ITEM 441 CONTRACTOR MIX DESIGN AND QUALITY CONTROL—GENERAL
441.01
Description
441.02
Composition
441.04 Antistrip Additive
441.05 JMF Field Adjustment
441.06
Monitoring
441.07 Quality
Control Program
441.08 Testing
Facilities
441.09 Quality
Control Tests
441.10 Control
Charts
441.11 Quality
Control Reports
441.12 Mixture
Deficiencies
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 (e.g.
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.
Determine Air Voids from specimens prepared and tested per Supplement
1036. 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 Laboratory. 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. According
to 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 µm) and No. 30 (600 µm)
sieves, minus the percent of total aggregate retained between the No. 30 (600
µm) 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.
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 µm)[1] |
10 to 22 |
12 to 25 |
12 to 25 |
No. 50 (300 µm)[1] |
6 to 15 |
5 to 18 |
5 to 18 |
No. 100 (150 µm)[1] |
4 to 10 |
2 to 10 |
2 to 10 |
No. 200 (75 µm)[1] |
2 to 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] AASHTO T 245
[6] Percent, Supplement
1036 [7] Percent, Supplement
1037 [8] Percent, two or more fractured faces ASTM D5821 |
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 µm)[1] |
12 to 30 |
12 to 30 |
12 to 30 |
No. 50 (300 µm)[1] |
5 to 20 |
5 to 20 |
5 to 20 |
No. 100 (150 µm)[1] |
2 to 12 |
2 to 12 |
2 to 12 |
No. 200 (75 µm)[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] |
4.0 |
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] AASHTO 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 µm)[1] |
12 to 30 |
12 to 30 |
12 to 30 |
No. 50 (300 µm)[1] |
5 to 18 |
5 to 18 |
5 to 18 |
No. 100 (150 µm)[1] |
2 to 10 |
2 to 10 |
2 to 10 |
No. 200 (75 µm)[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] |
4.0 |
4.0 |
4.0 |
VMA, min.[7] |
13 |
13 |
13 |
Special Designation |
|
|
|
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 µm)[1] |
12 to 30 |
12 to 30 |
12 to 30 |
No. 50 (300 µm)[1] |
5 to 18 |
5 to 18 |
5 to 18 |
No. 100 (150 µm)[1] |
2 to 10 |
2 to 10 |
2 to 10 |
No. 200 (75 µm)[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] |
4.0 |
4.0 |
4.0 |
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] AASHTO 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 (75 µm) 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
according to 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. Additionally perform more sampling and testing than the
minimum during production when the quality control tests show the asphalt
concrete being produced is outside the warning bands as shown in the
Contractor’s approved QCP. Immediately
resolve problems indicated by any out of warning band test and immediately
retest to validate corrections have returned the materials to within the
warning band limits. The Contractor may determine the method of
testing of the asphalt concrete beyond the minimum specified, and will detail
the methods technicians will follow in the Contractor’s approved QCP.
Should additional testing as required
above not be performed the DET, after consultation
with the Laboratory, will require the testing frequency be increased to all
tests each two hours of production for the remainder of the project. If this
occurs, the DET will request an opinion from the QCQC for action(s) against the technician and/or Contractor
including but not limited to warning, removal and/or a change of the facility
to Unconditional Acceptance.
Record
the results of every test performed.
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. Offset the AC Gauge for each JMF
on each project at the project’s start. Perform the offset using solvent
extraction methods for every QC sample according to Supplement
1038 and the AC Gauge Verification and Offset Record. Use solvent
extraction according to Supplement
1038 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. Only take SBR PG-Modified Binder samples
using a five gallon bucket, stirring its contents and transferring to the
required sample containers.
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 gradation test each
production day 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 µm) 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
according to Supplement
1036. Ensure that the cure temperature and specimen
compaction temperature are the same. 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. For hot mix asphalt use the JMF lab
compaction temperature. For warm mix asphalt according to 402.04 use a lab compaction temperature 30.0 ºF
(16.7 ºC) less than the JMF lab compaction
temperature for hot mix asphalt. Use a compaction temperature tolerance
of +/- 5.0 ºF (3.0 ºC). Record on the TE-199
if the mixture produced was ran at the asphalt plant as a
hot mix asphalt (HMA) or as a warm mix asphalt
(WMA) produced according to 402.09 or another approved method.
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 also 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
µm) 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 µm) sieve, and air voids to the nearest
0.1 percent.
B. Show the out of specification limits
specified in Table 441.10-1 and QCP Warning Band Limits on the control charts.
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
first paragraph) is performed do not include the result in accumulative
range calculations.
Stop production and immediately notify the Monitoring Team when either A or
B occurs:
A.
Any two tests in a row or any two tests in two days are outside of 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 an adequate correction to remedy problems is in place and the
Monitoring Team is satisfied. 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 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.
Mix Characteristic |
Out of Specification Limits |
||
Asphalt Binder Content[1] |
-0.3% to 0.3% |
||
1/2 inch (12.5 mm) sieve[1] |
-6.0% to 6.0% |
||
No. 4 (4.75 mm) sieve[1] |
-5.0% to 5.0% |
||
No. 8 (2.36 mm) sieve[1] |
-4.0% to 4.0% |
||
No. 200 (75 µm) sieve[1] |
-2.0% to 2.0% |
||
Air Voids[2] |
2.5% to 4.5% |
||
Air Voids[3] |
3.0% to 5.0% |
||
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; within the specification requirements and limits; 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.
Correct obvious pavement problems according to 401.15.
If the Department has any suspicion that other mixture composition or pavement
problems exist, the Monitoring Team will conduct an initial investigation
through review of data and/or 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 non-specification 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.
When
any out of specification material, based on quality control tests not within
the limits of Table 441.01-1, is sent to the
paving site the Engineer will determine disposition of the material according
to the Department non specification material policy.