PROJECT OFFICE MANUAL. The Department reserves the right to review any design through plant production, prior to using the design for Department work.

Transcription

1 REPLACES D..5 04/25/2013 PENNSYLVANIA DEPARTMENT OF TRANSPORTATION PROJECT OFFICE MANUAL PART 5-1 SUJECT MINIMUM QUALITY CONTROL PLAN FOR ITUMINOUS CONCRETE Section 409.2(e), Publication 408, Mixture Composition for Standard and RPS Construction, require the producer to test the materials, proportions, and the mixture at the bituminous concrete plant laboratory in order to verify conformance with the uniformity specified. These requirements may be modified or there may be additional requirements in other Publication 408 Sections, including but not limited to Sections 309, 311, 410, 411, and 419. The producer must also design a bituminous mix that meets all Department requirements. A copy of the completed mix design is to be submitted to the District Materials Engineer/Manager (DME/DMM) at least three weeks before the planned start of mixture production. The Department reserves the right to review any design through plant production, prior to using the design for Department work. Each bituminous concrete producer must prepare and submit a quality control plan to the DME/DMM for review annually at least three weeks before the planned start of mixture production. The purpose of this requirement is to insure that the producer will consistently produce a uniform and quality product within Department specifications. The following Quality Control Plan is the minimum plan designed to meet these standards: A. QC Organization Chart. 1. Names of personnel responsible for quality control. 2. Area of responsibility of each of the following individuals: a. Plant Superintendent b. QC Manager c. Technicians (include certification number) d. Other 3. List outside agencies, e.g., testing laboratories and a description of services provided.. Testing Plan with Action Points: 1. Production lot size 1000 Tons. 2. Sample in accordance with PTM No. 1.

2 Minimum Daily Testing. a) Section 409 Superpave: i) 50 tons to less than 150 tons: asphalt content, gradation and theoretical maximum specific gravity. ii) 150 tons or more: asphalt content, gradation, theoretical maximum specific gravity and volumetrics. 4. Asphalt Content: PTM No. 5 and AASHTO T 308, PTM No. 02 and ASTM T 164, or PTM No. 42 a) Frequency: Minimum Daily Testing and per PTM No. 1 for each established plant lot size. (Minimum daily testing may coincide with lot sample). i) After three tests, check multiple sample compliance (n 3): Table A (409). ii) After five tests, check running average compliance (n 3): Table A (409). iii) Action Point = JMF +/ 0.2% iv) Plot straight-line charts at n=1 and n=5 5. Gradation: PTM No. 5 and AASHTO T 30, PTM No. 39 or PTM No. 43 a) Frequency: Minimum Daily Testing and per PTM No. 1 for each established plant lot size. (Minimum daily testing may coincide with lot sample). i) After three tests, check multiple sample compliance (n 3): Table A (409) or Table (401). ii) After five tests, check running average compliance (n 3): Table A (409) or Table (401). iii) Action Point = JMF +/- 1.0% on the 5 µm (No. 200) sieve; +/ 3.0% on the 9.5 mm (3/8 inch) to the 150 µm (No. 100) sieves; +/ 5.0% on the 12.5 mm (1/2 inch) and larger sieves. iv) Plot straight-line charts for 2.36 mm (No. 8) and 5 µm (No. 200) sieves at n=1 and n=5, plot all other sieves at n=1 and n=5. 6. Theoretical Maximum Specific Gravity: AASHTO T 209 a) Frequency: Minimum Daily Testing and per PTM No. 1 for each established plant lot size. (Minimum daily testing may coincide with lot sample). i) Condition and test according to the current ulletin 2, Appendix I. ii) Plot on straight-line chart. (Action Point +/ 0.020). iii) CS-411 or TR-465 Certification: List the most recent theoretical maximum specific gravity or average value as specified in ulletin 2.

3 5-3. Volumetrics: a) Section 409 Superpave Material: i) Frequency: Minimum Daily Testing and per PTM No. 1 for each established plant lot size. (Minimum daily testing may coincide with lot sample). a. Perform volumetric analysis using the mixture composition results from the same sample. Mix Design mixture composition values are not valid for volumetric analysis during production. b. Prepare a minimum of two specimens (AASHTO T 312). c. Determine bulk specific gravity (AASHTO T 166). d. Calculate Air Voids (AASHTO R 35). (Use most recent theoretical maximum specific gravity or average value as specified in ulletin 2). e. Calculate VMA according to AASHTO R 35 and as specified in ulletin 2, Appendix I. f. Check compliance with Section 409 Table : 1. Air Voids each specimen must meet the +/ 2% tolerance and the average of the two specimens must meet the multiple specimen tolerance of +/ 1.5% 2. VMA each specimen must meet the minimum VMA tolerance for the appropriate mix size. g. Record the individual and average Air Voids test results in the plant book. h. Record the individual VMA test results in the plant book. i. Record Lab Density and F/A test results in plant book. j. Plot Air Voids, VMA, and F/A test results on straight-line charts. k. Establish action points for voids and VMA to be within 408 Specification limits. F/A may be monitored during production also. 8. Aggregate Stock Gradations: PTM No. 616, AASHTO T 2. AASHTO T 2 and ASTM D 5 a) Frequency: Weekly for each aggregate type and source used. 9. Hot in Gradations: PTM No. 43 a) Frequency: Weekly to determine screening efficiency. 10. Apparent Moisture Content: PTM No. 49 a) Frequency: Daily on each completed mixture containing a coarse aggregate with a water absorption exceeding 2.0%.

4 Check Recording Pyrometers (atch plant ulletin 2/1-6) a) Frequency: Daily (Drum or other ulletin 2/1-6 & 1-14) b) Date: Record the production date on each pyrometer chart. 12. Mix Temperature a) Frequency: Daily on the first load and a minimum of five loads. i) Document mix temperatures on all copies of the delivery ticket. (Hot mix delivery tickets as per POM...6 2, 3) 13. RAP Material a) Moisture Content: AASHTO T 255 i) Frequency: A minimum of Once Daily. b) Extraction for AC and gradation: PTM No. 5 or PTM No. 02 and PTM No. 39 i) Frequency: One for each 1000 tons of RAP used or weekly. c) Recovered Aggregate ulk Specific Gravity. Follow the practice outlined in ulletin 2, Appendix H for determination of RAP aggregate bulk specific gravity. i) Frequency: One for each 3000 tons of RAP used. c)d) Refer to POM, Part, Section, Page 22-1 for additional minimum requirements when incorporating RAP greater than 15% RAP and less than or equal to 35% RAP in a bituminous mixture under Tiers 2 and 3. RR (Reclaimed Asphalt inder Ratio), for the purpose of referencing POM, Part, Section, Page 22-1, is defined as the ratio of RAP asphalt binder in the mixture to the total asphalt binder content of the mix. 14. RAS Material a) Moisture Content: AASHTO T 255 i) Frequency: A minimum of Once Daily. b) Extraction for AC and gradation: PTM No. 5 or PTM No. 02 and PTM No. 39 i) Frequency: One for each 1000 tons of RAS used or weekly. c) Recovered Aggregate ulk Specific Gravity i) Frequency: One for each 3000 tons of RAS used

5 Drum Mix and Continuous Volumetric Proportioning Plants a) Aggregate Gradations: PTM No. 616 and AASHTO T 2, AASHTO T 2, AASHTO T 248 i) Frequency: Daily when shipping 50 tons or more of completed mix. Aggregates will be sampled from bituminous plant stockpiles. b) Aggregate Moistures: AASHTO T 255 and ulletin 2/1-13 i) Fine Aggregate a. Frequency: A minimum of Twice Daily. Aggregates will be sampled from bituminous plant stockpiles. ii) Coarse Aggregate a. Frequency: A minimum of Once Daily. Aggregates will be sampled from bituminous plant stockpiles. c) Gate Calibration (ulletin 2/1-5,1-14) i) Frequency: Annually for each type of material used or more frequently if required. d) ituminous Pump Calibration (ulletin 2/1-15) i) Frequency: Start of season and every four months thereafter or more frequently if required. e) elt Weight Scale Calibration (ulletin 2/1-14,15) i) Frequency: Start of season and then biweekly thereafter Plant Calibration and Verification Procedures a) 50 pound test weight certification. (ulletin 2/1-10) i) Frequency: Every three years by an outside agency. b) Plant Scale Check: PTM No. 410 i) Frequency: Full scale check at start of season and biweekly thereafter. c) Truck Scale Certification (ulletin 2/1-8) i) Frequency: Annually by an outside agency. d) In event of failure of automatic proportioning or recording devices: i) All provisions and criteria of ulletin 2, Chp.1, Sec will apply. e) Calibrate anti-strip meter to meet +/ 1.0% tolerance at start of season and every four months thereafter.

6 Laboratory Equipment Calibrations and Verifications: a) Volumeters, bitumenometers, and Pycnometers: PTM No. 03, PTM No. 04 i) Frequency: Twice a year. The first calibration will be conducted prior to mix design and production each year. b) Ignition Oven: PTM No. 5 i) Frequency: Annual calibration by the original manufacturer or by other outside agencies. c) Gyratory Compactor: AASHTO T 312 (ulletin 2/1-2, 3) i) Frequency: Perform calibrations and verifications as specified in AASHTO T 312 following manufacturer s recommendations. d) Internal Angle Calibration i) Frequency: Initially calibrated to 1.16 ±0.03 degrees and recalibrated at least every 12 months or more frequently depending on high use or manufacturer's recommendations. e) Gyratory Specimen Molds i) Frequency: Inspect molds prior to mix design and production each year and regularly through out the production season. The difference between the inside diameter of the mold and the diameter of the mold plate face (side presented to the specimen) shall not exceed 0.50 mm. On SGC models where the loading head contacts the specimen, the difference between the inside diameter of the mold and the diameter of the loading head shall not exceed 0.50 mm. f) Weighing Devices Certification i) Frequency: Annually by an outside agency. g) All other equipment will be calibrated at start of season and when needed. h) Document all calibrations, certifications and verifications. i) The producer will specify what procedures will be followed to provide required testing, in a timely manner, in case of any testing device/equipment failure Annual JMF Verification: [Specification 408/409.2(e) & ulletin 2/2A-10] a) Verify each JMF within the first two days of production. b) Perform asphalt content, gradation and volumetric tests.

7 5- c) Additional samples lifted in accordance with PTM No. 1 for each established plant lot size. i) Section 409 Superpave: a. If the mixture does not conform to the single and multiple sample tolerances of Section 409 Tables A and within the first two days of production, suspend shipping the mixture to the project. b. Do not ship to the project until after the Representative reviews and verifies that results conform to the single and multiple sample tolerances of Section 409 Tables A and. c. During JMF verification, mixture acceptance is according to the approved acceptance level of Section 409 Table C Corrective Action: a) Corrective action shall be taken and the action shall be documented if one or more of the following occurs: a. Section 409: 1. Single sample (n=1) results for the 2.36 mm (No. 8) sieve, the 5 µm (No. 200) sieve, or asphalt content are not within Section 409 Table A tolerances. 2. The average of multiple samples (n 3) for percent passing any sieve or asphalt content as determined according to Section 409.2(e)1.d, are not within Section 409 Table A tolerances. 3. Temperature of the mixture is not within Section 409 Table A tolerances 4. Voids do not meet the single (n=1) or multiple (n>2) specimen tolerances of Section 409 Table. 5. VMA is not within the single (n=1) specimen tolerances of Section 409 Table. 6. IA or QA sample results tested at the producer s plant are not within tolerances of Section 409 Tables A or.. After taking corrective actions, the completed mixture will be sampled within 150 tons of production. (i) After sampling, the mixture will be tested and results provided to the Representative within 500 tons of production. (ii) If less than three samples are tested for mixture composition, determine conformance with Table A by comparing each result to the multiple sample tolerances. (iii)if the mixture does not conform to the single and multiple sample tolerances in Section 409 Table A and the single and multiple

8 5-8 specimen tolerances in Section 409 Table, suspend production and shipping to the project and determine the cause of the problem. (iv) Provide a written explanation of the problem and a proposed solution to the Department. (v) After the Representative reviews the proposed solution and authorizes production to continue, resume production and perform JMF verification. (vi) During corrective actions and JMF verification, mixture acceptance is according to the approved acceptance level of Section 409 Table C Plot all laboratory results from LTS for QA and DQA samples. a) Compare these results to companion samples run at the plant. b) Document finding of comparison Certification of materials to project within one working day on Form TR-465 or Form CS-411. Form TR-465 or Form CS-411 shall be completed daily for both acceptance levels specified in Table C. C. Materials Storage and Handling 1. Aggregate/RAP/RAM/RAS stockpiles. [Specification 408/409.3(c)] a) Refer to POM, Part, Section, Page 22-1 for additional minimum requirements when incorporating RAP with RR > 0.20 greater than 15% RAP and less than or equal to 35% RAP in a bituminous mixture. 2. Cold-feed systems for aggregates/rap/ram/ras [Specification 408/409.3(c)] 3. Additives or modifiers for mixture. (ulletin 2/2A-11) 4. Modified asphalt/liquid additive storage tanks. (ulletin 2/2A-11) 5. Surge/storage silos for mixture. No more than one mixture represented by a single JMF maybe stored in a surge/storage silo at any given time. ulletin 2, Appendix G provides details concerning system approval, sampling, submission, and reporting. 6. All measuring and conveying devices, including calibration procedures.. Haul vehicle loading and tarping procedures. [Specification 408/409.3(c)]

9 Truck weighing policy meeting the requirements outlined in ulletin 2/1-8 & POM...2-1). D. Plant ook Documentation Use of electronic plant books (as per POM..6-1 to 6-3) 1. The plant book shall be maintained in an electronic version acceptable to the District Materials Engineer/Manager (DME/DMM). a. The entire electronic plant book shall be backed up daily by a method acceptable to the District Materials Engineer/Manager (DME/DMM). b. The Department Representative shall have access to the electronic plant book. c. The electronic plant book shall be printed if requested by the Department Representative. d. The electronic plant book shall be printed and/or saved to CD as requested by the Department Representative at the end of the production season. These are the minimum process control requirements and may be added to, or the frequency increased, by the producer or the Department Representative, to assure compliance.

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