asphalt quality assurance program · 2020-03-19 · • qc density testing either by thin lift...
TRANSCRIPT
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W.R. Bailey, P.E.
Asphalt Regional Meetings
Asphalt
Quality Assurance
Program
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QUALITY
ASSURANCE
PROCESS
CONTROL
(QC)
INDEPENDENT
ASSURANCE
(IA) ACCEPTANCE
(VST)
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Asphalt QA Program
• Contractor – Performs QC
• VDOT – Performs IA & VST • Asphalt Certification schools for contractors,
inspectors and testing personnel. • Plant Certification
• Field Certification
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Quality Control (QC)
• All activities performed to control the quality of
the asphalt mixture during production and
placement to fulfill the contractor requirements.
• Section 211
• Mix Design
• Contractor provides QC testing
• Section 315
• Mix Placement
• Contractor provides Field Control - Equipment
• Density Testing
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Independent Assurance (IA)
• Activities that are an unbiased and an independent
evaluation of all Operations, sampling and testing
procedures, and equipment used in the acceptance
program.
• VDOT provides IA during production and placement
• Inspection – observations
• Split sample tests
• Evaluations of Technicians
• AASHTO Materials Reference Laboratory
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Verification Sampling and Testing (VST)
• Validate the quality of the product
• Performed by VDOT
• VST should determine if the material is acceptable
per specification.
• VDOT uses split samples plus a statistical process
of examining Contractor QC test data to verify the
accuracy of sampling and testing used in the
acceptance decision.
• Plant
• VDOT uses independent samples
• Field
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Mix Design Approval Process
• Contractor submits mix design laboratory data
and forms to VDOT for initial approval.
• Limited production - contractor can produce up
to 500 tons or one day’s production. Gyratory
samples taken and analyzed by both VDOT and
Contractor for compliance with Specification
requirements and conformance to submitted mix
design.
• Full production approval granted after a
successful limited production trial.
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Asphalt Plant Quality Control
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Random Truck Sampling
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Sample Splitting
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VDOT uses the Contractor’s
test data (QC) in the
acceptance of plant produced
Asphalt mixtures
Asphalt Plant QA
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Producer Samples and Tests (QC)
• Perform Gradation and Asphalt Content testing
randomly every 500 tons
• Temperature Measurements 1st and 5th load then
at least once an hour
• Volumetric SUPERPAVE tests every 1,000 tons
• Air Voids (VTM)
• Voids in Mineral Aggregate (VMA)
• Voids filled with Asphalt (VFA)
• Rice test – Maximum Specific Gravity (Gmm)
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VDOT Responsibilities,
Samples and Tests
• Inspect Plant equipment and lab for compliance
with specifications – IA
• Split sample tests for gradation and Asphalt
Content are used for system wide IA and VST
purposes
• Volumetrics SUPERPAVE tests used for
verification purposes.
• Air Voids (VTM)
• Voids in Mineral Aggregate (VMA)
• Voids filled with Asphalt (VFA)
• Rice test – Maximum Specific Gravity (Gmm)
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Independent Assurance
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3 3
IA1
3 2 2 1 1 4 1 4 3 2 1 4
Lot 2 Lot 3 Lot 1 Lot 4
2
IA3 IA2 IA1 IA4
IA4 IA3 IA2
Matched Comparison
Analysis
4 3 4 2 QC
Sample
Comparison
IA
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3 3
IA1
3 2 2 1 1 4 1 4 3 2 1 4
Lot 2 Lot 3 Lot 1 Lot 4
2
IA3 IA2 IA1 IA4
IA4 IA3 IA2
2 1 2 1 3 4 1 3 2 1 3 4 QC
System
Comparison
Non Matched
Comparison VST
VST
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Comparison Reports
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4.4 4.6 4.8 5.0 5.2 5.4 5.6
Asphalt Content
f(x) Lab #1 Lab #2
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Comparison Reports
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4.4 4.6 4.8 5.0 5.2 5.6 5.8
Asphalt Content
f(x)
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Asphalt MITS - PLAID Reports
• Statistical Tests are performed on both Split Comparison and IA Samples.
• Any non comparison must be investigated, resolved and documented.
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Assessment of Random Samples
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Is this random?
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Summary – Asphalt Plant QA
• Statistics is the tool that VDOT uses to verify the quality of asphalt mixtures.
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Asphalt Field
Quality
Assurance
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Contractor Field QC Testing
• Depth Checks
• Cross Slope
• Straight Edge Transverse Joints
• QC Density testing either by Thin Lift Nuclear
gauge or through cores/plugs
• Joint Density
• Test and Test frequency will be determined by
Road & Bridge Specifications, Special Provisions
or as directed by the Engineer
• Cut plugs for VST at direction of Materials QA
technician.
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VDOT Project Staff Responsibilities IA
• Verifies Paving equipment meets specifications
• Verifies materials being used are from approved
sources
• Take Temperature measurements of AC at least
every hour
• Verifies that contractor personnel are performing
QC operations correctly
• Verifies Density testing being performed
• Joint Density
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VDOT/Materials VST and IA
• Perform VST testing on plugs
• IA testing
• Verify method of random selection
• Marking of test locations
• Observe QC testing at control strip
• Observe test sections.
• Obtain samples of cores from control strip to
reweigh in laboratory.
• Depth Control tests
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Asphalt Density Virginia Test Method
VTM-76
• Stratified Random Locations - QC
–Control Strip
–Test Sections
• Cores for Control Strips - IA
–6 cores for new mixes
• 2 cores per site
–2 cores
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STRATIFIED RANDOM LOCATIONS
5000 FEET
1000 ft.
1000 FOOT SECTIONS
TEST SECTION
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75
ft.
300 ft.
NUMBER OF
PASSES TARGET DENSITY
ROLLER
PATTERN CONTROL STRIP
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TEST THREE LOCATIONS
1
2
3
50 FEET
75 FEET
MARK TEST LOCATIONS
ORIENT GAUGE IN SAME DIRECTION
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DENSITY vs NUMBER OF PASSES
NUMBER OF PASSES
1 2 3 4 5 6 7 8
144.0
143.0
142.0
141.1
140.0
138.0
137.0
139.0
136.0
135.0
D
E
N
S
I
T
Y
(lb/ft3)
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Locations of nuclear readings are marked by
contractor.
VTM-76
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CONTROL STRIP
300 FEET
TAKE READINGS AT LEAST 1 FOOT FROM EDGE OF PAVEMENT
Using 5 roller passes
2
1
3
4
5
6
7
8
9
10
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Core locations are marked for cutting.
VTM-76
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Cores are cut …
VTM-76
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…and carefully
removed.
VTM-76
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MINIMUM DENSITY
REQUIREMENT
(Bulk Specific Gravity / Max Specific Gravity) * 100
(Table III-3)
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TABLE III-3 Density Requirements
Mixture Type
Min. Control
Strip Density (%)
SM-9.5A, 12.5A
92.5
SM-9.5D, 12.5D
92.2
SM-9.5E, 12.5E
92.2
IM-19.0A
92.2
IM-19.0D
92.0
BM-25.0 92.2
Note: The control strip density requirement is the percentage of
theoretical maximum density at the job-mix formula as
determined by Superpave Mix Design.
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Calibrated
Same gauge used at Control Strip
Nuclear Gauge
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QC Density Test Section
5000 FEET
TAKE READINGS AT LEAST 1 FOOT FROM EDGE OF PAVEMENT
Average of 10 readings (98 – 102% of control strip)
Density Readings 4 or 6 inches from the Joint
2
1 3
4
5
6
7
8
9
10
3 J
3 J
2 J
1 J
1 J
2 J
9 J 10 J
10 J 9 J
8 J 7 J 6 J 5 J
5 J 4 J 7 J 8 J 6 J
4 J
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QC Density Test Section
5000 FEET
TAKE READINGS AT LEAST 1 FOOT FROM EDGE OF PAVEMENT
Average of 10 readings (98 – 102% of control strip)
Density Readings 4 or 6 inches from the Joint
2
1 3
4
5
6
7
8
9
10
3 J 1 J 2 J 10 J 9 J 5 J 4 J 7 J 8 J 6 J
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Lot 2
Contractor must cut 2 cores for VST at the
direction of VDOT
Lot 5 Lot 1 Lot 3 Lot 4
Select one Test Section for VST
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VST Density Test Section
5000 FEET
CUT 2 CORES
Referee Procedure - Cut 3 more Cores
use average of all 5 for final decision
2
1
3
4
5
6
7
8
9
10 VST
VST
R-VST
R-VST
R-VST
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Lot 16 Lot 15
Failing
After Preceding
Lot 14 Lot 17 Lot 13
Determine Limits
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W.R. Bailey, P.E.
Asphalt Regional Meetings
Asphalt
Quality Assurance
Program