ensure that the mixing water tank, pump, and the piping are kept clean and free of leaks.

Provide documentation showing the date and results of calibration of the water-measuring device on each truck mixer. Provide copies if requested. Ensure that “calibrated” with the date of the last calibration is stenciled on the mixing water tank near the measuring device.

  1. Central Mixing Plant Truck. Ensure that mixers are equipped with electrically-actuated counters allowing easy verification of the number of revolutions of the drum. Ensure that the counter unit is positioned on the truck and plainly visible if the driver’s door is open.

  2. Transit Mixing Truck. If necessary, each transit mixer shall only use the mixing water tank and measuring device for providing tempering water.

Ensure that truck mixers used for transit mix concrete are equipped with an electrically operated counter unit, containing 2 counters, that is non-resettable except by use of a 110-volt device utilizing a nonstandard plug located at the batching plant. Use one counter to record only those revolutions at speeds recommended by the manufacturer of the truck mixer as mixing speed and to record the total of all such mixing revolutions from the time the truck is loaded. Use the other counter to record revolutions of the drum at all speeds and to record the total revolutions from the time the truck is loaded. Ensure that the unit includes an indicator on the front panel that shows if the instrument has been turned off or tampered with in any manner after being reset at the time of loading. Ensure that the counter unit and the resetting device conform to the NEC. Ensure that the counter unit is positioned on the truck and plainly visible if the driver’s door is open.

1010.03 Mobile Mixer   back to top

Ensure that the truck mixer is equipped with a cement bin of sufficient capacity to store and supply the quantity of dry cement required to produce the maximum volume as rated by the manufacturer. Ensure that the cement bin is free of moisture and contamination at all times.

Ensure that the truck mixer is equipped with aggregate bins of sufficient capacity to separately store the quantities of fine and coarse aggregates required to produce the maximum volume of concrete as rated by the manufacturer. Ensure that the truck mixer is equipped with the means to prevent contamination or intermixing of the fine and coarse aggregates during loading and transporting. Ensure that aggregate bins are covered when moisture can enter the bins.

Ensure that the truck mixer is equipped with the means for readily determining the level of aggregates within the aggregate bins without the need to climb up on the truck. Ensure that the aggregate is maintained at the proper level to allow the correct volume to enter the mix.

Ensure that the aggregate bins are equipped with vibrators or other means to maintain a smooth, even, and continuous flow of aggregate from the bins.

Ensure that the truck mixer is equipped with water tanks of sufficient capacity to store enough water to produce the maximum concrete volume at the slump specified for each concrete item, as rated by the manufacturer. When using concrete additives in the mix, ensure that the truck mixer is capable of storing the additives, incorporating them into the mix, and measuring the rate of flow of each additive into the mix.

Ensure that the truck mixer includes a feeder unit mounted under the compartment bins to deliver the ingredients to the mixing unit.

Ensure that each bin on the truck has an accurately controlled individual gate or feeding mechanism to form an orifice for volumetrically measuring the material drawn from each bin compartment. Ensure that the cement bin feeding mechanism is set to discharge, continuously and at a uniform rate, the required volumetric weight equivalent of cement. Ensure that the gates of the aggregate bins are calibrated at the various openings to discharge the required volumetric weight equivalent of aggregates. Equip the mixer truck with a material flow indicator attached to the metering gates to monitor the continuous flow of material. Ensure that the indicator sounds an alarm when a continuous flow of material does not pass through the metering gates.

Ensure that the truck mixer is equipped to allow checking of the calibration of the gate openings and meters by means of weight test samples.

Ensure that the calibration of the gate openings and meters are checked and certified for each concrete mix design at least once per year by a certified testing agency. If approved by the ME, a representative of the Contractor may perform the calibration if it can be shown that the representative is knowledgeable in the proper techniques of calibration. Notify the ME at least 1 week before the annual calibration date.

The ME may require a calibration check or a yield test at any time. The accuracy of the mixer to proportion the specified mix is acceptable if the calibration check shows that the equivalent weights of each component are within the tolerances specified in Table 1010.03-1.

Table 1010.03-1 Weighing Tolerances

Mixture Component

Tolerance

Cement

0 to + 4 percent

Fine Aggregate

±2 percent

Coarse Aggregate

±3 percent

Admixtures

±3 percent

Water

±1 percent

Ensure that the truck mixer is equipped with a revolution counter indicator allowing the reading of the volumetric weight equivalent of cement discharged during the concrete mixing operation.

Ensure that the truck mixer is equipped with fine and coarse aggregate dials to allow adjustment of the gates of the aggregate bins for volumetric proportioning of aggregates.

Ensure that the truck mixer is equipped with a water meter or gauge to register the discharge rate of water by volume entering the mix.

Ensure that the truck mixer is equipped with automatic means for maintaining the operating speed of the proportioning and mixing equipment. Ensure that the truck mixer is operated within ±8 percent of the manufacturer’s rated speed. Ensure that the tolerance is met whether the mixer is moving or standing still. Ensure that the truck mixer is equipped with a tachometer mounted on the unit to measure the operating speed.

Ensure that all indicators, dials, meters, tachometers, and controls are easily visible, in full view, and close enough to be read or adjusted by the operator while mixing concrete.

Instead of a time clock, the counter unit may contain a third counter, an electrically-operated timer that is non-resettable except by use of the 110-volt device.

1010.04 Small-Batch Mixer   back to top

Where small quantities of concrete or mortar are needed, provide a mixer with a minimum mixing capacity to produce a 1-bag mix. Use small-batch mixers according to the manufacturer’s recommendations.

Section 1011 – Precast and Prestressed Concrete Plant Equipment


1011.01 Precast Plant   back to top

  1. Plant Certification. Ensure that the plant manufacturing precast concrete members is certified in the applicable category by the NPCA, the American Concrete Pipe Association (ACPA) or PCI certified as specified in 1011.02. Provide written documentation of the certification to the ME upon request.

  2. Forms and Casting Beds. Ensure that forms and casting beds are carefully aligned, substantial and firm, braced, fastened tightly together to prevent mortar leakage, and strong enough to withstand the action of mechanical vibrators. Ensure that forms are constructed to allow movement of the members without damage during release of the prestressing force. Before placing concrete, obtain ME approval for the casting beds and all form work.

1011.02 Prestressed Plant   back to top

  1. Plant Certification. Ensure that the plant manufacturing prestressed concrete members is certified by PCI in the category applicable to the work. Ensure that the certification of the plant is in accordance with Appendix D, Option (A) of the PCI MNL-116. Provide written documentation of the certification to the ME upon request.

  2. Jacks. Ensure that prestressing is performed with jacking equipment. Use hydraulic jacks that are equipped with pressure gauges. Ensure that the combination of jack and gauge is calibrated by a certified testing agency, and provide calibration charts to the ME showing the relationship between dial gage pressure and force delivered. Ensure that jacks and pumps are calibrated as a unit, are clearly marked, and are used as a unit. Should other types of jacks be used, provide calibrated proving rings or other devices so that the jacking forces may be known.

    Ensure that the calibration of jacks and gauges is performed at least once per year. If any jack or gauge provides erratic results, or if gauge pressure and elongations indicate differing stresses of more than 5 percent, ensure that recalibration is performed immediately. Ensure that strand elongations are measurable to at least the nearest 1/16 inch.

  3. Forms and Casting Beds. Ensure that forms and casting beds are carefully aligned, substantial and firm, braced, fastened tightly together to prevent mortar leakage, and strong enough to withstand the action of mechanical vibrators. Ensure that forms are constructed to allow movement of the members without damage during release of the prestressing force. Obtain approval from the ME for the casting beds and all form work before placing concrete.

  4. Load Cells. Ensure that plants manufacturing prestressed concrete members have at least 2 calibrated load cells to verify stressing operations.

  5. Grouting Equipment. Provide grouting equipment according to Division II, Section 10 of the AASHTO Standard Specifications for Highway Bridges.

1011.03 ME’s Office   back to top

Provide and maintain in good condition an office, conveniently located, at the prestressing plant for the exclusive use of the ME during production and until all items have been shipped to the Project Limits. Ensure that the office has a minimum area of 200 square feet. Provide means to maintain office temperature between 68 and 80 °F. Ensure that the office doors and windows are equipped with adequate locks and provide the necessary keys to the ME. Provide convenient access to potable water and clean, functional sanitary facilities. Provide the ME with access to a facsimile (fax) machine and photocopier at the fabrication plant for Department or Project-related use. Provide telephone and fax service.

Ensure that the office also includes the following equipment:

  1. One telephone and direct, private telephone line with an answering machine or voice mail capability. Ensure the telephone line is free of monitoring or recording devices.
  2. One high-speed broad band connection with a minimum speed of 3 megabits per second (mbps) with dynamic IP address (DSL, Cable, etc.).
  3. Two desks and 2 chairs.
  4. One 3-drawer file cabinet with a lock and 2 keys.
  5. A stocked, 5-person first-aid box conforming to ANSI standards.

Last Document Correction:
April 28, 2011