8.10 ACCEPTANCE AND TESTING
8.11 FIELD TESTS AND CERTIFICATION OF MATERIALS
Project inspectors shall identify and inspect all materials received on a project before they are incorporated into work. Inspectors shall determine that proper inspection reports or certifications are on hand, and that no unusual alterations in characteristics of materials due to handling or other causes occurred.
Guide schedules attached to Materials I.M. 204 contain various field tests and sampling frequencies on asphalt materials and mixtures.
The Quality Management - Asphalt (QM-A) program was started in 1992 with the goal of improving the overall quality of HMA produced and giving the contractor the responsibility for mix design, sampling, testing, and making mix adjustments. In other words, contractors assumed start-to-finish responsibility for the product they produce and place. QM-A is the implementation of contractor process control for HMA mix production and placement. Field tests and certifications are the same for conventionally administered projects and QM-A projects. The major differences are the increased frequency of HMA sampling and testing, who performs the work, and contractor responsibility for conceiving and implementing mix changes to achieve specification compliance. Most administrative questions involving QM-A projects can be answered by referring to Materials I.M. 511 and the current specifications for Hot Mix Asphalt Mixtures.
Nearly all
Asphalt Materials
Acceptance of asphalt materials will be on the basis of certification from an approved
refinery or distribution terminal source. Formal approval of a source is to be issued by
the Office of Materials. Refer to Materials I.M. 437
for additional information.
Each shipment invoice covering certified materials delivered to a project shall have a signed certification statement as to type and grade, specific gravity or mass per liter, load quantity, batch number or other identification, project number, and compliance with appropriate Iowa DOT specifications. Copy of this invoice shall be furnished to project engineer or project inspector for review and filing.
Aggregates
Aggregate production and inspection are covered in detail by
Materials I.M.'s 204 and 209. Acceptance for
quality will be based on source monitoring and test results on assurance or project samples.
Acceptance of mixture gradation is outlined in Construction Manual
2.53and 3.22.
8.12 RESPONSIBILITY AND DOCUMENTING HMA MIXTURE PROPORTIONING CHANGES
District Materials Engineers have primary responsibility for authorizing changes made by the contractor to keep the mixture characteristics within all Specification and I.M. guidelines. They will inform project engineer of changes and follow up with written documentation. Each of these parties may designate a representative to approve desired change.
On QM-A projects, contractor has sole responsibility for making mix changes; however, District Materials Engineer or project engineer must be kept informed and involved in these changes. Mix change decisions must be an interactive process between contractor and agency.
The project engineer must also insure that required changes are implemented as soon as possible when mixture characteristics fall outside Specification 2303 and Materials I.M. 510 Appendix A limits. On each working day, project engineer shall determine if work for previous working day was within Specification and I.M. guidelines. If not, immediately consult with District Materials and the contractor to assure corrective action is taken.
Adjusting Asphalt Binder Contents
For determining whether asphalt binder content is within required guidelines, refer
to Specification 2303. Limits are given for
the air voids that are determined daily on a specimen in the District Materials Laboratory.
This will be calculated by District Materials according to
Materials I.M.s 321 and 501, based on the
Rice Procedure as per Materials I.M. 350. Project
engineer or designated representative (probably plant inspector) must get these air voids
daily from District Materials. Footnotes at the bottom of each applicable table in
I.M. 511 shall be reviewed carefully, because
they give precautions to follow for heavily traveled pavements as well as other requirements.
When test results for air voids (field and/or lab) are outside the limits given in Specification 2303, project engineer needs to contact District Materials to initiate changes in HMA mixture. When asphalt binder content changes are considered to adjust air voids, caution must be used to assure that adequate film thickness required in Materials I.M. 501 Appendix A, Table 1 is maintained. When the resulting film thickness is outside the specified range, procedures given in Construction Manual Appendix 2-34 (Table M) should be used to determine the appropriate price adjustment. Reductions in asphalt binder content must not reduce the target below calculated the minimum allowable asphalt binder content. Documentation of changes should be on "Daily HMA Plant Report" ( Form 800241).
On QM-A projects, job mix control is done essentially the same way except the contractor is responsible for sampling, testing, reporting results, and making appropriate mix changes. Also, HMA mix sampling and testing is performed up to four times per day at the HMA plant site so immediate results are available. For QM-A, the contractor is responsible for making meaningful mix changes before the lab void running average goes out of compliance. When a lab void running average goes out of compliance, the contractor must shut down and implement changes intended to correct the noncomplying voids. If the contractor fails to shut down voluntarily, the project engineer may shut down the contractor until corrective action is taken. A price adjustment for failure to shut down or make timely and meaningful mix proportion changes may be appropriate. The project engineer should coordinate closely with the District Materials Engineer for a resolution when lab voids are noncomplying on a QM-A project. Lab voids will be monitored daily by District Materials, but the project engineer must also remain informed of the test results.
Work using HMA mixtures with air voids outside the limits shall be avoided. If District Materials cannot be reached in a timely manner, project engineer shall change asphalt binder content as necessary to stay within Specification 2303guidelines and report this change to District Materials as soon as possible. Such changes will be reviewed later by District Materials and shall be documented by plant inspector on "Daily HMA Plant Report."
Documenting Corrective Action for Noncomplying Air Voids
Test on Specimens Taken from Constructed Pavement
Materials I.M. 204 also requires project engineers
to report tests for field air voids on mix samples from compacted roadway on "Daily HMA Plant Report."
Specification 2303 stipulates the required range for
these tests.
Range given for these voids is the average of all tests for each day's construction calculated by plant inspector.
When tests for these air voids are outside required range, density results shall first be reviewed. Example: If density results
When noncomplying tests for air voids in specimens taken from constructed pavement occur, project engineer will notify District Materials. Plant inspector will document noncompliance on "Daily HMA Plant Report" containing the noncomplying test results.
In response, District Materials Engineer will inform project engineer what changes in mix proportions, if any, should be made. District Materials Engineers will furnish project personnel written documentation for the decision or action taken.
Adjusting Aggregate Proportions
Contractor must occasionally adjust aggregate proportions to consistently comply with
job mix target gradation tolerance and to correct calibration errors.
Contractors shall initiate and make changes necessary to insure compliance under guidelines set forth by Specification 2303 and. Contractor shall not be allowed to make such changes without prior approval of project engineer.
For QM-A projects, the contractor shall also initiate and make appropriate changes. Although this must be done as an interactive procedure with project engineer, approval of the project engineer for these changes is not necessary as long as results are within the constraints of specifications and Materials I.M.'s.
Proportion changes of up to 5 percent for each material may be approved without delaying operations for qualifying tests. District Materials should be contacted when desired change is between 5 and 10 percent for each material. Single changes greater than 10 percent require a new mix design unless waived by project engineer.
Specification 2303 and I.M.s and 510 and 511 provide many of the guidelines needed for making mix change decisions. Project engineers are expected to reference these documents and communicate closely with District Materials prior to, during, and after the need for decisions concerning mix proportion changes so problems can be avoided.
Proportion changes shall be documented by plant inspector on "Daily HMA Plant Report."
Filler/Bitumen Ratio
Specification 2303 and Materials I.M.
510 Appendix A give explicit guidelines
that shall be followed in relation to filler/bitumen ratio. For Marshall mixes, the
filler/bitumen ratio is determined by dividing the percentage of cold feed material passing the
75 µm (#200) sieve by the total percentage of asphalt binder used, as determined by tank stick or
by actual mass (weight). For Gyratory mixes, the filler/bitumen ratio is determined by dividing
the cold feed material passing the 75 µm (#200) sieve by the "effective" percentage of asphalt
binder used, taking into account asphalt binder absorbed by the aggregate. See Materials I.M.
501 for additional information, including applicable equations and example calculations.
Plant inspector should determine how a proportion change will affect the filler/bitumen ratio before allowing contractor to make such a change.
If filler/bitumen ratio is outside the limits established in Specification 2303 and I.M. 510 Appendix A, a "Noncompliance Notice" (Form 820245) shall be issued immediately. If additional verification samples are taken, they must be run and an average calculated.
Plant inspector will then refer to Construction Manual 2.53. The average of all verification tests for the lot shall be used to determine filler/bitumen ratio.
When filler/bitumen ratio for an HMA mixture falls outside the limits established by specification for that material, the affected material will be considered noncomplying and subject to price adjustment. See Construction Manual Appendix 2-34 (Table J) for additional guidance.
8.13 DENSITY CONTROLS FOR HMA CONSTRUCTION
On non QM-A projects, a comparative laboratory density shall be determined for each lot from mixture samples obtained as prescribed by Materials I.M. 322. The contract documents will normally require that the contractor transport samples to the District Materials Lab. Such deliveries shall be done promptly. Prompt delivery requires that the contractor obtain hot box samples within several hours after daily production begins for immediate delivery to the District Materials Lab. Normally, the first hot box sample must be delivered by noon to report results the same day. District Materials personnel will perform the laboratory density tests. The contractor should deliver the first split aggregate sample with the hot box each day if gradation acceptance testing is performed in the District Materials Lab.
District Materials will promptly communicate test results back to inspection forces so they may be used to calculate comparative percentages. If more than one sample is used to determine laboratory densities for any lot with the same mixture, an average of that lot's laboratory densities shall be used.
If a laboratory density is not available from District Materials for a particular day's sample, the daily control shall be based on laboratory density for previous day's construction using the same mixture.
On QM-A projects, up to four paired hot box samples per day will be obtained by the contractor, as directed and witnessed by certified agency personnel (HMA Level 1 or HMA Sampler). One of each paired sample is then transported to the field lab for quality control testing. The hot box samples must be taken from behind the paver as prescribed by I.M. 322, by a technician with either HMA Level l or HMA Sampler certification. The grade inspector or plant monitor directs and witnesses contractor sampling to ensure it is properly done by appropriately certified personnel. The contractor will also transport the verification portion of the paired hot box samples, the split cold feed verification samples, and asphalt binder verification samples to the District Materials Lab on a daily basis. The inspector or plant monitor must properly identify and secure all verification samples with tamper-proof devices prior to transport by contractor personnel. No security measures are required if custody of samples is maintained by agency personnel.
An average of all laboratory compacted
Compacted HMA Samples
Density of pavement is determined from core samples cut by contractor,
normally on the next working day following construction.
Seven samples shall be cut from each lot of construction. For surface courses designed 25 mm (1 inch) or less in thickness, each one-half day's construction is designated as a lot. Each full day's production may be separated into two lots for determinations of quality index (density). This must be agreed to at preconstruction conference.
Specifications also describe a statistical procedure for field density evaluation together with a formula and schedule for payment adjustments when noncompliance occurs. Project inspection personnel shall observe the following when using the statistical procedure. These procedures are valid for all HMA projects.
Procedures for Construction of Test Strips
The specification entitled "Test Strip Construction for Class 1A and IB Compaction" requires the
contractor to construct a test strip for both intermediate and surface course mixtures subject to Class
1A compaction. Specifications further require test strips for surface course mixes requiring Class 1B
(primary road) compaction. Test strips are used to evaluate properties of HMA mixture and identify an
effective rolling pattern. For Class 1B compaction, field density compliance is not typically a problem,
therefore documentation of a test strip rolling pattern and nuclear gauge evaluation is optional for the
contractor. Test strips for Class 1B compaction on surface courses are required primarily to allow
evaluation and adjustment of mix properties, particularly lab voids, before the mix is placed as a surface
course.
Proper construction and documentation of test strip is the responsibility of the contractor. Documentation of test strip development and final rolling pattern should be provided by contractor to inspector.
The specifications outline several steps that must be followed to construct a test strip. Documentation of this procedure is required. If properly performed, compacting a control test strip using a nuclear gauge will establish a rolling pattern that achieves required density. Personnel participating in tests must include roller operators, nuclear gauge operator, paving supervisor, project inspector, and District Materials personnel. The following procedure describes steps to be taken by the contractor to effectively construct a test strip.
Vibratory rollers are typically used for breakdown rolling. Determine frequency (vibrations per minute) of roller which establishes maximum permissible rolling speed in meters (feet) per minute to assure 35 impacts/m (10 impacts per foot). Contractor should provide this roller information. It can be checked with a tachometer available from the Central Materials Office.
Estimate number of coverages of each roller to achieve required density. Determine number of passes necessary to accomplish estimated coverages considering width of roller. A coverage requires sufficient side-by-side passes to cover entire mat width once. Include the catch-up pass.
Knowing maximum roller speed and number of coverages estimated to achieve density, determine total meters per minute (m/min) of full width mat that roller can effectively compact. Assume 80% roller efficiency.
m/min (completed) = |
roller speed m/min
|
Compare m/min completed of roller to paver speed. If m/min completed is greater than paver speed in m/min, roller is adequate. If m/min completed is less than paver speed, additional rollers must be provided or paver speed must be reduced to equal or less than roller capacity.
Example:
Mat width = 3.5 m (11.5 feet)
Compacted thickness = .05 m (2 inches)
Production rate = 135 Mg/h (150 tons/hour)
Roller width = 1.83 m (6 feet)
Frequency = 2400 VPM
Assumptions:
Paver will operate 50 minutes per hour.
Roller efficiency is 80%.
Compacted density equals 2 350 kg/cu m (146.7 pcf).
Density will be achieved with 3 coverages.
A. Determine paver speed to match production
135 Mg/h (150 tons/hour) |
= 2.25 Mg/min (2.5 tons/min.) |
2.25 Mg/min (2.5 tons/min.)
|
= .96 cu m/min (34.08 cubic ft./min.) |
.96 cu m/min
|
= 5.5 m/min |
Minimum paver speed = (60/50) (5.5 m/min) = 6.6 m/min (21.65 ft./min.)
B. Determine maximum permissible speed of roller
2400 VPM
|
= 68 m/min (207 ft./min.) |
C. Determine total m/min of full width mat that can be compacted with three coverages.
Roller width = 1.83 m (6 feet)
A .15 m overlap per pass requires three passes per coverage. Nine passes required for three coverages.
Note: A catch-up pass is not needed in this case because third pass on third coverage will end at paver end of compacted area.
Completed m/min= | 68 m/min | x 0.80 (efficiency) = 6 m/min (18 ft./min.) |
9 passes |
Paver speed 6.6 m/min. Roller capacity is inadequate for the indicated paver speed, and appropriate changes to increase roller capacity will be necessary.
Above example considers a vibratory breakdown roller. From experience, we know a rubber-tired intermediate roller is typically needed to achieve interstate density requirements. Same procedure can be used to calculate capacity of rubber roller and compare to paver speed. The only difference is that roller speed is not based on impacts per meter, but rather effectiveness as determined by nuclear gauge testing.
Uniform operation of paver is a critical factor in obtaining consistent density results and smooth pavement. If paver is operated at erratic or excessive speed in short intervals, satisfactory results are difficult to achieve. When an excessive number of trucks arrive at paver simultaneously, paver operators are tempted to increase paver speed and quickly unload all waiting trucks, then stop paver, and await their return or next group. It is better to maintain appropriate paver speed and thereby assist in respacing the trucks. This does not sacrifice production, but maintains uniform rate of production which allows roller operator to maintain rolling speed and still keep up with paver.
Establish at least three points where nuclear testing will occur. Record location of
these points.
Change only one variable at a time. Always select a combination that will allow rollers to complete at least the same m/min of completed mat as the paver is producing.
All operating techniques are governed by mix behavior during the rolling process. It will
vary from job-to-job and from lift-to-lift.
Continue rolling and checking density until effective pattern is established. Develop density growth curves for each roller pattern used. Plot density vs. number of passes on graph paper. Contractor should provide copies of this documentation, including description and location of pattern used, to project inspector.
After a successful pattern is identified, complete rolling pattern again in another area and take longer nuclear counts to verify results. Document the successful pattern to be used in field book.
Test strip needs to be established under the same production conditions that will
prevail during normal paving operations, such as mix temperature and production rate.
Resolving Density - Void Conflicts
Project inspector should be aware that field laboratory and compacted voids will be tightly
controlled. This may require more compactive effort and even higher average density for
compliance. Field control will allow no more than 8% voids in compacted layer. Become familiar
with other controls by reading Materials I.M. 511
and asking questions of District Materials personnel.
For the case where specified density is met, but field laboratory voids or pavement voids are outside designated limits for more than one day, inspector should request a test strip. Test area should be a straight run of about 100 m (110 yards). Contractor will select combination of rollers to be used and preliminary rolling pattern. Nuclear gauge readings would normally be taken after each pass or series of passes.
Inspector would only observe this process. Documentation of type and amount of compactive effort shall be recorded. Inspector will then select and mark out 5 random core sites within test site. Density cores taken by contractor would be tested and results reported as soon as possible.
Cooperation between project inspector, District Materials, and contractor is essential to reach a timely solution. If all anticipated results are not met, further experimenting with a different combination of rollers and operation should be performed. Changes in gradation may be one of the first items looked at by District Materials. Changes in asphalt binder content would be one of the last items. Relief from minimum laboratory voids specified may only be approved by Office of Materials.
8.14 TESTING FOR SMOOTHNESS
Equipment for smoothness testing includes the 7.6 m (25-foot) California profilograph, rolling surface checker (bump cart), and 3 m (10-foot) straightedge. Pavement surfaces to be tested for smoothness with the 7.6 m (25-foot) profilograph are identified in Specifications 2316.01 and 2317.01. The contractor may choose to use a profilograph, in lieu of bump cart or straight edge, to check additional pavement areas for bumps. Unless the contract documents specifically indicate otherwise, paved shoulders are not considered part of the pavement surface and therefore are excluded from profilograph or bump cart testing, although reasonable smoothness from a workmanship standpoint would still apply. The contractor is responsible for providing the profilograph and for performing the testing.
Contractor should be encouraged to test directly behind the finish roller to allow correction of an identified 13 mm (0.5 inch) bump by re-rolling while mixture is still hot enough to be affected.
Use of Straightedge and Rolling
Surface Checker
Pavement smoothness specification does not relieve contractor of responsibility for proper
rolling and workmanship. Each pavement layer is to be inspected visually to insure that
surface is free of roller marks and distortion. Transverse joints are to be checked with
a 3 m (10-foot) straightedge. Surface courses inspected with a rolling surface checker
shall meet 3 mm (1/8 inch) tolerance. For lower courses, 6 mm (1/4 inch) smoothness tolerance
may be used.
Contracting authority will continue to provide rolling surface checker and conduct testing on all surfaces not tested by profilograph. However, corrections for surface irregularities shall be made, if possible, before mixture has cooled to 66 degrees C (150 degrees F). A large percentage of irregularities can be corrected by finish rollers above this temperature.
When rolling surface checker is used, it should be operated immediately behind finish rollers. Mixture buildup on the wheels of surface checking straightedge should be regularly removed.
The inspector operating the surface checking straightedge should also observe surface to insure that all roller marks or roller wheel depressions are smoothed out during the finish rolling. The inspector should observe the longitudinal joints carefully to insure that they have been smoothly rolled as specifications require. If surface is not being finished as specifications require, inspector shall stop construction until contractor takes corrective action.
8.15 CHECKING TRANSVERSE JOINTS FOR SMOOTHNESS
While the joint is being constructed and checked, inspector shall require the finishing machine to be stopped approximately 10 to 15 m (30 to 50 feet) from the joint. Construction shall not be permitted to continue until the checking has been completed. This permits repaving of the joint, with finishing machine, if straightedge should indicate a poor riding surface has been constructed.
2. The second check with the straightedge is made after finishing machine has constructed the new layer, but before rolling. Straightedge is used to locate irregularities in newly constructed layer and any irregularities found that must be corrected by hand tools. When straightedge indicates no high or low spots, compaction should be permitted with initial roller.
3. The third check with the straightedge is across the joint between cold pavement and hot mixture after compacted with initial roller. This third check indicates whether the correct amount of material has been placed. For instance, if freshly rolled layer is too high, it indicates too much material has been placed. If freshly rolled layer is too low, it indicates not enough hot mixture has been placed.
For that reason, high or low transverse joints are not usually corrected by additional rolling. Instead, corrections should be made by cutting or filling rolled surface while mixture is still warm and can be manipulated. If there are unusually high or low areas after rolling, paths must be shoveled through the pavement for finishing machine tracks. Finishing machine is then backed up to the joint and paving operation is started again.
Above procedure shall be repeated as necessary until straightedge indicates that a good riding joint has been constructed. If repeated repaving operations cause mixture to cool to the extent that reuse becomes impractical, it should be removed and wasted.
4. The final procedure for insuring proper construction at transverse joints is checking for true edge alignment. Edge of the freshly rolled layer should be carefully trimmed by hand tools until it matches the alignment of adjoining cold pavement.