dale s. decker eagle, colorado...jmf, mix properties will be same as lab design . mix design...
TRANSCRIPT
![Page 1: Dale S. Decker Eagle, Colorado...JMF, mix properties will be same as lab design . Mix Design Assumptions These assumptions are NOT normally true!!! Unfortunately, Don](https://reader035.vdocument.in/reader035/viewer/2022070713/5ed0131faf36fb567d19539b/html5/thumbnails/1.jpg)
Dale S. Decker
Eagle, Colorado
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Two Puzzle Pieces Today
• Plant Operations
• Lab Testing
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Plant
Operations
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Mix Design Assumptions
Plant can duplicate lab
design
If plant gradation &
asphalt content match
JMF, mix properties will be
same as lab design
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Mix Design Assumptions
These assumptions
are NOT normally
true!!!
Unfortunately,
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Don’t assume lab mix
properties can be
duplicated in HMA plant.
Mix verification through
plant critical.
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Plant Inspection Issues
• Verify Calibration of bin feed and
asphalt weigh system
• Verify temperatures constantly
• Ensure uniformity of mix
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Troubleshooting
Gradation
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Troubleshooting Gradation
• Compare gradations
–Extracted
–Combined aggregates
– Individual aggregate
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Troubleshooting Gradation
Extracted Gradation
• Sample from
–Truck
–Windrow
–Roadway
• Check against design targets
• Additional sampling if unmatched
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Troubleshooting Gradation
Combined Aggregate Gradation
• Aggregate conveyor
• Automatic sampler
–Verify against belt cuts
• Hot stop belt cut
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Troubleshooting Gradation
Individual Aggregate Gradation
• Sample leaving cold feed bins
• Container under feeder
• Hot stopped
• Loader buckets extracted from
feeding face of stockpile
–“Mini” stockpile
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Drum Mix – Plus P200
Gradation OK? Investigate
Extracted
•Gradation change of
individual material
•Stockpile segregation Combined
Individual
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Drum Mix – Plus P200
Gradation OK? Investigate
Extracted
•Feed bin out of
calibration
•Plugged feed bin
•Wrong mix design
Combined
Individual
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Drum Mix – Plus P200
Gradation OK? Investigate
Extracted
•Mix Segregation
Combined
Individual
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Drum Mix – Minus P200
Gradation OK? Investigate
Extracted
•Gradation change of
individual material
•Stockpile segregation Combined
Individual
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Drum Mix - MinusP200
Gradation OK? Investigate
Extracted
•Feed bin out of
calibration
•Plugged feed bin
•Wrong mix design
Combined
Individual
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Drum Mix – Minus P200
Gradation OK? Investigate
Extracted •Production rate
changes w/100% BHF
•Draft with partial BHF
•Uncalibrated BHF
return if partial
•Inclined dust screw
w/start & stop
•Mix segregation
Combined
Individual
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Troubleshooting Asphalt
Content Problems
• Drum
• Batch
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Inconsistent Binder Content
Error
• Segregation of mix
• Asphalt flow control
–Belt scales
–Asphalt meter
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Drum
• Automation determines asphalt
flow
• Belt scales must be calibrated
• Asphalt meter must be calibrated
–Calibrations should be done over
different speed ranges
Troubleshooting Asphalt
Content Problems
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Factors Affecting Asphalt
Content Accuracy
• Climatic conditions
–Extreme temperature swings
–Will scale maintain “zero”
• Aggregate Moistures
• Ignition oven effect of moisture
Continued
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Factors Affecting Asphalt
Content Accuracy
• Asphalts of different suppliers
may have different meter
calibration factors
• Account for binder in RAP/RAS
• Segregation of mix at plant
• BHF effect on
binder/gradation/asphalt content
in mix
Continued
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Consistent Binder Content
Error
• Possible calibration error
• Improper data input
–Meter calibration factor
–Specific gravity of binder
–Asphalt content of RAP/RAS
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Lab Testing
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Lab Testing
• Variability
• Test Procedures
• Inspection Issues
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Some
background…
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Statistics as a Tool
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Test Method Variability
• Is test method precise?
• Which of several methods is most
precise?
• What is quality of lab work?
• Has material become contaminated?
• What are appropriate manufacturing
targets?
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Variability Example
• Average adult male in U.S. is 5’9”
• Info not very helpful to
determine how tall to
make doorways
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Sources of Variability
• Within Lab
–Comparison of test results for
same tech in same lab
performing test at different
times
• Between Lab
–Comparison of test results for
two techs in different labs
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Variability
Sampling
23%
Testing
43%
Materials/
Construction
34%
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Examples of Variability
• Aggregate sampled consistently
from one side of a stockpile
–Gradation may be influenced by
wind blown particles
• Mix consistently sampled from
edge of paved lane
–Segregation can influence test
methods
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Test Variation
When result outside range
Re-evaluate test results
before applying any penalty
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Layer
Thickness
in Specified
Limits
Asphalt
Content
in Specified
Limits
Independent Variables
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Air
Voids
within
Limits
VMA
within
Limits
Both Air Voids and
VMA within Limits
Dependent Variables
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VFA
within
Limits
Dependent Variables
Air Voids, VMA and VFA
all within Limits
VMA
within
Limits
Air Voids
within
Limits
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Statistics
in
Pavement
Construction
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Statistics
The mathematics of the collection,
organization, and interpretation of
numerical data
American Heritage Dictionary
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Statistics
The science that scares the hell
out of normal people.
Dale Decker
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Accuracy Versus
Precision
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Accuracy
Poor Precision
Good Accuracy (unbiased)
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Precision
Good Precision
Poor Accuracy (biased)
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Accuracy & Precision
Good Precision
Good Accuracy (unbiased)
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9-18
Risk
Analysis
Good
Material
Bad
Material
Accept
Reject
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We don’t know what we know
• Good technology many times not
used properly
• Test methods/design procedures
“customized”
• “Don’t have time” to do it properly
• NIH syndrome
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Key Testing Parameters
• Ignition Oven
• Maximum Specific Gravity (Gmm)
• Gradation
• Bulk Gravity of Compacted Mix
(Gmb)
Specific Comments on
potential sources of variability
follow
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It’s easy to get lazy…
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Diligence is Required
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For All Tests
• Critical to follow standard test
methods
–Every technician in every lab
must run every test exactly the
same way!
•Both contractor and DOT
• Tests are not an acceptable place
for individuality!
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Testing Highlights
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Ignition Oven
• Use AASHTO requirements for
sample weight
• Ensure oven is calibrated
• Verify complete burn
• Ensure that oven vent is not
impeding exhaust gas flow
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Maximum Specific Gravity
• Use AASHTO requirements for
sample preparation
–Size of sample
–Temperature
–Timing for performing tests
• Calibrated vacuum system
• Proper water temperature
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Gradation
• Inspection of sieves
–Wire
–Soldering
• Don’t overload sieves
• Verify weight for original versus
retained sample to meet spec
requirements
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Aggregate Specific Gravity
• Critical materials property
• Can make a huge difference in
volumetric calculations
• Must keep up-to-date
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Bulk Gravity Test (Gmb)
• Maintain water temperature and
volume
• Consistency in getting SSD
condition
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Rule-of-Thumb
0.100 change in aggregate blend S.G.
Binder requirement changes 0.2% by wt
To maintain equivalent asphalt content
by volume for same VMA
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Specific Gravity vs. Binder %
Aggregate
S.G.
Asphalt
Binder
Does not account for binder changes due to
absorption
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Variability
Error in computing combined
aggregate blend bulk S.G. of
0.030
VMA error of ~ 1%
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Performance Testing
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Performance Testing
• Complicated process
• Challenge is to use lab data
to predict performance on
road
• Many variables in real world
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Key Elements for
Performance Test
• Must be economical and easy-to-use
• Need standardized test
• Must be applicable to mix design
and QC
• Procedure should be precise and
accurate
• Results must correlate to field
performance
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Performance Testing
• Critical to future development
in industry
• Allows evaluation of new
materials
• Can offer innovation
opportunities for contractor
• Minimizes risk for design/build
and warranty projects
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PAGE 2-2
The Goal!
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Dale S. Decker
Eagle, CO