Quality Assurance Essentials

Emulsion Task Force Meeting

By: Colin A. Franco, P.E.Associate Chief Engineer

RIDOT

Denver - May 21-22, 2017

Quality Assurance - Definition

AASHTO R10 & TRB Circular E-C173

Quality Assurance – All those planned and

systematic actions necessary to provide

confidence that a product or facility will perform

satisfactorily in service …

• Applies to projects on the NHS

• State administered and locally administered

• Including Design-Build - 23CFR637.207(b)

“All provisions of 637.207(a) are applicable to Design-Build projects and other alternative contracting methods.”

• Non-NHS projects

• Many States apply same QA procedures as NHS

Applicability of 23 CFR 637

QA Program

Agency Acceptance

Dispute Resolution

Independent Assurance

Contractor QC

Lab Qualification

Personnel Qualification

Core Elements of a

Quality Assurance Program

Core Elements of a QA Program

Quality Assurance

QualityControl

AgencyAcceptance

Independent AssuranceDispute Resolution

LaboratoriesPersonnel

• All acceptance activities must be carried out by the Agency or their “Designated Agent”

• Agency independently performs: Acceptance (Verification) Testing

Agency Acceptance

Acceptance Program• Acceptance program. All factors that

comprise the Agency determination of

the quality of the product as specified in

the contract requirements. These

factors include:

• verification sampling,

• testing,

• inspection

Acceptance Function

• Acceptance is not focused on directing the methods used to achieve conformance

• The primary objectives of agency acceptance are:

• Measure the Quality of all materials produced

and placed by the contractor

• Determine the corresponding payment

the contractor should receive

Acceptance Function

• Quality measurement is achieved through three general acceptance activities:

• Monitoring the adequacy of contractor QC activity

• Performing acceptance inspection to identify visually deficient work

• Performing Acceptance sampling and testing for key quality characteristics

• Agency is obtaining information to confirm that all products meet the specified

quality level

Independent Assurance - “Activities that are an unbiased and

independent evaluation of all the sampling and testing

procedures used in the Quality Assurance Program”

Independent Assurance - IA

• Provide an assessment of

personnel proficiency and

equipment for both

agency and contractor

Independent Assurance activities:

Scope of IA Activities

• Performed by Agency or Designated Agent personnel who are not

directly responsible for project Acceptance sampling and testing

• Provides periodic independent evaluation of QC and Acceptance

personnel and their equipment

• Not used to make a determination of work quality or

acceptability

Independent Assurance – IA (cont.)

Quality Control - QC - “The system used by a Contractor

party to monitor, assess and adjust their production or

placement processes to ensure that the final product will

meet the specified level of quality.”

Definition

Contractor Quality Control

• QC is the responsibility of the Contractor

• The party producing or placing the product is in the best position to exercise Quality Control

Contractor Responsibility for Quality Control

Scope of Quality Control Activities

• Contractor’s QC system should address:

• Materials production processes

• Materials transportation and handling

• Field placement procedures

• Calibration and maintenance of equipment

• Activities (sampling, testing and inspection) to maintain each process in control

• Means to make timely adjustments and corrections

Contractor QC Operating Documents

• Quality Control Plan - A project specific document prepared by the contractor

which identifies QC personnel and procedures that will be used to maintain

production and placement processes in control and meet the

agency specification requirements.

• Central Laboratories

• Consultant Labs used for Independent Assurance (IA)

• Consultant Labs used for Dispute Resolution

Requirements for Laboratory Accreditation

“Laboratories that are

capable as defined by

appropriate programs

established by each

Agency.”

Qualified Laboratories

• Laboratory Qualification

Program

• All other Labs performing

sampling and testing that is

utilized in the Agency’s

acceptance decision

Laboratory Qualification

Qualified Personnel - “Personnel who are capable as

defined by appropriate programs established or

recognized by each Agency.”

Definition

Qualified Personnel

Personnel who are recognized by a formal certifying

body as qualified to perform specific procedures.

Definition

Certified Personnel

• Formal training

• On-the-job training

• Specified re-

qualification intervals

• Proficiency demonstration

• A written exam

• A process for disqualification or decertification

A complete personnel qualification/certification

program should include, at minimum:

Requirement for Personnel

Qualification / Certification

• Dispute Resolution - The procedure used

to resolve discrepancies between the

Agency’s Acceptance and Contractor’s QC

testing results that could impact

payment.

• Dispute Resolution system required when

QC results used in Acceptance decision.

Materials Testing Dispute Resolution

• Can be performed within the DOT

• Use of accredited third party

laboratory can be used.

Responsibility for Dispute Resolution

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5. Tests performed during the construction of the

emulsified application process

6. Tests associated with post construction/in-

service performance

P - Process Control performed by the contractor/vendor over all production operations. This will entail

the constant monitoring of equipment, materials, and production activity to insure that the materials

meet all applicable requirements and are produced within specifications

PE - Product evaluation is based on compatibility with established standards and

specifications, tested properties, performance history and suitablity to specific

applications performed by the puchasing agency or independent laboratory.

IA - Independent assurance are activities that are an unbiased and independent

evaluation of all the sampling and testing (or inspection) used in the QA program

SECTION DESCRIPTION

A - Acceptance testing performed by the agency, or its designated agent, to evaluate acceptability of

the final product. Also called verification sampling and testing when specifically used to validate the

contractor's data

C. Material conformance testing

4. Tests and processess to establish the design and construction criteria utilizing specific materials and resources

B. Process control tests conducted during the

manufacturing of the emulsion liquid

2.

AS

PH

AL

T

EM

UL

SIO

N G

RA

DE

S

SCRUB

TACK COAT

1. List of various applications for bitumen emulsions

2. List of the all grades of bitumen emulsions that can be used for

each application

3. Describes the various tests associated with the

manufacturing of bitumen emulsions

PERFORMANCE TESTS

TH

ER

MA

L C

RA

CK

ING

RE

SIS

TA

NC

E

C.

GENERAL

A. Lists test performed when designing the emulsion

liquid to be manufactured

3.

MANUFACTURING OF LIQUID BITUMEN EMULSION

5.

CONSTRUCTION

SAND SEAL

MIX

ES

1.

EM

UL

SIO

N A

PP

LIC

AT

ION

S

NOVA

6.

IN-SERVICE PERFORMANCE REQUIREMENTS FUNCTION

AND DURABILITY

4. DESIGN/

PRECONSTRUCTION

ENGINEERING

SH

OV

ING

RA

VE

LIN

G

CO

MP

AC

TA

BIL

ITY

B.

MATERIAL MANUFACTURING

(STABILITY/CONSISTENCY)

ST

AB

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AC

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G

SK

ID

BR

EA

KIN

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Quality Assurance Testing

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FOAM ASPHALT

CHIP SEAL

SAMPLE

CR

S-2

, C

MS

-2,

RS

-2,

HF

MS

-2 W

LA

TE

X

AS

TM

D244,

P,

PE

, A

PE

, A

D 6

930,

EN

12847

AS

TM

D244,

EN

13075-1

, N

F T

66-

019

AS

TM

D244,

D7276

PA

TT

I A

dh

esio

n

Test,

PE

, A

, IA

AS

TM

D244

A A A A A A A A A A

SK

ID T

ES

TE

R -

A A A

D 7

000

A A A

VIRGIN

RECYCLED

CIR

5. Tests performed during the construction of

the emulsified application process

6. Tests associated with post construction/in-

service performance

P - Process Control performed by the contractor/vendor over all production operations. This will entail

the constant monitoring of equipment, materials, and production activity to insure that the materials

meet all applicable requirements and are produced within specifications

PE - Product evaluation is based on compatibility with established standards and

specifications, tested properties, performance history and suitablity to specific

applications performed by the puchasing agency or independent laboratory.

IA - Independent assurance are activities that are an unbiased and independent

evaluation of all the sampling and testing (or inspection) used in the QA program

SECTION

DESCRIPTION

A - Acceptance testing performed by the agency, or its designated agent, to evaluate acceptability of

the final product. Also called verification sampling and testing when specifically used to validate the

contractor's data

C. Material conformance testing

4. Tests and processess to establish the design and construction criteria

utilizing specific materials and resources

B. Process control tests conducted during the

manufacturing of the emulsion liquid

2.

AS

PH

AL

T

EM

UL

SIO

N G

RA

DE

S

SCRUB

TACK COAT

1. List of various applications for bitumen

emulsions

2. List of the all grades of bitumen emulsions that can

be used for each application

3. Describes the various tests associated with

the manufacturing of bitumen emulsions

PERFORMANCE TESTS

TH

ER

MA

L C

RA

CK

ING

RE

SIS

TA

NC

E

A. Lists test performed when designing the

emulsion liquid to be manufactured

5.

CONSTRUCTION

SAND SEAL

MIX

ES

1.

EM

UL

SIO

N A

PP

LIC

AT

ION

S

NOVA

6.

IN-SERVICE PERFORMANCE REQUIREMENTS FUNCTION

AND DURABILITY

4. DESIGN/

PRECONSTRUCTION

ENGINEERING

SH

OV

ING

RA

VE

LIN

G

CO

MP

AC

TA

BIL

ITY

ST

AB

ILIT

Y

FA

TIG

UE

CR

AC

KIN

G

SK

ID

BR

EA

KIN

G R

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SW

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P T

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IGN

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Quality Assurance Testing

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FOAM ASPHALT

CHIP SEAL

Questions

?