ITEM 441 CONTRACTOR MIX DESIGN AND QUALITY CONTROL—GENERAL

441.01 Description

441.02 Composition

441.03 Use of Reclaimed Pavement

441.04 Antistrip Additive

441.05 JMF Field Adjustment

441.06 Monitoring

441.07 Quality Control Program (QCP)

441.08 Testing Facilities

441.09 Quality Control Tests

441.10 Control Charts

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 or 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.

Develop a Quality Control Program (QCP) for the purpose of design and control of the asphalt concrete according to this specification. Submit the QCP to the Department for review and approval. The Department will closely monitor this QCP.

Compose the asphalt concrete of aggregates and asphalt binder. Develop a JMF to comply with the specified composition limits and mix design criteria and submit it to the Laboratory for approval prior to the start of production.

During production of the mixture, perform quality control procedures adequate to furnish assurance to the Engineer that the mixture delivered to the paving site reasonably conforms to the specification requirements and can be incorporated in the work with satisfactory results.

The Contractor’s control of the mixture is based on the composition of samples the Contractor takes and analyzes, according to the approved QCP.

441.02 Composition. Before producing asphalt concrete, submit a proposed JMF for each combination of aggregates in writing to the Laboratory. Base the optimum percentage of asphalt binder selected for each JMF on the results of the specified tests evaluated, insofar as practical, as recommended in Chapter 5 of the Asphalt Institute Manual Series No. 2. The optimum percentage of asphalt binder is the percentage that yields the Design Air Voids, provided that the other requirements of Table 441.02-1 are met. Provide a mix design with at least four graph points, including a minimum of two graph points above and two graph points below the optimum asphalt binder content. For each JMF submitted, include test data to demonstrate that mixtures conforming to the proposed JMF will have properties as specified. Submit the proposed JMF and all supporting data on forms the Laboratory approves. In addition, submit the following samples of asphalt concrete conforming to the proposed JMF for Laboratory examination and evaluation:

A. A 5-pound (2000 g) minimum uncompacted sample (all mixes).

B. A 10-pound (4000 g) minimum uncompacted sample (Type lH only).

C. A total of three Marshall specimens (Type lH only).

The Laboratory may require additional samples of individual materials or of asphalt concrete conforming to the proposed JMF.

The Laboratory may perform additional tests to ensure adequate mix performance. The Laboratory may perform these tests on material conforming to a proposed JMF or on material obtained during production of an approved JMF. Based on the results of these tests, the Laboratory may require the Contractor to design a new JMF. Allow time for this additional testing.

The Contractor may begin asphalt concrete production after the Laboratory approves the JMF and the District is properly notified. This JMF approval by the Laboratory is subject to field verification. It is the intent of this specification that the materials used in the production of the asphalt concrete will result in a mixture that conforms to the JMF. If the produced asphalt concrete mixture fails to conform to the JMF, the Laboratory may reject the JMF and require the Contractor to establish a new JMF.

Do not apply the gradation requirements of 703.05 for fine aggregate.

In the JMF, propose definite single values for:

A. The percentage (in units of one percent) of aggregate passing each specified sieve, except the No. 200 (75 mm), based on the dry weight of aggregate.

B. The percentage (in units of one-tenth of 1 percent) of aggregate passing the No. 200 (75 mm) sieve, based on the dry weight of aggregate.

C. The percentage (in units of one-tenth of 1 percent) of asphalt binder to be added, based on the total weight of mixture.

D. The value (calculated to the nearest one-tenth) of the fines to asphalt (F/A) ratio, which is the percentage of aggregate passing the No. 200 (75 mm) sieve divided by the percentage of asphalt binder. If the F/A ratio using total asphalt binder content is greater than 1.0, then 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.

E. The value (calculated to the nearest percentage point) of the Fifty to Thirty (F-T) value, which 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.

The composition limits and properties of Table 441.02-1 are extreme ranges within which the JMF must be established. Use the criteria for Medium Traffic Volumes unless otherwise specified.

Use a 2-hour cure for all mix samples used in the design process. Ensure that the cure temperature for all samples is the mix holding temperature used before specimen compaction.

For Type 1H mixes, ensure that the coarse aggregate retained on the No. 4 (4.75 mm) sieve has a minimum of 65 percent mechanically crushed particles. A mechanically crushed particle is a particle having rough angular edges. Count particles exhibiting mechanically crushed characteristics as mechanically crushed regardless of how the fracture occurred. 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.

If a Type 1H asphalt concrete mix is used, use a PG 70-22M asphalt binder.

If a Type 2 asphalt concrete mix designed for a Heavy traffic volume is specified, use a PG 64-28 asphalt binder regardless of the amount of reclaimed asphalt concrete pavement used in the mix. Perform the analysis specified in 441.03.

For all driveways and all asphalt concrete used under guardrails, regardless of the PG binder specified use PG 64-22 asphalt binder and use a Type 1 medium gradation designed using either Medium or Heavy design requirements.

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	+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
[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 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	+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] 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 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 to16	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] AASHTO 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] AASHTO T 245 [6] Percent, Supplement 1036 [7] Percent, Supplement 1037

441.03 Use of Reclaimed Pavement. In addition to the requirements of 401.04, the Contractor may use more than 10 percent of reclaimed asphalt concrete pavement, provided the reclaimed asphalt concrete pavement is included in the mix design process to establish the JMF in accordance with 441.02. For surface courses, the Contractor may use up to a maximum of 20 percent of reclaimed asphalt concrete pavement. For intermediate courses, the Contractor may use up to a maximum of 35 percent of reclaimed asphalt concrete pavement. These percentages are based on the dry weight of all the materials used.

Whenever more than 10 percent of reclaimed asphalt concrete pavement is used, conform to the requirements of the specified asphalt binder for the asphalt binder proposed for use in the mixture, by a combination of reclaimed asphalt binder, virgin asphalt binder, and rejuvenating agents. Specify the percentages of reclaimed asphalt concrete pavement, virgin aggregates, virgin asphalt binder, and rejuvenating agents (if used) required to meet the JMF. Meet the quality and gradation requirements of this specification for all materials used.

Determine final reclaimed asphalt concrete pavement gradation and asphalt binder content on four separate stockpile (or roadway for concurrent grinding) samples all agreeing within 0.4 percent for asphalt binder content and 5 percent passing the No. 4 (4.75 mm) sieve. Report all 4 test results and an average in the JMF submittal.

If greater than 20 percent of reclaimed asphalt concrete pavement is used, then use the viscosity of the recovered asphalt binder from the reclaimed asphalt concrete pavement in the analysis and submit it to the Laboratory with the proposed JMF.

441.04 Antistrip Additive. If the proposed JMF meets any of the following requirements:

A. Contains any gravel coarse aggregate, or

B. Contains more than 25 percent natural sand, or

C. Contains more than 20 percent reclaimed asphalt concrete pavement containing gravel coarse aggregate, or

D. 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 and 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. The TSR of the asphalt concrete mix shall be 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. The Laboratory will maintain a list of approved sources of hydrated lime. To become an approved source, a source shall submit certified test data to the Laboratory showing their hydrated lime conforms to AASHTO M 303, Type 1.

Annual submittal of certified test data by January 1 each year will be necessary to maintain approval. Provide the Engineer the following information for each shipment of hydrated lime:

1. Letter of certification.

2. Production date.

3. Shipment date.

4. Shipment destination.

5. Batch or lot number.

6. Net weight.

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, product information, recent supplier State project information using the liquid antistrip material, and letter of certification.

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 according to Supplements 1004, 1051, and 1052. These tests may be performed on material conforming to a proposed JMF or on material obtained during production of an approved JMF. 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. 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 for the hydrated lime supplier.

Store and introduce antistrip additives into the plant according to Supplement 1053. The Laboratory shall approve the antistrip additive storage and feed systems prior to the start of production. The Laboratory may require modifications in the method of introducing the antistrip additive into the mix, if the antistrip additive is not being properly dispersed into the mix.

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. If, during production, the Contractor determines from the results of quality control tests that adjustments are necessary to the mix design to achieve the specified properties in place, the Contractor may adjust the JMF gradation within the below limits without a redesign of the mixtures.

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, except 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 Monitoring Teams for the purpose of observing, testing and reviewing the Contractor’s QCP for conformance with these Specifications. The Department may obtain comparison samples by split samples with the Contractor or independent samples from the plant or roadway. The Department will test and analyze these samples according to the standard procedure for a comparison with the Contractor’s quality control tests. If there is good comparison, production may continue. If there is poor comparison, the Department will review the Contractor’s program more closely. Based on their review, the Monitoring Team may at any time disallow production to continue. The Department will notify the Contractor in writing to stop production.

441.07 Quality Control Program (QCP). Conform to 403.

441.08 Testing Facilities. Provide testing facilities at the plant site conforming to Supplement 1041, with suitable space for Monitoring Team members to conduct a review of the work.

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.

The Department expects the Contractor to perform more sampling and testing than the minimum specified, especially at the start of production and during production when the quality control tests show the asphalt concrete being produced is near or outside the Warning Band Limits. 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 and turn them over to the DET at the end of the project or the end of the production year.

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 from an asphalt concrete sample used in an AC Gauge test (ignition oven sample). 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. Perform testing with an asphalt ignition oven according to Supplement 1054.

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 three compacted specimens and a corresponding MSG determination. Use the MSG to calculate the air voids of the compacted specimens. If a single air void test is less than 2 percent or greater than 6 percent, take and test a sample immediately. If two consecutive tests are outside this 2 to 6 percent range, cease production.

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 for all samples is the mix holding temperature used prior to specimen compaction.

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. The Department will verify the MTD if the MSG determination has a deviation from the MTD of less than or equal to 0.020. If the MTD is not verified, establish a new 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. 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 7.1. 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.

After establishing the MTD, if the range difference in any three consecutive tests is greater than 2 percent for air voids or 8 percent for material passing the 4.75 mm (No. 4) sieve, notify the Monitoring Team. Continuing range deficiencies will be a reason for ceasing production.

Measure the temperature of the mixture and record and 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 Engineer’s review. The Laboratory may observe, review, and approve the procedures at any time. Retain copies of all records documenting the Contractor’s additional quality control inspections and tests throughout the life of the Contract and furnish them to the Engineer on request.

Multiple random non-specification individual tests or multiple range deficiencies can be cause for redesign. When production problems exist beyond a production day, a Contractor’s representative holding a Level 2 qualification is required to be at the asphalt plant until a full production day is achieved with results satisfactory to the DET. 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.

441.10 Control Charts. Post control charts at all times showing each individual test result and the moving average of three tests, 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 as determined by a solvent sample or ignition oven sample analysis, the percent asphalt binder content as determined by the AC Gauge, the MSG and the percent air voids. Round all percentages to the nearest whole percent; however, round asphalt binder content, the No. 200 (75 mm) sieve, and air voids to the nearest 0.1 percent.

B. Plot the moving average in red starting with the third test.

C. Show the Specification and Warning Band Limits on the control charts. These limits are specified in Table 441.10-1.

D. Label each control chart to identify it and its producer. Include an example when submitting the QCP for approval.

E. Record the range for three tests (moving range) under the appropriate running average point on the chart.

In the event two consecutive tests enter the Warning Band Limits, notify the Monitoring Team.

In the event the moving average falls outside the specification limits, cease operations. Do not resume production until corrective action has been taken and the Monitoring Team has approved.

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, how the problem was evaluated, 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 with all supporting documentation no later than specified. Ensure the report is complete with a concise statement of quality control activity related to the previously stated assurance purpose.