Asphalt QC 2000Asphalt QC 2000

The Adventure Begins….The Adventure Begins….

TopicsTopics

TerminologyTerminology SpecificationsSpecifications Sampling and TestingSampling and Testing Reporting/CQRReporting/CQR Who Does What?Who Does What? Lube & Oil ChangeLube & Oil Change All in 20 Minutes!All in 20 Minutes!

In a Nutshell…..In a Nutshell….. Payment based on Contractor’s (Quality Control) test Payment based on Contractor’s (Quality Control) test

data that has been verifieddata that has been verified FDOT runs Verification tests at a lesser frequencyFDOT runs Verification tests at a lesser frequency

– Split-sample at plant by project personnelSplit-sample at plant by project personnel– Independent sample at District LabIndependent sample at District Lab

Payment is based on density on the roadway and air voids, Payment is based on density on the roadway and air voids, asphalt content and gradation at the plantasphalt content and gradation at the plant– Percent Within Limits (PWL) – larger quantitiesPercent Within Limits (PWL) – larger quantities– Pay Table – smaller quantitiesPay Table – smaller quantities– Big Change!Big Change!

General Details Include….General Details Include….

Initial lot size mandatory 2000 tonsInitial lot size mandatory 2000 tons– Following lots may be 2000 or 4000 tonsFollowing lots may be 2000 or 4000 tons– Contractor’s option w/Engineer’s ApprovalContractor’s option w/Engineer’s Approval– Deleted Initial Production Test Strip – No “Pause”Deleted Initial Production Test Strip – No “Pause”

Typical lot size 4000 tonsTypical lot size 4000 tons– English and Metric the sameEnglish and Metric the same

4 sublots per lot (1000 tons each)4 sublots per lot (1000 tons each) Plant lot and roadway lots are the samePlant lot and roadway lots are the same All sampling performed by the ContractorAll sampling performed by the Contractor FDOT establishes FDOT establishes whenwhen to sample to sample

– Several options availableSeveral options available

Who’s on First?Who’s on First?OldOld NewNew WhoWho

AcceptanceAcceptance VerificationVerification Project Personnel Project Personnel (CEI)(CEI)

Quality ControlQuality Control Quality ControlQuality Control Contractor Contractor PersonnelPersonnel

Independent Independent AssuranceAssurance

Independent Independent Verification/Verification/

Independent Independent AssuranceAssurance

District Materials District Materials PersonnelPersonnel

Referee TestingReferee Testing Resolution Resolution SystemSystem

District Materials District Materials LaboratoryLaboratory

General Overview - PlantGeneral Overview - Plant

Engineer (VT) directs Contractor (QC) when to Engineer (VT) directs Contractor (QC) when to samplesample– Random basis – generated by Excel SpreadsheetRandom basis – generated by Excel Spreadsheet

– 1/sublot (1/1000 tons or 1/500 tons)1/sublot (1/1000 tons or 1/500 tons)

– QC splits out and boxes up Verification and QC splits out and boxes up Verification and Resolution SamplesResolution Samples

Tests include:Tests include:– Asphalt Content (FM 5-563 only)Asphalt Content (FM 5-563 only)

– Gradation (FM 1-T 030)Gradation (FM 1-T 030)

– Air Voids (AASHTO TP-4 & FM 1-T 209)Air Voids (AASHTO TP-4 & FM 1-T 209)

Verification - PlantVerification - Plant

Performed by Agency - FDOT or Performed by Agency - FDOT or Consultant (CTQP Plant Level I)Consultant (CTQP Plant Level I)– Tests run at plantTests run at plant

Split-sample – randomly selected – 1/lot Split-sample – randomly selected – 1/lot (1/4000 tons or 1/2000 tons)(1/4000 tons or 1/2000 tons)– Same tests as QCSame tests as QC

Precision statement comparison with QC Precision statement comparison with QC resultsresults– GGmmmm, G, Gmbmb, P, Pbb, P, P-200-200, P, P-8-8

Table 334-4Table 334-4Between-Laboratory Precision ValuesBetween-Laboratory Precision Values

PropertyProperty Maximum DifferenceMaximum Difference

GGmmmm 0.0190.019

GGmbmb 0.0220.022

PPbb 0.44%0.44%

PP-200-200FM 1-T 030 (Figure 2)FM 1-T 030 (Figure 2)

PP-8-8FM 1-T 030 (Figure 2)FM 1-T 030 (Figure 2)

Between-Laboratory Precision Between-Laboratory Precision ValuesValues

Verification – Plant (Cont’d)Verification – Plant (Cont’d)

If all results compare:If all results compare:– Accept material Accept material

– Payment based on Contractor’s QC resultsPayment based on Contractor’s QC results

If the results don’t compare:If the results don’t compare:– VT tests remaining sublot samples for property (or VT tests remaining sublot samples for property (or

properties) in question.properties) in question.

– If only initial unfavorable comparison: accept If only initial unfavorable comparison: accept material and pay based on QC resultsmaterial and pay based on QC results

– If two or more unfavorable: ResolutionIf two or more unfavorable: Resolution» Samples sent to District LabSamples sent to District Lab

Independent Verification - Independent Verification - PlantPlant

District Materials takes two samples per District Materials takes two samples per 12,000 tons12,000 tons– Tested at District LabTested at District Lab

Same tests as QCSame tests as QC Results have to meet requirements of Results have to meet requirements of

Master Production RangeMaster Production Range– Go or no go….Go or no go….

Table 334-5Table 334-5Master Production Range Master Production Range

CharacteristicCharacteristic ToleranceTolerance

Asphalt Binder Content (%)Asphalt Binder Content (%) Target ± 0.55Target ± 0.55

Passing No. 8 Sieve (%)Passing No. 8 Sieve (%) Target ± 5.50Target ± 5.50

Passing No. 200 Sieve (%)Passing No. 200 Sieve (%) Target ± 1.50Target ± 1.50

Air Voids (%)Air Voids (%) 4.00 ± 1.504.00 ± 1.50

Density, %GDensity, %Gmmmm :  

Coarse Graded (minimum)Coarse Graded (minimum) 93.0093.00

Fine GradedFine Graded N/AN/A

Note: Density based on an average of 5 randomly located coresNote: Density based on an average of 5 randomly located cores

Quality Control Sampling and Quality Control Sampling and Testing – RoadwayTesting – Roadway

Core locations identified by VTCore locations identified by VT– Tonnage basisTonnage basis

Contractor cuts five cores per sublotContractor cuts five cores per sublot– Example: 1000 ton sublot, 12 ft wide laneExample: 1000 ton sublot, 12 ft wide lane

» 150 lb/sy = 1 core/2000 feet150 lb/sy = 1 core/2000 feet

» 200 lb/sy = 1 core/1500 feet200 lb/sy = 1 core/1500 feet

» 250 lb/sy = 1 core/1200 feet250 lb/sy = 1 core/1200 feet

» 300 lb/sy = 1 core/1000 feet300 lb/sy = 1 core/1000 feet

QC tests cores per FM 1-T 166QC tests cores per FM 1-T 166 Retains cores for Verification/ResolutionRetains cores for Verification/Resolution

Verification - RoadwayVerification - Roadway

Tests performed by Verification TechnicianTests performed by Verification Technician– Tests run at plantTests run at plant

Same-cores Same-cores – VT tests all five cores from a randomly selected VT tests all five cores from a randomly selected

sublotsublot– Same test as QCSame test as QC

Precision statement comparison with QC resultsPrecision statement comparison with QC results– GGmb mb = 0.022= 0.022

Compare favorably: Pay based on QC resultsCompare favorably: Pay based on QC results– If not: similar to plant ResolutionIf not: similar to plant Resolution

Independent Verification Independent Verification RoadwayRoadway

District Materials directs Contractor to District Materials directs Contractor to take five additional cores from take five additional cores from same same sublotsublot as plant IV sample as plant IV sample

Results have to meet requirements of Results have to meet requirements of Master Production RangeMaster Production Range– Average density must meet minimum…Average density must meet minimum…– Go or no go….Go or no go….

CompensationCompensation

If two or less sublots: use Small Quantity Pay If two or less sublots: use Small Quantity Pay Table based on average deviations from targetTable based on average deviations from target

If three or more sublots: use the estimated If three or more sublots: use the estimated Percent Within Limits (PWL) for the lot, based Percent Within Limits (PWL) for the lot, based on the following characteristics:on the following characteristics:– DensityDensity– Air VoidsAir Voids– AC ContentAC Content– P-200P-200– P-8P-8

Compensation (Cont’d)Compensation (Cont’d)

Pay factor for each characteristic is determinedPay factor for each characteristic is determined Composite Pay factor is based on:Composite Pay factor is based on:

– 35%35% DensityDensity

– 25%25% Air VoidsAir Voids

– 25%25% AC ContentAC Content

– 10%10% P-200P-200

– 5%5% P-8 P-8

All calculations by Excel spreadsheetAll calculations by Excel spreadsheet– Not by hand!Not by hand!

ReportingReporting Contractor reports all QC test results, quantities, etc.:Contractor reports all QC test results, quantities, etc.:

– Daily Asphalt Plant Quality Control ReportDaily Asphalt Plant Quality Control Report– Daily Asphalt Roadway Quality Control ReportDaily Asphalt Roadway Quality Control Report– Inputs into CQRInputs into CQR

CEI reports all Verification test results and Verification CEI reports all Verification test results and Verification activities:activities:– Verify mix spread rate, tack spread rate, mix temperature, Verify mix spread rate, tack spread rate, mix temperature,

etc.etc.– Asphalt Plant Verification ReportAsphalt Plant Verification Report– Asphalt Roadway Verification ReportAsphalt Roadway Verification Report– Inputs into CQRInputs into CQR

Forms currently under developmentForms currently under development CQR access through District Construction Office CQR access through District Construction Office

Other Related IssuesOther Related Issues

Implementation date: July 2002 LettingImplementation date: July 2002 Letting– All projectsAll projects

No Type S/FC-3 projectsNo Type S/FC-3 projects– Specification only works with SuperpaveSpecification only works with Superpave

FC-9.5 & FC-12.5 (FC-6) accepted per 334FC-9.5 & FC-12.5 (FC-6) accepted per 334 FC-5 specified in 337FC-5 specified in 337

– Tolerances based on FC-5 construction dataTolerances based on FC-5 construction data– Pay factors weighted differentlyPay factors weighted differently– Criteria 3/8” No.4 & No. 8 sieve, and Binder ContentCriteria 3/8” No.4 & No. 8 sieve, and Binder Content

Specification Refresher Course Specification Refresher Course

Thank You!Thank You!

QC 2000 - Asphalt

Welcome… to the Real World.

Industry Perspective QC 2000 Asphalt

Specifications

Jim WarrenAsphalt Contractors

Association of Florida, Inc.

Contractor perspectives…

Old:– What good will this do?– Oh No!, Not another new specification!– Lets go back to S-1

Now:– It’s no so bad… I see some positives.– We’re trained, we’re equipped… Lets

Roll! Opportunities

What's different from the old system?

Same Superpave Mix as before Still going to test it the same way –

no new tests More QC responsibilities than before Must change focus from average to

uniformity about average (big change)

Its still Hot, Black, and Sticky.

What’s in it for the contractor?

More flexibility to run your operation. More responsibility and authority to make

sure the job is done right. Less reliance of others for decisions of when

to pave, adjustments to make, etc. Less rework, fewer call-backs, less wasted

profits and opportunity costs. QC tests finally mean something. Finally, a payback for investing in QC

personnel and equipment. Mo money (if you know what you’re doing).

What’s in it for the Industry?

Levels the playing field for bidding. Improves the image of the Industry…

Asphalt is State-Of-The-Art. Continuously improving our product –

You want it? We can deliver on time, on budget.

Eliminates lesser products from gaining a foothold in our market.

Secures and protects the highway asphalt paving market due to superior performance and lower life-cycle cost.

What does Industry need to do to make it work?

Educating your crews – “It’s not business as usual anymore” “This ain’t no S-1” Think P401.

Stress the importance of attention to detail “Every ton counts!”

Mgmt. Attitude – you can make this work! If you believe it, exude it… it will happen. Attend the refresher course – A Gotta! Get

up to speed faster through a better understanding of the specification.

Making it Work!

Schwartzkoff Rule #13: “When placed in command – take charge”

Warren Corollary to Rule 13: “When placed in leadership, lead!”

Mgmt. Attitude – you can make this work!

If you believe it, exude it… it will happen.

Every Ton Counts!

What’s in it for the Agency?

Better, more reliable product. No need to look anywhere else for products. Flexibility to inspect where needed… Less $ spent on inspection means more $

for product (asphalt, bridges, etc.) Meets the National goal of “Get In, Do the

Job, Get Out and Stay Out” Schwartzkoff “Rule #14: Do the Right

Thing” Warren Corollary to Rule #14. Add “the

First Time”

What does the Agency need to do make it work?

Have some patience – change takes time – big changes don’t happen overnight.

Cooperate during the transition Expect some mistakes, be willing

to work them out Attend the refresher course – get

up to speed faster through better understanding of the specification.

Refresher Course Objective:

The objective of this 1-day program is to familiarize the participant with the new QC2000 asphalt specifications. Upon completion of this program, the participant will be able to:– - Identify what’s different under these new

specifications compared to current specifications,– - Understand the respective roles and duties of

the parties involved, and – - Understand the acceptance process.

Refresher Course Agenda:

Introduction Definitions Review Specifications

– (234, 285, 320, 330, 334, 337) The Matrix Walking through the Plant & Roadway Checks & Balances Calculations and Spreadsheet Forms, Case Studies, & Q&A Quiz

The MatrixQC Agency Agency Agency

Operation Frequency Pav-L1 Pav-L2 Plnt-L1 Plnt-L2 QC Mgr. RDWY-VT Plant-VT IA OtherSubmit QC Plan for approval 1 per job xApprove QC Plan 1 per job EngineerLocate trucks to sample at Plant per random xSample Mix at plant per random - + 100# x assistMonitor Mix Temperature at Plant 1st 5 loads, every 5th DelegateProcess control Testing see QC plan DelegateProcess and Run QC tests 1 per sublot xProcess and Run VT tests 1 per Lot xGeneral Inspection Duties ANTCO x x x x x x x xScale Checks weekly xMonitor Mix Temperature at Roadway 1st 5 loads, every 5th delegateCheck Prime, Tack, & ARMI Spread rates min 2 per day, ANTCO delegateCheck Mix Spread Rate per 200 tons, ANTCOCollect Truck Tickets each truck delegateTurn truck tickets in to Daily xObtain Random Numbers from Plant VT 1 per Lot xMonitor Roadway Density with Nuke gauge min per 1500 ft, ANTCO xMonitor roadway temp with infrared gauge ANTCO xMark Core Locations Per sublot x xDrill Cores, patch holes, & transport cores Per sublot xCheck Cross-slope 100ft/250 ft delegateCheck Thickness Frequently delegateVerify Cross-slope 1st 2 days, as needed xStraightedge Transverse Joints each xPerform Rolling Straightedge test per Lot xSawcut and Test Roadway Cores per sublot x xVerify Roadway cores Per LotIA Cores - Locate 5 per 12,000 tons xIA Cores - Sample, patch each xIA Cores - Transport, Trim, Test each xComplete Daily QC Reports daily x xTurn Daily QC Reports into Daily xResolution Testing as needed ResolutionVerification Reports per test/lot x xTurn Verfication Reports into per lotEnter data into QC2000 Spreadsheet per test/sublot xRun QC-VT Analysis per Lot xEnter data into CQR ? XMonthly certifications monthly X

What’s in it for the Taxpayer?

The Smooth Ride… Achievable Goals:

– No rutting– No cracking– No potholes

Renewable Surface (roof) as part of entire paving system.

A pavement that delivered the biggest bang for the buck that lasts.

The Best Paving Product – second to none.