ITEM 441 CONTRACTOR MIX DESIGN AND QUALITY CONTROL—GENERAL
441.07 Quality Control Program
441.11 Quality Control Reports
441.01 Description. This specification includes general
requirements applicable to all types of asphalt concrete pavements where the
Contractor is
responsible for performing the mix design and quality control. Deviations from these general requirements
will be covered in the specific requirements for each type. The requirements of Item
401 apply, except as follows.
Control all production processes to assure the Engineer that the mixture delivered to the paving site is uniform in composition, conforms to the specification requirements and that the placed mixture is free of any defect (ex. segregation, tenderness, lack of mixture and texture uniformity, raveling, flushing, rutting, holes, debris etc.) within the Contractor’s control at project completion.
441.02 Composition
Compose the asphalt concrete of approved
aggregates, asphalt binder and, if required, other modifiers. Develop a JMF to comply with the mix design criteria and
submit it to the Laboratory on approved forms at least two weeks prior to the
start of production for preliminary approval.
The Laboratory may perform additional tests on
lab or plant produced mixtures to ensure adequate mix performance. Based on the results of these tests, the
Laboratory may require the Contractor to
design a new JMF. Allow time for this
additional testing.
Perform
the mix design and supply all required data in a manner taught in Level 2
Asphalt Technician school, Level 3 Asphalt Mix Design
school and in the Asphalt Institute
Manual Series No. 2. Use a 2-hour
cure for all mix samples. Ensure the
cure temperature and specimen compaction temperature are the same. Select the JMF asphalt binder content using
the Design Air Voids and ensure the JMF meets the other requirements of Table 441.02-1. Provide a mix design with at least four
asphalt binder content points, including
a minimum of two points above and two points below the JMF asphalt binder
content. Submit no more than two JMFs for each asphalt concrete pay item per
project. Additional submittals are at
the discretion of the Labortary. Submit
a 5-pound (2500 g) minimum uncompacted sample (all mixes) representing the
JMF. Submit additional samples as requested
by the Laboratory.
Do not start mix production without a preliminary JMF approval and 48 hour notification of the District. Final approval of a JMF will be based upon field verification. Per 441.12 the JMF can be rejected for failure to verify in the plant or at the project
Do not
apply the gradation requirements of 703.05
for fine aggregate.
If the F/A ratio using total asphalt binder
content is greater than 1.0 recalculate it using the effective asphalt binder
content. Calculate the effective asphalt
binder content according to Chapter 4 of the Asphalt Institute Manual Series No. 2. The value (calculated to the nearest
percentage point) of the Fifty to Thirty (F-T) value, is the percent of total
aggregate retained between the No. 50 (300 mm) and No. 30 (600 mm) sieves, minus the percent of total
aggregate retained between the No. 30 (600 mm) and No. 16 (1.18 mm) sieves.
For Type 1H mixes ensure that a minimum of 50 percent of the virgin fine
aggregate is sand manufactured from stone, gravel or air-cooled slag. If the sand is manufactured from gravel,
ensure that it is crushed from gravel material retained on the 3/8 inch (9.5
mm) sieve.
Use a PG
70-22M asphalt binder for Type 1H mix.
Use a PG 64-28 asphalt binder for Type 2 mix for heavy traffic volume
regardless of the amount of reclaimed asphalt concrete pavement. Use a PG 64-22 asphalt binder and Type 1
medium gradation for asphalt concrete for driveways and under guardrails.
Identify the PG Binder supplier, as well as the polymer
type if applicable, on the JMF submittal.
A change in polymer asphalt binder or polymer source will require a
redesign. Provide on one page neatly
summarized, dated test results for the requirements of Table 702.01-1. Ensure data is no more than two months
old. If SBR polymer is added at the
asphalt concrete mixing plant, provide in the JMF data from the SBR polymer
supplier for total solids (percent) and ash (percent) according to the 702.14. As well, provide the target amount of SBR
polymer greater than or equal to 3.5 percent to achieve the properties
specified. Include a letter of certification from the polymer supplier
verifying percent butadiene in the SBS or SBR polymer. Report in the JMF submittal results of
temperature-viscosity testing for mixing and compaction temperatures. For polymer asphalt binders supplier
recommended temperatures may be used in lieu of the temperature-viscosity
results, but the temperature-viscosity results must still be reported.
Table 441.02-1
Course |
Type 1 Surface |
||
Traffic |
Heavy |
Medium |
Light |
1 1/2 inch (37.5
mm)[1] |
|
|
|
1 inch (25.0 mm)[1] |
|
|
|
3/4 inch (19.0 mm)[1] |
100 |
|
|
1/2 inch (12.5 mm)[1] |
95 to 100 |
100 |
100 |
3/8 inch (9.5 mm)[1] |
70 to 85 |
90 to 100 |
90 to 100 |
No. 4 (4.75 mm)[1] |
38 to 50 |
45 to 57 |
45 to 57 |
No. 8 (2.36 mm)[1] |
20 to 37 |
30 to 45 |
30 to 45 |
No. 16 (1.18 mm)[1] |
14 to 30 |
17 to 35 |
17 to 35 |
No. 30 (600 mm)[1] |
10 to 22 |
12 to 25 |
12 to 25 |
No. 50 (300 mm)[1] |
6 to 15 |
5 to 18 |
5 to 18 |
No. 100 (150 mm)[1] |
4 to 10 |
2 to 10 |
2 to 10 |
No. 200 (75 mm)[1] |
2-6 |
|
|
Asphalt Binder[2] |
5.6 to 10.0 |
5.8 to 10.0 |
6.0 to 10.0 |
Virgin Asphalt Binder (min.) |
|
5.0 |
5.2 |
F/A Ratio, max.[3] |
1.2 |
1.2 |
1.2 |
F-T Value[4] |
+2 |
+2 |
|
Blows[5] |
75 |
50 |
35 |
Stability, min.,
pounds[5] |
1800 |
1200 |
750 |
(N) |
(8006) |
(5338) |
(3336) |
Flow, 0.25 mm[5] |
8 to 14 |
8 to 16 |
8 to 18 |
Design Air Voids[6] |
3.5 |
3.5 |
3.5 |
VMA, min.[7] |
14 |
16 |
16 |
Special Designation |
1H |
|
|
Coarse Agg Mech Crush[8] |
65 |
|
|
[1] Sieve, percent passing [2] Percent of total mix [3] Using effective asphalt binder content [4] Percentage points maximum [5] T 245 [6] Percent, Supplement
1036 [7] Percent, Supplement
1037 [8] Percent, two or more fractured faces ASTM
D5821 |
Table 441.02-1 (continued)
Course |
Type 1 Intermediate |
||
Traffic |
Heavy |
Medium |
Light |
1 1/2 inch (37.5 mm)[1] |
|
|
|
1 inch (25.0 mm)[1] |
|
|
|
3/4 inch (19.0 mm)[1] |
|
|
|
1/2 inch (12.5 mm)[1] |
100 |
100 |
100 |
3/8 inch (9.5 mm)[1] |
90 to 100 |
90 to 100 |
90 to 100 |
No. 4 (4.75 mm)[1] |
50 to 72 |
50 to 72 |
50 to 72 |
No. 8 (2.36 mm)[1] |
30 to 55 |
30 to 55 |
30 to 55 |
No. 16 (1.18 mm)[1] |
17 to 40 |
17 to 40 |
17 to 40 |
No. 30 (600 mm)[1] |
12 to 30 |
12 to 30 |
12 to 30 |
No. 50 (300 mm)[1] |
5 to 20 |
5 to 20 |
5 to 20 |
No. 100 (150 mm)[1] |
2 to 12 |
2 to 12 |
2 to 12 |
No. 200 (75 mm)[1] |
|
|
|
Asphalt Binder[2] |
5.0 to 10.0 |
5.0 to 10.0 |
5.0 to 10.0 |
F/A Ratio, max.[3] |
1.2 |
1.2 |
1.2 |
F-T Value[4] |
+2 |
+2 |
|
Blows[5] |
75 |
50 |
35 |
Stability, min., pounds[5] |
1800 |
1200 |
750 |
(N) |
(8006) |
(5338) |
(3336) |
Flow, 0.25 mm[5] |
8 to 14 |
8 to 16 |
8 to 18 |
Design Air Voids[6] |
4 |
3.5 |
3.5 |
VMA, min.[7] |
16 |
16 |
16 |
Special Designation |
|
|
|
[1] Sieve, percent passing [2] Percent of total mix [3] Using effective asphalt binder content [4] Percentage points maximum [5] T 245 [6] Percent, Supplement
1036 [7] Percent, Supplement
1037 |
Table 441.02-1 (continued)
Course |
Type 2 Surface |
|
||
Traffic |
Heavy |
Medium |
Light |
|
1 1/2 inch (37.5 mm)[1] |
100 |
100 |
100 |
|
1 inch (25.0 mm)[1] |
95 to 100 |
95 to 100 |
95 to 100 |
|
3/4 inch (19.0 mm)[1] |
85 to 100 |
85 to 100 |
85 to 100 |
|
1/2 inch (12.5 mm)[1] |
65 to 85 |
65 to 85 |
65 to 85 |
|
3/8 inch (9.5 mm)[1] |
|
|
|
|
No. 4 (4.75 mm)[1] |
35 to 60 |
35 to 60 |
35 to 60 |
|
No. 8 (2.36 mm)[1] |
25 to 48 |
25 to 48 |
25 to 48 |
|
No. 16 (1.18 mm)[1] |
16 to 36 |
16 to 36 |
16 to 36 |
|
No. 30 (600 mm)[1] |
12 to 30 |
12 to 30 |
12 to 30 |
|
No. 50 (300 mm)[1] |
5 to 18 |
5 to 18 |
5 to 18 |
|
No. 100 (150 mm)[1] |
2 to 10 |
2 to 10 |
2 to 10 |
|
No. 200 (75 mm)[1] |
|
|
|
|
Asphalt Binder[2] |
4.0 to 9.0 |
4.0 to 9.0 |
4.0 to 9.0 |
|
F/A Ratio, max.[3] |
1.2 |
1.2 |
1.2 |
|
F-T Value[4] |
+2 |
|
|
|
Blows[5] |
75 |
50 |
35 |
|
Stability, min., pounds[5] |
1800 |
1200 |
750 |
|
(N) |
(8006) |
(5338) |
(3336) |
|
Flow, 0.25 mm[5] |
8 to 14 |
8 to 16 |
8 to 18 |
|
Design Air Voids[6] |
4 |
4 |
4 |
|
VMA, min.[7] |
13 |
13 |
13 |
|
Special Designation |
|
|
|
|
[1] Sieve, percent passing [2] Percent of total mix [3] Using effective asphalt binder content [4] Percentage points maximum [5] T 245 [6] Percent, Supplement
1036 [7] Percent, Supplement
1037 |
Table 441.02-1 (continued)
Course |
Type 2 Intermediate |
||
Traffic |
Heavy |
Medium |
Light |
1 1/2 inch (37.5 mm)[1] |
100 |
100 |
100 |
1 inch (25.0 mm)[1] |
95 to 100 |
95 to 100 |
95 to 100 |
3/4 inch (19.0 mm)[1] |
85 to 100 |
85 to 100 |
85 to 100 |
1/2 inch (12.5 mm)[1] |
65 to 85 |
65 to 85 |
65 to 85 |
3/8 inch (9.5 mm)[1] |
|
|
|
No. 4 (4.75 mm)[1] |
35 to 60 |
35 to 60 |
35 to 60 |
No. 8 (2.36 mm)[1] |
25 to 48 |
25 to 48 |
25 to 48 |
No. 16 (1.18 mm)[1] |
16 to 36 |
16 to 36 |
16 to 36 |
No. 30 (600 mm)[1] |
12 to 30 |
12 to 30 |
12 to 30 |
No. 50 (300 mm)[1] |
5 to 18 |
5 to 18 |
5 to 18 |
No. 100 (150 mm)[1] |
2 to 10 |
2 to 10 |
2 to 10 |
No. 200 (75 mm)[1] |
|
|
|
Asphalt Binder[2] |
4.0 to 9.0 |
4.0 to 9.0 |
4.0 to 9.0 |
F/A Ratio, max.[3] |
1.2 |
1.2 |
1.2 |
F-T Value[4] |
+2 |
|
|
Blows[5] |
75 |
50 |
35 |
Stability, min., pounds[5] |
1800 |
1200 |
750 |
(N) |
(8006) |
(5338) |
(3336) |
Flow, 0.25 mm[5] |
8 to 14 |
8 to 16 |
8 to 18 |
Design Air Voids[6] |
4 |
4 |
4 |
VMA, min.[7] |
13 |
13 |
13 |
Special Designation |
|
|
|
[1] Sieve, percent passing [2] Percent of total mix [3] Using effective asphalt binder content [4] Percentage points maximum [5] T 245 [6] Percent, Supplement 1036 [7] Percent, Supplement 1037 |
441.03 Use of Reclaimed Pavement. Comply with the requirements of 401.04,
441.04 Antistrip Additive. If the proposed JMF contains any gravel coarse aggregate, or contains more than 25 percent natural sand, or contains more than 20 percent reclaimed asphalt concrete pavement containing gravel coarse aggregate, or is designed according to Item 442 conduct the following tests:
A. Moisture damage potential test according to
Supplement
1051.
B. Washed gradation according to AASHTO T 11 as modified by Supplement
1004.
C. Adherent fines test for each component
according to ASTM D 5711.
Modify the
mix with one of the following antistrip additives if the results of the
moisture damage potential test show the Tensile Strength Ratio (TSR) of the
asphalt concrete mix to be less than 0.80 for 442 mixes or 0.70 for all other
mix types:
A. Liquid Antistrip Material.
Include liquid antistrip
material at a rate of 0.5 to 1.0 percent by weight of the asphalt binder. However, if 442 is specified, include liquid
antistrip material at a rate of 0.50 to 1.25 percent by weight of the asphalt
binder. Ensure the TSR of the asphalt concrete mix is greater than or equal to
0.80 after the addition of the liquid antistrip material.
B. Hydrated Lime. Include
hydrated lime in the dry form at a rate of 1.0 percent by the dry weight of
aggregate for asphalt concrete. Conform
to AASHTO M
303, Type 1 for hydrated lime.
Ensure the TSR of the asphalt concrete mix is greater than or equal to
0.80 after the addition of the hydrated lime.
Provide the Engineer the
following information for each shipment of hydrated lime: Letter of
certification, Production date, Shipment
date, Shipment destination, Batch or lot number and Net weight. The Laboratory
may obtain samples of the hydrated lime at any time to verify quality. If the quality of the hydrated lime is in
question, the Laboratory may require independent laboratory testing.
Include the
antistrip additive in the mix design.
Submit the following to the Laboratory with the proposed JMF:
A. All TSR data (before and after the addition
of the antistrip additive).
B. Rate of addition of the liquid antistrip
material, if used.
C. If using liquid antistrip material submit
product information, information on use by other State DOTs using the liquid antistrip material, and a
letter of certification. If using hydrated lime submit certified test data
showing the hydrated lime conforms to AASHTO M 303,
Type 1.
D. Results of the washed gradation test of
the individual components of the mix used in determining the combined
gradation.
E. Results of the adherent fines testing for
each component.
The
Laboratory may perform additional tests on lab or plant produced mix according
to Supplements 1004,
1051,
and 1052. If a change in the aggregate production is
suspected, the Department may require the Contractor to
perform washed gradations on components and calculate adherent fines to
determine the need for additional TSR review.
Store and introduce antistrip additives into the plant according to
Supplement 1053.
Obtain Laboratory approval of the
antistrip additive storage and feed systems prior to the start of
production.
Provide
delivery tickets to the Engineer at the end
of the project and at the end of each construction year on a multiple year
project. The Engineer will verify the
number of pounds of antistrip additive used is within 10 percent of the
calculated amount of antistrip additive required for the total weight of
asphalt binder, based on the JMF, used in the asphalt concrete.
441.05
JMF Field Adjustments. During production the Contractor may
adjust the JMF gradation within the below limits without a redesign of the
mixture. Limit adjustments of the JMF to
conform to actual production, without a redesign of the mixture, to ±3 percent passing the 1/2 inch (12.5 mm), No.
4 (4.75 mm), and No. 8 (2.36 mm) sieves and ±1 percent passing the No. 200 (75mm) sieve. Do not exceed the limits in Table
441.02-1 in the adjusted JMF. The
adjustment on the 1/2 inch (12.5 mm) sieve applies only to Type 1H and Type 2
mixes. Determine the need for any JMF
gradation adjustments in the time specified.
Should no adjustments be made, the Department will base acceptance on
conformance to the original JMF. After
the time period specified, the Department will allow no further adjustment of
the JMF.
Should a redesign of the mixture become
necessary, submit a new JMF according to the requirements for the initial
JMF. A new acceptance lot will begin
when a new JMF established by a redesign of the mixture becomes effective. Make any adjustment of this new JMF as
provided for the original JMF. Record
both the design JMF and the adjusted JMF in effect during production of an
acceptance lot on the Quality Control Report for that lot. In the event that a new design JMF is
proposed and approved, also make a notation on the ticket for the first load
produced under the new design JMF.
441.06 Monitoring. The Department will establish District Monitoring Teams for the purpose of verifying all Contractor mixture production processes. Verification may be accomplished by obtaining split samples or independent samples from the plant or roadway. If the mixture quality verifies then production may continue. If mixture quality does not verify then the Monitoring Team and Contractor will cooperatively investigate and resolve the problem. Whenever results are disputed the Laboratory will investigate and conduct additional testing to resolve. Based on their review, the Monitoring Team may at any time disallow production to continue.
441.07
Quality Control Program. Submit a Quality Control Program (QCP)
according to 403.03. Include an example control chart per 441.10 with the QCP.
Use quality control technicians working in the plant lab during all
mixture production and that are approved by the Department. Technician approval will be according to
Supplement 1041.
441.08
Testing Facilities. Provide testing facilities at the plant site
conforming to Supplement 1041.
441.09 Quality Control Tests. Perform quality control tests to control the asphalt concrete mix within the specifications. Ensure that these quality control tests measure the asphalt binder content, gradation, air voids, and Maximum Specific Gravity (MSG) according to the Contractor’s approved QCP. Perform each quality control test a minimum of one time each half of a production day or night (two tests per production day or night), or one each 1400 tons (1300 metric tons), whichever is less.
Perform more sampling and
testing than the minimum specified at the start of production and during
production when the quality control tests show the asphalt concrete being
produced is near or outside the specification limits of Table 441.10-1. Immediately resolve problems indicated by an
out of specification test and immediately retest to validate corrections. The Contractor may
determine the method of sampling and testing of the asphalt concrete beyond the
minimum specified, and should detail the methods in the Contractor’s approved
QCP. Record all quality control testing
on the Quality Control Report according to 441.11.
Perform the
required quality control tests as follows:
A. Asphalt Binder Content.
Determine the asphalt binder content of a sample of asphalt concrete by
performing an Asphalt Content (AC) Gauge test according to Supplement 1043. Make all printouts available for review by
the Monitoring Team at any time. Use solvent extraction according to Supplement
1038
for tests used in the AC Gauge offset process, for when an AC Gauge problem
exists, and for testing cooled samples that cannot adequately be tested in an
AC Gauge test.
Total, for each day’s production, the flow meter printouts for SBR polymer added at the asphalt concrete mixing plant. Calculate the percent of polymer versus neat asphalt binder in the mix each day and record on the TE-199. Hold calculation worksheets and printouts in the plant laboratory for review by the Monitoring Team. A +/- 0.2 percent tolerance from the target amount of SBR polymer will be used as a guide for an acceptable amount of SBR polymer, but will not be consistently low.
Determine the
moisture content of the asphalt concrete for each AC Gauge test. Maintain the moisture content at 0.8 percent
or less.
B. Gradation. Perform at least one of the daily gradations
on aggregate remaining after removing the asphalt binder with a solvent from an
asphalt concrete sample used in an AC Gauge test (solvent sample) or on
aggregate remaining after removing the asphalt binder with a preapproved
asphalt ignition oven according to Supplement
1054 and from an asphalt concrete sample used in an AC Gauge test (ignition
oven sample). Use only an asphalt
ignition oven to obtain an aggregate sample from an asphalt concrete sample
having a polymer modified PG Binder. The DET may make an exception for this for
SBS polymer as long as no issues arise.
Correct each solvent sample for ash.
Perform all other gradations on solvent samples, ignition oven samples,
or on samples obtained according to the Contractor’s approved QCP.
The gradation
results of all the sieves must be representative of the JMF. If the Contractor fails
to control the entire gradation, the Laboratory may require a redesign
according to 441.02.
When the F-T
value is specified for a mix in 441.02 calculate it for
each gradation analysis. Maintain the
F-T value at +4 percentage points or less for these mixes.
Calculate the
F/A ratio for every solvent sample or ignition oven sample analysis. Maintain the F/A ratio so no F/A ratio is
greater than 1.2 for all mixes. Use the
asphalt binder content determined by the AC Gauge for calculating the F/A
ratio. If the F/A ratio is greater than
1.0, recalculate the F/A ratio using the effective asphalt binder content. Calculate the effective asphalt binder
content on the calculation sheet using the asphalt binder content determined by
the AC Gauge and attach it to the Quality Control Report. Use bulk and effective aggregate specific
gravities and remaining values needed in the calculation from the approved
JMF. Do not deviate from these values
without the Laboratory’s approval. If
the F/A ratio is greater than 1.0 for ignition oven samples, calculate the F/A
ratio using the percent passing the No. 200 (75 mm) sieve from a washed gradation of the
ignition oven sample according to AASHTO
T 30.
C. Air
Voids and MSG. Determine the air voids of the asphalt
concrete by analyzing a set of compacted
specimens and a corresponding MSG determination. Use the MSG to calculate the air voids of the
compacted specimens. Use a 1-hour cure
for all mix samples used in voids analysis.
The Contractor may use
a 2-hour cure time if voids are consistently near the low void warning
band. In this case, use the 2-hour cure
for all voids testing through the remainder of the project. Ensure that the cure temperature and
specimen compaction temperature are the same.
Use a compaction temperature tolerance of +/- 5.0 ºF (3.0 ºC).
Calculate the
Voids in Mineral Aggregate (VMA)
value for every set of compacted specimens according to Supplement 1037.
Calculate the average of all the MSG determinations performed each production day and report this average on the Quality Control Report. When the range of three consecutive daily average MSG determinations is equal to or less than 0.020 average these three average MSG determinations to determine the Maximum Theoretical Density (MTD). After the MTD is established, compare all individual MSG determinations to the MTD
Whenever
compacted specimens are to be made and an MSG determination is to be run, take
a sample of sufficient size to run a corresponding AC Gauge test. When the air void and MSG test results are
recorded reference them to the AC Gauge test of the sample.
D. Other Requirements. Supply proper
containers and take two 1 quart (1 liter) asphalt binder samples from the first
transport truck load of each different asphalt binder grade of the project
before incorporation into the storage tank.
Label the samples with binder grade, supplier, project number and date
and retain them in the plant laboratory for future reference by the
Department. Discard the samples at
project finaling if not taken by the Monitoring Team.
Retain a split sample for each AC Gauge
test and MSG test and all compacted specimens for monitoring by the
Department. Maintain MSG samples in the
state described in ASTM D 2041,
Section 9.2. The Contractor may
dispose of the AC Gauge test samples after two days and all other split samples
after seven days if the Department does not process the split samples.
Measure the
temperature of the mixture and record.
Validate the results on the load tickets at least once during each hour
of production.
The Contractor may conduct additional testing of any type. Record such additional testing along with all other quality control records and have these records readily available for the Monitoring Team’s review. The Laboratory may observe, review, and approve the procedures at any time.
441.10
Control Charts. Maintain up to date control charts showing
each individual test result and the moving accumulative range as follows:
A. Plot tests showing the
percent passing for the 1/2 inch (12.5 mm), No. 4 (4.75 mm), No. 8 (2.36
mm), and No. 200 (75 mm) sieves the percent asphalt binder content,
the MSG and the percent air voids. Round
all percentages to the nearest whole percent; except, round asphalt binder
content, the No. 200 (75 mm) sieve, and air voids to the nearest
0.1 percent.
B. Show the Specification and
Warning Band Limits on the control charts.
These limits are specified in Table 441.10-1.
C. Label each control chart to
identify the project, mix type and producer.
D. Record the moving
accumulative range for three tests under each test point on the chart for air
voids and asphalt binder content.
Accumulative range is defined as the positive total of the individual
ranges of two consecutive tests in three consecutive tests regardless of the up
or down direction tests take. If more
than the minimum required testing (i.e. two tests per production day or night, 441.09 paragraph 2) is performed do not include the result
in accumulative range calculations.
Stop production and notify the
Monitoring Team when any of these occur:
A. Any
two tests in a row or any two tests in two days are outside the specification
limits of Table 441.10-1.
B. Any
four consecutive moving accumulative ranges greater than specification limits
of 2.50 percent for air voids or 0.60 percent for asphalt binder content
occur.
Any mixture sent to the paving
site without stopping production and notifying the Monitoring Team when
required by this specification will be considered non-specification material.
Do not restart production until
discussing with the Monitoring Team and the team is satisfied an adequate
correction to remedy problems is in place.
Following a shutdown restart production in a manner acceptable to the
DET. When production problems cannot be
solved within one day after a plant shut down a Contractor’s representative holding a Level 3 Asphalt Department approval is required to be at the
asphalt plant until a full production day is achieved with results satisfactory
to the Monitoring Team.
TABLE 441.10-1
Mix Characteristic |
Specification Limits |
Warning Band Limits |
Asphalt Binder Content[1] |
-0.3% to 0.3% |
-0.2% to 0.2% |
1/2 inch (12.5 mm) sieve[1] |
-6.0% to 6.0% |
-5.0% to 5.0% |
No. 4 (4.75 mm) sieve[1] |
-5.0% to 5.0% |
-4.0% to 4.0% |
No. 8 (2.36 mm) sieve[1] |
-4.0% to 4.0% |
-3.0% to 3.0% |
No. 200 (75 mm) sieve[1] |
-2.0% to 2.0% |
-1.8% to 1.8% |
Air Voids[2] |
2.5 to 4.5 |
2.7 to 4.3 |
Air Voids[3] |
3.0 to 5.0 |
3.2 to 4.8 |
MSG[4] |
-0.012 to 0.012 |
|
[1] deviation from the JMF [2] for Design Air Voids of 3.5% [3] for Design Air Voids of 4.0% [4] deviation from the MTD |
441.11 Quality Control Reports. Use Department Form TE-199 for the Quality
Control Report. Record all test results
on the Quality Control Report. Document
all decisions regarding responses to test results on the Quality Control Report
(referring to the particular test), including reasons why a particular problem
may exist what action was taken to correct the problem (plant operation or
testing), and what communication with Department personnel took place. Submit one Quality Control Report to the DET
no later than specified. Retain copies
of all records documenting the quality control inspections and tests throughout
the life of the Contract and furnish them to the DET on request.
441.12 Mixture Deficiencies. Control
all production processes to assure the Engineer that the mixture
delivered to the paving site is uniform in composition per specification requirements,
conforms to the JMF and that the placed mixture is free of any defect (ex. segregation, tenderness, lack of mixture and
texture uniformity, raveling, flushing, rutting, holes, debris etc.) within the
Contractor’s control at project completion. Correct obvious pavement problems according
to 401.15.
If any suspicion that other mixture composition or pavement problems
exist the Monitoring Team will conduct an initial investigation thru review of
data and sampling of the asphalt pavement.
Should a Department investigation determine that the Contractor’s QCP is
not controlling the mixture in a manner to achieve mixture quality as described
above the Contractor quality control data may be rejected. In that case the Department will conduct a
thorough test investigation based on samples from the roadway and use those
test results in determining disposition of the material.
A mixture is not uniform in composition if multiple random non-specification individual
tests or any four consecutive non-specification moving accumulative ranges
exist. The mixture can be rejected, production can be stopped and/or a redesign
can be called for by the Department. The
Laboratory will not approve any redesign it determines is unsatisfactory to
provide acceptable mix performance.
Submit this new design for approval according to 441.02
and at no additional cost to the Department.
If any non-specification mixture is sent to the paving site the Engineer will
determine disposition of the material according to policy.