Mix Optimization Fundamentals W ORLD OF A SPHALT N ASHVILLE, TENNESSEE M ARCH 24, 2016 S HANE B UCHANAN, OLDCASTLE M ATERIALS

Transcription

1 Mix Optimization Fundamentals W ORLD OF A SPHALT N ASHVILLE, TENNESSEE M ARCH 24, 2016 S HANE B UCHANAN, OLDCASTLE M ATERIALS

2 Session Focus and Discussion Items Importance of mix optimization Mix optimization areas Fundamental mix properties Aggregate variability impact Effective utilization of recycled materials Communication

3 Session Takeaways Understand the total picture concept of mix design so that optimization can take place Understand the importance of aggregate consistency on quality Manage recycled products to ensure optimum addition levels and benefits Understand obstacles to mix optimization and how to overcome them

4 Optimization Importance and Value

5 Mix Optimization Represents Significant Opportunity Designing an optimized mix can help separate yourself from competition and ensure competitiveness For example: 0.1% liquid asphalt binder has impact of ~$0.55 per mix ton ($550 / ton AC) Contribution of liquid asphalt binder to total mix cost has increased dramatically AC is 65 to 70% of Material Cost

6 Asphalt Binder Price Trend 2016 World of Asphalt Mix Optimization tion Fundamentals

7 Mix Optimization Should be Important to YOU! Mix optimization represents a huge opportunity (one that must not be passed up) Reducing the virgin liquid demand by 0.1% x $300 to $550 per ton liquid / ton x 45 M tons = $15,750,000 to $24,750,000 Reducing production cost (e.g., lower cost materials, lower energy, etc.) by $0.01 $450,000 You MUST focus on saving pennies any way possible "If you look after the pennies, the dollars will look after themselves." -J. Paul Getty

8 Mix Design

9 What is Mix Design? Remember both Performance and Economics What are the specifications? What aggregates are available? What asphalt binder is available? What does past experience provide? Did some mixes work better than others? "Boonsborough Turnpike Road" between Hagerstown and Boonsboro, Maryland in 1823.

10 The Mix Design Cycle Mix Design is a Balance (3 legged stool) Materials Selection Producability Constructability You must not design a mix in a vacuum! Get input from production and construction personnel Know the cost of mix components Conduct mix audits to understand what worked and what didn t Decision Redesign Accept Tweak

11 What is a Good Quality Mix Design? Depends on how we define Good Quality. Good Quality is not defined by any one of these factors Cheap Expensive Quick High binder replacement Constructible / workable Penalty free Consistent A Good Quality mix must be at least partially defined as one that meets the requirements of the job (specification compliance consistency and performance) intended performance while being designed using an optimized approach.

12 Pendulum of Asphalt Mix Performance OPTIMUM DRY WET

13 Mix Optimization Path

14 Key Concepts in Mix Optimization Understand the fundamentals of asphalt mixes and know what drives economics and performance Take a fresh look at mixes to locate potential for unrealized economic and performance gains Having done things the same way for many years is not an excuse for not trying to improve Emphasize the need for clear communication between mix designers and management Quality control personnel should be engaged with the business process Be involved and make recommendations It s quality control, not quality monitoring. Take action. Don t wait until the problem happens before your voice is heard!

15 Perform Critical Review of Historical Mixes Review the design, production and construction of historical mixes Thoughts: Identify successful mixes (maximized profitability, minimized cost, good producability and constructability). Tweak existing mixes to increase success. Eliminate the mixes with significant issues. Design new mixes based on past successful performing mixes Don t re-invent the wheel (they are always round!) Don t stop trying to advance the ball forward! Opportunity that exists must be acted upon.

16 Get the Important Items in the Design First Important things need to get in the mix design before less important things take up all the optimization opportunity Big Rocks and Little Rocks Big rocks may be recycle, capped aggregates, alternate aggregate products, etc. Little rocks are other materials that are necessary, but may limit the big rocks. Source:

17 Optimization Ideas to Maximize Success

18 Ideas on Mix Optimization 1. Be up to date on specifications. Has something changed that could make for a more economical mix? 2. Review mix volumetrics to make sure you know what you think you know. 3. Take advantage of lost opportunities to utilize capped products (internal and external sources). 4. Use the lowest absorption aggregates possible. Consider total cost of use (aggregate, drying, transportation, etc.). 5. Accurately determine aggregate specific gravities and maximize higher specific gravity aggregate use. 6. Investigate the gradation/property variability of used aggregates. Saving a nickel and losing a dime is not a good deal 7. Understand the impact of aggregate properties and blend grading on asphalt content and mix volumetrics. 8. Manage recycle products to ensure optimum addition levels and economic benefit 9. Avoid pressure from construction to increase asphalt content of mixes to help obtain density. Evaluate other options (temperature, rollers, aggregate structure, etc.) 10. Learn to effectively communicate within your company and to outside suppliers/customers to overcome potential obstacles. Mix engineering is a continuous improvement process, not just a one time look!

19 Be Up to Date on Specifications! Make sure you know the target so you can maximize opportunities DO NOT leave opportunity on the table You might fail to maximize opportunities, but you must try What are the current specifications? Have special provisions been created? Blanket or job specific SP? Be actively involved in association/dot liaison activities Understand the specifications better than the person who wrote them!

20 Mix Volumetrics Review of the Basics Make sure you know what you think you know Never be too proud to ask questions Pride and ego will lead to $ lost What are volumetric properties? Volume based/determined properties

21 HMA Volumetrics (Basic Knowledge, Often Overlooked) Mix is air, asphalt, and aggregate Everything during mix design comes back to the very basics of this diagram Critical to understand what mix volumetrics mean, not just how to calculate using a formula Mix designers should work a phase diagram from start to finish at least once

22 2016 World of Asphalt Mix VOL (cm 3 ) G mb = MASS (g) air asphalt G b = P b = 5% by mix absorbed asphalt pores not filled w/ ac aggregate G sb = G se = 2.731

23 VOL (cm 3 ) MASS (g) air asphalt G b = absorbed asphalt pores not filled w/ ac aggregate G sb = G se = Air Voids = 7.6% Effective Asphalt Content = 4.6% VMA = 18.2 % Absorbed Asphalt Content = 0.4% VFA = 58.2 % Max Theo Sp Grav = World of Asphalt Mix

24 VMA: Understand What It Means, Not Just How to Calculate It VMA is the volume of air voids and effective binder (binder not absorbed into the aggregate) Excludes the portion of binder absorbed into the aggregate Volume air = cm 3 Volume effective AC = cm 3 Volume total = 1 cm 3 VMA = (( ) / 1) x 100 = 18.2%

25 Plotting VMA in Mix Design The optimum binder content of a mix is normally located near the bottom of the VMA vs binder content curve. Why does the curve have this shape? Binder initially acts as a lubricant which aids in aggregate packing to a maximum state. Afterwards, excess binder acts to push the aggregate apart resulting in a lower density.

26 Factors Influencing VMA Factor Aggregate Gradation Aggregate Shape Aggregate Texture Asphalt Absorption Dust Content Baghouse Fines/Dust Generation Plant Production Temperature HMA Temperature During Paving Haul Time Aggregate Handling Effect on VMA Dense aggregate blend grading decrease VMA Rounded aggregates decrease VMA Smooth/polished aggregates decrease VMA Increased asphalt absorption results in lower effective asphalt content and lower VMA (for same compaction level) Higher dust contents increase surface area, decrease film thickness and tend to lower VMA Same as above Higher production temperatures decrease asphalt binder viscosity, resulting in more asphalt absorption, lower effective asphalt content and lower VMA Higher temperatures during paving increases mix viscosity, resulting in lower air voids and lower VMA Longer haul times allow for more asphalt absorption, lower effective asphalt content and lower VMA More steps in handling increases potential for degradation, resulting in more fines and lower VMA.

27 Aggregate Grading Impact on VMA Think of VMA as the void space in the aggregate blend With AV constant, VMA is tied directly to AC% Fill the space in the most economical manner possible while maintaining performance Move away from Maximum Density line (in either direction) increases VMA Reducing No. 200 increases VMA For 9.5 and 12.5 NMS mixes, the minus No. 8 is especially critical Decrease for coarse graded mixes Increase for fine graded mixes

28 Determine How Much VMA is Needed Depends on many factors including VMA minimum specification, VMA control during production, VMA as pay item, historical VMA production collapse, aggregate Gsb variability impacts, VMA production variability The decision should be made locally, BUT it should be well thought out and documented. Generally 0.3 to 0.7% VMA is lost during production. Very dependent on breakdown potential of aggregates If you are paid on VMA, use historical VMA variability to minimize the amount of extra VMA targeted for during design Strongly suggest reviewing VMA requirements through statistical measures. AASHTO M323 Mix Nominal Max Size Minimum VMA, % REMEMBER: Every 0.25% of unnecessary VMA results in $0.50 (w/ $500 / ton liquid) of unnecessary mix cost!

29 Asphalt Content Can Be Estimated Phase relationships can be used to back out the estimated asphalt content for the mix Given Aggregate blend percentages with associated specific gravities (% aggregate solid volumes; bulk, effective, and apparent) Required air voids (% of total volume) Required voids in mineral aggregate (VMA) Base this value on historical VMA collapse during production (e.g., VMA design + 0.7% during production) If you are paid on VMA, use historical VMA variability to minimize the amount of extra VMA targeted for during design Properties Values Aggregate Blend Gsa Aggregate Blend Gsb Blend Water Absorption, % 0.56 Estimated Asphalt Absorption, % 0.29 Aggregate Blend Gse Assumed Trial AC, % 5.00 Volume Solid Apparent (Vsa), ml Volume Solid Bulk (Vsb), ml Volume Solid Effective (Vse), ml Air Voids, % 4.00 VMA, % Volume Asphalt Absorbed (Vac abs), ml 0.28 Mass Asphalt Absorbed (Mac abs), g 0.28 Percent Binder Absorbed (Pba) 0.30 Percent Binder Effective (Pbe) 4.70 Volume Binder Effective (Vbe), ml 4.59 Volume Binder Total (Vbt), ml 4.88 Volume Total Mix (Vt), ml Volume Air Voids (Va), ml 1.67 Va + Vbe, ml 6.25 VMA ((Va+Vbe / Vt)*100) VMA (Design - Actual) 0.99 Estimated AC% to Achieve Design VMA, % 0.50 Adjusted AC to Achieve Target VMA 5.48 New Pbe 5.18 New Vbe 5.06 New Vbt 5.35 New Vt New Va 1.69 New Va + Vbe 6.74 Target VMA (% of total mix check) 16.00

30 Asphalt Mix Rules of Thumb 0.1% Asphalt Content = ~0.25% VMA Coarse mixes have greater sensitivity to AC% than finer graded mixes 1.0% P200 = 0.3% to 1% Air Voids and VMA Increased distance away from the maximum density line (0.45 power curve) yields more void space This space will be either air or asphalt

31 Aggregate Items

32 Utilize Surplus or Capped Products When Possible Capped products have been written off the books Using these products can potentially reduce materials costs Applicable for externally or internally supplied products Examples: Screenings, manufactured sand Test to ensure quality is present Good fit for 9.5 or 4.75 mm mixes Must balance with needed RAP use RAP replaces fines at a 90% level Fine fractionated RAP replaces at 100% Cautions: 1. Make sure the materials perform appropriately in the design. 2. Do not be guilted into using capped products! 3. Make sure sufficient quantities exist for the job(s).

33 Specific Gravity and Absorption: Basic Building Blocks Specific gravity (G s ) is the ratio of aggregate weight to the weight of an equal volume of water Dimensionless number (no units attached)

34 Apparent Specific Gravity, G sa

35 Bulk Specific Gravity, G sb

36 Effective Specific Gravity, G se

37

38 Monitoring G se During Production G se is an aggregate property For a given mix design, the relationship between G se to G sa and G sb should not change (within test variability) Relationship may change based on mix temperature (binder absorption) If mix temperature is constant and a change is seen, something has changed in the aggregate blend (e.g., heavy vs. light aggregate). Aggregate Control Chart Develop control chart showing the Gsa and Gsb of the aggregate blend and the Gse determined values. Identify trends before problems show up. FHWA RAP Expert Task Group

39 Maximizing Success: Monitor Gse Aggregate Gravity Control Chart

40 Impact of Aggregate Specific Gravity Understand the impact of changing specific gravity Variable gravities will impact volumetrics Changing aggregate gravities can impact binder volume in the mix Heavy aggregate relative to design = higher binder volume (and vice versa) 0.1 Gsb = 0.2% AC Do your gravities change around your quarry/pit? Probably! How much? 0.01 Gsb = 0.3% VMA

41 Beware of Fine Aggregate Specific Gravity Issues! With some aggregates, the accurate determination of SSD with the cone test is difficult Angularity and high fines content may make the fine aggregate appear wetter than actual Result is the sample being dried past the true SSD condition Absorption too high and G sb too low VMA issues may result If possible (allowed), wash the fine aggregate over the No. 200 sieve prior to testing

42 NCHRP 4-35 Project (Report 805)

43 Using Low Absorption Aggregates When possible try to use the lowest absorption aggregates as possible Negative impacts of high absorption are widespread AC absorption Drying costs Mix production decrease Mix production variability Dry aggregates vs wet aggregates Absorption of x % does not mean the same for all aggregates Pore space is the key Larger pore space allows the aggregate to drain/dry more efficiently

44 Using Low Absorption Aggregates - $ Impact Asphalt absorbed into surface pores is non-effective ( wasted ). Example: Agg. 1 = 1.5% absorption Agg. 2 = 1.0% absorption Assume asphalt absorption = 50% of water absorption. Additional cost for using Agg. 1 = * $550 per ton asphalt $1.4 per mix ton Caution: Do not use WMA just to try and lower AC.

45 Hidden Cost of Aggregates - Moisture How much water are you buying? Moisture content is water weight / solid aggregate weight How much does it cost to dry the aggregate? $ / dry ton = ($ / wet ton) x (1 + w / 100) Example 5,000 tons of W10 s purchased from a quarry at $18.00 / ton with 5.6% moisture at delivery $ / dry ton = ($18.00 / ton) x ( /100) = $18.78 Dry inventory = 5,000 tons / (1 + w/100) = 4,734 tons

46 More on Moisture Typical rules of thumb The Rule 1% increase in aggregate moisture content increases the plant drying cost by 11% 1% increase in aggregate moisture decreases plant production rate by 11% Example: Aggregate blend has 5% total moisture after rain with plant production normally at 400 tph with aggregates at 2% moisture. Increased cost to dry aggregate = (5-2%) x 11% = 33% Production rate decrease with wet aggregate = 3% x 11% = 33% x 400 tph = 132 tph decrease down to 268 tph. ve+tampa%2c+fl+33610&mkt=en&form=hdrsc4

47 Aggregate Consistency and Quality

48 Take Time to Understand Basic Statistics and Use Them to Your Advantage The standard deviation is an indication in the spread of the data Data falls within the normal distribution 68, 95, 99.7% Use statistics to optimize your operations (i.e. just the right amount of safety factor)

49 Importance of Aggregates to Asphalt Mixes Aggregates have substantial downstream impacts Inconsistent supply may/will present problems. Gradation control and volumetrics In place density Pay Performance Aggregates must be recognized as a main factor which drives mix success or failure. Aggregate Quality Analysis Pilot

50 Importance of Aggregates to Asphalt Mixes An asphalt producer needs an aggregate product that is produced using a highly capable process. Capable process is defined by Accuracy: Production grading is close to the target which the asphalt producer used to design their mixes Precision: Production grading variability is as low as possible. Just being within spec is generally not good enough Goal IS NOT to just keep the bowling ball out of the gutter Low precision + High variability Goal IS to target a strike with every roll High precision + Low variability Aggregate Quality Analysis Pilot

51 Investigate the Production Variability of Available Aggregates You MUST know and understand the gradation variability of available aggregates Inconsistent supply WILL impact mix grading and volumetrics Accurate and precise aggregate grading Accurate means the average remains near where the mix design was developed Precise means the standard deviation (variability) is small You can work with a grading that is at the high or low side of a target size grading Example: Either coarse or fine 78 s are OK, BUT, don t give me coarse 78 s one day and fine 78 s the next! Pay attention to aggregate facilities Does varying the plant production modes impact product grading or shape? Different crusher loads have substantial impact

52 Accuracy (Avg.) and Precision (Std. Dev.)

53 A Look at Product Variability Each mix will have critical sieves No. 4, No. 8, No. 200 e.g. Understand how aggregate variability impacts these critical sieves Variability is of special concern with PWL specs The largest clean stone product variability will be 1 to 2 sieves below the top POOR 2016 World of Asphalt Mix Optimization Fundamentals ntal

54 Another Look at Product Variability Aggregate plant operational factors drive variability (good and bad) Modes Fines processing (screw, air) Primary product focus for sales Most plants yield roughly 1/3 clean stone, 1/3 base, and 1/3 fines However, primary products will dictate other products GOOD 2016 World of Asphalt Mix Optimization i Fundamentals ntal

55 What are Acceptable Levels of Variability? Do you know your typical variability for key properties? Property Acceptable Standard Deviation? Asphalt Content < 0.15 to 0.20 % Coarse aggregate (+No. 4 blend) < 2 % Fine aggregate (- No. 4 blend) < 1 to 1.5 % P200 (blend) < 0.5 % Air voids and VMA < 0.3 to 0.4 % Field density < 1.0 to 1.5 % Film thickness < 0.50 microns Acceptable May Vary for Different Situations

56 What Should You Do to Help Maximize Success? 1. Define what is excessive variability? Investigate individual product variability with typical mixes Determine critical sieves and products 2. Request historical data from supplier 3. Address excessive variability issues with the aggregate supplier Sometimes this is YOU! 4. Start/maintain effective communication with aggregate supplier 5. Recognize that you can affect variability after obtaining from aggregate supplier Proper stockpiling / loading techniques must be maintained 6. Use available tools to evaluate variability Excel, Stonemont QC,, etc.

57 Maximizing Success Stonemont Product Evaluation Clearly establish the problem: Stonemont Product Evaluation Good, but doesn t show trends

58 Maximizing Success Stonemont Control Chart Stonemont Run or Control Charts to Illustrate Changes Over Time Same information as with product evaluation, but trends can be easily identified

59 Maximizing Success: Variability Illustrator Variability Illustrator Determine the sensitivity of PWS to production average and standard deviation. Results can be used to show 1) the impact of current production and 2) how production can be improved INPUT CALCULATED Variability Illustrator Average % Passing 55 PWS Standard Deviation Standard Deviation, % Upper Spec Limit (USL) Lower Spec Limit (LSL) Avg. + (2*Std. Dev.) Avg. - (2*Std. Dev.) Abs Deviation from Mid-Target Band % Above USL % Below LSL Percent Within Specification Click to Update Table Average Percent Passing Percent Within Specification ("What If") Table

60 Maximizing Success: Variability Illustrator Variability Illustrator, cont. Question: What is the maximum variability and still maintain a desired PWS? Answer: Function of proximity of production average to mid band grading and gradation band width. Production averages differing from band mean will result in less PWS for a given band tolerance. Use these data as guidance to improve your process.

61 Maximizing Success: Aggregate Blending Aggregate blends are very seldom truly optimized Aggregate cost is more that just $ x per ton! Must consider the total picture when evaluating blends Blending involves more than just getting a blend to meet the specification points. Total picture includes aggregate product availability, moisture, asphalt absorption, and variability of grading Must move beyond a deterministic approach into a probabilistic approach, which considers variability and offers the ability to evaluate risk. Stop blending just based on average grading Successful contractors will understand statistics and use them to their advantage! Don t be blind to the total cost of aggregate ownership

62 Aggregate Blend Total Cost of Ownership Aggregate cost is more that just $ x per ton! Cost components of aggregate Material (solid + moisture) Transport Drying energy Asphalt absorption Asphalt plant production Consistency and impact on downstream performance / pay! FHWA RAP Expert Task Group

63 Recycled Products

64 Manage and Utilize Recycle Products for Maximum Return Conduct inventory analysis of recycled products How much do you have and how much will you use? How much will you be obtaining? Can you use this as it s obtained? (i.e., can you add to stockpiles?) Evaluate the quality and consistency of the recycled products What is the RAP source? DOT work, general RAP, plant waste, etc. What is the RAS source? Manufactured waste, post consumer tear offs Characterize Evaluate impact of recycle use on asphalt binder selection and tankage capacity Treat recycled products during production the same as virgin aggregates. At higher recycled percentages (~35 to 40%+), this is a MUST! Cover/paved stockpiles Multiple recycle bins

65 Manage and Utilize Recycle Products for Maximum Return Let s go back to the How much can you use? question What allowed by the specifications? What capable by the plant? Plant type (batch, parallel flow, counter flow, etc.) How many recycle bins? Using RAP only, RAS only, or RAP+RAS? Keep SAFETY in mind always (e.g., high RAP + clogged feeder = problems) Maximize opportunity with regards to specifications/production/laydown

66 Estimated Value of Recycle Products Assumptions: $5 per ton RAP cost, $15 per ton RAS cost, $10 per ton aggregate cost 1.58 Savings ($ per Ton for Each % Recycle Used) Recycle AC, % Recycle RAP RAS RAP RAS AC, $

67 What Type of RAP Do You Have? Understand that millings and general RAP are different Both can provide a good quality product, but understand they are different

68 Take Time to Analysis RAP (Especially Grading) Many times, graphs can provide a more complete understanding Suggestion: plot standard deviation along with coefficient of variation (COV) to get complete picture of variation (BTW, do the same for virgin aggregates)

69 RAP Testing Thoughts

70 RAP Testing Thoughts

71 So What are Acceptable RAP Property Tolerances? NCAT recommendations on RAP AC and grading. Can you make RAP with higher variability work? Yes, but it becomes more difficult!

72 RAP and Virgin Aggregate: Consistency NCAT study evaluated 74 RAP stockpiles in 14 states, and 60 virgin aggregate stockpiles in 6 states RAP would found to have lower grading variability Is this surprising? Probably not, RAP has been sized and processed more than virgin aggregate Is it always the case? No, but likely What is your case?

73 Fractionated RAP is Not Always More Consistent NCAT RAP Study Data (fractionated vs unfractionated RAP)

74 Utilize RAP Fractionation When Beneficial

75 Evaluate the Blended Binder (Virgin + Recycled) It is critical to understand the blending of virgin and recycled binders. Blended binders (stiff recycle binder + softer virgin binder) are likely to have a higher high temp grade and a higher low temp grade. PG may become a PG MUST understand that the RAP binder and RAS binder are NOT the same! 20% binder replacement from RAP and RAS differ Evaluate desired blends of RAP and RAS to determine the impact on the composite PG grade.

76 Binder Blending Analysis Steps Determine the binder contents of the RAP and/or RAS. Determine the continuous PG grade for the virgin, RAP and/or RAS binders. What does continuous PG grade mean? PG ~ PG for example. Ask binder supplier for virgin PG grading (should be readily available) Different binders have varying levels of cushion on the high and low ends. Based on feedstock and refining process. Sample recycle and determine the average continuous PG grade Two to three samples per recycle product

77 Recycled Material Blending Calculation Blending equations can be used to estimate the allowed RAS or RAP (in this case) to maintain the desired final PG performance. Tblend = temperature requirement for final blend of RAP AC and virgin AC Tvirgin = critical temperature for virgin asphalt binder Trap = critical temperature (high or low) of the RAP binder determined from extraction, recovery, and PG grading. %RAP = Tblend Tvirgin Trap Tvirgin

78 Recycled Material Example Blending Calculation Given: Desire to maintain a -22C low temperature through the use of a PG binder (i.e., a PG binder bump from -22 to a -28). Tblend = Tvirgin = (from testing of virgin PG binder) Trap = (from extraction/recover of RAP binder) Maximum %RAP allowed to maintain -22C temperature using a PG virgin binder is 38.1% (-28.7) %RAP = = 38.1% (-28.7)

79 Blending Analysis Develop a blending program which quickly shows the allowable recycle addition to meet the end results PG binder requirements. Use this for better selection of virgin PG grades and recycle loading BINDER BLENDING ANALYSIS Maximum % RAP Allowed (100% RAP BR) Maximum % RAS Allowed (100% RAS BR) Desired % RAP (Weight of Total Mix) Desired % RAS (Weight of Total Mix) % BR from RAP % BR from RAS % BR Total (Actual) % of Total BR from RAP % of Total BR from RAS % BR Total (Allowable) PASS Pass or Fail Achieved PG Low Temperature, C Desired PG Low Temperature, C Fail Pass AAPT 2016

80 The Roadway and Plant A commonly heard phrase is We can t get density, can you raise the AC a little? Sounds benign, but presents a problem How many times has that same question been asked before? Might have developed AC Creep over the years. Exhaust all possibilities on the road before even thinking of raising AC% How much do extra roller passes or an extra roller cost per ton? Varies, but likely not to same level as AC% increase.

81 Communication

82 Mix Optimization Challenges and Obstacles COMPLACENCY Norman Vincent Peale said Opportunities are usually disguised as hard work, so most people don't recognize them. COMMUNICATION Various LOBs need to work together instead of being independent Silo mentality is a killer! Mix designers must know the cost of materials during mix design Who makes the final call on producing a high RAP mix? Designer can set the table with a mix design, but then what? Remember, we are all on the same team!

83 The Continuous Nature of Mix Optimization Performance Management Process Conduct an initial review of your mixes for opportunities Get ALL parties to the table for input, discussion and buy in Mix designers, production/operations (asphalt and internal aggregate), executive management Develop action plan for mix optimization Assign responsible parties Develop deadlines for task completion Develop measures for determination of success. Conduct periodic review of mix optimization work conducted and potential opportunities You can never rest! Always remember. Your competitor is working when you are not!

84 Maintain Focus on Quality! Customers won t necessarily buy your product because it has quality, but they certainly won t buy it if it does not. Quality doesn t start in the quality control department Must be top driven throughout all levels of a company Success is neither magical nor mysterious. Success is the natural consequence of consistently applying the basic fundamentals. (Jim Rohn)

85 Thank You! Shane Buchanan, Ph.D., P.E. Asphalt Performance Manager Oldcastle Materials Company (cell)