CERTIFIED TECHNICIAN HOT MIX ASPHALT I PRODUCTION TESTING (HMA-IPT)

Transcription

1 CERTIFIED TECHNICIAN HOT MIX ASPHALT I PRODUCTION TESTING (HMA-IPT) HIGHWAY TECHNICIAN CERTIFICATION PROGRAM University of Wisconsin-Platteville 049 Ottensman Hall 1 University Plaza Platteville, WI Office Phone;

2 Fax: Intro - 1

3 Intro - 1 PREFACE The WisDOT Hot Mix Asphalt IPT Certification course manual was prepared and developed by the Highway Technician Certification Program (HTCP) staff, the HTCP instructors, and other contributors from the Wisconsin Department of Transportation (WisDOT) and the highway industry. The information contained in this course manual is intended to be used to train Hot Mix Asphalt I - Production Testing technicians in meeting the requirements of the WisDOT Quality Management Program. The intent of this manual is to illustrate the related AASHTO/ASTM test standards and also discuss the WisDOT Quality Management Program for Asphaltic Mixtures. It is the responsibility of the WisDOT Certified Technician in HMA-IPT to obtain and follow all current WisDOT asphaltic mixture specifications, policies and procedures. The WisDOT Hot Mix Asphalt IPT certification manual was developed in conjunction with these valuable resources: 1. Superpave Mix Design, Asphalt Institute, Superpave Series No. 2 (SP-2), 2. Hot Mix Asphalt Paving Handbook NAPA, AASHTO, US Army Corps of Engineers, FHWA, FAA, American Public Works Association, National Association of County Engineers 3. Hot Mix Asphalt for Seniors and Graduate Students, U.S. Department of Transportation, Federal Highway Administration, FHWA-IF The Aggregate Handbook, National Stone, Sand, and Gravel Association 5. Supervisors Safety Manual, ACKNOWLEDGEMENTS The following HTCP Hot Mix Asphalt Technical Manual committee members and class instructors have been very instrumental, along with many others, as contributors in developing the content of this course manual: John Jorgenson, Mathy Construction Steve Bloedow, Rock Road Co. Patrick Shuda, WisDOT NC Region (Wisconsin Rapids) Signe Reichelt, Payne & Dolan, Inc. Judie Ryan, WisDOT Bureau of Technical Services Joe Kyle, Rock Road Companies, Inc. Karl Runstrom, Northeast Asphalt Debbie Schwerman, WAPA WisDOT Technical Hot-Line, the Regions and Bureau of Technical Services Representatives: SW Nancy.Busche@dot.wi.gov Madison Nancy Busche SW Steven.Ames@dot.wi.gov LaCrosse Steve Ames SE James.Boggs@dot.wi.gov Waukesha James Boggs NE Brian.Jandrin@dot.wi.gov Green Bay Brian Jandrin NC Patrick.Shuda@dot.wi.gov WI Rapids Patrick Shuda NC Dean.Gritzmacher@dot.wi.gov Rhinelander Dean Gritzmacher NW Michele.Morrow@dot.wi.gov Eau Claire Michele Morrow NW Thomas.Rossmann@dot.wi.gov Superior Tom Rossman BTS Judith.Ryan@dot.wi.gov Madison Judie Ryan

4 Intro - 1 TABLE OF CONTENTS Course Overview Introduction and Syllabus TOPIC A TOPIC B TOPIC C TOPIC D TOPIC E TOPIC F TOPIC G TOPIC H TOPIC I TOPIC J TOPIC K TOPIC L TOPIC M TOPIC N TOPIC O TOPIC P TOPIC Q TOPIC R History of WisDOT Quality Management Program How Asphalt Mixtures Behave HMA Aggregates Types of Asphalt Mixing Plants WisDOT HMA Pavement Types (and Mix Design Specifications) HMA Quality Management Program Summary Safety Random Sampling Procedure Sampling Asphaltic Mixtures from Truck Box Reduction of Asphaltic Mixtures to Testing Size AASHTO T Preparing and Determining the Density of Hot-Mix Asphalt (HMA) Specimens by Means of the Superpave Gyratory Compactor AASHTO T 166 Bulk Specific Gravity of Compacted SGC Bituminous Mixtures Using Saturated Surface-Dry AASHTO T 209 Maximum Specific Gravity of Bituminous Mixture WisDOT No Procedure, Asphalt Extraction Using Solvent Formulas, Calculations and Worksheets WisDOT Quality Control Charts WisDOT Quality Management Program Guide/CMM 8-36 QMP-HMA Data Entry APPENDIX: 1 Laboratory Mix Design Reports (WisDOT E-mixes), Additional Test Procedures 2 Standard Specification, Section 450 and 460, HTCP Laboratory Examination, QMP Award, Corrections, HTCP Course Evaluation

5 Intro - 1 MAJOR TABLES AND FIGURES REFERENCE LIST B-1 Asphalt Cement Time Temperature Dependency B-2 Visco-Elastic Behavior of Asphalt B-3 Example of PG Binder Designation B-4 Aggregate Stone Skeletons B-5 Stockpile Behavior of Cubical and Rounded Aggregate B-6 Rutting From Weak Subgrade B-7 Rutting from Weak Mixture B-8 Alligator (Fatigue) Cracking B-9 Low Temperature Cracking D-1 Batch Plant Components D-2 Batch Mix Facility Vibratory Screens and Hot Bin D-3 Drum Mix Facility Components D-4 Drum Plant Components E-1 Mix Design Applications E-2 Aggregate Gradation Master Range E-3 Table Mixture Requirements F-1 Verification Program G-1 Material Safety Data Sheet (MSDS) I-1 Single Dump Loading I-2 Multiple Dump Loading I-3 Sampling Plan for a Truck Box I-4 Example of Sample Labeling J-1 Initial Sample Reduction J-2 Sample Reduction for Testing K-1 Superpave Gyratory Compactor K-2 SGC Mold Configuration and Compaction Parameters

6 Intro - 1 Wisconsin Department of Transportation CERTIFIED TECHNICIAN HMA-IPT Syllabus Monday 8:00-8:30 Registration, Course Overview, and Definitions (Acronyms) 8:30-9:00 Introduction to Hot-Mix Asphalt 9:00-9:30 HMA Aggregates 9:30-10:30 Types of Asphalt Plants 10:30-11:45 WisDOT Specifications 11:45-12:45 Lunch Break 12:45-1:00 QC Overview 1:00-1:15 Safety 1:15-4:15 Laboratory Demonstration Reduction of Asphaltic Mixtures to Testing Size WisDOT 1560 HMA Solvent Extraction (including sieve analysis) AASHTO T 209 HMA Maximum Specific (G mm ) o (Including Dryback Procedure) AASHTO T Preparing and Determining the Density of Hot-Mix Asphalt (HMA) Specimens by Means of the Superpave Gyratory Compactor AASHTO T 166 HMA Bulk Specific (G mb ) Aggregate Specific Gravity Course and Fine (G sb ) Aggregate Angularity (CAA & FAA) 4:15-5:00 Random Sampling Procedure Tuesday 8:00-8:45 Sampling Asphaltic Mixtures from Truck Box Reduction of Asphaltic Mixtures to Test Size 8:45-10:00 Recording Data to Worksheets Formulas and Calculations 10:00-11:30 Hands-On Asphaltic Mixture Laboratory 11:30-12:30 Lunch Break

7 Intro - 1 Tuesday (afternoon) 12:30-3:00 Hands-On Asphaltic Mixture Laboratory Testing 3:00-4:00 WisDOT HMA Field Control Charts 4:00-5:00 Set-UP Specified Control Charts and Plot Student Asphaltic Mixture Test Data Results Wednesday 8:00-9:00 Additional Testing Procedures (Appendix B) 9:00-12:00 Hands-On Asphaltic Mixture Laboratory Testing 12:00-1:00 Lunch Break 1:00-4:00 Hands-On Asphaltic Mixture Laboratory Testing 4:00-5:00 Plot Student Asphaltic Mixture Test Data on Control Charts Thursday 8:00-9:00 Appendix Items 9:00-11:30 Hands-On Asphaltic Mixture Laboratory Testing 11:30-12:30 Lunch Break 12:30-1:30 Plot Student Asphaltic Mixture Test Data on Control Charts 1:30-2:30 Review/Analyze/Troubleshoot Class Data and Wrap-Up 2:30-3:30 Review latest WisDOT Quality Management Program Guide/ Procedure Manual and Specifications 3:30-3:45 Data Entry 3:45-5:00 Course Review and Questions Friday 8:00-12:00 Written Examination (Four Hours Maximum) Course Evaluation ADJOURN

8 Intro - 1 Course Overview Introduction The Highway Technician Certification Program (HTCP) welcomes you to the Hot-Mix Asphalt IPT course. This course requires 36 hours of classroom attendance. The course content will cover types of asphalt plants, WisDOT QV/CA asphaltic quality management program procedures, WisDOT standard specifications, statistical quality control, and laboratory testing, such as: sampling, quartering, gyratory compaction, bulk specific gravity, rice maximum specific gravity, and WisDOT 1560 asphaltic solvent extraction. Course Prerequisites Student candidates must have successfully completed one construction season of field experience or equivalent education prior to enrollment and be certified as an Aggregate Technician I. A person may earn 3.6 continuing education units (CEU s) upon successful completion of this course. Certification Requirements The written examination will be limited to a maximum duration of four (4) hours. The written examination will be open book and open notes and will consist of short answer questions, multiple-choice questions, and essay problems. A student will be required to obtain a passing score of 70 percent to be certified as a Hot-Mix Asphalt IPT. Recertification Requirements Recertification is mandatory every three (3) years. The HTCP will send a recertification notice to each certified technician and the firm or agency prior to the expiration date of the highest certification level(s) of certification obtained. The certified technician must apply for recertification before the expiration date of the highest level(s) obtained. Each certified technician is responsible for obtaining his/her recertification. Revocation/Suspension of Certification Upon written request from any individual, firm, agency, or contractor associated with the HTCP, the HTCP director will provide technical assistance in investigating any alleged report(s) of either certified technician incompetence or act(s) of malfeasance. The HTCP director will then notify WisDOT of the report findings concerning certified technician incompetence or misconduct.

9 Intro - 1 Highway Technician Certification Program Goal The principle goal of the Highway Technician Certification Program (HTCP) is to certify that individuals have demonstrated the abilities to engage in quality control/quality assurance activities in highway work contracted by the Wisconsin Department of Transportation (WisDOT). Welcome The HTCP welcomes you to the Hot-Mix Asphalt Production Testing training/certification course. First of all, please make sure you have satisfied all Certified HMA Technician I course prerequisites before completing this course. Certification for Hot Mix Asphalt Production Testing will be granted only if you successfully complete this course and have satisfied all course prerequisites. Introduction of Course Participants At this time, you will be asked to introduce yourself, company name, years of service to the asphalt industry and your present occupational duty. What Do You Expect From This Training Course? This is your opportunity, as a course participant, to ask the course instructor to cover any other topics related to asphalt paving mixtures. Please list and identify any additional related asphalt paving mixture topics below: Duties and Responsibilities of a Certified Technician for Hot-Mix Asphalt Production Testing The duties and responsibilities of a Certified Hot-Mix Asphalt Production Tester (HMA- IPT) involve: Knowing which samples and tests are required, being able to perform them, and computing the test data results Knowing who is responsible for sampling and testing asphalt Knowing the proper frequency of sampling and testing and being able to sample and test as required by specification

10 Knowing the mathematical random number process for selecting a sample location and when it is required by specification Knowing the specification requirements and evaluating test results in relation to these specifications Being able to properly prepare, maintain, and analyze control charts and to control production process by making troubleshooting adjustments which comply to the asphaltic mixture specifications Being able to maintain records in an organized manner and documenting sampling and testing performed and actions taken as a result of sampling and testing required by specification Acronyms Pertaining to Hot-Mix Asphalt AASHTO AC AMRL ASTM CA CAA ESAL FAA G b G mb G mm G sa G sb G se HMA JMF NAPA NCAT NCHRP NMAS P b P be P ba PBR P s QC QMP QV RAP SGC SHA SHRP SMA SSD TSR VFA VFB VMA VTM or V A WAPA WMA American Association of State Highway & Transportation Officials Asphalt Cement (Liquid Binder) AASHTO Materials Research Laboratory American Society for Testing & Materials Contractor Assurance Coarse Aggregate Angularity Equivalent Single Axle Load Fine Aggregate Angularity Specific Gravity of the Binder Bulk Specific Gravity (Asphaltic Mixture) Maximum Specific Gravity of the Mixture Apparent Specific Gravity (Aggregate) Bulk Specific Gravity (Aggregate) Effective Specific Gravity (Aggregate) Hot-Mix Asphalt Job Mix Formula National Asphalt Pavement Association National Center for Asphalt Technology National Cooperative Highway Research Program Nominal Maximum Aggregate Size % Binder Effective % Binder % Binder Absorption % Binder Replacement % Stone Quality Control Quality Management Program Quality Verification Recycled Asphalt Pavement Superpave (or SHRP) Gyratory Compactor State Highway Agency Strategic Highway Research Program Stone Matrix Asphalt Surface Saturated Dry Tensile Strength Ratio Voids Filled with Asphalt Voids Filled with Binder Voids in Mineral Aggregate Voids in Total Mix (Air Voids) Wisconsin Asphalt Pavement Association Warm Mix Asphalt

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12 TOPIC A: History of WisDOT Quality Management Program A-0

13 TOPIC A: History of WisDOT Quality Management Program A-1 Below is a chronological outline of some of the recent history of HMA (hot-mix asphalt) in Wisconsin and the specifications that controlled design and production Rut Resistant HMA (RRHMA mixes) were brought about due to trouble in achieving VMA and in-place density. Crush counts lowered Natural sand restrictions increased to allow for greater use Density target changed to reflect a percent of Gmm Lower VMA requirements 1990 Letter Mixes (A,B,C,D,E) begin to identify mix types based on traffic loading A (Highest traffic volume): 5% air void target for lab design and adjusted to 4% in the field; VMA calc d using Gsb B (High traffic volume in urban sections): mixture adjusted to 3.5% air voids in the field; VMA calc d using Gsb C (Moderate traffic volume in rural state and CTH roadways): 4% air void target for lab designs; VMA calc d using Gse D (Lower traffic volume, usually single agg product): Sliding VMA scale based on aggregate top size and calc d using Gse E (Lease restricted mixes, temporary, and repair applications): Engineers suggested composition, no mix specifications Creation of RAP designs, primarily for the C mix applications, along with additional improvements and controls for the other letter mixes QMP program further developed and heading towards implementation (new HTCP classes). C and D mixes eliminated Contractor verification testing on state projects eliminated 1993 & 1994 Changes made to the specification to address low binder contents and segregation ESAL criteria used in developing HV - MV - LV mixtures Lessen the use of coarse gradations with thin film thickness and increase mixtures using small stones and thicker binder coating QMP requirement goals of 80% in 1993 and 100% by the end of 1994 Success in producing SMA test sections for future performance evaluation

14 TOPIC A: History of WisDOT Quality Management Program A through 1998 Recognition of the national SHRP conclusions and begin movement towards evaluating the use of the Superpave gyratory compactor in Wisconsin Development and implementation of Warranty for HMA specifications along with production of initial jobs under this specification Implementation of the SHRP Performance Graded binder specification (1997) 1999 through 2001 Superpave specifications modified and implemented as the mix design methodology of choice Superpave replaces HV mixes (little change to the materials requirements already in place) Special HTCP HMA courses updated and presented statewide to aid in education and training for the projected changes E-Mixes defined and related to 20 year life ESALs as suggested by AASHTO for the Superpave design system (in developing a national standard) WisDOT E-Mix specification to be implemented at a goal of 100% for 2001 (eliminating use of HV-MV-LV mixes) HMA quality control strategy is evolving from quality control/quality assurance (QC/QA) to contractor assurance/quality verification (CA/QV). The year 2004 marked the 10 th anniversary of 100% QMP state highway construction in Wisconsin 2014 Present HMA, Hot Mix Asphalt, begins to migrate to a name now more reflective of the product, Asphaltic Mixtures

15 TOPIC B: How Asphalt Mixtures Behave B-0

16 TOPIC B: How Asphalt Mixtures Behave B-1 Reference: Background of Superpave Asphalt Mixture Design and Analysis, National Asphalt Training Center, Pub. No. FHWA-SA , February 1995 ASPHALT MIXTURES Asphalt concrete (sometimes referred to as hot-mix asphalt or simply HMA ) is a paving material that consists of asphalt binder and mineral aggregate. Because HMA contains both asphalt binder and mineral aggregate, the behavior of the mixture is affected by the properties of the individual components and how they react with each other. The mix design system determines the correct proportion of asphalt binder and aggregate required to produce an asphaltic mixture with the properties and characteristics needed to withstand the effects of traffic and environment for many years. ASPHALT BINDER BEHAVIOR The asphalt binder, which can be asphalt cement or modified asphalt cement, acts as a binding agent to glue aggregate particles into a cohesive mass. Because it is impervious to water, the asphalt binder also functions to waterproof the mixture. When bound by the asphalt binder, mineral aggregate acts as a stone framework to give strength and toughness to the system. Almost every asphalt cement and mixture characterization test must be accompanied by a specified test temperature (Figure B-1). 140 o F 77 o F Figure B-1. Asphalt Cement Time Temperature Dependency Asphalt cement is sometimes referred to as a visco-elastic material because it simultaneously displays both viscous and elastic characteristics (Figure B-2). At high temperatures, asphalt cement acts almost entirely as a viscous fluid. In other words, when heated to a high temperature (e.g., > 212F / 100C), it displays the consistency of a lubricating fluid such as motor oil. At a very low temperature (e.g., < 32F / 0C), asphalt cement behaves most like an elastic solid. That is, it acts like a rubber band. When loaded, it stretches or compresses to a different shape. When unloaded, it easily returns to its original shape. At intermediate temperatures, which also happen to be

17 TOPIC B: How Asphalt Mixtures Behave B-2 those in which pavements are expected to function, the asphalt binder has characteristics of both a viscous fluid and elastic solid. elastic Stiffness Response to Load viscous elastic solid viscous fluid Temperature, C Figure B-2. Visco-Elastic Behavior of Asphalt The PG (performance grade) specifications help in selecting a binder grade (Figure B-3) that will limit the contribution of the binder to low temperature cracking, rutting, and fatigue cracking of the asphalt pavement within the range of climate and traffic loading for any particular project site. Modified asphalt binders are produced to alter and improve the properties of the asphalt to enhance the long-term performance of pavements. avg 7-day max pavement temp (147F) (- 8F) PG Lowest pavement design temp MINERAL AGGREGATE BEHAVIOR Figure B-3. Example of PG binder designation A wide variety of mineral aggregate has been used to produce HMA. Some materials are referred to as natural aggregate because they are simply mined from river or glacial deposits and are used without further processing to manufacture HMA. These are often called Abank-run@ or Apit-run@ materials. Processed aggregate can include natural aggregate that has been separated into distinct size fractions, washed, crushed, or otherwise treated to enhance certain performance characteristics of the finished HMA. However, in most cases processed aggregate is quarried and the main processing consists of crushing and sizing. An existing pavement can be removed and reprocessed to produce new HMA. Reclaimed (recycled) asphalt pavement or RAP is a growing and important source of aggregate for asphalt pavements.

18 TOPIC B: How Asphalt Mixtures Behave B-3 Regardless of source or processing method, aggregate is expected to provide a strong, stone skeleton to resist repeated load applications. Cubical, rough-textured aggregates provide more strength than rounded smooth-textured aggregates (Figure B-4). Even though a cubical piece and rounded piece of aggregate may possess the same inherent strength, cubical aggregate particles tend to lock together, resulting in a stronger mass of material. Rounded aggregate particles tend to slide by each other. Cubical Aggregate Figure B-4. Aggregate Stone Skeletons Rounded Aggregate Contrasting aggregate shear strength behavior can easily be observed in aggregate stockpiles (i.e.: crushed aggregates form steeper, more stable piles than rounded aggregates). Engineers refer to the slope on stockpiles as the angle of repose. The angle of repose of a crushed aggregate stockpile is greater than that of an uncrushed aggregate stockpile (Figure B-5). Figure B-5. Stockpile Behavior of Cubical and Rounded Aggregate

19 TOPIC B: How Asphalt Mixtures Behave B-4 To ensure a strong aggregate blend for HMA, engineers have typically specified aggregate properties that enhance the internal friction of the mixture. Normally, this is accomplished by specifying a certain percentage of crushed faces for the coarse portion of an aggregate blend and restricting use of rounded natural sands in the fine portion (FAA, Fine Aggregate Angularity). ASPHALT MIXTURE BEHAVIOR While the individual properties of HMA components are important, asphalt mixture behavior is best explained by considering asphalt cement and mineral aggregate acting as a system. One way to understand asphalt mixture behavior is to consider the primary asphalt pavement distress types that engineers try to avoid: permanent deformation, fatigue cracking, and low volume temperature cracking. Permanent Deformation (Rutting) Permanent deformation is the distress that is characterized by a surface cross section that is no longer in its proper position. It is called permanent deformation because it represents an accumulation of small amounts of deformation that occurs each time a load is applied. This deformation cannot be recovered. Wheel path rutting is the most common form of permanent deformation. While wheel path rutting can have many causes (e.g., underlying HMA weakened by moisture damage, abrasion, traffic densification), it has two principle causes. In one case, the rutting is caused by too much repeated stress being applied to the native soil (i.e., subgrade), subbase, or base below the asphalt layer (Figure B-6). original profile asphalt layer weak subgrade or underlying layer subgrade deformation Figure B-6. Rutting from Weak Subgrade The other principle type of rutting (and that which is of most concern here) results from accumulated deformation in the asphalt layers (Figure B-7).

20 TOPIC B: How Asphalt Mixtures Behave B-5 original profile weak asphalt layer Figure B-7. Rutting From Weak Mixture shear plane While the largest portion of the resistance to permanent deformation of the mixture is provided by the aggregate, the portion provided by the asphalt binder is very important. Binders which have low shear characteristics minimize cohesion. Thus the mixture begins to behave more like an unbound aggregate mass. Fatigue Cracking Like rutting, fatigue cracking is a distress type that most often occurs in wheel paths where repeated heavy loads are applied. An early sign of fatigue cracking is intermittent longitudinal wheel path cracks (i.e., in the direction of traffic). Fatigue cracking is a progressive type of distress because at some point, the initial cracks will join, which in turn causes more cracks to form. An intermediate stage of fatigue cracking is sometimes called alligator cracking because the crack patterns resemble an alligator s skin (Figure B-8). In some extreme cases, the final stage of fatigue cracking is a pothole. Potholes form when several of the pieces become dislodged under the action of traffic. Figure B-8. Alligator (Fatigue) Cracking

21 TOPIC B: How Asphalt Mixtures Behave B-6 Low Temperature Cracking As its name indicates, low temperature cracking is a distress type that is caused by colder climate conditions rather than by applied traffic loads. Low temperature cracks form when an asphalt pavement layer shrinks in cold weather. It is characterized by transverse cracks (i.e., perpendicular to the direction of traffic) that occur at a surprisingly consistent spacing (Figure B-9). Low temperature cracks occur primarily from a single cycle or event of low temperature. Some engineers, however, also believe it s a fatigue phenomenon due to the cumulative effect of many cycles of cold weather. Figure B-9. Low Temperature Cracking The asphalt binder plays a central role in low temperature cracking and, in general, harder asphalt binders are more prone to low temperature cracking than soft asphalt binders.

22 TOPIC C: HMA Aggregates C-0

23 TOPIC C: HMA Aggregates C-1 HMA Aggregates There are five general steps needed to prepare individual stockpiles of aggregates: Excavation, Transporting, Crushing, Sizing and Stockpiling, and Washing. Once stockpiles have been prepared, two or more stockpiles are typically blended together to produce a final gradation for a given construction application. Aggregate use for HMA also requires that standard source properties be measured for: Toughness (LA wear abrasion test to determine resistance to mechanical degradation) Soundness and/or Freeze-Thaw (to estimate resistance to weathering) Deleterious Materials (for contaminants such as clay lumps, wood, shale, chert) Gradation (sieve analysis to determine distribution of particle sizes) In addition, there are consensus properties that are measured as well: Aggregate Particle Shape (% crush for coarse and fine aggregates, CAA, and FAA) Flat & Elongated Particles (tendency for particle breakage) Sand Equivalency (clay content) Specific Gravity (G) All matter has mass and occupies space. Specific gravity can be defined as the weight of a body compared with the weight of an equal amount of water at 39 o F/4 o C (this is essentially the temperature at which water is densest). The densities of ordinary substances vary from the least dense, hydrogen gas (density of grams per cubic centimeter) to the element osmium, which at 22 grams per cubic centimeter is only slightly denser than gold or platinum. A material s specific gravity is a ratio of the Amass to volume@ of an object to that of water at the same temperature (density of a substance divided by the density of water). A specific gravity value is expressed as how much greater the weight of the mineral is to an equal amount of water. Water has a specific gravity of If a mineral has a specific gravity of 2.725, it is times heavier than water. A ton of aggregate with a low specific gravity has a greater volume and will take up more space than a ton of aggregate with a higher specific gravity. Consequently, low specific gravity aggregate (high volume) requires more binder in order to coat the particles, to the same degree, as the same tonnage of higher specific gravity aggregates (low volume). Volumes of irregular-shaped objects are determined by the displacement of water and can be calculated by : volume of object = object wt. in air - object wt. in water. Mineral

24 TOPIC C: HMA Aggregates C-2 aggregate is porous and can absorb water and binder to a variable degree. That degree of absorption also varies with each aggregate source. There are three methods of measuring aggregate gravities to help take into account this variability: Apparent Specific Gravity (G sa ): volume excludes all pore space Effective Specific Gravity (G se ): volume includes partial pore space Bulk Specific Gravity (G sb ): total volume includes all pore space Gsa = smaller vol = larger gravity Gse = medium vol = medium gravity Gsb = larger vol = smaller gravity Specific Gravity Tests for Aggregates Two tests are needed in order to determine the specific gravity for aggregate components. Coarse aggregate (retained on the #4 / 4.75 mm sieve) Fine aggregate (passing the #4 / 4.75 mm sieve) Coarse Aggregate Specific Gravity (ASTM C127/AASHTO T85) Dry aggregate Soak in water for 24 hours Decant water Use pre-dampened towel to get SSD condition Determine mass of SSD aggregate in bucket Determine mass under water Dry to constant mass Determine oven dry mass

25 TOPIC C: HMA Aggregates C-3 Calculations G sb = A / (B - C) A = mass oven dry B = mass SSD C = mass under water G sa = A / (A - C) Water absorption capacity, % Absorption % = [(B - A) / A] * 100 Fine Aggregate Specific Gravity (ASTM C128 / AASHTO T 84) Dry aggregate Soak in water for 24 hours Spread out and dry to SSD Add 500 g of SSD aggregate to pycnometer of known volume o Pre-filled with some water Add more water and agitate until air bubble have been removed Fill to line and determine the mass of the pycnometer, aggregate and water Empty aggregate into pan and dry to constant mass Determine oven dry mass

26 TOPIC C: HMA Aggregates C-4 Fine Aggregate Specific Gravity Calculations G sb = A / (B + S - C) A = mass oven dry B = mass of pycnometer filled with water C = mass pycnometer, SSD aggregate and water S = mass SSD aggregate G sa = A / (B + A - C) Water absorption capacity, % Absorption % = [(S - A) / A] * 100 Sand Equivalence, SE (AASHTO T 176) Measured on the material passing the # 4 (4.75mm) The greater the SE value, the more sand and less clay there is Clay on the aggregate particles reduces binder adhesion to the stone Clay Content flocculating solution graduated cylinder clay reading A = Clay reading B = Sand reading SE = B * 100 / A suspended clay sedimented aggregate sand reading 69 Coarse Aggregate Angularity, CAA Particle count conducted on R # 4 material and based on fractured faces One fractured face Two fractured faces

27 TOPIC C: HMA Aggregates C-5 Fine Aggregate Angularity, FAA (AASHTO T 304) Measured on the material between the # 8 (2.36mm) and the # 100 (.150mm) Based on air voids in a free falling loose sample Uses Method A (washed sample built back to a standard gradation) Fine Aggregate Angularity funnel fine aggregate sample cylinder of known volume (V) measured mass M Uncompacted voids = V - M / G sb V x 100% 60 Flat and Elongated Particles (ASTM D 4791) Tested on the R # 4 (4.75mm) material Ratio of maximum to minimum dimension 5 1

28 TOPIC C: HMA Aggregates C-6 Voids in the Mineral Aggregate (VMA) VMA is defined as the volume of void space between the aggregate particles of a compacted mixture that includes the air voids and the volume of binder not absorbed into the aggregate (effective binder content, P be ). In essence, it is a re0resentation of the packing characteristics of the aggregate particles and determines the amount of space available for air voids and binder to fit in between the particles. Illustration of VMA in a Compacted Mix Specimen (Note: For simplification, the volume of absorbed asphalt is not shown.) Gmb Ps VMA 100 Gsb Where P s = (100 P b ) VMA100 - G mb P b G sb

29 TOPIC D: Types of Asphalt Mixing Plants D-0

30 TOPIC D: Types of Asphalt Mixing Plants D-1 The purpose of the hot-mix asphalt plant is to blend together different sized aggregates with asphalt binder to produce a high quality asphaltic mixture which can be placed and compacted into a durable asphaltic concrete pavement. Types of Asphalt Mixing Plants There are primarily two types of asphalt mixing plants used in Wisconsin: Batch Drum Batch Mix Facility Components Cold Feed Bins The production of Hot-Mix Asphalt (HMA) begins with aggregate stored in cold bed bins. (See Figure D-1 Batch Plant Components.) The cold feed bins are the primary feeders and main control of the asphalt plant. The cold feed bins must be calibrated before project start-up. A cold feed bin must be set up for each aggregate source, and each aggregate source percentage must be adjusted to meet the requirements on the asphaltic mix design report. The appropriate cold feed bin aggregate stockpiles and specified percentages make up the final production of the Job Mix Formula aggregate blend. Fourteen Major Parts: 1. Cold bins 9. Hot bins 2. Cold feed gate 10. Weigh box 3. Cold elevator 11. Mixing unit or pugmill 4. Dryer 12. Mineral filler storage 5. Dust collector 13. Hot asphalt cement storage 6. Exhaust stack 14. Asphalt weigh bucket 7. Hot elevator 8. Screening Unit Figure D-1. Batch Plant Components

31 TOPIC D: Types of Asphalt Mixing Plants D-2 An asphalt mixing facility has lots of moving conveyor belts and parts, so BE ALERT! SAFETY FIRST. From the cold feed bin, the aggregates are moved by a cold feed elevator to the dryer. The dryer has a burner, which provides the heat energy for evaporating the moisture in the aggregates and heats typ equipped with longitudinal flights, which lift the aggregates and drop them through the hot burner gases. Once the aggregate material has been dried, the heated aggregate is discharged form the dryer and lifted to the top of an enclosed hot elevator. The hot dust gases are passed through a dust collect system to remove dust particles to be reintroduced back into the HMA by either an augering or flow metering system, as required. The hot elevator delivers the material to the tower unit, which will rescreen the aggregates vibrating screens designed to separate the aggregates into different sized aggregate hot bins (see Figure D-2). Figure D-2. Batch Mix Facility Vibratory Screens and Hot Bins

32 TOPIC D: Types of Asphalt Mixing Plants D-3 After the material has been separated by the vibrating screens, the material is stored in hot bins. The computer control system then proportions the hot aggregates in the bins into the weight hopper, which is mounted on a set of scales. Once the aggregates have been weighed, they are introduced into the pugmill, where the hot liquid asphalt binder is added. The hot asphalt binder has been weighed and stored in a weight bucket and is sprayed onto the hot dry mixed aggregate. After the aggregates and asphalt cement have been mixed into the homogenous mixture, it is discharged directly into a truck or is transferred into a storage silo from which it may be loaded. Drum Mix Facility Components Cold Feed Bins Like the batch plant facility, the drum plant facility also uses cold feed bins as the primary feeder and control of the asphalt mixing facility. The secondary control in a drum mix facility is a conveyor belt scale, which weighs the aggregate before entering the drum. Troubleshooting cold feed bins is very similar to the batch plant facility. The basic parts of the drum mix plant: (See Figure D-3) Aggregate cold feed bins Conveyor and aggregate weighing systems Drum mixer (dryer) Dust collection system Hot mixer conveyor Mix surge silo Control trailer Asphalt storage tank Figure D-3. Drum Mix Facility Components

33 TOPIC D: Types of Asphalt Mixing Plants D-4 As shown in Figure D-4, controlled gradations of aggregates are deposited in the cold feed bins (1) from which they are fed in exact proportions into a cold feed conveyor (2). An automatic aggregate weighing system (3) monitors the amount of aggregate flowing into the drum mixer (4). The weighing system is interlocked with the controls on the asphalt storage pump (5), which allows asphalt from the storage tank (6) and introduces it into the drum where asphalt and aggregate are thoroughly blended by the drum=s rotating action. A dust collector (7) captures excess dust escaping from the drum. From the drum, the hot-mix asphalt concrete is transported by hot-mix conveyor (8) to a surge silo (9) from which it is loaded into trucks and hauled to the paving site. All plant operations are monitored and controlled from instruments in the control van (10). Figure D-4. Drum Plant Components

34 TOPIC E: WisDOT HMA Pavement Types & Mix Design Specs E-0

35 TOPIC E: WisDOT HMA Pavement Types & Mix Design Specs E-1 WisDOT HMA Pavement Types The type of HMA mix design will be specified as part of the project specifications. Selection of the appropriate HMA pavement type was developed on expected traffic loadings. The traffic loadings are defined in Equivalent Single Axle Loads (ESALs) the pavement is expected to carry in the design lane over a projected 20-year life. Design ESALS (millions) Compaction Parameters Typical Roadway Applications Nini Ndes Nmax < Applications include roadways with very light traffic volumes, such as local roads, country roads, and city streets where truck traffic is prohibited or is at a very minimal level. Traffic on these roadways would be considered local in nature, not regional, intrastate, or interstate. Special purpose roadways serving recreational sites or areas may also be applicable to this level < Applications include many collector roads or access streets. 1 - < Medium trafficked city streets and the majority of county roadways may be applicable to this level. 3 - < Applications include many two-lane; multilane, divided, and partially or completely controlled access 10 - < roadways. Among these are medium to highly trafficked city streets, many state routes, US highways, and some rural interstates Applications include the vast majority of the US Interstate system, both rural and urban in nature. Special applications such as truck-weighing stations or truck-climbing lanes on two-lane roadways may also be applicable to this level. Table E-1. Mix Design Applications

36 TOPIC E: WisDOT HMA Pavement Types & Mix Design Specs E Aggregate Gradation Master Range Ensure that the aggregate blend, including RAP and mineral filler, conforms to the gradation requirements in table The values listed are design limits; production values may exceed those limits. Sieve Size PERCENTS PASSING DESIGNATED SIEVES Nominal Size 50.0 mm mm 25.0 mm 19.0 mm 12.5 mm 9.5 mm SMA 12.5 mm SMA 9.5 mm 37.5 mm mm 90max mm max mm max mm max mm max mm m PERCENT MINIMUM VMA Table Aggregate Gradation Master Range and VMA Requirements Unless the contract designates otherwise, ensure that the nominal size of the aggregate used in the mixture conforms to the following: PAVEMENT LAYER NOMINAL SIZE Lower layer pavement mm Upper layer pavement mm Stone matrix layer pavement mm The HMA mix type for the WisDOT mix design will be specified as part of the project specifications. For example, a type 12.5mm HMA mixture is listed as part of the project specifications. The asphalt mix designer is responsible to design an HMA mixture, which satisfies both the 12.5mm mix property requirements and the WisDOT aggregate gradation master requirements. The following table is an example of the WisDOT mixture requirements and represents the mix design limits for maximums and minimums. While the total of these properties is not monitored in the field on a regular basis, it should be noted that whenever adjustments are made to the original mix design JMF, these properties must be met as well.

37 TOPIC E: WisDOT HMA Pavement Types & Mix Design Specs E-3 Table MIXTURE REQUIREMENTS Mixture type E E - 1 E - 3 E - 10 E - 30 E - 30x SMA ESALs x 106 (20 yr design life) < < < < < LA Wear (AASHTO T 96) 100 revolutions(max % loss) revolutions(max % loss) Soundness (AASHTO T 104) (sodium sulfate, max % loss) Freeze/Thaw (AASHTO T 103) (specified counties, max % loss) Fractured Faces (ASTM 5821) (one face/2 face, % by count) 60 / 65 / 75 / / / / /90 Thin or Elongated (ASTM D4791) (max %, by weight) (5:1 ratio) (5:1 ratio) (5:1 ratio) (5:1 ratio) (5:1 ratio) (5:1 ratio) (3:1ratio) Fine Aggregate Angularity (AASHTO T304, method A, min) Sand Equivalency (AASHTO T 176, min) Gyratory Compaction Gyrations for Nini Gyrations for Ndes Gyrations for Nmax Air Voids, %Va Ndes) 4.0 (96.0) 4.0 (96.0) 4.0 (96.0) 4.0 (96.0) 4.0 (96.0) 4.0 (96.0) 4.0 (96.0) % Nini <=91.5[1] <=90.5[1] <=89.0[1] <=89.0 <=89.0 <=89.0 % Nmax <=98.0 <=98.0 <=98.0 <=98.0 <=98.0 <=98.0 Dust to Binder Ratio[2] (% passing 0.075/Pbe) Voids filled with Binder (VFB or VFA, %) Tensile Strength Ratio (TSR) (ASTM 4867) [4] [5] [4] [4] [3] [4] [3] [4] [3] [4] no antistripping additive with antistripping additive Draindown at Production Temperature (%) [1] The percent maximum density at initial compaction is only a guideline. [2] For a gradation that passes below the boundaries of the caution zone(ref. AASHTO MP3), the dust to binder ratio limits are [3] For 9.5mm nominal maximum size mixtures, the specified VFB range is 73-76%. [4] For 37.5mm nominal maximum size mixes, the specified VFB lower limit is 67%. [5] For 25.0mm nominal maximum size mixes, the specified VFB lower limit is 67% 0.30

38 TOPIC F: WisDOT HMA Quality Management Progam F-0

39 TOPIC F: WisDOT HMA Quality Management Progam F-1 Quality Management Programs The quality of HMA can be defined in terms of the characteristics (e.g., asphalt content, air voids, density) required to achieve a specific level of excellence. Quality control, or process control, of HMA denotes mixing and placing the HMA ingredients (aggregates and asphalt) so that it is reasonable to expect the pavement to perform properly. Random sampling, as a piece of process control, is a procedure whereby every portion of mixture has an equal chance of being selected as a representative sample. Process control also provides a means of adequate checks during production to minimize the contractor s risk of having the mixture rejected. Quality control is described as contractor activities, efforts to meet specification requirements, and maintaining a given level of production with respect to acceptable levels of uniformity. Quality assurance is those activities providing a confidence level that the product will be or is, in fact, satisfactory. Acceptance testing is a check on the finished product to determine the degree to which the goals of contract/specification compliance and product quality have been attained. In addition, independent assurance is conducted to produce an unbiased/independent evaluation of the sampling and testing procedures used within the QMP. WisDOT Quality Control Program Requirements Personnel Requirements Laboratory Requirements Required Testing (and Calculated Properties) o Aggregate Gradation o Mixture Bulk Specific Gravity (Gmb) o Mixture Maximum Specific Gravity (Gmm) o Air Voids (Va) o VMA o Percent Binder Content Random Sampling and Sampling Frequency Documentation o Records o Control Charts Control Limits Warning Bands Job Mix Formula Adjustments Corrective Action Assurance/Verification Testing

40 TOPIC F: WisDOT HMA Quality Management Program F-2 HMA Quality Management Program Summary Quality Management Program General Contractor shall provide and maintain a quality control (QC) program Mix design - JMF Process control inspection, sampling and testing Process adjustments related to the production and placement of HMA Provide optional contractor assurance (CA) Department will provide product verification (and Independent Assurance as specified in ). Conduct verification testing of independent samples. Observe sampling and testing performed by the contractor. Monitor required production Direct the contractor to take additional samples at any time during production Contractor Testing (for a Contract of 5000 Tons of Mixture or Greater) Personnel Requirements Laboratory Requirements Required Testing at a specified Frequency Asphaltic content (AC) in percent Bulk specific gravity of the compacted mixture according to AASHTO T166. Maximum specific gravity according to AASHTO T 209. Air voids (Va) by calculation according to AASHTO T 269. Voids in the mineral aggregate (VMA) by calculation according to AASHTO.R35. The above testing program shall be conducted for each design mixture at the specified frequency ( , paragraph 5). Test Requirements for Contracts Other Than 5000 ton or Greater See Sections & 3 & 4 Documentation Records Control Charts Control Limits Job Mix Formula Adjustment

41 TOPIC F: WisDOT HMA Quality Management Program F-3 Corrective Action When running average values trend toward the warning limits, consider taking corrective action. Whenever the running average values exceed the warning limits, notify the engineer. If two consecutive running average values exceed the warning limits, stop and make adjustments. Failure to stop production causes mixture to be considered unsatisfactory. Reduced payment will be applied. If the process adjustment improves the mixture running average to within the limits, no reduction. If the adjustment does not improve the running average the mixture will be considered unsatisfactory and a reduced payment will be applied Optional Contractor Assurance General Contractor assurance (CA) testing is optional and is conducted to further validate production testing. Personnel Requirements Laboratory Requirements Facility meeting WisDOT Laboratory Qualification Program requirements and different from lab (equipment or personnel) being used for QC Testing No specified frequency (optional). Assurance samples are to be comparison samples to QC samples. In the event a separate or additional sample is taken, the contractor may, with the engineer's approval, use that sample as a replacement for one of the required random QC tests for that day. Documentation Notification of the CA test results will be within 2 working days after receipt of the samples. Allowable Differences Acceptable differences between the QC and CA split sample test results defined in Department Testing - Quality Verification Program General The engineer will conduct verification tests to determine the quality of the final product. Verification testing is intended to measure characteristics in predicting relative performance. Personnel Requirements Laboratory Requirements Furnish and maintain a laboratory meeting the department s laboratory qualification program requirements as a minimum.

42 TOPIC F: WisDOT HMA Quality Management Program F-4 Department Verification Testing Requirements Bulk specific gravity (Gmb) of the compacted mixture according to AASHTO T 166. Maximum specific gravity (Gmm) according to AASHTO T 209. Calculate Air Voids (Va) according to AASHTO T 269. Calculate VMA according to AASHTO R35 Testing is conducted for each design mixture at the following minimum frequency: FOR TONNAGES TOTALING: Less than 501 tons... no tests required From 501 to 30,000 tons... one test More than 30,000 tons... add one test for each additional 30,000-ton increment Documentation Document daily: observations of QV sampling, review of mix adjustments, QC/CA test results Acceptable Verification Parameters Va; within a range of 2.7 to 5.3 percent. VMA; within 1.5 of the minimum requirement for the mix design NMAS If QV test results are outside the above acceptable parameters, the engineer investigates immediately (using dispute resolution procedures). If production continues, the engineer provides additional Assurance testing until such time that the material meets the acceptable parameters or as the engineer and contractor mutually agree. Dispute Resolution The QV-ret sample and the nearest available previous QC-ret sample will be referee tested by the department s bureau of highway construction AASHTO accredited laboratory and certified personnel. Notification of referee test results will be within 2 working days after receipt of the samples. Referee test results, mixture project data, any inspection of the completed pavement will be analyzed according to the department s QMP guide/procedure manual. Corrective Action All unacceptable material will be removed and replaced Reduced payment for unsatisfactory mixtures (left in place) will be applied at 50 percent of the contract price for unacceptable air void content and 75 percent for unacceptable VMA. This payment adjustment includes both mixture and binder.

43 TOPIC F: WisDOT HMA Quality Management Program F-5 4 Key Elements : QC testing: based on day s production levels (contractor) CA testing: establish a point of production testing assurance (second party) QV testing: determine product quality (department) And. a Dispute Resolution Process Figure F-1. Verification Program

44 TOPIC G: Safety G-0

45 TOPIC G: Safety G-1 Project Safety Precautions Safety is of prime importance while serving your occupational duty on the Wisconsin Department of Transportation (WisDOT) construction projects. Approximately 15% of all accidents are caused by unsafe mechanical or physical conditions. The other 85% of accidents result from absentmindedness, negligence, or ignorance of risk. No mysteries should surround an accident. All personnel involved with the project must be able to identify potentially dangerous situations and be prepared for preventive corrective action. Diagnosis of Any Accident There are five key elements in the diagnosis of any accident. 1. The agency or source of the accident; the item(s) directly related to the accident. 2. The type of accident; manner in which the person(s) were injured. 3. The unsafe condition; unsafe practice of person(s). 4. The unsafe act; unsafe practice of the person. 5. The body part and type of injury Each contributing element should be carefully analyzed and reported so a plan of corrective action can be developed and carried out to prevent future unnecessary accidents. While conducting your occupational duties on your project remember to keep in mind the following considerations: Know Your Safety Officer 1. Emergency Phone Numbers 2. Nearest Hospital Location Safety Equipment 1. First Aid Kit 2. Fire Extinguishers 3. Fireproof Gloves 4. Eye Protection 5. Ear Protection 6. Hardhats 7. Safety Vest 8. Proper Ventilation Equipment Operators Always keep good eye contact with operators when working close to heavy equipment.

46 TOPIC G: Safety G-2 Material Safety Data Sheet (MSDS) The Material Safety Data Sheet (MSDS) identifies the product, hazardous ingredients, physical data, fire and explosion data, health hazard data, emergency and first aid procedures, reactivity data, spill or leak procedures, special protection information, and special precautions associated with the use of the chemical. Generally, the MSDS should be located nearest to the area where the chemical is being used or stored. Also, a MSDS master copy should be kept on file at the main office of the company or agency. For example, refer to figure G-1. Material Safety Data Sheet (BIOACT High Flash). WisDOT uses BIOACT High Flash for breaking down petroleum distillates from the coated asphalt particles in a Hot-Mix Asphalt (HMA) mixture. Effects of High Temperatures As an asphalt technician you may be faced with working in a high temperature environment. Working in high temperatures causes your body to work harder (increasing your heart rate) to cool off your body. The capillaries in your skin dilate to bring more blood to the surface so both the rate of cooling and the temperature of the body are increased. You need to be aware of three high temperature conditions which may be life threatening: Heatstroke (also known as sunstroke) occurs when the body is unable to cool itself. Symptoms are hot dry skin, severe headache, visual disturbances, rapid temperature rise, and loss of consciousness. Heat stroke is the most serious of the high temperature conditions. The victim should be removed from the high temperature environment immediately and the body should be cooled as quickly as possible (being wrapped in cool wet sheets). Professional medical help should be obtained as soon as possible. Heat cramps may result from exposure to high temperatures for a relatively long period of time, typically accompanied by heavy exertion with excessive loss of salt and moisture from the body. Heat cramps cause cramping of the muscles of either the skeletal system or the intestines. Heat Exhaustion may result from physical exertion in a high temperature environment. The body cannot react enough to cool itself. Symptoms of heat exhaustion consist of relatively low temperature, paleness, weak pulse, dizziness, profuse sweating, and a cool mist to the skin. Heat cramps and exhaustion may be treated with the use of salt tablets. Generally, an adequate supply of salt is provided by a well-balanced diet.

47 TOPIC G: Safety G-3 Carrying and Lifting An asphalt technician will constantly be exposed to carrying and lifting as part of sampling and testing duties. The general rules to lifting and carrying include: 1. Never permit personnel to overexert themselves when lifting or carrying. Keeps loads small by carrying or lifting smaller size samples. 2. Lift gradually, without jerking to minimize the effects of accelerated lifting. 3. Keep the load close to your body. 4. Lift without twisting your body. Hot-Mix Asphalt Safety Precautions The stored asphalt binder and the hot-mix asphalt on your project is generally heated to 290 F. Extreme caution and good judgment must be exercised while sampling and testing hot-mix asphalt materials. Mishandling of these materials may induce severe burns to workers leading to compensation and/or loss from occupational duties.

48 TOPIC G: Safety G-4 Figure G-1. Material Data Sheet (BIOACT High Flash) MATERIAL SAFETY DATA SHEET PETROFERMTM INC First Coast Highway Fernandina Beach, Florida (904) I. IDENTIFICATION Product Name: BIOACT High Flash Synonyms: CAS #: II. HAZARDOUS INGREDIENTS Weight OSHA PEL or Component Percent ACGIH TLV This product is non-hazardous as determined by the criteria set forth in appendices A and B of FR III. PHYSICAL DATA Boiling Point (760 mm Hg): 470 degrees 525 degrees F % Volatile (By Weight): Not determined. Specific Gravity (H2O = 1): 0.8 (25 degrees C) Vapor Pressure (20 degrees C): < 0.5 mm Hg Vapor Density (Air = 1): >1 Evaporation Rate (BUAC = 1): <1 Appearance and Odor: Water-white liquid, with a faint hydrocarbon odor. Solubility in Water: Emulsifiable. IV. FIRE AND EXPLOSION DATA Flash Point: 216 degrees F (ASTM D93-85, Pensky Martens Closed Cup Method). Flammable Limits (% By Volume in Air): 1.2% LEL.5.0%UEL Extinguishing Media: Water, alcohol foam, dry chemical, carbon dioxide. BIOACT is a registered trademark of Petroferm TM Inc. Special Fore Fighting Procedures: Selfcontained positive pressure breathing apparatus and protective clothing should be worn in fighting fires involving chemicals. Unusual Fire and Explosions Hazards: None known V. HEALTH HAZARD DATA SYMPTOMS/EFFECTS OF OVEREXPOSURE Inhalation: High vapor concentration may cause headaches and stupor. Ingestion: Low order of toxicity. Can cause irritation of the stomach and intestines resulting in nausea and vomiting. Skin: Repeated or prolonged contact with skin may cause irritation, reddening and dermatitis. Eyes: Contact with eyes will cause irritation. Listed Carcinogens: None. EMERGENCY AND FIRST AID PROCEDURES Inhalation: Remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Ingestion: Do not induce vomiting; seek medical attention. Skin: Remove contaminated clothing. Thoroughly wash affected area with soap and water; use skin cream if irritation is severe. Call a physician if irritation persists. Eyes: Immediately flush eyes with water for 15 minutes. Call a physician if irritation persists.

49 TOPIC G: Safety G-5 Figure G-1. Material Data Sheet (BIOACT High Flash) BIOACT High Flash VI. REACTIVITY DATA Stability: BIOACT High Flash is stable Conditions to Avoid: Temperatures above 525 deg F Incompatibility: Strong oxidizing agents. Hazardous Decomposition Products: None, other than normal products of combustion. Hazardous Polymerization: Will not occur. Conditions to Avoid: None known. IX. SPECIAL PRECAUTIONS Precautions to be taken in Handling and Storing: Store in original container, preferable in a cool, ventilated, fire-resistant building. Avoid overheating or freezing. Other Precautions: Since empty containers may retain product residues (vapor, liquid, or solid) all labeled precautions must be observed. VII. SPILL OR LEAK PROCEDURES Steps to be Taken if Material is Released or Spilled: Absorb spill with inert material, then place in chemical waste container. For large spills, dike for later disposal. Observe government regulations. Waste Disposal Method: Waste treat or incinerate used material in compliance with all applicable government regulations. VIII. SPECIAL PROTECTION INFORMATION Respiratory: Not normally required. Use NIOSH/MSHA approved respirator if ventilation is not sufficient. Ventilation: Mechanical (general) ventilation should have an airflow of 55 CFM. Clothing/Gloves: Solvent resistant gloves are recommended for al use with all industrial chemicals. Eye Protection: Safety glasses/goggles are recommended for use with all industrial chemicals. Other Protective Equipment: Eyewash facilities. X. ADDITIONAL INFORMATION Regulatory Status: None of the components of BIOACT High Flash appear on any of the EPA s lists of toxic or hazardous substances, or on the SARA 313 toxic chemicals list (40CFR372.65). Because of the low vapor pressure of the product, high vapor concentrations are not normally encountered. None of the ingredients obtained in the product are listed in the Threshold Limit Value and Biological Exposure Indices complied by the American Conference of Governmental Industrial Hygienists. All the components of this product ate listed on the TSCA inventory. Date: 01/31/92 We believe that the information contained herein is current as of the date of this Material Safety Data Sheet. Since the use of this information and of these opinions and the conditions of use of the product are not within the control of PETROFERM in., it is the user s obligation to determine the conditions of safe use of the product.

50 TOPIC H : Random Sampling Procedure H-0

51 TOPIC H : Random Sampling Procedure H-1 Random Sampling Sampling Hot Mix Asphalt At the beginning of each day, the contractor shall specify the anticipated tonnage to be produced. The frequency of sampling is then determined from the latest "Quality Management Program, Asphaltic Mixture specification. The anticipated tonnage shall be split into equal increments and a sample obtained randomly from each increment Refer to the latest copy of QMP specification to obtain the current required sampling frequencies. Example for Expected Production of 1900 Ton per Day: Number of Samples per day - 3 (per QMP specification) Increments = 633 tons (days production divided by required samples) Sample 1 - From 50 to 633 tons Sample 2 - From 634 to 1267 tons Sample 3 - From 1268 to 1900 tons The approximate location of each sample within the increments shall be determined by selecting random numbers from Table 1 of ASTM Method D-3665 according to the procedures in Sections 5.2 to 5.7 or by using a calculator that has a random number generator. The random numbers selected are used in determining when a sample is to be taken and shall be multiplied by the tonnage increments defined for the day. This number shall then be added to the final tonnage of the previous increment to yield the approximate total tonnage when the sample is to be taken. In allowing for plant start-up variability, this procedure calls for the first sample to be taken at 50 ton or greater per production day. Example 1: Required Tonnage Random No. Increments * + Final Sample Sample Range ASTM D-3665 Random No. Prev. Increm. Tonnage = = = 1682 This procedure is to be used for any number of samples per day. It is intended that the plant operator not be advised ahead of time of when samples are to be taken. If the plant operator is involved in records a Pb (%AC) to match up with the mix sample tonnage, then notification need not be earlier than 30 minutes prior to the mix sample being taken.

52 TOPIC H : Random Sampling Procedure H-2 RANDOM SAMPLING METHOD ASTM D 3665 Discussion and student problems will reference ASTM D 3665 method provided in the back of this section. STUDENT PROBLEM #1: 1) At the beginning of the day, the contractor told the QC person that they anticipated asphalt mix production of 2700 tons. Using the procedures in sections 5.2 to 5.7 and table 1 of ASTM Method D-3665, determine the following: a) Utilize the latest version of WisDOT section 460, Quality Management Program, Asphaltic Mixture specification to determine the number of random samples to be collected. b) Select the random numbers (obtain instructions from section 5.2 to 5.7, table 1, ASTM Method D-3665). Actual Sample No. 1 st Table No. 2 nd Table No. Line No. Column No. Random No. c) Determine the tonnage sampling plan. + Final Tonnage Tonnage Random Increment Ton Previous = Tonnage Sample No. Range Number X Random No. Increment Sampling

53 TOPIC H : Random Sampling Procedure H-3 RANDOM SAMPLING METHOD ASTM D 3665 STUDENT PROBLEM #2: 2. At the beginning of the day, the contraction told the QC person that they anticipated asphalt mix production of 1200 tonnage. Using the procedures in sections 5.2 to 5.7, and table 1, of ASTM Method D-3665 determine the following: a) Utilize the latest version of WisDOT section 460. Quality Management Program, Asphaltic Mixture specification to determine the number of random samples to be collected. b) Select the random numbers (obtain instructions from section 5.2 to 5.7, table 1, ASTM Method D-3665). Actual Sample No. 1 st Table No. 2 nd Table No. Line No. Column No. Random No. c) Determine the tonnage sampling plan. + Final Tonnage Tonnage Random Increment Ton Previous = Tonnage Sample No. Range Number X Random No. Increment Sampling

54 TOPIC H : Random Sampling Procedure H-4 RANDOM SAMPLING METHOD ASTM D 3665 STUDENT PROBLEM #3: 3. At the beginning of the day, the contraction told the QC person that they anticipated asphalt mix production of 3500 tons. Using the procedures in sections 5.2 to 5.7 and table 1 of ASTM Method D-3665, determine the following: a) Utilize the latest version of WisDOT section 460, Quality Management Program, Asphaltic Mixture specification to determine the number of random samples to be collected. b) Select the random numbers (obtain instructions from section 5.2 to 5.7, table 1, ASTM Method D-3665). Sample No. 1 st Table No. 2 nd Table No. Line No. Column No. Random No. c) Determine the megagram sampling plan. + Final Tonnage Tonnage Random Increment Ton Previous = Tonnage Sample No. Range Number X Random No. Increment Sampling

55 TOPIC H : Random Sampling Procedure H-5 Random Sampling A typical random numbers chart follows on the next two pages. Here is how you use it to select a random number. A. The area under the bell curve, the normal distribution curve is segmented into 1000 equal pieces. Each of these areas is represented by a 3 digit decimal number. The first number is.001, the 23 rd number is.023, the 552 nd number is.552, etc., and the last number is B. The chart is printed on two pages. You may combine them on one sheet for convenience. It is a good practice to alternate pages. Use the page on the left then the page on the right. For the next number use the page on the right then the page on the left. (You select these numbers by simply pointing at them with your fingers or a pencil, with your eyes shut. C. Point at a number. Write down the first number you ve selected. Assume it is This is the first number in the chart. Point again. Use the second half of the chart on the right. Write down the second number you ve selected. Assume it is This is the last number in the chart. D. The rows of numbers that go up and down (vertical) are the line numbers. There are 100 lines. Use the first two digits of our first number, which are 2 and 7 or 27. This identifies line 27. The rows of numbers that go across (horizontal) are the column numbers. There are 10 columns. Note that the first column number is 0. Use the first digit of our second number, 0.119, which is 1. This identifies the second column. Our random number is The key thought to remember when using this method for statistical sampling is It takes two numbers to get one number. E. There are nine exceptions to this procedure. Those exceptions are.001,.002,.003,.004,.005,.006,.007,.008, and.009. (The number is not in the chart). In the event that one of these numbers is selected in the pointing process, disregard that number and point at another. Student Question: What happens if you select in the pointing process? Answer: Use line 100.

56 TOPIC H : Random Sampling Procedure H-6 CHART OF RANDOM NUMBERS

57 TOPIC H : Random Sampling Procedure H-7 CHART OF RANDOM NUMBERS Continued

58 TOPIC H : Random Sampling Procedure H-8 This material explains in detail the WisDOT method for statistical sampling. This doesn t replace the AASHTO Standards (i.e. T-2, etc.) or the ASTM standards (i.e. D-3665, etc.) that are referenced in those AASHTO Standards. You can get a copy of the AASHTO Standards at: American Association of State Highway & Transportation Officials 444 N. Capitol Street, N.W. Suite 249 Washington, DC (202)

59 TOPIC I: Sampling Asphaltic Mixtures from Truck Box I-1 Video: Hot Mix Asphalt-Truck Box Sampling

60 TOPIC I: Sampling Asphaltic Mixtures from Truck Box I-2 Checklist for HMA Sampling Observe sample to be random by asking for documentation Observe sample to be representative Insure complete identifying/label information: Paving Contractor Type of Asphalt Mixture QV/QV-ret WisDOT Mix Design ID # State Project ID # Percent Binder (%AC) Date Daily Tonnage Sampled Previous QC Sple # Current Gsb Full name of sampler (and contact phone #) Obtain a copy of mixture loadout ticket Minimum sample size < 12.5mm (1/2 ) 70 LB 19.0mm -25mm (3/4 1 ) 100 LB > 37.5mm (1-1/2 ) 160 LB Separate trucks for QC & QV samples Expedite samples to the Regional Lab (same/next day) as there are specification requirements for completion of testing. Checklist for HMA Sampling Observe sample to be random by asking for documentation Observe sample to be representative Insure complete identifying/label information: Paving Contractor Type of Asphalt Mixture QV/QV-ret WisDOT Mix Design ID # State Project ID # Percent Binder (%AC) Date Daily Tonnage Sampled Previous QC Sple # Current Gsb Full name of sampler (and contact phone #) Obtain a copy of mixture loadout ticket Minimum sample size < 12.5mm (1/2 ) 70 LB 19.0mm -25mm (3/4 1 ) 100 LB > 37.5mm (1-1/2 ) 160 LB Separate trucks for QC & QV samples Expedite samples to the Regional Lab (same/next day) as there are specification requirements for completion of testing.

61 TOPIC I: Sampling Asphaltic Mixtures from Truck Box I-1 Truck Loading Procedures Proper truck loading procedure may help alleviate problems with segregation (typically consisting of larger-sized aggregate particles rolling down the side of the pile) of Hot- Mix Asphalt (HMA) during load-out. When loading HMA into a truck, a single dump will produce segregation of HMA material all around the inside edges of the truck box (refer to figure I-1, Single Dump Loading). Figure I-1. Single Dump Loading (Produces segregation all around the inside edges of the truck box) Figure I-2. Multiple Dumps (Minimizes the segregated area within the truck box) Using multiple dumps reduces the surface area exposed to segregation, which, in turn, minimizes the segregation problem. The multiple dumps should be made as close as possible to the front and rear and the final dump should be placed in the center (refer to Figure I-2, Multiple Dumps). Sampling From the Truck Box Sampling from a truck box is the contractor s responsibility. This sampling presents some safety hazards because it is necessary to climb atop the truck box and stand on the hot mixture while sampling. Special care should be exercised by the contractor (or his designated representative) as the sample is obtained to prevent falls or burns. Sample Device. The shovel or other approved sampling device shall be of such size and configuration that each increment of a sample can be obtained in one attempt without spilling or roll off. In order to satisfy this requirement with a flat bottom shovel, it is necessary to attach two to four inch vertical sides to the shovel. The total sample size is required to be enough material to meet the testing and retained requirements as set by the QMP. For guidance on amount of material needed see Topic Q (Procedure , page 4).

62 TOPIC I: Sampling Asphaltic Mixtures from Truck Box I-2 When the last batch has been dumped into the truck box, establish a reference point on the surface of the load, either at the high point if a conical shape exists or near the middle of the truck box if the surface shows no such conical shape. Then establish at least three incremental sample points about midway between the previously established point and the sides of the truck and equally spaced around the load (see sketch). At these sampling points, remove the upper two to three inches of mixture and then insert the sampling shovel or other approved device into the mixture to extract the sample increments and place increments in a sample container. The total sample for a 12.5 mm mix shall weigh at least 70 lb. X - Reference Point A - Sample Point B - Sample Point C - Sample Point Figure I-3. Sampling Plan for a Truck Box Sample Identification The contractor is responsible for procuring and splitting of samples. When the sample is an aggregate sample, it shall be split, placed in bags with plastic liners, and labeled as directed below. When a mixture sample is procured, it shall be quartered, placed in a bag and labeled as directed below. The label shall include: 1. Contractor 2. QC, QC-ret, QV, or QV-ret 3. State Project ID 4. Date 5. Sample Number 6. Type of Asphaltic Mixture 7. State Verification Mix Design Number 8. Percent Binder 9. Tonnage Sampled 10. Current G sb HTCP QC-ret Prj. ID : / 15 / 01 sple 4 3 E mm % AC 1,206 ton Figure I-4. Example of Sample Labeling

63 TOPIC J: Reduction of Asphaltic Mixtures to Testing Size J-0

64 TOPIC J: Reduction of Asphaltic Mixtures to Testing Size J-1 WisDOT METHOD OF REDUCTION OF HMA SAMPLES TO TESTING SIZE The entire sample in the containers shall be mixed and quartered on a clean, smooth, metal surfaced table. The quartering process shall proceed as follows: Note: Accumulative/total tons, representing mix design production is to be recorded on the QC data sheets. Reduction of HMA Samples to Testing Size For QC sample reduction the HMA sample in the containers is mixed and quartered. The quartering process shall then proceed as follows: Step 1. Quarter the sample into Test and Retained samples. Place entire sample on table, quickly re-mix and quarter to minimize temperature loss. Quarter the Test & Retained samples as shown on the sketched example. For 12.5mm mixes start with at least a total of 70lbs (32kg) of HMA (see Figure 3). Superpave Sample 70lbs (32kg) Diagonal quarters, as indicated on the sketch, shall be combined to form the Retained sample (A + C) and the Test sample (B + D). The Retained sample is bagged, labeled and stored in a safe dry place. The Retained samples may be tested using the Rule of Retained. The Test sample (B + D) is then further quartered for the specified tests. Continue the quartering process in Step 2 for the Test materials until individual samples are in the oven. Step 2. The 35 lbs (17 kg) of HMA material for testing, from Step 1, is to be further reduced for testing according to the following sketch (see Figure 4).

65 TOPIC J: Reduction of Asphaltic Mixtures to Testing Size J-2 Figure 5. MINIMUM TESTING SAMPLE SIZES NOTE: For QV (and some CA) samples: a Solvent Extraction Gradation (WisDOT 1560) isn t required, so when quartering, the skewed areas may be smaller in size but all four pieces are combined for the Rice Test (Gmm). Use of Alternative Quartering Devices (Quartermaster) Use of other devices to assist in the quartering procedures may be used with approval of the Department. The Quartermaster is one such device and may be used for the initial two splits of the HMA (to process the QC & QA split, as well as the QC Test & QC Retained split).

66 TOPIC K: AASHTO T K-0 Preparing and Determining the Density of Hot-Mix Asphalt (HMA) Specimens by Means of the Superpave Gyratory Compactor

67 TOPIC K: AASHTO T 312 K-1 Reference: Background of Superpave Asphalt Mixture Design and Analysis, National Asphalt Training Center, Demonstration Project 101, Publication No. FHWA-SA SUPERPAVE GYRATORY COMPACTION TEST EQUIPMENT The SGC (Figure K-1) is a mechanical device comprised of the following system of components: reaction frame, rotating base, and motor loading system, loading ram, and pressure gauge height measuring and recordation system mold and base plate Compaction Key Components of Gyratory Compactor height measurement reaction frame tilt bar control and data acquisition panel loading ram mold rotating base 13 Figure K-1. Superpave Gyratory Compactor The reaction frame provides a structure against which the loading ram can push when compacting specimens. The base of the SGC rotates and is affixed to the loading frame. It supports the mold while compaction occurs at an angle of 1.25 degrees, which is the compaction angle of the SGC. The electric motor drives the rotating base at a constant speed of 30 revolutions per minute.

68 TOPIC K: AASHTO T 312 K-2 Specimen height measurement is an important function of the SGC. By knowing the mass of material placed in the mold, the diameter of the mold, and the specimen height, an estimate of specimen density can be made at any time throughout the compaction process. The SGC uses a mold (Figure K-2) with an inside diameter of 150 mm and a nominal height of 250 mm. A base plate fits in the bottom of the mold to afford specimen confinement during compaction. Figure K-2. SGC Mold Configuration and Compaction Parameters

69 TOPIC K: AASHTO T 312 K-3 Significance and Use The compaction procedure for the Superpave method of mix design compacts asphaltic mixture into SGC specimens approx 5.75 (150mm) in diameter and approx 4.5 (115mm) in height. The SGC specimens are used to determine percent air voids, density and tensile strength ratio. 2 Place HMA sample in an oven for a 1 hour maximum at o F. in flat pan(s) to bring mix to compaction temperature 4 Load HMA mix (generally grams for WisDOT mixes) into the compaction mold(s) in 1 charge. Rotate the pan around the mold to avoid segregation Laboratory Equipment 1. Superpave Gyratory Compactor 2. Metal Spatula 3. Thermometer 4. 2 Compaction molds 5. 4 Specimen Protection Discs 6. Metal Trowel 7. 2 pans If the mix sample, after quartering, is still within the acceptable temperature range, for compaction, then further stabilizing of temperature in an oven is not required. 3 Place a specimen protection disc into the bottom of the pre-heated compaction mold(s). 5 With a spatula, lightly level the mix to be flat on the top. Place another specimen protection disc on top of the mixture.

70 TOPIC K: AASHTO T 312 K-4 6 Ensure the mixture is at a compaction temperature of F (132C 137 o C). 8 Perform compaction with a Superpave Gyratory Compactor and apply the specified number of gyrations on each SGC specimen (using Ndes from the mix design). removal of the bottom paper. 10 After extruding, cool all SGC specimens laying flat for a minimum of 1 hour and 45 minutes before conducting the bulk specific gravity test procedure. Refer to the section for AASHTO T166 (Bulk Specific Gravity of Compacted Bituminous Paving Mixtures Using Saturated Surface-Dry Specimens). 7 Load the gyratory compactor with the specimen (according to the manufacturer s instructions) 9 Extrude specimen and remove protection discs from each side of compacted SGC specimen and let cool. 11 Label each specimen Note: when handling very fine or tender mixtures it s recommended to extrude the compacted sample only partially and cool for up to 10 minutes before completely extruding and

71 TOPIC L: AASHTO T 166 (WisDOT Overview) L-0 Bulk Specific Gravity of Compacted SGC Bituminous Mixtures Using Saturated Surface-Dry

72 TOPIC L: AASHTO T 166 (WisDOT Overview) L-1 Significance and Use This test method covers the determination of bulk specific gravity (Gmb) and density of specimens of compacted bituminous mixtures. 2 Weigh each SGC specimen in air and record. (designate this weight as A). 5 Surface dry the specimen by blotting quickly with a damp towel and then weigh in air, and record (designated this weight as B). Laboratory Equipment 1. Water Bath 2. Water temp Control Device 3. Electronic Balance/Scale 4. Under Water Weigh Device 5. Timer 6. Damp Towel 3 Water bath temperature is to be maintained at 77F + 2F (24C-26C). 6 Perform Gmb calculation and calculate to three decimal places. (0.001) 1 Allow newly compacted SGC specimens to cool for a period of one hour not to exceed two hours. 4 Immerse the specimens in 77F + 2F (24C-26C) water bath for 3 to 5 minutes. Weigh in water, and record (designate this weight as C). Example: G G G mb mb mb Gmb = A B - C A B - C

73

74 TOPIC M: AASHTO T 209 (WisDOT Overview) M-0

75 TOPIC M: AASHTO T 209 (WisDOT Overview) M-1 Significance & Use The maximum specific gravity (G mm ) and density of bituminous paving mixtures is an important property whose values are influenced by the composition of the mixtures in terms of types and amounts of aggregates and bituminous materials. 1. It is used to calculate values for percent air voids in compacted bituminous paving mixtures. 2. It provides target values for the in-place compaction of paving mixtures. 3. It is essential when calculating the amount of binder absorbed by the internal porosity of the individual aggregate particles in a bituminous paving mixture. 1 Obtain the appropriate sample of asphaltic mixture. 2 After the G mm sample has been subjected to oven heating (mirror the G mb sample), thoroughly break up mixture so that particles of the fine aggregate portion are not larger than ¼ inch. A fan may be used to aid in the cooling process. 4 Add enough potable water, of 77 o F + 2F (24C- 26C) to completely cover the mix sample by approximately 1 inch (25mm). 5 With spatula stir to help release any trapped air. Laboratory Equipment 1. Vacuum Pycnometer 2. Manometer 3. Vacuum Pump 4. Thermometer 5. Water Bath 6. Protective Gloves 7. Weigh Pan 8. Large Flat Pan 9. Potable Water 10. Cooling Fan 3 Add asphaltic mixture to the dry precalibrated pycnometer flask. Weigh and record. 6 Ensure a small piece of fine wire mesh covers the exit hose of the pycnometer vacuum cover to minimize the possibility of fine material loss.

76 TOPIC M: AASHTO T 209 (WisDOT Overview) M-2 7 Apply vacuum for minutes once the internal pycnometer has reached less than 30 mm Hg. of vacuum pressure (maintain in a range ± 2.25, 25.5 to 30.0). 9 At the completion of minutes vacuum period, use caution to release the internal vacuum pressure slowly (mercury filled manomaters could explode through the end of the glass tube if done too quickly). 11 Allow the sample (temperature and pressure) to stabilize for a period of 10 minutes (+ 1 minute) 8 Agitate pycnometer flask approximately every 2 minutes during the vacuum period. 10 Add potable water of 77F + 2F (24C 26C) to fill the pycnometer flask by floating the container in the water bath, being careful not to introduce additional air bubbles. 12 Place the lid on pycnometer flask and carefully, slowly with even pressure, press lid so that excess water spurts out of the calibration port (this ensures the same amount of water is being compared to the water measured for the calibrated volume of the pycnometer).

77 TOPIC M: AASHTO T 209 (WisDOT Overview) M-3 13 Remove the pycnometer from the water bath and dry completely the outside perimeter of lid and pycnometer. Optional (provided the room temperature is being maintained between 70F - 80F ( 21C 27C) 12a. Next, place lid on pycnometer so that excess water spurts out of the calibration port. 10a. Add potable water of 77F + 2F (24C 26C) to fill the pycnometer flask to 1/16 inch below the pycnometer flask surface edge, being careful not to introduce additional air bubbles. 14 Weigh and record pycnometer flask, lid, water and asphaltic mixture. Example of Rice Test equipment setup: 11a. Let pycnometer flask, lid and HMA mixture stand for minute to stabilize temperature and pressure. 12a. Next, place lid on pycnometer so that excess water spurts out of the calibration port.

78 TOPIC M: AASHTO T 209 (WisDOT Overview) M-4 15 Prepare asphaltic mixture for dry back process. A dry back test is required to determine if the pores of the aggregates have been properly sealed with a bituminous film. The dry back procedure will measure any additional water, in grams, that has penetrated the seal of the bituminous film. The dry back is used to correct the G mm value. Weigh dry pan. 16 Drain water from the G mm asphaltic mixture by decanting over 75 m (No 200) sieve, cloth or paper towel. 17 Spread sample in pan to dry. A fan may be used to expedite the drying process. 18 Determine when the asphaltic mixture and pan are visibly free of standing water and begin weighing the asphaltic mixture and pan at 15 minute intervals. When the asphaltic mixture and pan reaches a constant weight of within 0.5 gram of the previous 15 minute weighing, record this as the final weight of pan and final saturated surface dry (SSD) weight on your worksheet. Perform G mm calculation (three decimal places to the right)

79 TOPIC N: WisDOT No Procedure, Asphalt Extraction Using Solvent N-0

80 TOPIC N: WisDOT No Procedure, Asphalt Extraction Using Solvent N-1 HMA Extraction Gradation Using Solvent WISCONSIN DEPARTMENT OF TRANSPORTATION DIVISION OF TRANSPORTATION SYSTEM DEVELOPMENT BUREAU OF TECHNICAL SERVICES MATERIALS MANAGEMENT SECTION 1. Scope Field Solvent Extraction Method for Determining the Aggregate Gradation of Asphaltic Mixture Samples WisDOT Test Method No December 14, This is a quick method to determine the gradation of the aggregate from an asphaltic mixture when the asphalt content of the mixture is known. 2. Apparatus 2.1 Pans (approximately 12 by 8 by 3 deep), bowls (approximately 10 quarts) or pails (approximately 10 quarts). 2.1 Balance shall be an electronic type with a 5-20 kg capacity and sensitivity to 0.1 g. 2.3 Solvent shall be a biodegradable, high flash and nontoxic asphalt extractant. 3. Procedure 3.1 Obtain a representative sample of the mixture. Note that the mixture sample size needs to be larger than the specified minimums required for the mixture aggregate size when determining the gradation (this is in order to account for the weight of the binder being washed out). Dry the sample for 10 to 20 minutes in an oven at 275 F + 20 F (124C 146C), weigh and record to the nearest 0.1 gram. RAP stockpile samples shall be heated until dry, approximately 30 to 60 minutes. 3.2 Determine the percent asphalt being added to the mixture at the time the sample was obtained (could be from the settings of the asphalt plant for plant produced mixtures) and record. For RAP stockpile samples, use the asphalt content shown for the RAP on the mixture design.

81 TOPIC N: WisDOT No Procedure, Asphalt Extraction Using Solvent N Place warm mixture in a pan, pail or bowl and cover with solvent (due to the flammability potential of the solvents, it s not recommended to heat the solvent prior to adding to the mixture sample). Gently agitate the sample, frequently, with a spoon or spatula. Keeping the sample warm during the soaking process will aid in extracting the binder from the aggregate. Continue to soak and agitate the sample for 15 to 30 minutes (30 to 60 minutes for RAP mixtures or RAP stockpiles samples). Note: Excessive soaking time in the solvent will require more water washes and will cause more smoking during the drying operation. 3.4 Decant the solvent, pouring over a No. 8 sieve nested over a No. 200 sieve. Dispose of the used solvent by an approved method. Add water, agitate and decant over the same sieves. Continue washing with water until the wash water is clear (straw). Material retained on either of the sieves is washed back into the sample. Decant off any excess water. Care should be taken to avoid the loss of particles. Note: It has been the Wisconsin experience that, on average, two full-strength solvent washes, before proceeding with the final water wash(es) will aid in extracting the binder from the aggregate when using RAP mixtures.

82 TOPIC N: WisDOT No Procedure, Asphalt Extraction Using Solvent N Dry the sample to a constant weight in an oven or on a hot plate. Stir the cleaned aggregate sample during the drying process to free trapped moisture. Avoid excessive temperature in the drying process. 3.6 Conduct a sieve analysis on the extracted aggregate (AASHTO Test Method T 27) in order to identify the gradation of the sample. 4. Calculation 4.1 Calculate the total dry weight of the aggregate as follows: Where: Wagg = Wmix * ( 1 (AC% / 100) ) Wagg = Total dry weight of the aggregate Wmix = Total dry weight of the mixture determined in section 3.1 AC% = Percent asphalt determined in section Calculate the gradation as required using the dry weight of aggregate (Wagg) as determined above. 5. Report 5.1 The results of the sieve analysis should be reported to the nearest 0.1 percent. NOTE: Field experience has demonstrated that High Flash solvent performs better applied to an asphaltic mixture sample that is warm. Always follow the specified pre-soaking and rinse conditions. Document anytime in which High Flash solvent is soaked other than the prescribed pre-soaking duration. Always comply with the specified test and safety procedures!

83 TOPIC O: Formulas, Calculations, and Worksheets O-0

84 TOPIC O: Formulas, Calculations, and Worksheets O-1 DESCRIPTION OF TERMS Term Identifier Description Air Voids V a or VTM total volume of the small air pockets between coated aggregate particles; expressed as a percentage of the bulk volume of the compacted paving mixture Voids in the Mineral Aggregate Effective Asphalt Content Voids Filled with Asphalt Aggregate Bulk Specific Gravity Aggregate Effective Specific Gravity Asphalt Binder Specific Gravity VMA P be VFA G sb G se G b the volume of inter-granular void space between the aggregate particles of a compacted paving mixture that includes the air voids and effective asphalt content; expressed as a percentage of the total volume of the compacted paving mixture the total asphalt content of the paving mixture less the portion of asphalt binder that is absorbed by the aggregate particles; expressed as a percentage of the total weight of the compacted paving mixture the portion of the VMA that contains asphalt binder; expressed as a percentage of the total volume of mix or VMA the ratio of the mass in air of a unit volume of aggregate, including permeable and impermeable voids, to the mass of an equal volume of water, both at the same temperature the ratio of the mass in air of a unit volume of aggregate, excluding voids permeable to asphalt, to the mass of an equal volume of water, both at the same temperature the ratio of the mass in air of a given volume of asphalt binder to the mass of an equal volume of water, both at the same temperature

85 TOPIC O: Formulas, Calculations, and Worksheets O-2 Mixture Bulk Specific Gravity Theoretical Maximum Specific Gravity of the Mix Volume of Absorbed Asphalt G mb G mm V ba the ratio of the mass in air of a given volume of compacted HMA to the mass of an equal volume of water, both at the same temperature the ratio of the mass of a given volume of HMA with no air voids to the mass of an equal volume of water, both at the same temperature. the volume of asphalt binder that has been absorbed into the pores of the aggregate STANDARD CONVENTIONS The following conventions are used to abbreviate binder, aggregate, and mixture characteristics: Specific Gravity (G): G xy x - y - b = binder s = aggregate (i.e., stone) m = mixture b = bulk e = effective a = apparent m = maximum theoretical Mass (P) or Volume (V) Concentration: P xy or V xy x - y - b = binder s = aggregate (i.e., stone) a = air e - effective a = absorbed (Note: standard conventions do not apply to V ba and P fa )

86 TOPIC O: Formulas, Calculations, and Worksheets O-3 FORMULAS AND CALCULATIONS: BULK SPECIFIC GRAVITY (G mb ) DETERMINATION G mb A B C Determine the Bulk Specific Gravity, G mb, for the following (calculate to three decimal places): Given: Weight in Air (A) = g Weight in Water (C) = g SSD Weight (B) = g MAXIMUM SPECIFIC GRAVITY (G mm ) DETERMINATION G mm A A B C Determine the Maximum Specific Gravity, G mm, for the following (calculate to three decimal places: Given: Dry Weight of Mix (A) = g Weight of Pot + Water (B) = g Weight of Pot + Mix + Water (C) = g

87 TOPIC O: Formulas, Calculations, and Worksheets O-4 CALCULATING AIR VOIDS The air void (%V a ) determination is a relationship between maximum specific gravity (G mm ) and bulk specific gravity (G mb ). Calculate to one decimal place. G Va,% - G mm G mm Calculate the percent V a (using the average G mb given). Calculation should be expressed to one decimal place. Given: G mb = G mm = mb 100 VOIDS IN MINERAL AGGREGATE, VMA, CALCULATIONS VMA is calculated using the aggregate bulk specific gravity, G sb, from the contractor mix design, the asphalt content (P b determined from the amount of asphalt being added at the time of sample), and the average SGC specimen bulk specific gravity, G mb, as follows (calculate to one decimal place: Note: Pb = Ps (or % stone) G mb x VMA P b G mb Ps,% or VMA G sb Gsb Determine the Voids in Mineral Aggregate, VMA, with the following data. (Calculate VMA to one decimal place.) Given: P b = 5.4 G mb = G sb = 2.742

88 TOPIC O: Formulas, Calculations, and Worksheets O-5 When a hot mix plant aggregate bin percentage is changed by five percent or more from the job mix formula, calculate the G sb as follows: Gsb P1 P P1 P2 G G PN P G N N *Where P is the component blend % and G is the component G sb Note: If the G sb =s of the interchange materials are essentially the same, do not recompute. AGGREGATE EFFECTIVE SPECIFIC GRAVITY, (G se ) In the G se calculation, the volume of the aggregate includes all the aggregate internal void spaces except those that absorb asphalt. Calculate to three decimal places. G se (100 - P 100 G mm b P - G ) b b Determine the G sa (Aggregate Effective Specific Gravity) of the mix design with the following (calculate to three decimal places): Given: P b = 5.40 (tank stick) G b = G mm = (daily avg)

89 TOPIC O: Formulas, Calculations, and Worksheets O-6 DETERMINATION OF PERCENT OF ASPHALT CONTENT (P b ) P b Gb 100 G mm G se G se G mm G b Determine the Percent Asphalt Content (P b ) of the mix design with the following (calculate to one decimal place): Given: G se = G b = G mm = (single test result) ADDITIONAL USEFUL FORMULAS Observe the effective specific gravity and the bulk specific gravity of the aggregate blend have been calculated, an estimate of the absorbed asphalt content (P ba ) can be made using the following equation: P ba 100 G se G G sb G se sb G b Understanding that the absorbed asphalt content is expressed as a percentage of the mass of the aggregate, an estimate of the effective asphalt content (P be ) of the HMA mixture can be made using the following equation: P be P b Pba Ps 100 ANSWERS TO PROBLEMS Page O-3: Bulk Specific Gravity = 2.422; Maximum Specific Gravity = Page O-4: Percent Air Voids = 4.9; Voids in Mineral Aggregate = 16.4 Page O-5: Aggregate Effective Specific Gravity = Page O-6: Percent Asphalt Content = 5.4

90 TOPIC O: Formulas, Calculations, and Worksheets O-7 DESIGN # Sple ID # MixType : Gmb : compacted Bulk SpGr A / (B - C) Gsb (design) Gse (current) Date : Spl ID Dry Wt (A) Wt Smrgd (C) SSD Wt (B) Vol (B - C) Gmb 1 2 Average Compaction Effort : Gmm (Pb) (Rice / Max SpGr) total % binder in Mix 1 Flask / Pot ID # Dryback (SSD) of Mix 2 Wt. of Flask + Mix Dryback PAN ID # 3 Wt. of Flask Minutes/Time Pan + mix A Dry Wt. of Mix (2-3) 0:00 = A1 * SSD Wt. of Mix (4-5) 15 D Wt. of Flask + Water 30 E Wt. of Flask + Water + Mix 45 F Gmm = A / (A+D-E) 60 G Gmm (w/ssd) = A / (A1+D-E) 75 4 Final SSD wt of Pan + mix Tare Wt. of Pan * Using Dryback Corr Factor Gmm corrected for reheat A1 = [(A*CF) / 100] + A 90 Solvent Extraction Gradation : wt Mix * [ 1 - (Pb / 100)] = wt Agg % Va wt of Mix sample = wt Agg = (Gmm-Gmb) / Gmm*100 Sieve Sizes Cumm wt retained % Retained % Passing 25.0mm - 1 " /4" / /8 % VMA # [Gmb * (100 - Pb) / Gsb] # # # # 50 % VFB # 100 (VMA - Va) / VMA * # 200

91 TOPIC O: Formulas, Calculations, and Worksheets O-8 DESIGN # Sple ID # Date : MixType : Gsb (design) Gmb : compacted Bulk SpGr A / (B - C) Gse (current) Spl ID Dry Wt (A) Wt Smrgd (C) SSD Wt (B) Vol (B - C) Gmb Compaction Effort : Ndes = 75 Gmm (Rice / Max SpGr) (Pb) total % binder in Mix 5.4 Average 1 Flask / Pot ID # 21 Dryback (SSD) of Mix 2 Wt. of Flask + Mix Dryback PAN ID # 3 Wt. of Flask Minutes/Time Pan + mix A Dry Wt. of Mix (2-3) 0:00 = A1 * SSD Wt. of Mix (4-5) 15 D Wt. of Flask + Water E Wt. of Flask + Water + Mix F Gmm = A / (A+D-E) 60 G Gmm (w/ssd) = A / (A1+D-E) 75 4 Final SSD wt of Pan + mix Tare Wt. of Pan * Using Dryback Corr Factor Gmm corrected for reheat A1 = [(A*CF) / 100] + A 90 Solvent Extraction Gradation : wt Mix * [ 1 - (Pb / 100)] = wt Agg % Va wt of Mix sample = wt Agg = (Gmm-Gmb) / Gmm*100 Sieve Sizes Cumm wt retained % Retained % Passing 25.0mm - 1 " /4" / / % VMA # [Gmb * (100 - Pb) / Gsb] # # # # % VFB # (VMA - Va) / VMA * #

92 TOPIC O: Formulas, Calculations, and Worksheets O-9 DESIGN # Sple ID # Date : MixType : Gsb (design) Gmb : compacted Bulk SpGr A / (B - C) Gse (current) Spl ID Dry Wt (A) Wt Smrgd (C) SSD Wt (B) Vol (B - C) Gmb Compaction Effort : Ndes = 75 Average Gmm (Rice / Max SpGr) (Pb) total % binder in Mix Flask / Pot ID # 21 Dryback (SSD) of Mix 2 Wt. of Flask + Mix Dryback PAN ID # 3 Wt. of Flask Minutes/Time Pan + mix A Dry Wt. of Mix (2-3) :00 = A1 * SSD Wt. of Mix (4-5) 15 D Wt. of Flask + Water E Wt. of Flask + Water + Mix F Gmm = A / (A+D-E) G Gmm (w/ssd) = A / (A1+D-E) Final SSD wt of Pan + mix Tare Wt. of Pan * Using Dryback Corr Factor Gmm corrected for reheat A1 = [(A*CF) / 100] + A Solvent Extraction Gradation : wt Mix * [ 1 - (Pb / 100)] = wt Agg % Va wt of Mix sample = wt Agg = (Gmm-Gmb) / Gmm*100 Sieve Sizes Cumm wt retained % Retained % Passing 25.0mm - 1 " /4" / / % VMA # [Gmb * (100 - Pb) / Gsb] # # # # % VFB # (VMA - Va) / VMA * #

93

94 TOPIC P: WisDOT Quality Control Charts P-0

95 TOPIC P: WisDOT Quality Control Charts P-1 Control Charts Control charts provide a means for the contractor to identify when corrections should be made during production. The plotted data, particularly those for the average values, show trends as they develop. As trends move toward the limits, the contractor will have advance warning to assess action options and correct the production process. Control charts do not identify the source of the process variability. When a contractor investigates an undesirable trend, it may be determined that something (an assignable cause) happened in the process that has caused the trend. An example may be when a hole develops in a sieve and increases in size with use. Ideally, the inferior sieve would be found and replaced with a suitable sieve before the process advanced to a point where test results would be out of specification. This latter condition may result in stoppage of the manufacturing operations and/or possible penalties to the contractor. Benefits of Control Charts Early Detection of Trouble Decrease Variability Establish Process Capability Reduce Price Adjustment Costs Decrease Inspection Frequency Basis for Altering Spec Limits Permanent Record of Quality Provide a Basis for Acceptance Instill Quality Awareness In reality, control charts, when properly used, should provide an early detection system for identifying potential trouble spots for the contractor. Obviously, the contractor should review control charts regularly to stay on top of the production process. Depending on the severity of the data or data trend being produced, the contractor may react by taking immediate corrective action or determine to monitor the process a while longer before deciding on a course of action.

96 TOPIC P: WisDOT Quality Control Charts P-2 When the moving average trend for any of the control chart values is towards the warning limits, the contractor shall consider corrective action. Corrective action shall always be documented. The corrective action undertaken may be to increase the sampling and testing rate, to inspect laboratory equipment, to inspect plant equipment, to initiate adjustments in controlling the process, and/or to change materials or quantities and combinations of these actions. In addition to documenting corrective actions, resulting effects of the corrective actions shall be recorded. When the moving average for any of the control chart values exceeds the warning limits, the contractor shall notify the engineer. This should be done immediately, as soon as the value is determined. If a second consecutive moving average value for a particular property exceeds the warning limits, the contractor will stop production and make adjustments. Corrective Action When any moving average value is trending towards the warning limits, the contractor shall consider correction action. When any single moving average value exceeds the warning limits (enters the warning band), the contractor shall notify the engineer. When a second consecutive moving average value exceeds the warning limits (in the warning band), the contractor will stop production and make adjustments. Note: Failure by the contractor to control the production process can be grounds for the material to be considered unsatisfactory. Quality through production control is the responsibility of the contractor. Any disregard by the contractor to attend to controlling the process or for making no effort to take corrective action, when warranted, is grounds for material to be considered unsatisfactory. Should the contractor encounter a situation, in which he/she is unable to get the process under control in a timely manner, consideration should be given to various alternatives. If the material is obviously defective or inferior, the contractor should not use the material on the project.

97 TOPIC P: WisDOT Quality Control Charts P-3 The following control chart legend is used: Upper Warning Limit - UWL Upper Warning Band - UWB JMF Target Band TB (area between Warning Limits) Lower Warning Limit - LWL Lower Warning Band LWB JMF Limit control limits (defines unacceptable property parameters) QC Individual Test Result QC Moving Average of 4 QC Non Random Test. QC-ret Individual Test Result... X UWB AIR VOID Chart JMF Limit UWL TB LWL LWB Test # JMF Limit 12

98 TOPIC P: WisDOT Quality Control Charts P-4 CONTROL CHART EXAMPLES AIR VOIDS UWB JMF Limit UWL TB X LWB Limit Test # LWL JMF EXAMPLE A: At test point 5 a trend of the running average toward the warning band has developed and the contractor should consider corrective action. At point 6 the contractor notifies the engineer that the first moving average is in the warning band. At point 7 the contractor notifies the engineer that the second consecutive moving average is in the warning band. At this point the contractor shall stop production and make adjustments. Production shall only be restarted after notifying the engineer of the adjustments made. In this example the moving average after four additional individual tests (point 11) is back within the target band.

99 TOPIC P: WisDOT Quality Control Charts P-5 Student Problem: WisDOT Quality Control Charts 1) Utilize the test data shown below, for the No. 8 (2.36 mm) sieve, calculate the moving (running) average of four for each test battery of data. The JMF target for the No. 8 (2.36 mm) sieve is 50.0%. Date Test 2.36 mm Ave (4) 8/01/ /02/ /03/ /06/

100 TOPIC P: WisDOT Quality Control Charts P-6 2) Set-up the attached control chart for the No. 8 (2.36 mm) sieve in accordance with the latest copy of the quality management program specifications: a) Establish and plot the upper and lower control limits (JMF Limits) b) Establish and plot the upper and lower warning limits. c) Plot and connect the individual contractor QC data points. d) Plot and connect the moving (running) average data e) Identify and explain the corrective action responsibility at test # 3-2 and 3-3. f) Identify and explain the corrective action responsibility at test # 4-1. g) Identify and explain the corrective action responsibility at test # 4-2.

101 TOPIC P: WisDOT Quality Control Charts P-7 Student Problem: ANSWER 1) Utilize the test data shown below, for the No. 8 (2.36 mm) sieve, calculate the moving (running) average of four for each test battery of data. The JMF target for the No. 8 (2.36 mm) sieve is 50.0%. Date Test 2.36 mm Ave (4) 8/01/ /02/ /03/ /06/

102 TOPIC P: WisDOT Quality Control Charts P-8

103 TOPIC Q: WisDOT QMP Guide / CMM 8-36 QMP-HMA Q-0 DISCLAIMER: Continuing changes in conditions, construction materials, and construction technologies require changes in specifications. This specification was current when printed. Effort is made to keep this manual as up to date as possible. Refer to your specific contract documents to ensure contract compliance. Access the Wisconsin Department of Transportation Doing Business website at for the latest version of the Construction and Materials Manual.

104 Construction and Materials Manual Chapter 8 Section 36 Materials Testing, Sampling, Acceptance QMP - HMA July 2014 Page 1 Wisconsin Department of Transportation Materials sampling and testing methods and documentation procedures prescribed in chapter 8 of the CMM are mobilized into the contract by standard spec and standard spec Hot Mix Asphalt (HMA) Quality Management Program sampling, testing, materials properties, and documentation as prescribed in CMM 8-36 are called into the contract by standard spec General This section addresses the standard specification for Quality Management Program (QMP), Asphaltic Mixture. The QMP for Hot Mix Asphalt (HMA) is detailed in standard spec The following information is provided as additional reference, interpretation, and guidance for procedures outlined in those specifications. Overview - WisDOT QMP Requirements: - Personnel and required certifications CMM and standard spec ) - Laboratory facilities (CMM and standard spec ) - Random sampling and sampling frequency (CMM and standard spec ) - Required testing (and calculated properties) (CMM and standard spec ) - Mixture bulk specific gravity (G mb ) - Mixture maximum specific gravity (G mm ) - Air voids (V a ) - VMA (voids in mineral aggregate) - Aggregate gradation - Percent binder content - Documentation (CMM and standard spec ) - Records - Control charts - Control limits (standard spec ) - Warning bands - Job mix formula adjustments (CMM and standard spec ) - Corrective action (standard spec ) - Optional contractor assurance (CMM and standard spec ) - Verification program (CMM and standard spec ) The following sections identify and further attempt to clarify procedures used during field production of HMA under the QMP Definitions Rule of Retained: Split samples for comparison testing are retained. In order to test a retained portion of any sample, communications must occur between the department and contractor QMP teams. The department has ownership of QMP required split samples. There is implied joint ownership between contractor and department on any additional QC samples recorded. Limiting Liability: Additional assurance testing can be performed to validate contractor production data. Identifies conforming material for consideration during the dispute resolution process in determining any need for price adjustments (does not exclude price reductions within contractor QMP). Mixture production days: Days of production of a specific design mixture being tested under QMP. No more than two working days is intended for getting test results. Working days: Calendar day, except Saturdays, Sundays, and department-specified holidays. Non-Conforming materials: Mixture not meeting acceptable verification parameters, but allowed to be left in

105 CMM 8-36 QMP - HMA place with appropriate payment reduction. Unacceptable materials: Mixture not meeting acceptable verification parameters and being required to be removed and replaced. Teams: Personnel listed on QMP organizational charts Personnel Requirements (Through HTCP) The following list summarizes minimum personnel requirements and associated certifications to satisfy QMP Asphalt activities. 1. QC: Production process - Sampling and testing: HMATech at a level recognized for mixture production testing (formerly known as HMATech 1). - Production process changes: HMATech at a level recognized for production process control and troubleshooting (formerly known as HMATech 2). - Mix design: at a level recognized for doing mix design work (formerly known as HMATech 3). 2. CA: Production assurance - Sampling and testing: HMATech at a level recognized for mixture production testing (formerly known as HMATech 1). - In the event other properties are being evaluated, have an appropriate certification. 3. QV: Department quality verification - Sampling and testing: at a level recognized for mixture production testing (formerly known as HMATech 1). - Production process change review: at a level recognized for doing mix design work (formerly known as HMATech 3) Laboratory Requirements The laboratory must be: - Furnished with equipment to comply with daily testing and communication requirements (calibrated testing equipment, phones, faxes, copy machines, etc.). - Located at the plant site and operational before production. - A Wisconsin Laboratory Qualification Program participant. Any laboratory producing air void test data to comply with QMP requirements must have a Superpave Gyratory Compactor (SGC). The intent is for the G mm and G mb materials to be tested at the same facility CA Laboratory A separate set of equipment must be used (inclusive of SGC) to compare QC split samples Sampling Hot Mix Asphalt At the beginning of each day the contractor determines the anticipated tonnage to be produced. The frequency of sampling (minimum number of required tests for the day s anticipated production) is defined by the latest (QMP) HMA mixture standard spec A test sample is obtained randomly from each sublot. Example 1 The approximate location of each sample within the prescribed sublots is determined by selecting random numbers using ASTM Method D-3665 or by using a calculator or computerized spreadsheet that has a random number generator. The random numbers selected are used in determining when a sample is to be taken and will be multiplied by the sublot tonnage. This number will then be added to the final tonnage of the previous sublot to yield the approximate cumulative tonnage of when each sample is to be taken. To allow for plant start-up variability, the procedure calls for the first random sample to be taken at 50 tons or greater per production day (not intended to be taken in the first two truckloads). Random samples calculated for July 2014 Page 2

106 0-50 ton should be taken in the next truck (51-75 ton). Example 2 CMM 8-36 QMP - HMA Required Sample Sublot Sample Tonnage Range Random No. ASTM D-3665 Sublot Sample Ton (Random No. x Sublot ton) End of Previous. Range Cumulative Sample Tonnage RN x 600= RN x 900= RN x 1200= This procedure is to be used for any number of samples per day. If production doesn t allow obtaining the next randomly generated sample, then an arbitrary sample will be taken whenever practical to fulfill the sampling frequency requirement defined in standard spec (5) (Document reasons for any non-compliance). Note: If this scenario occurs by definition this sample qualifies as being a random sample within the QMP program frequency requirements. It s intended that the plant operator not be advised ahead of time when samples are to be taken. If the plant operator is involved in recording a Pb (%AC) to match up with the mix sample tonnage, then notification need not be earlier than 60 minutes before the mix sample being taken. If belt samples are used during troubleshooting, the blended aggregate will be obtained when the mixture production tonnage approximates the sample tonnage. For plants with storage silos, this could be up to 60 minutes in advance of the mixture sample that s taken when the required tonnage is shipped from the plant. QC Sample: CA Sample: QV Sample: - Sample size only requires one test portion and one retained portion. - Must be a companion/split sample with QC (for direct data comparison). - If an arbitrary CA sample is taken, the QC team must test the companion split in order to be considered for limiting liability. - Must be directly observed by the engineer. - Engineer takes immediate possession. - The initial split of QV and QV-retained, can be performed by using a quartermaster. If the contractor performs this split, the engineer, before taking possession, must directly observe it Sampling from the Truck Box Sampling will be the contractor's responsibility. Truck box sampling presents some safety hazards because it is necessary to climb atop the truck box and stand on the hot mixture while sampling. Special care should be exercised by the contractor or his designated representative as the sample is procured to prevent falls or burns. A shovel or other department approved sampling device should be of such size and configuration that the sample can be obtained without spilling or roll off. Note: To satisfy this requirement with a flat bottom shovel, it is necessary to attach 2- to 4-inch vertical sides to the shovel. July 2014 Page 3

107 CMM 8-36 QMP - HMA Sample Location in Truck Figure 1 Truck Box Sampling When the last batch has been dumped into the truck box, the sampler must establish a reference point on the surface of the load, either at the high point, if a conical shape exists, or near the middle of the truck box if the surface shows no such conical shape. Then at least three incremental sample points should be established about midway between the previously established point and the sides if the truck and equally spaced around the load as seen below in Figure 1. The sampling shovel or other approved device can be inserted into the upper two to three inches of mixture to extract the sample increments QC Sample Sizes: - Minimum sample sizes are referenced below and are guidance for meeting requirements for test completion. Mixture NMAS Sample Size < 12.5mm (1/2") 70 lb 19.0mm mm (3/4" 1") 100 lb > 37.5mm ( 1-1/2") 160 lb - The total sample for larger NMAS (nominal maximum aggregate size) mixtures will be enough to provide the required minimum testing sample size as defined in Figure 3. - The retained split must be half of the QC sample CA Sample Sizes: Test sample size may vary based on the tests chosen, but still needs to be large enough to accommodate a split for parallel testing and data comparison QV Sample Sizes: Use same guidance as QC sample size (trouble shooting may involve need for a gradation) Sample Identification The contractor is responsible for obtaining and splitting samples. When the sample is an aggregate sample it must be split, placed in bags with plastic liners, and labeled as directed below. When a mixture sample is procured, it must be quartered, place in a bag, and labeled as directed below. Figure 2 provides an example label. The label must include the following items. 1. Contractor Testing Lab and Certified Technician Name 2. QC, QC-ret, QV, QV-ret 3. State project ID 4. Date 5. Sample number 6. Type of asphaltic mixture 7. State mix design ID (250-XXXX-YR) July 2014 Page 4

108 CMM 8-36 QMP - HMA 8. Percent binder 9. Daily tonnage sampled 10. Current G sb Figure 2 Example of Sample Labeling NOTE: The cumulative/total tons representing mix design production are to be recorded on the QC data sheets Reduction of HMA Samples to Testing Size For QC sample reduction the HMA sample in the containers is mixed and quartered. The quartering process should then proceed as follows: Step 1: 1. Quarter the sample into Test and Retained samples. Place entire sample on table, quickly re-mix and quarter to minimize temperature loss. Quarter the Test & Retained samples as shown on Figure 3. For 1/2" mixes start with at least a total of 70 lbs of HMA. Figure 3 Superpave Sample, 70 lbs 2. Diagonal quarters, as indicated on the sketch, must be combined to form the retained sample (A + C) and the test sample (B + D). The retained sample must be bagged, labeled, and stored in a safe dry place. The retained samples may be tested using the rule of retained (see Definitions section). 3. The test sample (B + D) is then further quartered for the specified tests. Continue the quartering process in Step 2 for the test materials until individual samples are in the oven Step 2: The 35 lbs of HMA material for testing from Step 1 is to be further reduced for testing according to the following sketch (see Figure 4). July 2014 Page 5

109 CMM 8-36 QMP - HMA Figure 4 Superpave Sample, (35 lbs) Figure 5 Minimum Testing Sample Sizes For QV (and some CA) samples a Solvent Extraction Gradation (WisDOT Test Method1560) isn t routinely required Use of Alternative Sampling / Quartering Devices (ex: Quartermaster) Use of other devices to assist in the sampling and quartering procedures may be used with approval of the department. The Quartermaster is one such device. A picture of a Quartermaster device is shown in Figure 6. Figure 6 Quartermaster Quartering Device July 2014 Page 6

110 CMM 8-36 QMP - HMA Example Required Testing and Calculated Properties Note: If calculations result in a need to round from an exact half (x.x50), round even. Example: becomes 14.2 and becomes QC Tests QC testing must be completed, and data posted, on the day the sample was taken or as approved by the engineer. For administration of projects requiring only one, two, or three single tests per mix design, apply the following tolerances table for mixture evaluation: - Va = % - VMA = from required minimums for Table AC = within 0.34 of JMF For results not meeting the above ranges, apply pay in accordance with the Produced Outside JMF Limits guidance listed in standard spec (6) CA Tests CA tests, by definition in the standard specifications, are at the contractor s option. A failure to limit liability of one tested property does not jeopardize the limiting liability of all properties. It should be noted that CA testing not completed before department QV samples are taken might not impact recommendations made during dispute resolution unless other communications have occurred between QC/QV teams. The contract language mentions two working days after the sample has been obtained by the contractor as the time within which the CA personnel must respond with data to the QC team. The intent is to provide information and feedback to the QC team as soon as practical in case there is data disagreement. The interpretation is to mean that the time starts when the QC team procures the sample (ex: a QC/QC-ret sample obtained on day 4 and intended to be tested, would need to be selected by CA on day 4, 5 or 6, with results reported no later than day 6). If the QC-retained mixture sample temperature is 230F or higher when delivered to the testing facility, quartering may start immediately. If the temperature is below 230F, place in a 300F oven, until workable for quartering, not to exceed two hours. Microwaves are not to be used to reheat an HMA sample. If the difference between the QC and CA test results are outside the allowable differences, the reason must be investigated immediately CA Data Analysis CA test results are evaluated according to the flow chart Evaluation of CA Test Results, located at the end of this procedure QV Tests The following tests are to be performed in determining product Quality Verification: -Bulk specific gravity of the mixture (G mb per AASHTO T 166) -Maximum specific gravity of the mixture (G mm per AASHTO T 209) -Air voids (Va per AASHTO T 269, calculation) -Voids in the mineral aggregate (per AASHTO R 35, using current field G sb ) July 2014 Page 7

111 CMM 8-36 QMP - HMA WisDOT Test Method No (Revised ) Scope 1. This is a quick method to determine the gradation of the aggregate from an asphaltic mixture when the asphalt content of the mixture is known Apparatus 1. Pans (approximately 12 by 8 by 3 deep), bowls (approximately 10 quarts) or pails (approximately 10 quarts). 2. Balance must be an electronic type with a 5-20 kg capacity and sensitivity to 0.1g. 3. Solvent must be a biodegradable, high flash and nontoxic asphalt extractant Procedure 1. Obtain a representative sample of the mixture. Note that the mixture sample size needs to be larger than the specified minimums required for the mixture aggregate size when determining the gradation (this is in order to account for the weight of the binder being washed out). Dry the sample for 10 to 20 minutes in an oven at 275 F ± 20 F (124C 146C), weigh and record to the nearest 0.1 gram. RAP stockpile samples must be heated until dry, approximately 30 to 60 minutes. 2. Determine the percent asphalt being added to the mixture at the time the sample was obtained (could be from the settings of the asphalt plant for plant produced mixtures) and record. For RAP stockpile samples, use the asphalt content shown for the RAP on the mixture design. 3. Place warm mixture in a pan, pail or bowl and cover with solvent (due to the flammability potential of the solvents, it s not recommended to heat the solvent prior to adding to the mixture sample). Gently agitate the sample, frequently, with a spoon or spatula. Keeping the sample warm during the soaking process will aid in extracting the binder from the aggregate. Continue to soak and agitate the sample for 15 to 30 minutes (30 to 60 minutes for RAP mixtures or RAP stockpiles samples). Note: Excessive soaking time in the solvent will require more water washes and will cause more smoking during the drying operation. 4. Decant the solvent, pouring over a No. 8 sieve nested over a No. 200 sieve. Dispose of the used solvent by an approved method. Add water, agitate and decant over the same sieves. Continue washing with water until the wash water is clear (straw). Material retained on either of the sieves is washed back into the sample. Decant off any excess water. Care should be taken to avoid the loss of particles. Note:It has been the Wisconsin experience that, on average, two full-strength solvent washes, before proceeding with the final water wash will aid in extracting the binder from the aggregate when using RAP mixtures. 5. Dry the sample to a constant weight in an oven or on a hot plate. Stir the cleaned aggregate sample during the drying process to free trapped moisture. Avoid excessive temperature in the drying process. 6. Conduct a sieve analysis on the extracted aggregate (AASHTO Test Method T 27) in order to identify the gradation of the sample Calculation 1. Calculate the total dry weight of the aggregate as follows: Wagg = Wmix * (1-(AC%/100)) July 2014 Page 8

112 Where: Wagg = Total dry weight of the aggregate CMM 8-36 QMP - HMA Wmix = Total dry weight of the mixture determined in section 3.1 AC% = Percent asphalt determined in section Calculate the gradation as required using the dry weight of aggregate (Wagg) as determined above Report 1 The results of the sieve analysis should be reported to the nearest 0.1 percent. 2 Field experience has demonstrated that high flash solvent performs better when applied to an asphaltic mixture sample that is warm. Always follow the specified pre-soaking and rinse conditions. Document anytime in which high flash solvent is soaked other than the prescribed pre-soaking duration. Always comply with the specified test and safety procedures HMA Compaction - AASHTO T Preheat specimen molds (charging funnels, spatulas, etc.) to 300F. 2. Heat sample, in an open container, to a compaction temperature of 275F + 5F in an oven between 285F 320F for no more than 1 hour. If binder modifiers or additives are used, compact to the supplier s temperature recommendations. After quartering to test size, if the mix sample is within the proper compaction temperature range, then the specimen can be compacted without further heating. 3. Place specimen protection disc into the bottom of the mold and charge the mold with the mix sample. The sample size should be enough to attain a final specimen height of 115mm + 5mm and is unique to the mix design. For Wisconsin aggregates and designs a range of g is generally appropriate. Charging the mold should be accomplished in one lift action or motion so as to avoid segregating the sample inside the mold. Additional funnels or scoop chutes may be used in order to accomplish this. 4. Lightly level off the top of the sample and place a specimen protection disc on top. 5. Load the mold into the SGC and compact to the appropriate N des for the mixture type being produced by applying 600kPa 18kPa, at an internal angle of After compaction is completed the specimen is extruded, protection papers removed, the briq is labeled, and cooling by fan is required for a period of 1 hr, not to exceed 2 hrs. If the mixture is extremely fine or tender, then the initial 5-10 minutes of cooling should take place while the specimen is only partially extruded to aid in handling. 7. Height measurements should be recorded and retained with each specimen. 8. Reheat the mold for a minimum of 5 minutes if reusing for the second specimen. All SGCs being used for QMP specimen preparation will conform to the requirements for calibration as listed in the departments Laboratory Qualification Program. Recalibration may be necessary if the testing variation between labs exceeds allowable differences or when a continued bias exists in the data attributed to the preparation of the specimen Bulk Specific Gravity (G mb ) AASHTO T 166 Determine bulk specific gravity, G mb, using AASHTO T166. Weigh the specimens in air and record (designated this weight as A). - Immerse the specimens in 77 2F water bath for 3 to 5 minutes. - Weigh in water, and record (designating this weight as C). - Surface dry the specimens by blotting quickly with a damp towel and then weigh in air (include any water that may drain from voids in specimens), and record (designating this weight as B). - Calculate the G mb to three decimal places (0.001). Determine the average bulk specific gravity for both specimens. If one of the individual specimens deviates by more than ±0.015 from the average, results are considered suspect and a new set of specimens is to be compacted from the contractor retained sample (following the rule-of-retained). If a or greater variability exists between QC and reheated samples (matching QC-retained portion), then a G mb Reheat Correction Factor is to be determined to aid in troubleshooting. G mb Reheat Correction Factor (Calc d to 0.001) = G mb (Un-reheated) / G mb (Reheated) July 2014 Page 9

113 CMM 8-36 QMP - HMA Then apply the correction factor to the reheated sample by: Corr G mb = G mb (Reheated) When comparing the uncorrected G mb to the corrected G mb, if the difference is less than 0.005, then the correction factor will not be used Maximum Specific Gravity of the Mixture (G mm ) - AASHTO T 209 Determine maximum specific gravity, G mm, using AASHTO T Use the appropriate sample size Figure 5. - Subject the G mm sample to the same heating condition and time period as the G mb material. - Begin to cool the sample. While sample is cooling, break up sample to pieces no greater than ¼, and continue to cool to an ambient room temperature. - Place material into a calibrated container and determine the actual dry weight of the sample. - Add 77F water to cover the sample. - Apply required vacuum for minutes, agitating material every 2 minutes minimum. - After the vacuum time period, completely fill the container with 77F water and determine the volume of the sample. - Bowl Method: by suspending the container underwater and weighing - Flask Method: by weighing the container filled with water and sample (in air). - Correct the G mm with a dryback test procedure or by applying a dryback correction factor if aggregates have a moisture absorption of > 2.0% (see next subsection). - Calculate the G mm to three decimal places, Dryback Procedure (Corrected G mm ) for Absorptive Aggregates (AASHTO T 209, Supplemental Procedure for Porous Aggregates) - Run a dryback procedure on Day 1-Sample 1, and determine a dryback correction factor for that test. Average the test dryback correction factor with the design JMF dryback correction factor and apply to the test data for a new G mm. If the new average correction factor changes the G mm by less than then use the design JMF dryback correction factor until otherwise determined by additional testing. - Run a dryback procedure every other day of production on the first test sample, or any time there is a change in binder content greater than 0.1%, or a change in component blend percentages greater than 10% (or 20% combined), using the same averaging method as above to validate the original design JMF dryback correction factor. - If any average dryback correction factor changes the G mm by more than 0.010, check for math or testing error first, otherwise a new dryback correction factor must be established by running drybacks on the next three samples. Average the new dryback correction factors and establish that average as the new JMF dryback correction factor. - If a or greater variability exists between QC and reheated samples (matching QC-retained portion), then a G mm reheat correction factor is to be determined to aid in troubleshooting. It should be calculated to G mm Reheat Correction Factor = G mm (Un-reheated) / G mm (Reheated) - Then apply the correction factor to the reheated sample: Corrected G mm = G mm (reheated) * correction factor. - When comparing the uncorrected G mm to the corrected G mm, if the difference is less than 0.005, then the correction factor will not be used Air Voids (%V a ) AASHTO T 269 The air void (%V a ) determination is a relationship between maximum specific gravity (G mm ) and bulk specific gravity (G mb ). Calculate to one decimal place. July 2014 Page 10

114 CMM 8-36 QMP - HMA Voids in Mineral Aggregate (VMA) VMA is calculated using the aggregate bulk specific gravity, G sb, from the contractor mix design (unless a blend change has occurred in which case a new Gsb will be calculated), the asphalt content (P b determined by ), and the average SGC specimen bulk specific gravity, G mb, as follows (calculate and record to 0.1.): 100 P b = P s (or % stone) Aggregate Effective Specific Gravity, (G se ) In the G se calculation, the volume of the aggregate includes all the aggregate internal void spaces except those that absorb asphalt. Calculate and record to three decimal places (0.001). Where: - G mm = end of previous days average. - P b = end of previous days tank stick. - G b = binder specific gravity from the mix design. Calculate this G se at the beginning of each day and use that value for current day s calculations. If there is a change in binder content then recalculate a new G se with the next available sample (consider it being nonrandom) and average with the previous G se : Where: - G mm = current sample test result. - P b = reflecting the intended change (assumed). - G b = from the mix design. A change in binder source or grade requires a check of the G b Percent of Asphalt Content (Pb) Option is to use a plant gauge reading method and record and chart the Pb reading as close to representing the sample as possible. When calculating the Pb (an additional option for record and charting) use the following equation: Where: - G mm = current sample test result. - Gse = previous day. - G b = mix design. Pb method selected should be used consistently to chart and calculate any related mixture properties for project. Plant gauge readings may involve a calibration procedure and use of a correction/correlation factor. July 2014 Page 11

115 CMM 8-36 QMP - HMA Additional Formulas and Example Calculations 1. Determining the asphalt absorption, P ba, for the following: Given: G se = G sb = G b = Determining the effective asphalt content, P be, of the asphaltic mixture for the following: Given: P b = 5.3 P ba = 0.8 P s = Determining the percent voids filled with asphalt (VFA) for the following compacted mixture: Given: VMA = 14.4 V a = Determining the dust to binder ratio (or DP: Dust Proportion): Given: Pbe = 4.5 % passing = Field Adjusted JMF The JMF may be adjusted in the field based on production test results according to the procedures in WisDOT method When the JMF asphalt content is changed by 0.2% or more (start new running average for G mm ), the compaction target maximum density for the day of the target change can be calculated using the most recent G se and percent asphalt binder (P b ) for the new JMF and G b (binder specific gravity) at 77/77 F from the mix design Field TSR Tests The tensile strength ratio is determined according to the procedures in ASTM Method D After manufacturing the specimens at the plant, they may be tested in an offsite laboratory. Use distilled water for saturating and soaking the test specimens RAP Sampling And Testing The requirement for aggregate gradation testing prior to incorporation to the mix has been eliminated. July 2014 Page 12

116 CMM 8-36 QMP - HMA RAM Stockpile Samples The minimum test sample size must be determined from extracted aggregate gradation size per AASHTO T164. That has been divided into aggregate gradation numbers as follows: Nominal Max Size (mm) Minimum Weight of Test Sample (grams) When test results indicate that a change has occurred in the RAM asphalt content, a change in the design RAM asphalt percentage may be requested by the contractor or the engineer. The request will include at least two recent RAM extractions and also identify all applicable mix designs to be affected. For each affected mix design a new Pbr (Percent binder replacement will be calculated and reported). The requested change will be reviewed for the department by an HTCP Certified HMA Technician at a level recognized for mix design, and a revised JMF can be issued HMA Quality Management Program Documentation The contractor is responsible for documenting all observations, records of inspection, and test results on a daily basis. Results of observations and records of inspection must be noted as they occur in a permanent field record. The testing records and control charts must be available in the QC laboratory at the asphalt plant. The contractor must maintain standardized control charts. Test results obtained by the contractor must be recorded on the control charts the same day the tests are conducted. The aggregate gradation test data must be recorded on the standardized control charts for all randomly selected production samples tested. Sieve sizes for aggregate gradation tests must include the maximum aggregate sieve size, the NMAS sieve, and any following sieves falling below: 1" (25.0mm), 3/4"(19.0mm), 1/2"(12.5mm), 3/8"(9.5mm), # 4 (4.75mm), #8(2.36mm), # 16 (1.18mm), # 30 (600μm), # 50 (300μm) # 100 (150μm) and # 200(75μm) Documentation QC Records In addition to the requirements of the Records subsection of the standard specification, the contractor must provide: - A cumulative tonnage value to the engineer on a daily basis. - Random number generation results and associated tonnage for QMP sampling - Binder Inventories (inclusive of incremental tonnages used to calculate binder usage for test samples and documentation validating calibration checks) - When submitting charts and running average calculation sheets the contractor mix design ID and WisDOT 250 report number must be included on each sheet. Full name of qualified sampler, tester and qualified lab locations should be on individual sample test property worksheets. - Blend change history - Individual sample test property worksheets (Note: More detailed information may be requested or observed during actual production for evaluation purposes. In order to verify compliance with appropriate test procedure requirements, this information needs to be made available during that on-site evaluation). Records should be the original (handwritten or electronic) documents. However, the original source documents should be maintained in the project records. If the data is entered directly into an electronic document then that is acceptable as the source document. If the original document is handwritten and then transferred to an electronic document, the original handwritten document should be maintained as the source document. When supplying the original "source" document, a scanned copy is acceptable. Electronic documents are considered to be acceptable during construction, but the original documents need to be submitted after project completion for final project closeout CA Records When CA testing is completed a CA worksheet is filled out and sent to the QV team. Results from CA testing are posted on the QC charts for the appropriate property. The CA data point should be represented by a unique symbol (ex: blue X ). July 2014 Page 13

117 CMM 8-36 QMP - HMA QV Records Results of QV testing are posted to the appropriate QC charts for air voids and VMA and represented with a unique symbol (ex: red "X") Quality Verification Program Monitoring Contractor QMP Pre-Construction The QV team is responsible for obtaining the following information: - Obtain WisDOT test number of the quality test report for the aggregate source being used. If source quality testing hasn t been completed, notify the department s Bureau of Technical Services laboratory. - Obtain the WisDOT test number of the mix design intended for use or a copy of the contractor's mix design, the review report, if available, from department s Materials Tracking system, and any contract special provisions. - Verify that the QC team personnel have the proper certifications. - Verify that the QC Laboratory facility is WisDOT qualified and has the equipment required by the QMP specification (inclusive of communication devices). Review any procedures for determining reheat correction factors and for the G mm dry back correction factor (if applicable). Discuss any necessary calibrations, or pending recalibrations, for the gyratory compactor and what procedure will be used During Production During production, the QV team should, as often as they feel necessary: 1. Random Sampling: - Check the QC procedures for proper random number generation for all samples. - Verify the QC team is aware they are not to inform the plant before the random sampling will occur. 2. Samples: - Ensure all required samples are being taken for mixture properties and blended aggregate gradations. - Ensure that proper sampling and splitting procedures are being used and the field sample size is large enough to accomplish required testing. - Ensure that stockpile samples are taken and tested for reclaimed asphaltic pavement (RAP) when applicable. - Ensure tensile strength ratio (TSR) tests have been conducted at proper intervals when using anti-stripping agents. - Ensure that the retained samples (mix and blended aggregate) are properly labeled and stored in a dry protected area. 3. Testing: - Observe the reduction of the field samples to test size. - Observe the testing procedures paying attention to temperature of test samples before compaction, compaction efforts, times allotted between tasks, dry backs, etc. - Review data calculations. 4. Control charts: - Check to see that required control charts are present and up to date. - Check to see that control limits and warning bands are accurately drawn. - Check to see that the proper values are being plotted correctly. 5. Documentation: - Check to see that records of compliance are being documented and are up to date. - Check to see that adjustments to mixtures and JMF changes are noted on field records. - Check to see that records have been provided to the QV team on a daily basis Verification Sampling Product quality verification sampling is the responsibility of the department s QV team. July 2014 Page 14

118 CMM 8-36 QMP - HMA Design Mixtures Samples from the truck box will be taken by a member of the contractor QC team, and directly observed by the QV team member. In addition, if the initial split (QV / QV-retained) is performed by the contractor, it is also to be directly observed by the QV team member. The QV team will determine and document the random sampling procedure employed for mixture verification samples. Any or all of the following methods may be used: - Production tonnage. - Specific week during production. - Specific day-of-the-week during production. - Time-of-day. If some other method is used, it should be mutually agreed upon between the QV and QC teams and documented before taking place. The contract language specifies two mixture production days after the sample has been obtained by the contractor as the time within which the QV personnel must respond to the QC team relative to the agreement of data results. The intent is to provide information and feedback to the QC team as soon as practical in case there is data disagreement and the potential need to stop mix production. If the QV mixture sample temperature is 230 degrees F or higher when delivered to the testing facility, quartering may start immediately. If the temperature is below 230F, place in a 300F oven, until workable for quartering, but not to exceed two hours. Microwaves are not to be used to reheat an HMA sample Determining Acceptable Verification Parameters Whenever a flag has been raised by disagreement of QV test results with the defined acceptable parameters, immediate investigation will occur using additional testing, troubleshooting, and dispute resolution actions Additional Testing WisDOT s Bureau of Technical Services laboratory is to test QV-retained and nearest available backward QCretained sample. Example 4 A QV sample taken after QC test 5-3 falls outside acceptable parameters. The WisDOT BTS lab tests retained portion of non-compliant QV sample, along with QC-ret sample 5-3. If that retained sample doesn t exist, the next nearest backward sample is 5-2, etc. If there are no backward retained QC samples, then liability for that mixture may include back to production start-up. The QV team is to provide QC retained split sample testing on the nearest any forward QC sample as soon as practical, and continue at a minimum frequency of 1 in 10 until the QC and QV team mutually agree that the problem has been solved in a forward direction. If comparison testing is being performed by the department to resolve a dispute as demonstrated in CMM , acceptable verification parameters for air voids and VMA will both be determined unless otherwise mutually agreed on by the contractor and the engineer to focus on the material property in dispute (ex. G mm, VMA, etc.). This is to allow something other than a full set of testing when trying to resolve a dispute focused on one testing parameter. In addition, when the QV team is back on the site to obtain the additional QC-retained samples, another QV sample will be taken. Example 5 The QV sample taken after QC test 5-3 falls outside acceptable parameters. The QV team returns to the plant site on day 7 and obtains QC-ret sample 5-4 for testing, QC-ret 5-3 to send to the WisDOT-BTS lab, and directs a new QV sample be taken representing day Troubleshooting The following points are to be considered and re-checked: - Calculations. - QC data trends. - Any CA testing trends or bias. - Equipment calibration records. July 2014 Page 15

119 CMM 8-36 QMP - HMA - Sampling and splitting observations/notes. - Proper use of re-heat correction factors Dispute Resolution For the test results of the QV retained portion, the contract language specifies two working days after receipt of the sample. The receipt day refers to receipt of the sample at the department s Bureau of Technical Services AASHTO accredited laboratory. The intent is to provide test information and feedback to the QC/QV team as soon as practical and targeting within 7 working days of the date of the QV sample. At the completion of dispute resolution testing (QV-ret and nearest backward QC-ret) the WisDOT - Bureau of Technical Services AASHTO accredited laboratory personnel dealing with asphalt mix designs will determine and recommend a range of non-compliant tons based on, but not limited to, the following information: - Project QC data and production trends. - Project CA data. - Any additional forward testing. - JMF changes and cause for change. - Differences between QV, QC and CA comparison testing (single points and running averages). - Affected mixture properties in conjunction with intended application. - Design mixture production and performance history. In determining unacceptable or non-compliant materials, the department s Bureau of Technical Services AASHTO accredited laboratory personnel dealing with asphalt mix designs will provide documentation to the QV team recommending tonnages to be affected. A standard recommendation will be assessed based on data meeting established tolerance levels for split sample testing. A standard recommendation will be assessed based on data meeting the following established tolerance levels for split sample testing: - Gmm Warning Band Limit (WBL): less than or equal to Gmb Warning Band Limit (WBL): less than or equal to Gmm Job Mix Formula Limit (JMFL):less than or equal to Gmb Job Mix Formula Limit (JMFL): less than or equal to The general process flow chart for dispute resolution is shown in Figure 7. Example scenarios are provided in Figure 8. In the event that the range of liability is determined to be at the QV tonnage point (isolated problem), a standard pay adjustment equivalent to 50 tons will be assessed, unless QMP Quality Control pay adjustments are controlling (standard spec ). There is no intent to use multiple pay adjustments, but the lowest percent pay will supersede others. The QV team will further complete documentation responsibilities by determining the dollar amount for any affected mixture tonnage and will forward that information to appropriate project personnel and the QC team. Figure 9 is an example of a spreadsheet used to calculate pay adjustments. July 2014 Page 16

120 CMM 8-36 QMP - HMA Figure 7 HMA Dispute Resolution Flow Chart Footnotes: 1. If the QV "FAILS" during production, pull additional QV sample. 2. If the QC-ret sample does not meet JMFL tolerances (regardless of air voids and VMA), tonnages in question continue forward and backwards until a CA sample has been established to limit liability. 3. If no CA sample limit of liability has been established, the potential is such that the tonnage subject to a pay adjustment can be from the beginning of mix design production to the end. 4. When assessing tonnages for pay reductions, keep the following items in mind: - Consider start-up (1 or 2 day paves). - Look at running averages, did contractor recognize the need for a change, and did they respond to that need? - Consider sample tonnage,how close to start-up are the QC test results? - How far "out" is the sample, is there an explanation/documentation/communication as to why? - Consider making tonnage increments half-way between sample tonnages that were tested. July 2014 Page 17

121 CMM 8-36 QMP - HMA Figure 8 HMA Verification Dispute Resolution Scenarios July 2014 Page 18

122 CMM 8-36 QMP - HMA Figure 8 Example of HMA Verification Dispute Resolution Scenarios (cont'd) July 2014 Page 19

123 CMM 8-36 QMP - HMA Figure 9 Adjustment Calculation Example Footnote: 1. Contact Bureau of Technical Services, Materials Laboratory Unit 2 for further assistance. July 2014 Page 20

124 CMM 8-36 QMP - HMA Evaluation of CA Test Results July 2014 Page 21

125 CMM 8-36 QMP - HMA Evaluation of QV Test Results July 2014 Page 22

126 TOPIC R: Data Entry R-1

127 TOPIC R: Data Entry R-2 MATERIAL DATA REPORTING FOR QC, QA, QV, IA ON HIGHWAY CONSTRUCTION PROJECTS The above is from the Atwood Systems website:

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130 Construction and Materials Manual Chapter 8 Section 10 Materials Testing, Sampling, Acceptance Materials - General Wisconsin Department of Transportation Materials sampling and testing methods and documentation procedures prescribed in chapter 8 of the CMM are mobilized into the contract by standard spec and standard spec Control of Materials Approval of Materials Used in Work The service life of a highway is dependent upon the quality of the materials used in its construction, as well as the method of construction. Control of materials is discussed in standard spec The spec provides that only materials conforming to the requirements of the contract must be used, and the contractor is responsible for furnishing materials meeting specified requirements. Only with permission of the engineer can the contractor provide materials that have not been approved, as long as the contractor can provide evidence that the material will be approved later. The department's intention is to hold payment of items until the required materials information is provided by the contractor. The standard specs encourage recovered and recycled materials to be incorporated into the work to the maximum extent possible, consistent with standard engineering practice. Standard spec and Wisconsin statute require the use of American made materials to the extent possible. On federally funded projects, all steel products must be produced in the United States, and manufacturing and coating processes must be performed in the U.S. These "Buy America" requirements are discussed in CMM Contractor and Department Designated Materials Persons Standard spec requires the contractor to designate a dedicated materials person (CDMP) who will be responsible for submitting all contractor materials information to the engineer. The department should also designate a dedicated materials person (WDMP) who will be in direct contact with the contractor's designee. Standard spec requires the CDMP to communicate with all subcontractors to ensure that sampling, testing, and associated documentation conforms to the contract. The contract also makes the CDMP responsible for submitting materials information from the prime contractor and subcontractors to the WDMP, promptly reporting out-of-specification test results, collecting and maintaining all required materials certifications, and regularly communicating with the WDMP regarding materials issues on the contract. The WDMP should provide a project-specific sampling and testing guide (E-Guide) to the contractor at the preconstruction conference. The E-Guide is created from the following site: Both the CDMP and WDMP should review and supplement the E-guide before work operations begin to ensure that testing methods, frequencies, and documentation requirements conform to the contract. The CDMP and WDMP are charged with working together throughout the life of the contract to ensure that contract materials requirements are met and any issues that might arise related to either non-conformance or non-performance are dealt with promptly. The ultimate goal is to make sure that problems with materials are brought to light and timely corrective action taken before those materials problems compromise the quality or acceptability of the completed work. The CDMP should coordinate contractor materials related activities and do the following: - Establish methods and work expectations with the WDMP. - Provide all QMP test data and control charts from the prime contractor and subcontractors. - Deal with all materials-related concerns from the WDMP. The WDMP is responsible for administration of the contract with regards to contract materials requirements and should do the following: - Communicate or meet weekly with the CDMP to discuss outstanding materials issues on the contract. - Monitor the submittals from the CDMP to ensure timeliness and completeness. - Review contractor submittals to verify materials requirements are met. - Inform the Project Leader of non-conforming materials issues and discuss actions to be taken. - Prepare materials documentation for inclusion into the project files. June 2013 Page 1

131 CMM 8-10 Materials - General Approval of Materials All materials used in a project are subject to the engineer's approval before incorporation into the work. Approval of materials is discussed in standard spec Approval is generally accomplished by material tests and/or analysis. This can be done by using approved product lists, certification, or sampling and testing. Unless the contract specifies otherwise, the contractor must follow manufacturer's recommended procedures for products incorporated into the work. Refer to CMM 8-45 for details of acceptance types Quality Management Program Sampling and testing on WisDOT projects is performed according to the Quality Management Program (QMP). QMP is presented in CMM 8-30 and the following CMM sections Independent Assurance Program The Independent Assurance Program (IAP) is an element of the Quality Management Program intended to ensure that test data from project acceptance testing is reliable, including sampling procedures, testing procedures, and testing equipment. Quality verification (QV), quality assurance, (QA), and quality control (QC) are integral parts of the IAP. Further information about the Independent Assurance Program can be found in CMM Quality Verification (QV) Quality verification (QV) sampling is done by a department representative, and is taken independently from the quality control samples to validate the quality of the material Quality Assurance (QA) Under the quality assurance (QA) program, a department representative observes sampling and testing performed by the contractor, by testing split samples. Further detail about quality verification and quality assurance is provided in CMM Quality Control (QC) Quality control for materials testing includes all contractor/vendor operational techniques and activities that are performed or conducted to fulfill the contract requirements Nonconforming Materials General The department does not want material not meeting contract specifications incorporated into the work. Standard spec gives the engineer the authority to either reject nonconforming materials or to allow the nonconforming materials to remain in place. If materials are found to be unacceptable before or after placement into the work, the engineer may reject the materials, and the contractor must remove the materials from the site at no cost to the department. Materials that have been tested and approved at their source or otherwise previously approved, but have become damaged or contaminated before use in the work, are also subject to rejection by the engineer. To ensure consistency in the decisions made for acceptance of non-conforming material or workmanship, the engineer should involve the region oversight engineer before finalizing any decision. This will help keep central office informed about contractor or material problems that may require action with a change in specifications or discipline of a contractor. If any technical questions remain about the acceptance or rejection of nonconforming materials refer to the appropriate technical expert in the Bureau of Technical Services Nonconforming Materials Allowed to Remain in Place Deciding Whether or not to Allow Material to Stay in Place Good engineering judgment is required when making decisions on nonconforming materials. The engineer may choose to approve nonconforming materials, allow them to remain in place, and adjust the contract price. When making the decision to direct the contractor to remove and replace the materials versus leave the materials in place, it's important to consider the following: - Long-term consequences on quality and durability. - Implications on the project's life cycle costs, service life, serviceability, and maintenance. - Socioeconomic, environmental, and aesthetic considerations. - Impacts on traffic, staging, and construction timeframes Deciding Whether or Not to Apply Price Reduction After the engineer has decided to allow nonconforming materials to remain in place, he or she must carefully evaluate each situation in deciding whether to take a price reduction. The goal is to achieve consistency statewide in administering price reductions for nonconforming materials that are allowed to remain in place. June 2013 Page 2

132 CMM 8-10 Materials - General Results of retests and related quality tests should be considered. The following list includes some examples of the types of factors the engineer must consider to decide if a price reduction is warranted and how much it should be: - Has the contractor been conscientious to provide quality by carefully controlling materials and construction operations? - Has the contractor been proactive and made good use of QC data to maintain and improve quality? - Did the engineer provide the contractor with non-conforming test results within the contractual timeframe, if specified? - If timeframes are not specified, did the engineer provide non-conforming test results in time for the contractor to make process or materials corrections? - Upon becoming aware of a materials quality problem, has the contractor responded quickly to correct it? - Is the nonconforming test an isolated incident or a recurring situation? - How does the nonconforming test compare to the rest of the project data: - Have material test results been well within specification requirements or consistently at the very limit of what is acceptable? - How many tests are nonconforming vs. how many tests have passed? - How far out of spec is the non-conforming test? Price Reductions Specified in the Contract with Administrative Items If price reductions are included in the specifications or special provisions for certain nonconforming items, the price reductions should be administered using the appropriate 800 series administrative items. Since the price reductions are included in the contract language, the engineer can add the 800 series items to the contract without going through the complete change order process. Approval by a DOT representative and contractor representative are not necessary, though it's good practice to communicate the changes to all parties. Further guidance on the 800 series administrative items is provided in CMM For payment of nonconforming items with associated administrative items, pay for the installed quantity and bid price of the work item under the original bid item. The pay reduction will be accounted for using the administrative item. Compute the price reduction by multiplying the quantity of nonconforming material by the original unit price and the percent price reduction. The pay units of all administrative items are DOL. Document all calculations, and pay for the (negative) total calculated price reduction as the pay quantity, with 1 dollar as the pay unit. Example 1 - Contractor placed total of 19,000 SY of Concrete Pavement 9 inch SY (12' x 500') is 1/8" - 1/2" under plan thickness - Standard spec directs to pay 80% contract price for this range (20% reduction) - Bid unit cost is $35/SY Using original bid item, pay 19,000 SY at $35/SY = $655,000 Compute price reduction = 670 SY x $35 x = -$4,690 Add the administrative item Nonconforming Thickness Pavement to the contract, with unit price of $1.00 Pay quantity of -$4,690 Net pay = $655,000 - $4,690 = $650,310 Paying for nonconforming items this way allows for clean tracking of as-built quantities. The use of administrative items can easily be tracked to monitor specific items that are frequently the target of price reductions. This can help the department develop improved specifications and construction methods Price Reductions Not Specified in the Contract If specific price reductions are not outlined in the contract specifications or special provisions, standard spec gives the engineer the option to take a price reduction on nonconforming materials allowed to remain in place. The engineer has latitude to decide whether a price reduction is appropriate, and what amount the price reduction should be. For payment of nonconforming items, use full quantity and bid price of the work item. Apply the price reduction by submitting a change order that creates a new item with the same bid item number but with the supplemental June 2013 Page 3

133 Construction and Materials Manual Chapter 8 Section 45 Materials Testing, Sampling, Acceptance Materials Testing and Acceptance - General Wisconsin Department of Transportation Materials sampling and testing methods and documentation procedures prescribed in chapter 8 of the CMM are mobilized into the contract by standard spec and standard spec Acceptance Procedures, Documentation, and Reporting Documentation and reporting for materials acceptance is equal in importance to Item Record Account documentation. The basis of acceptance for contract materials is accomplished in several ways, depending on the material. The type of reporting and documentation is a function of the acceptance type. Materials test reporting and documentation is to be done using the WisDOT electronic Materials Tracking System (MTS). The MTS is a computerized filing and reporting system for construction materials tests and documents. All construction materials tested and inspected for WisDOT projects are reported on the MTS. The overall MTS has three basic components, the MTS (LAN/WAN attached), Materials Information Tracking System (MIT), and the Materials Tracking website. Region and central office laboratory personnel can enter data directly into the Oracle database via a Local Area Network (LAN) attachment provided through the MTS. The MIT is used for entering tests from the field. The engineer should follow these guidelines for material documentation: - Inspect all manufactured products as soon as possible after delivery. - Include all approved lists, certified sources, and pre-qualified products. - Record in the project record relevant inspection information. - Verify that products delivered match the certifications, approved list, etc. - Review all Certifications of Compliance and Certified Reports of Test and Analysis. - Reference all Certifications, shop inspection reports, and other external documents using the MTS/MIT prefix 900 report. All materials documentation and reporting must be completed and entered in the MTS no more than 60 working days after the work completion date. Manufactured products must be inspected at the job site as soon as possible after arrival for evidence of damage or noncompliance even though these materials are covered by prior inspection testing or certification. Those materials normally source inspected, but which arrive at the job without appropriate marking, indicating that they have been accepted at the source, must be field inspected or tested and the basis for acceptance must be documented in the inspector s diary Materials Testing and Acceptance Guide The Materials Testing and Acceptance Guide, CMM 8-50 details many of the sampling, testing, and documentation requirements for various materials. The instructions shown in this guide are recommended minimum requirements. In many cases, it may be appropriate to increase the frequency and scope of certain testing and acceptance activities in order to properly administer the materials specifications. In all cases, it is appropriate to closely observe produced materials for visual evidence of changes in quality and to then adjust testing frequencies, as required, to adequately evaluate their quality. Sampling and testing procedures of certain unique materials are described in the standard specs and other contract documents. The instructions in this guide are intended to supplement those in other contract documents E-Guide E-Guide is an automated system that produces condensed sampling, testing and documentation guidance for material requirements for a project. It generates the guidance in two basic ways. For the project bid items, the system automatically generates guidance. For non-standard special provision (SPV) items, the system requires manual input of the SPV material requirements contained in the project proposal. CMM 8-50 should be cross checked when an E-Guide is developed since it contains detailed information and it breaks material information out by type. The E-Guide system for developing a project specific sampling and testing guide is available at: The WisDOT project material coordinator shall prepare the E-Guide and provide a copy to the contractor's material coordinator. Consult the region materials engineer or region person responsible for construction July 2014 Page 1

134 CMM 8-45 Materials Testing and Acceptance - General materials for guidance when developing the E-Guide. The E-Guide does not supersede material requirements in the Standard Spec or the CMM. The contractor is contractually bound to supply the information if required in the Standard Spec, CMM or Special Provisions. The region materials engineer or region person responsible for this area must be consulted regarding doubts as to the adequacy of compliance of source inspected materials, need for field inspection and reports, waiver of testing, unlisted items, evaluation of certifications, or other questions regarding acceptance procedures. Table 1 below defines the general documentation requirements for each materials acceptance type. Table 2 provides the MTS prefixes for all material types. Figure 1, Figure 2, and Figure 3 show example test reports. July 2014 Page 2

135 CMM 8-45 Materials Testing and Acceptance - General Table 1 Documentation Requirements for Different Acceptance Types Documentation Required Acceptance Type MIT/MTS Document MTS Documentation Time Line Remarks MTS Report. Verification tests- C.O. Laboratory Various MTS prefixes as appropriate. See Table 2 for a list of prefixes. No later than one week after completion of test. Test entry by C.O. Lab personnel. Materials Diary entry MTS reference report. Approved Product Lists- WisDOT Reference on MTS prefix 900 or 155 No later than 60 days after contract work completion date. Test entry by project personnel. Form DT 1823, Report of Shop Inspection. MTS reference report. Materials Diary entry. Source or Shop Inspection Reference on MTS prefix 900 or 155 No later than 60 days after contract work completion date. Test entry by project personnel. Source sampled materials tested and reported by C.O. personnel (see verification tests C.O. Lab above). Cert. of Compliance MTS reference report. Materials Diary entry. Manufacturers Certification of Compliance Reference on MTS prefix 900 or 155 No later than 60 days after contract work completion date. See note below [1]. Cert. Report of Test MTS reference report. Materials Diary entry Certified Report of Test Reference on MTS prefix 900 or 155 No later than 60 days after contract work completion date. See note below [1]. Verification tests-mts Report. Field Sampling and Testing Aggregates- MTS prefix 162, 217 HMA- MTS prefix 254 HMA Nuclear Density- MTS prefix 262 Concrete Cylinders MTS prefix 130 Earth Work Density- MTS prefix 232 No later than one week after completion of test. All aggregate and HMA QV testing done must be entered by the qualified lab doing the testing. When QV and Companion Cylinder testing is done the data must be entered by the qualified laboratory doing the testing. Quality Management Program (QMP) Quality Control (QC) tests. MTS Report. MRS Report (Structures Masonry Data)- contractor entry. MRS Report (IRI ride data) contractor entry. Field Sampling and Testing MTS Report 155 No later than 60 days after contract work completion dateprefix 155 data. MRS data is to be input by the contractor as it is developed. Refer to Figure 1, Figure 2, and Figure 3 for examples of prefix 155 reports for verification of contractor QMP and QC testing. [1] Certifications must be evaluated promptly for adequacy, completeness, and compliance with the specifications. The certification reviewer must make appropriate notations, initial, and date the document when the review is completed. July 2014 Page 3

136 Appendix 1: WisDOT Test Method no TSR ASTM D4687 Laboratory Mix Design Reports (WisDOT E-Mixes)

137 WISCONSIN DEPARTMENT OF TRANSPORTATION SMA Asphalt Draindown Test Procedure WisDOT Test Method No Scope 1.1 This test method covers the determination of the amount of draindown in an uncompacted SMA mixture sample when the sample is held at elevated temperatures comparable to those encountered during the production, storage, transport, and placement of the mixture. 1.2 The values stated in gram-millimeter units are to be regarded as the standard. 1.3 This standard may involve hazardous materials, operations, and equipment. This standard does not purport to address all of the safety problems associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. 2. Referenced Documents - AASHTO Standards, T-245 Resistance to Plastic Flow of Bituminous Mixtures Using Marshall Apparatus and M 92 Standard Specification for Wire-Cloth Sieves for Testing Purposes. 3. For the purpose of this test method, draindown is considered to be that portion of the asphalt cement which separates itself from the sample as a whole and is deposited outside the wire basket during the test. (Note: any noticeable aggregate particles that are deposited outside the basket should be added back into the mixture and not counted as draindown. Alternatively the test should be rerun.) 4. Summary of Method - A sample of SMA mixture to be tested is prepared in the laboratory or obtained from field production. The sample is placed in a wire basket, which is positioned on a pre-weighed paper plate. The sample, basket, and plate are placed in a forced air oven for one hour at a preselected temperature. At the end of one hour, the basket containing the sample is removed from the oven along with the paper plate and the paper plate is weighed to determine the amount of draindown that occurred. 5. Significance and Use - This test method can be used to determine whether the amount of draindown measured for a given SMA mixture is within acceptable levels. It also provides an evaluation of the draindown potential of an SMA mixture produced in the field. 6. Apparatus 6.1 Oven, capable of maintaining the temperature in a range from 120E - 175E C (250E - 350E F). The oven should maintain the set temperature to within " 2E C (" 3.6E F). 6.2 Paper plates of appropriate size. The paper plates used should be of appropriate durability to withstand the oven temperature. 6.3 Standard cylindrical shaped basket meeting the dimensions shown in Figure 1. The basket shall be constructed using standard 6.3 mm (0.25 inch) sieve cloth as specified in AASHTO M Spatulas, trowels, mixer, and bowls as needed. 6.5 Balance accurate to 0.1 gram.

138 7. Sample Preparation 7.1 Laboratory Prepared Samples For each mixture tested, the drain down characteristics should be determined at the anticipated plant production temperature. Duplicate samples should be tested Dry the aggregate to constant mass and sieve it into appropriate size fractions as indicated in AASHTO T 245, section Determine the anticipated plant production temperature or select a mixing temperature in accordance with AASHTO T 245, Section The asphalt cement supplier=s recommendations should be sought when using modified asphalt cement Weigh into separate pans for each test sample the amount of each size fraction required to produce completed SMA mixture samples having a mass of 1200 grams. The aggregate fractions shall be combined such that the resulting aggregate blend has the same gradations as the job mix formula. Place the aggregate samples in an oven and heat to a temperature not to exceed the mixing temperature established in by more than approximately 28E C (50E F).

139 7.1.5 Heat the asphalt cement to the temperature established in Place the heated aggregate in the mixing bowl. Add any stabilizer (Note 1) as directed by the supplier and thoroughly mix the dry components. Form a crater in the aggregate blend and add the required amount of asphalt. The amount of asphalt shall be such that the final sample has the same asphalt content as the job-mix formula. At this point, the temperature of the aggregate and asphalt cement shall be within the limits of the mixing temperature established in Using a spatula (if mixing by hand) or a mixer, mix the aggregate (and stabilizer) and asphalt cement quickly, until the aggregate is thoroughly coated. 7.2 Plant Produced Samples For plant produced samples, duplicate samples should be tested at the plant production temperature Samples may be obtained during plant production by sampling the mixture at the trucks prior to the mixture leaving the plant. Samples obtained during actual production should be reduced to the proper test sample size by the quartering method. Note 1 - Some types of stabilizers such as fibers or some polymers must be added directly to the aggregate prior to mixing with the asphalt cement. Other types must be added directly to the asphalt cement prior to blending with the aggregate. 8. Procedure 8.1 Transfer the laboratory produced or plant produced uncompacted SMA mixture sample to a tared wire basket described in 6.3. Place the entire sample in the wire basket. Do not consolidate or otherwise disturb the sample after transfer to the basket. Determine the mass of the sample to the nearest 0.1 gram. 8.2 Determine and record the mass of a paper plate to the nearest 0.1 gram. Place the basket on the paper plate and place the assembly into the oven at the temperature as determined in for 1 hour " 1 minute. 8.3 After the sample has been in the oven for 1 hour, remove the basket and paper plate. Determine and record the mass of the paper plate to the nearest 0.1 gram. 9. Calculations 10. Report 9.1 Calculate the percent of mixture which drained by subtracting the initial paper plate mass from the final paper plate mass and divide this by the initial total sample mass. Multiply the result by 100 to obtain a percentage Report the average percent drainage at the test temperature.

140 TSR ASTM D 4867 Significance and use This test method can be used to test asphalt concrete mixtures in conjunction with mixture design testing to determine the potential for moisture damage, to determine whether or not an antistripping additive is effective, and to determine what dosage of an additive is needed to maximize the effectiveness. This test method can also be used to test mixtures produced in plants to determine the effectiveness of additives under the conditions imposed in the field. Laboratory Equipment 1. Vacuum Chamber 2. Vacuum Pump 3. Manometer 4. Scale or Balance 5. Water Baths (3) 6.Mechanical or Hydraulic Testing Machine 7. Loading Strips 2 Obtain the appropriate asphaltic mixture sample from the field sample(s) or prepare a laboratory batch which will produce 6 specimens. 3 After batching, oven cure ( F). 4 Compact the specimens with the predetermined count from the TSR Trials Worksheet. 5 Cool all of the specimens in the mold(s) to the hand touch, then extrude with hydraulic jack apparatus. 1 Gravity by AASHTO T 166 and Maximum Specific Gravity by AASHTO T 209. Calculate air voids and plot no. of verses percent air voids. Connect data points and determine specified gyration count, which is between the range of 6% - 8% air voids. 6 Sort the specimens into two equal subsets so the average air voids of the two subsets are approximately equal. Store one at room temperature. Wet Conditioned Dry SubSet

141 7 Partially saturate each specimen of the wet subset by applying a vacuum. The goal is to partially saturate each specimen to a saturation point between 55% and 80% volume of water. If the applied partial vacuum does not satisfy reach at least the 55% saturation point additional vacuum may be applied. Percent saturated condition is calculated as per worksheet. Any specimen saturated more than 80% is over saturated and must be discarded from the subset. 9 Adjust the temperature of the moistureconditioned subset by soaking in a water bath for 2 hours at degrees Fahrenheit ( degree Celsius. 10 Adjust the temperature of the dry subset by soaking in a water bath. At degrees Fahrenheit ( degrees Celsius. Apply the load at 2 in./min until maximum load is reached and record maximum load. 12 Continue loading until the specimen fractures. Break the specimen open and visually estimate and record the approximate degree of moisture damage, if any. Inspect all surfaces, including the failed faces, for evidence of racked or broken aggregate, that may influence test results and record all observations. 8 Moisture condition the partially saturated specimens by soaking in distilled water at degrees Fahrenheit ( degrees Celsius) for 24 hours. 11 Determine the tensile strength at degrees Fahrenheit ( degree Celsius of both subsets. Place a specimen into the loading apparatus and position the loading strips so that they are parallel and centered on the test specimen. 13 Calculate the individual specimen strength values and subset averages to compare by ratio (avg wet strength divided by the avg dry strength) and determine the TSR value (per worksheet).

142 Effect of Moisture on Asphalt Concrete (ASTM D 4867) Asphalt Cement Content (P b ): % Unconditioned Samples Conditioned Samples (A) Diameter, in (B) Height, in (C) Mass in air, g (D) Mass SSD, g (E) Mass under water, g (F) Volume, cm 3, = (D E) (G) Bulk specific gravity (H) Max. specific gravity (I) Air voids, % = 100 (1 G/H) (J) Vol of voids, cm 3 = (I x F/100 Initial Vacuum Saturation Conditioning (K) Mass SSD (L) Vol of absorbed water, cm 3 = K C (M) % Saturation 100 (L/J) Calculations (O) Failure load, lb (P) Tensile strength, psi (2 0) / ( A B) Average tensile strength ratio (P 4 + P 5 + P 6 ) / (P 1 + P 2 + P 3 ) * 100

143 TESTING SAWED OR CORED PAVEMENT SAMPLES Determine pavement bulk specific gravity using AASHTO T166 (ASTM D-2726) for specimens that contain moisture. Immerse the specimens in F water bath for 3-5 minutes and weigh in water, designate this weight as C. Surface dry the specimens by blotting quickly with damp towel and then weigh in air (include any water that may drain from voids in specimens), designating this weight as B. Oven-Dry the specimen back to a constant weight, in an oven set to 230F + 9F (105C - 115C), designating this weight as A. Calculate the Gmb to three decimal places, Pavement Gmb = A B-C Note: When using pavement cores to evaluate the percentage of compaction effort (inplace density) you can divide the core Gmb by the Gmm, then multiply by 100 (Gmb/Gmm* 100) to get the percent compaction. If the moisture has not been completely dried out of the core, then the resultant percent compaction may be artificially high (air voids will appear to be a bit lower than actually are).

144 Core ID Thickness A1 apparent dry wt C Sbmrgd wt B SSD wt A oven-dry wt D Volume ( B - C ) Gmb ( A/D ) Apparent Gmb ( A1/D ) Pan Tare wt Dryback min 0 min 30 min 60 min 90 min Final Drybck - Pan wt = A Core ID Thickness A1 apparent dry wt C Sbmrgd wt B SSD wt A oven-dry wt D Volume ( B - C ) Gmb ( A/D ) Apparent Gmb ( A1/D ) Pan Tare wt Dryback min 0 min 30 min 60 min 90 min Final Drybck - Pan wt = A

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159 Appendix 2 Standard Specification Section 450 and 460 WisDOT Standard Specifications can be found at: HMA-IPT Laboratory Exam Corrections HTCP Course Evaluation

160 450.1 Description Section 450 General Requirements for Asphaltic Pavements (1) This section describes requirements common to plant mixed asphaltic bases and pavements. Exceptions and additional requirements are specified in 455 through Materials Acronyms and Definitions (1) Interpret materials related acronyms used in sections 450 through 499 as follows: FRAP Fractioned reclaimed asphaltic pavement HMA Hot mix asphalt JMF Job mix formula PG Performance graded RAP Reclaimed asphaltic pavement RAS Recycled asphalt shingles SMA Stone matrix asphalt VMA Voids in mineral aggregate WMA Warm mix asphalt (2) Interpret materials related definitions used in sections 450 through 499 as follows: Asphaltic binder The principal asphaltic binding agent in HMA. including asphalt cement and material added to modify the original asphalt cement properties. Filler A finely divided mineral aggregate added to asphaltic mixtures to improve mixture properties. Fractioned reclaimed asphaltic pavement Material resulting from cold milling or crushing existing asphaltic pavement processed to control gradation properties. Leveling layer Initial layer placed thinner than the minimum required under Lower layer Any asphaltic pavement layer that will not be exposed to traffic when the pavement structure is complete. A pavement structure may have multiple lower layers. Reclaimed asphaltic pavement Material resulting from cold milling or crushing existing asphaltic pavement. Recycled asphalt shingles Waste material from a shingle manufacturing facility, either new or used material salvaged from residential roofing operations, or any combination of these materials ground to ensure that 100 percent will pass a 1/2 sieve and processed to remove deleterious material. Not for Contract Administration Upper layer The asphaltic pavement layer exposed to traffic when the pavement structure is complete. A pavement structure has only one upper layer. Warm mix asphalt Any asphaltic mixture that contains a warm mix additive, or utilizes a warm mix process, as part of its mixture design that has the ability to reduce the mixing and compaction temperature requirements below the typical temperatures used for that application Aggregate Sampling and Testing (1) The department and the contractor will sample and test according to the following methods, except as revised with the engineer's approval: Sampling aggregates... AASHTO T2 Material finer than No. 200 sieve... AASHTO T11 Sieve analysis of aggregates... AASHTO T27 Mechanical analysis of extracted aggregate... AASHTO T30 Sieve analysis of mineral filler... AASHTO T37 Liquid limit of soils... AASHTO T89 Plastic limit of soils... AASHTO T90 Plasticity index of soils... AASHTO T90 Effective with the December 2014 Letting Standard Specifications

161 Los Angeles abrasion of coarse aggregate... AASHTO T96 Freeze-thaw soundness of coarse aggregate... AASHTO T103 Sodium sulfate soundness of aggregates... AASHTO T104 Extraction of bitumen... AASHTO T Construction Equipment Batch Plants Plant Scales (1) Provide beam, springless, dial, or digital scales on weigh boxes and silos. Use scales of a standard make and design accurate to within 0.5 percent of the maximum required load. For each plant, provide at least ten standard 50 pound weights accurate to within 0.1 percent. For each scale, provide a suitable cradle or platform for applying test loads. (2) If using beam scales for aggregate, provide a separate beam for each size of aggregate. Also provide a device that warns when the applied load is within 200 pounds of the required load. (3) If using beam scales for asphaltic materials, provide a tare beam and a full capacity beam with a minimum graduation no greater than 2 pounds. Also provide a device that warns when the applied load is within 20 pounds of the required load. (4) If using dial scales, provide a standard make springless scale designed, constructed, and installed to be vibration free. Ensure that all dials are plainly visible to the operator at all times. Equip with adjustable pointers for marking the weight of each material batched. (5) If using digital scales, conform to National Bureau of Standards Handbook Automatic Batching (1) On contracts with 10,000 tons or more, provide automated batch plants. Ensure that the plants' control system can coordinate mixture proportioning, timing, and discharge by the operation of a single control. Also provide an automatic batch weighing, cycling, and monitoring system. (2) On contracts with less than 10,000 tons, if the contractor elects to use batch plant automatic systems, conform to the requirements here under The contractor need not use automatic recordation. If the contractor elects to use automatic recordation, conform to for truck loads, or for batch weights. (3) Ensure that the system accurately proportions mixture components by weight or volume in the proper order and controls the mixing cycle sequence and timing. Provide interlocks that ensure that the scale is at zero before a batch can start and that the batch is mixed completely before discharge. Do not start subsequent batches before completely discharging the previous batch. Also provide interlocks that ensure that all batch materials are in the mixer before the batch can discharge. Ensure that unauthorized personnel cannot alter mix designs and that equipment emits an audible signal if discharging a batch with out-of-tolerance component weights. Ensure that this signal is loud enough to hear throughout the plant area under normal operating conditions. Not for Contract Administration (4) Provide adjustable timing devices to control individual component batching and mixing operations. Provide auxiliary interlock cutoff circuits necessary to stop automatic cycling whenever an weighing error exceeding a specified tolerance occurs or when another part of the control system malfunctions. (5) Ensure that the batching system automatic control can stop the cycle in the underweight check position and the overweight check position for each material to check tolerance limits. (6) Ensure that the scale system is equipped with a device that applies pressure to a scale lever to simulate batching operations for tolerance checks. (7) Consistently deliver materials within the full range of batch sizes within the following tolerances: MATERIAL PERCENT OF TOTAL MATERIAL BATCH WEIGHT Coarse aggregate Fine aggregate Aggregate for use with salvaged or reclaimed pavement materials Mineral filler Salvaged or reclaimed asphaltic pavement material Asphaltic material Effective with the December 2014 Letting Standard Specifications

162 Zero return for aggregate Zero return for salvaged or reclaimed material Zero return for asphaltic material (8) Unless providing separate tolerance controls for batching mineral filler, reduce aggregate tolerances to +/- 0.5 percent for aggregates delivered before the filler. (9) Ensure that the total weight of the batch does not vary by more than +/- 2.0 percent of the designated batch weight. (10) Ensure that the electrical circuits for the above delivery tolerances of each cutoff interlock are capable of providing the total span for the full allowable tolerance for maximum batch size. Provide tolerance controls automatically or manually adjustable to provide spans suitable for less than full-size batches. Ensure that the automatic controls and interlock cutoff circuits are consistently coordinated with the batching scale or meter within an accuracy of 0.2 percent of the scale or meter nominal capacity [1] throughout the full range of the batch sizes. [1] Nominal capacity of a scale is defined as the maximum quantity which the scale or meter can measure. (11) If the automatic control or monitoring systems break down, the contractor may operate the plant manually for up to 2 working days Recording Batch Weights (1) On contracts involving 10,000 tons or more of asphaltic mixtures, unless the contractor elects to record truck loads as provided in , produce an automatic digital record for each batch indicating the proportions of each aggregate component, mineral filler, and asphaltic material. (2) Provide a digital recorder that can print multiple copies of mixture reports that give the total weight of asphaltic mixture and asphaltic material both per load and per batch. Include weights of the individual aggregates and fillers. Reports need not provide tare weight and may use accumulative weights. Ensure that reported weights are accurate within +/- 1 kg/500 kg. Allow sufficient time for the scale to come to rest before printing each weight. (3) The contractor may use mixture storage silos with digital recorder equipped batch plants if the department determines the storage silo output is coordinated with the recorded batch weights. (4) If the recording system breaks down, the contractor may operate the plant without automatic recording for up to 2 working days Recording Truck Loads (1) If not using automatic batch recording, install a digital recorder as part of the platform truck or storage silo scales. Ensure that the recorder can produce a printed digital record of at least the gross or net weights of delivery trucks. Provide gross, tare, and net weights as well as date, time, ticket number, project, and mix type; but not all of this data need be on by the printout system. Ensure that scales cannot be manually manipulated during the printing process. Provide an interlock to prevent printing until the scales come to rest. Size the scales and recorder to accurately weigh the heaviest loaded trucks or tractor-trailers hauling asphaltic mixture. Ensure that recorded weights are accurate to within 0.1 percent of the nominal capacity of the scale. Not for Contract Administration (2) If the digital recorder breaks down, the contractor may manually record weights for up to 2 working days Asphaltic Mixture Hauling Vehicles (1) Provide trucks for hauling asphaltic mixtures with tight, clean, and smooth boxes. The contractor may thinly coat boxes with a release agent chosen from the department's approved products list. Drain excess release agent after coating. Equip each box with a cover big enough to protect the mixture. Do not use trucks that show oil leaks of any magnitude Transfer Devices (1) Ensure that transfer devices have surge bin capacity adequate to pave continuously at a uniform speed. If maintaining uniform and continuous paving, the engineer may allow the contractor to omit the surge bin. Do not use devices that cause vibrations or other motion that adversely affect the finished ride Pavers (1) Ensure that the screed or strike-off assembly produces a finished surface of the required evenness and texture without tearing, shoving, or gouging the mixture. Use a screed adjustable for the required crown and cross section of the finished pavement. Effective with the December 2014 Letting Standard Specifications

163 (2) Ensure that pavers are equipped with an activated screed or strike-off assembly and use activation at all times during paving unless the engineer allows otherwise. Do not extend the screed with one or more static extensions totaling more than 12 inches at either screed end, except at the shoulder end for paving shoulders. (3) Provide pavers with department-approved automatics that control the elevation and slope of the screed. The department will not require automatic controls when paving entrances, approaches, side road connections, small irregular areas, or if the engineer determines using automatic controls is impracticable. Use both grade and slope controls whenever automatics are required, except the engineer may waive the longitudinal or grade control requirement for the final surface. Ensure that the operator can adjust or vary the slope throughout super elevated curves and transitions. Also ensure that the system allows the sensor to operate on either side of the paver. (4) If automatics break down, the contractor may pave under manual control only until the end of that working day Compaction Equipment (1) Ensure all rollers are in good mechanical condition, capable of operating both forwards and backwards, and the operating mechanism allows for starting, stopping, or reversing direction in a smooth manner, without loosening or distorting the surface being rolled. (2) Equip all rollers with a drum or tire lubricator. Do not lubricate with petroleum or tar products Constructing Asphaltic Mixtures General (1) Notify the engineer at least one business day before paving. Unless the contract provides otherwise, keep the road open to all traffic during construction. Prepare the existing foundation for treatment as specified in 211, unless the contract specifies otherwise. (2) Do not place asphaltic mixture when the air temperature approximately 3 feet above grade, in shade, and away from artificial heat sources is less than 36 F. The contractor may place lower layer and base course mixtures at a lower temperature with the engineer's written approval. (3) Do not place asphaltic mixture between October 15 and May 1, regardless of temperature, without the engineer's written approval or direction. Do not construe the engineer's non-approval as grounds for extending contract time. The department will conduct the final inspection and determine acceptance when the contractor completes placement. (4) If the engineer directs or allows placing asphaltic mixtures between October 15 and May 1, either at the contractor's request or to complete the work to the stage the contract requires, perform the work at the contractor's risk. The department may subsequently revoke acceptance based on the results of a postacceptance inspection in May. Restore all pavement damage or defects the engineer attributes to temperature or other weather conditions occurring between October 15 and May 1 by repairing or replacing pavement as the engineer directs. Not for Contract Administration (5) If the engineer directs placing asphaltic mixtures between October 15 and May 1 for department convenience, the department is responsible for damage or defects the engineer attributes to temperature or other weather conditions occurring between October 15 and May 1. (6) Place asphaltic mixture only on a prepared, firm, and compacted base, foundation layer, or existing pavement substantially surface-dry and free of loose and foreign material. Do not place over frozen subgrade or base, or where the roadbed underlying the foundation or base is temporarily unstable from the effects of frost heaving. Unless the contract provides otherwise, incorporate loose roadbed aggregate as a part of preparing the foundation, in shoulder construction, or dispose of as the engineer approves Preparing and Storing Mixtures (1) Heat and combine aggregate and asphaltic material to produce a mixture within the temperature range the mixture design specifies when discharged from the mixer. Mix until achieving a homogeneous mixture with uniformly coated aggregate. The contractor may store the mixture in silos Transporting and Delivering Mixtures (1) Deliver the mixture to the paver receiving hopper at a temperature within 20 F of the temperature the asphaltic material supplier recommends. Cover all loads during inclement weather or when the ambient air temperature falls below 65 F. Effective with the December 2014 Letting Standard Specifications

164 (2) If depositing asphaltic mixture on the roadway, provide equipment to pick up substantially all of the asphaltic mixture from the roadway and load it directly into the paver receiving hopper. Use either a device integral to the paver or intermediate transfer equipment Correcting Base (1) Before placing asphaltic base or surface courses, correct the existing pavement by filling potholes, sags, and depressions; altering the existing crown; or other corrections the engineer requires. Place asphaltic lower layer mixtures where and as the engineer directs. The contractor may hand place or use blade graders or mechanical spreaders to place mixture used for wedging, leveling layers, or filling holes. Feather the mixture out to become co-planar with adjoining areas and, unless the engineer directs otherwise, compact uniformly as specified in Spreading and Finishing Mixture (1) Place asphaltic mixtures in layers to the typical sections the plans show with self-propelled pavers. Pave at a constant speed, appropriate for the paver and mixture, that ensures uniform spreading and strike-off with a smooth, dense texture and no tearing or segregation. Do not pave faster than the average delivery rate of asphaltic mixture to ensure, as nearly as possible, continuous paving. (2) If placing the initial lane of a given layer, sense off a tight string line, a mobile string line, or a traveling straightedge whichever the engineer approves for the specific field conditions. On subsequent lanes of the layer, the contractor may sense off the adjacent lane surface. (3) Avoid raking over machine spread and finished material on surface courses to the extent possible to prevent segregation. (4) The contractor may spread material by hand in areas not accessible to pavers. Dump material outside the placement area, spread into place with shovels, and shape to the required grade and contour with rakes and lutes. Do not rake material from a pile of dumped material. (5) Do not haul over any portion of a placed layer until after the final rolling is complete on that portion. (6) If a longitudinal joint other than the notched wedge joint is constructed, place multi-lane pavement so that each day's placement in all lanes ends at the same station, unless the engineer directs or allows otherwise Compaction General (1) Unless the contract specifies otherwise for the particular type of work, compact using the ordinary compaction procedure. After spreading and strike-off and while still hot, compact each layer thoroughly and uniformly by rolling. Roll during daylight hours unless providing artificial light the engineer finds satisfactory. Use the appropriate number of rollers to achieve the specified compaction, surface finish, and smoothness requirements. Ensure that the compacted surface is smooth and true to the established crown and grade. Not for Contract Administration (2) Roll the entire surface until achieving the specified compaction and, to the extent practicable, eliminating all roller marks. If turning or reversing the roller, or other operations, causes any scuffing or displacement, immediately correct the damage and revise the rolling procedure to prevent further damage. Keep roller wheels moistened to keep mixture from sticking to them. Do not use excess water. Do not disturb the line and grade elevation of edges of the asphaltic pavement or surfacing. (3) Along forms, curbs, headers, walls, and at other places not accessible to the roller, compact the mixture thoroughly with hot hand tampers or mechanical tampers giving equivalent compression. On depressed areas, use a trench roller or other engineer-approved equipment. (4) Remove and replace, with fresh hot mixture, any material that is loose and broken, mixed with dirt, or is in any way unacceptable. Also remove and replace areas with excess asphaltic material. Compact replaced mixture immediately to conform with the adjacent placement Ordinary Compaction (1) Unless the contract specifies otherwise, compact all patching, leveling, and wedging layers of asphaltic pavement or surfacing; all layers of plant mixed asphaltic base and base widening; driveways; and other non-traffic areas until no further appreciable consolidation is visible under the action of the compaction equipment. Use 2 or more rollers per paver if placing more than approximately 165 tons of mixture per hour. Effective with the December 2014 Letting Standard Specifications

165 (2) The engineer will assess the compacted density using the methods specified for the particular type of work Applying Tack Coat (1) Apply tack coat as specified in to each layer of a plant-mixed asphaltic base or pavement that will be overlaid with asphaltic mixture under the same contract Jointing (1) Place all layers as continuously as possible without joints. Do not roll over an unprotected end of freshly laid mixture unless interrupting placement long enough for the mixture to cool. If interrupting placement, ensure proper bond with the new surface. Form joints by cutting back on the previous run to expose the full depth of the layer. After resuming placement, place the fresh mixture against the joint to form intimate contact and be co-planar with the previously completed work after consolidation. (2) If an asphaltic mat adjoins an older high-type asphaltic mat, cut back the old mat on a straight line to form a butt joint for over full depth of the new mat. (3) Construct notched wedge longitudinal joints for all mainline paving if the pavement thickness conforms to the minimums specified in , unless the engineer directs or allows an alternate joint. Taper each layer at a slope no greater than 12:1. Extend the taper beyond the normal lane width, or as the engineer directs. Ensure that tapers for all layers directly overlap and slope in the same direction. (4) Place a 1/2 to one inch vertical notch after compaction at the top of tapers on all layers. Place the finished longitudinal joint line of the upper layer at the pavement centerline for 2-lane roadways, or at the lane lines if the roadway has more than 2 lanes. (5) Construct the tapered portion of each layer using an engineer-approved strike-off device that will provide a uniform slope and will not restrict the main screed. Apply a weighted steel side roller wheel, as wide as the taper, to the tapered section. Compact the initial taper section to as near the final density as possible. Apply a tack coat to the taper surface before placing the adjacent lane. (6) Clean longitudinal and transverse joints coated with dust and, if necessary, paint with hot asphaltic material, a cutback, or emulsified asphalt to ensure a tightly bonded, sealed joint Surface Requirements (1) Test the surface at engineer-selected locations with a 10-foot straightedge or other engineer-specified device. Ensure that upper layers show no variation greater than 1/8 inch between any 2 surface contacts. Ensure that lower layers, shoulder surfacing, and surfacing on temporary connections and bypasses show no variation greater than 1/4 inch between any 2 surface contacts. (2) Remove and replace or otherwise correct, using engineer-approved methods, all humps or depressions exceeding the specified tolerance Paving Shoulders (1) Conform to the other requirements under except, if constructing shoulders separately and the placement width is too narrow to accommodate the required pavers and rollers, the contractor may use engineer-approved alternate spreading and compaction equipment. Alternate equipment must be capable of satisfactorily laying mixture to the required width, thickness, texture, and smoothness. Not for Contract Administration Safety Edge sm (1) Construct safety edge monolithically with and extending beyond the edge of pavements that have no paved shoulder, have paved shoulders 3 feet wide or less, and at other locations the plans show. Safety edge is not required on edges that abut other HMA or concrete elements or where the engineer excludes for constructability issues. (2) Compact conforming to Ensure that after final rolling the safety edge angle is within the tolerances the plans show. The contractor may use full depth sawing to remove formed edges integrally placed with pavement where safety edge is not required. (3) Use a paver equipped with a wedge maker from the department's approved products list capable of constructing the specified edge cross section. Do not use a single plate strike off. (4) Place the finished shoulder material to the top of the safety edge conforming to Effective with the December 2014 Letting Standard Specifications

166 Maintaining the Work Revise (1), the contractor is required to protect and maintain the work under part 1. This change was implemented in ASP 6 effective with the December 2013 letting. (1) Protect and repair the prepared foundation, tack coat, base, paved traffic lanes, shoulders, and seal coat. Correct all rich or bleeding areas, breaks, raveled spots, or other nonconforming areas in the paved surface Measurement (1) The department will measure asphaltic mixtures by the ton of mixed aggregate and asphaltic material incorporated in the work unless the measurement subsection for a particular application specifies otherwise. Provide the engineer with weigh tickets showing the net weight of each load of material delivered. The department or department-authorized testing firms or agencies will test the contractor's truck, storage silo, or plant scales. (2) For minor quantities of mixtures and if the engineer approves, the contractor may report batch weights from plant scales as described in , instead of truck or storage silo scale weights Payment (1) All costs of furnishing, maintaining, and operating the truck scale or other weighing equipment and furnishing the weigh tickets is incidental to the contract. (2) Nonconforming material allowed to remain in place is subject to price adjustment under (3) If the engineer directs or allows placing asphaltic mixtures between October 15 and May 1, either at the contractor's request or to complete the work to the stage the contract requires, the contractor shall bear the cost of restoring damage or defects the engineer attributes to temperature or other weather conditions occurring between October 15 and May 1. (4) If the engineer directs placing asphaltic mixtures between October 15 and May 1 for department convenience, the department will not assess disincentives for density or ride on pavement the department orders the contractor to place when the temperature, as defined in (2), is less than 36 F. (5) Full-depth sawing to remove integrally placed safety edge where not required is incidental to the contract. Not for Contract Administration Effective with the December 2014 Letting Standard Specifications

167 460.1 Description Section 460 Hot Mix Asphalt Pavement (1) This section describes HMA mixture design, providing and maintaining a quality management program for HMA mixtures, and constructing HMA pavement. Unless specifically indicated otherwise, references within 460 to HMA also apply to WMA Materials General (1) Furnish a homogeneous mixture of coarse aggregate, fine aggregate, mineral filler if required, SMA stabilizer if required, recycled material if used, warm mix asphalt additive or process if used, and asphaltic material Aggregates General. (1) Provide coarse aggregates from a department-approved source as specified under Obtain the engineer's approval of the aggregates before producing HMA mixtures. (2) Furnish an aggregate blend consisting of hard durable particles containing no more than a combined total of one percent, by weight, of lumps of clay, loam, shale, soft particles, organic matter, adherent coatings, and other deleterious material. Ensure that the aggregate blend conforms to the percent fractured faces and flat & elongated requirements of table If the aggregate blend contains materials from different deposits or sources, ensure that material from each deposit or source has a LA wear percent loss meeting the requirements of table Freeze-Thaw Soundness (1) If the aggregate blend contains materials from different deposits or sources, ensure that material from each deposit or source has a freeze-thaw loss percentage meeting the requirements of table and Aggregate Gradation Master Range Revise table to increase VMA by 0.5% for E-3 mix designs with 12.5 and 9.5 mm aggregates. This change was implemented in ASP 6 effective with the January 2014 letting. (1) Ensure that the aggregate blend, including recycled material and mineral filler, conforms to the gradation requirements in table The values listed are design limits; production values may exceed those limits. TABLE AGGREGATE GRADATION MASTER RANGE AND VMA REQUIREMENTS PERCENTS PASSING DESIGNATED SIEVES SIEVE NOMINAL SIZE 37.5 mm 25.0 mm 19.0 mm 12.5 mm 9.5 mm SMA 12.5 mm SMA 9.5 mm 50.0-mm mm mm 90 max mm 90 max mm 90 max mm 90 max mm 90 max mm µm % MINIMUM VMA [1] 15.0 [2] Not for Contract Administration [1] 14.5 for E-3 mixes. [2] 15.5 for E-3 mixes. (2) Unless the contract designates otherwise, ensure that the nominal size of the aggregate used in the mixture conforms to and the following: PAVEMENT LAYER NOMINAL SIZE Effective with the December 2014 Letting Standard Specifications

168 Lower layer pavement mm Upper layer pavement mm Stone matrix layer pavement mm Asphaltic Binders (1) The department will designate the grade of asphaltic binder in the contract. The contractor may use virgin binder, modified binder, a blend of virgin and recovered binder, or a blend of modified and recovered binder. Ensure that the resultant asphaltic binder conforms to the contract specifications Additives Hydrated Lime Antistripping Agent (1) If used in HMA mixtures, furnish hydrated lime conforming to ASTM C977 and containing no more than 8 percent unhydrated oxides. Percent added is by weight of the total dry aggregate Liquid Antistripping Agent (1) If used in HMA mixtures, add liquid antistripping agent to the asphaltic binder before introducing the binder into the mixture. Provide documentation indicating that addition of liquid antistripping agent will not alter the characteristics of the original asphaltic binder performance grade (PG) Stone Matrix Asphalt Stabilizer (1) Add an organic fiber, an inorganic fiber, a polymer-plastic, a polymer-elastomer, or approved alternate stabilizer to all SMA mixtures. If proposing an alternate, submit the proposed additive system, asphaltic binder, and stabilizer additive, along with samples of the other mixture materials to the department at least 14 days before the project let date. The department will approve or reject that proposed alternate additive system no later than 48 hours before the project let date. (2) Use a single additive system for all SMA pavement in the contract Warm Mix Asphalt Additive or Process (1) Use additives or processes from the department's approved products list. Follow supplier or manufacturer recommendations for additives and processes when producing WMA mixtures Recycled Asphaltic Materials (1) The contractor may use recycled asphaltic materials from FRAP, RAP, and RAS in HMA mixtures. Stockpile recycled materials separately from virgin materials and list each as individual JMF components. (2) Control recycled materials used in HMA by evaluating the percent binder replacement, the ratio of recovered binder to the total binder. Conform to the following: MAXIMUM ALLOWABLE PERCENT BINDER REPLACEMENT RECYCLED ASPHALTIC MATERIAL LOWER LAYERS UPPER LAYER RAS if used alone RAP and FRAP in any combination RAS, RAP, and FRAP in combination[1] [1] When used in combination the RAS component cannot exceed 5 percent of the total weight of the aggregate blend Recovered Asphaltic Binders (1) Establish the percent of recovered asphaltic binder from FRAP, RAP, and RAS for the mixture design according to AASHTO T164 using the appropriate dust correction procedure. If production test results indicate a change in the percent of recovered asphaltic binder, the contractor or the engineer may request a change in the design recovered asphaltic binder. Provide the department with at least 2 recent extraction samples supporting that change. Ensure that those samples were prepared according to CMM 8-65 by a WisDOT qualified laboratory. (2) The contractor may replace virgin binder with recovered binder up to the maximum percentage allowed under without changing the asphaltic binder grade. If using more than the maximum allowed under , furnish test results indicating that the resultant binder meets the grade the contract originally specified. Not for Contract Administration Effective with the December 2014 Letting Standard Specifications

169 HMA Mixture Design Revise table to require VFB of 68-80% for E-0.3 mixes and revise footnote 3 to specify a VFB range of for 12.5 and 9.5 mm aggregates. This change was implemented in ASP 6 effective with the January 2014 letting. (1) For each HMA mixture type used under the contract, develop and submit an asphaltic mixture design according to the department's test method number 1559 as described in CMM 8-66 and conforming to the requirements of table and table The values listed are design limits; production values may exceed those limits. The department will review mixture designs and report the results of that review to the designer according to the department's test method number TABLE MIXTURE REQUIREMENTS Mixture type E E - 1 E - 3 E - 10 E - 30 E - 30x SMA ESALs x 10 6 (20 yr design life) < < < < < 30 >= 30 LA Wear (AASHTO T96) 100 revolutions(max % loss) revolutions(max % loss) Soundness (AASHTO T104) (sodium sulfate, max % loss) Freeze/Thaw (AASHTO T103) (specified counties, max % loss) Fractured Faces (ASTM 5821) (one face/2 face, % by count) Flat & Elongated (ASTM D4791) (max %, by weight) Fine Aggregate Angularity (AASHTO T304, method A, min) Sand Equivalency (AASHTO T176, min) / 65 / 75 / / / / /90 5 (5:1 ratio) 5 (5:1 ratio) 5 (5:1 ratio) 5 (5:1 ratio) 5 (5:1 ratio) Not for Contract Administration 5 (5:1 ratio) 20 (3:1ratio) Gyratory Compaction Gyrations for N ini Gyrations for N des Gyrations for N max Air Voids, %V a (%G mm N des ) 4.0 (96.0) 4.0 (96.0) 4.0 (96.0) 4.0 (96.0) 4.0 (96.0) 4.0 (96.0) % G mm N ini <= 91.5 [1] <= 90.5 [1] <= 89.0 [1] <= 89.0 <= 89.0 <= (96.0) % G mm N max <= 98.0 <= 98.0 <= 98.0 <= 98.0 <= 98.0 <= 98.0 Dust to Binder Ratio [2] (% passing 0.075/P be ) Voids filled with Binder (VFB or VFA, %) [4] [5] [4] [3] [4] [3] [4] [3] [4] [3] [4] Tensile Strength Ratio (TSR) (ASTM 4867) no antistripping additive with antistripping additive Draindown at Production 0.30 Temperature (%) [1] The percent maximum density at initial compaction is only a guideline. [2] For a gradation that passes below the boundaries of the caution zone (ref. AASHTO MP3), the dust to binder ratio limits are [3] For 9.5mm and 12.5 mm nominal maximum size mixtures, the specified VFB range is 70-76%. [4] For 37.5mm nominal maximum size mixes, the specified VFB lower limit is 67%. [5] For 25.0mm nominal maximum size mixes, the specified VFB lower limit is 67%. Effective with the December 2014 Letting Standard Specifications

170 Quality Management Program General (1) Provide and maintain a QC program defined as all activities, including mix design, process control inspection, sampling and testing, and process adjustments related to producing and placing HMA pavement conforming to the specifications. The contractor may also provide an optional CA program. (2) The department will provide product quality verification as follows: 1. By conducting verification testing of independent samples. 2. By periodically observing contractor sampling and testing. 3. By monitoring required control charts exhibiting test results and control parameters. 4. By the engineer directing the contractor to take additional samples at any time during production. (3) Refer to CMM 8-36 for detailed guidance on sampling, testing, and documentation under the QMP Contractor Testing Required Quality Control Program Personnel Requirements (1) Provide HTCP-certified sampling and testing personnel. Provide at least one full-time HMA technician certified at a level appropriate for sampling and production control testing at each plant site furnishing material to the project. Before mixture production begins, provide an organizational chart in the contractor's laboratory. Include the names, telephone numbers, and current certifications of all personnel with QC or CA responsibilities. Keep the chart updated. (2) Ensure that sampling and testing personnel are minimally qualified as follows [1] : - HMA technician certified at a level appropriate for sampling and production control testing. - HMA ACT [2]. [1] After informing the engineer, a non-certified person under the direct observation of a certified HMA technician may sample for a period not to exceed 3 calendar days. [2] A certified HMA technician must coordinate and take responsibility for the work an ACT performs. No more than one ACT can work under a single certified technician. (3) Have a certified HMA technician ensure that all sampling and testing is performed correctly, analyze test results, and post resulting data. (4) Have an HMA technician certified at a level appropriate for process control and troubleshooting or mix design available to make necessary process adjustments Laboratory Requirements (1) Conduct QC testing in a facility conforming to the department's laboratory qualification program. (2) Ensure that the laboratory has at least 320 square feet of workspace and has a telephone for exclusive use by QMP personnel. Ensure that all testing equipment conforms to the equipment specifications applicable to the required testing methods Required Sampling and Testing Contracts with 5000 Tons of Mixture or Greater (1) Furnish and maintain a laboratory at the plant site fully equipped for performing contractor QC testing. Have the laboratory on-site and operational before beginning mixture production. Not for Contract Administration (2) Obtain random samples and perform tests according to CMM Obtain HMA mixture samples from trucks at the plant. Perform tests the same day taking the sample. (3) Retain the split portion of the contractor HMA mixture and blended aggregate samples for 14 calendar days at the laboratory site in a dry, protected area. The engineer may decrease this 14-day retention period. At project completion the contractor may dispose of remaining samples if the engineer approves. (4) Use the test methods identified below, or other methods the engineer approves, to perform the following tests at a frequency greater than or equal to that indicated: Blended aggregate gradations: Drum plants: Effective with the December 2014 Letting Standard Specifications

171 - Field extraction by CMM 8-36 WisDOT Test Method Belt samples, optional for virgin mixtures, obtained from stopped belt or from the belt discharge using an engineer-approved sampling device and performed according to AASHTO T11 and T27. Batch plants: - Field extraction by CMM 8-36 WisDOT Test Method Asphalt content (AC) in percent: AC by calculation. AC by nuclear gauge reading, optional. AC by inventory, optional. Bulk specific gravity of the compacted mixture according to AASHTO T166. Maximum specific gravity according to AASHTO T209. Air voids (V a ) by calculation according to AASHTO T269. VMA by calculation according to AASHTO R35. (5) Test each design mixture at a frequency at or above the following: TOTAL DAILY PLANT PRODUCTION FOR DEPARTMENT CONTRACTS SAMPLES in tons PER DAY [1] 50 to to to to greater than 4200 see footnote [2] [1] Frequencies are for planned production. If production is other than planned, conform to CMM [2] Add a random sample for each additional 1500 tons or fraction of 1500 tons. (6) Also conduct field tensile strength ratio tests according to ASTM D4867 on all mixtures requiring an antistripping additive. Test each full 50,000 ton production increment, or fraction of an increment, after the first 5000 tons of production. Perform required increment testing in the first week of production of that increment. If field tensile strength ratio values are either below the spec limit or less than the mixture design JMF percentage value by 20 or more, notify the engineer. The engineer and contractor will jointly determine a corrective action Contracts with Less Than 5000 Tons of Mixture (1) Conform to modified as follows: Not for Contract Administration - The contractor may conduct QC tests in an off-site laboratory. - No field tensile strength ratio testing is required Contracts with Less Than 500 Tons of Mixture (1) The engineer may waive QC testing on contracts with less than 500 tons of mixture. If testing is waived, acceptance will be by visual inspection unless defined otherwise by contract change order. (2) If HMA density testing is waived under , QC testing is also waived Temporary Pavements (1) The engineer may waive all testing for temporary pavements, defined for this purpose as pavements that will be placed and removed before contract completion Documentation Records (1) Document all observations, inspection records, mixture adjustments, and test results daily. Note observations and inspection records in a permanent field record as they occur. Record all process adjustments and JMF changes. Submit copies of the running average calculation sheets for blended Effective with the December 2014 Letting Standard Specifications

172 aggregate, mixture properties, and asphalt content along with mixture adjustment records to the engineer each day. Submit testing records and control charts to the engineer in a neat and orderly manner within 10 days after paving is completed. (2) Continue charts, records, and testing frequencies, for a mixture produced at one plant site, from contract to contract Control Charts (1) Maintain standardized control charts at the laboratory. Record contractor test results on the charts the same day as testing. Post CA test results on the charts as data becomes available. Record data on the standardized control charts as follows: - Blended aggregate gradation tests in percent passing. Of the following, plot those sieves the design specifications require: 37.5-mm, 25.0-mm, 19.0-mm, 12.5-mm, 9.5-mm, 2.36-mm, and 75-µm. - Asphalt material content in percent. - Air voids in percent. - VMA in percent. (2) Plot both the individual test point and the running average of the last 4 data points on each chart. Show QC data in black with the running average in red and CA data in blue. Draw the warning limits with a dashed green line and the JMF limits with a dashed red line. The contractor may use computer generated black-and-white printouts with a legend that clearly identifies the specified color coded components Control Limits Revise (1) to change the percent asphaltic content JMF limits to -0.3 and the warning limits to This change was implemented in ASP 6 effective with the January 2014 letting. (1) Conform to the following control limits for the JMF and warning limits based on a running average of the last 4 data points: ITEM JMF LIMITS WARNING LIMITS Percent passing given sieve: 37.5-mm +/ / mm +/ / mm +/ / mm +/ / mm +/ / mm +/ / µm +/ /- 1.5 Asphaltic content in percent Air voids in percent +/ /- 1.0 VMA in percent [1] [1] VMA limits based on minimum requirement for mix design nominal maximum aggregate size in table (2) Warning bands are defined as the area between the JMF limits and the warning limits Job Mix Formula Adjustment Rewrite to clarify that the production VMA running average must meet the specified minimum percent VMA if reducing the asphalt content. This change was implemented in ASP 6 effective with the January 2014 letting. (1) The contractor may request adjustment of the JMF according to the department's test method number Have an HMA technician certified at a level appropriate for process control and troubleshooting or mix design submit a written JMF adjustment request. Ensure that the resulting JMF is within specified master gradation bands. The department will have a certified Hot Mix Asphalt, Mix Design, Report Submittals technician review the proposed adjustment and, if acceptable, issue a revised JMF. Not for Contract Administration (2) The department will not allow adjustments that do the following: - Exceed specified JMF tolerance limits. - Reduce the JMF asphalt content unless the production VMA running average meets or exceeds the minimum VMA design requirement defined in table for the mixture produced. Effective with the December 2014 Letting Standard Specifications

173 (3) Have a certified Hot Mix Asphalt, Troubleshooting, Process Control technician make related process adjustments. If mixture redesign is necessary, submit a new JMF, subject to the same specification requirements as the original JMF Corrective Action (1) When running average values trend toward the warning limits, consider taking corrective action. Document all corrective actions undertaken. Include all test results in the contract files and in running average calculations. (2) Notify the engineer if running average values exceed the warning limits. If two consecutive running average values exceed the warning limits, stop production and make adjustments. Do not restart production until after notifying the engineer of the adjustments made. Do not calculate a new running average until the fourth test after the required production stop. (3) If the process adjustment improves the property in question so that the running average after 4 additional tests is within the warning limits, the contractor may continue production with no reduction in payment. (4) If the adjustment does not improve the properties and the running average after 4 additional tests stays inside the warning bands, the mixture is nonconforming and subject to pay adjustment. (5) If the contractor fails to stop production and make adjustments when required, all mixture produced from the stop point to the point when the running average is back inside the warning limits is nonconforming and subject to pay adjustment. (6) The department will reduce payment for nonconforming QMP HMA mixtures, starting from the stop point to the point when the running average is back inside the warning limits, as follows: PAYMENT FOR MIXTURE PRODUCED WITHIN PRODUCED OUTSIDE ITEM WARNING BANDS JMF LIMITS Gradation 90% 75% Asphalt Content 85% 75% Air Voids 70% 50% VMA 90% 75% [1] For projects or plants where the total production of each mixture design requires less than 4 tests refer to CMM [2] Payment is in percent of the contract unit price for both the HMA Pavement and Asphaltic Material bid items. The department will reduce pay based on the nonconforming property with lowest percent pay. The asphaltic material quantity is based on the JMF asphalt content. The department will administer pay reduction under the Nonconforming QMP Asphaltic Material and the Nonconforming QMP HMA Mixture administrative items. (7) If the running average values exceed the JMF limits, stop production and make adjustments. Do not restart production until after notifying the engineer of the adjustments made. Continue calculating the running average after the production stop. [1] [2] Not for Contract Administration (8) If the air voids running average of 4 exceeds the JMF limits, the material is nonconforming. Remove and replace unacceptable material at no additional expense to the department. The engineer will determine the quantity of material to replace based on the testing data using the methods in CMM 8-36 and an inspection of the completed pavement. If the engineer allows the mixture to remain in place, the department will pay for the mixture and asphaltic material at 50 percent of the contract price. (9) If the running average of 4 exceeds the JMF limits for other properties, the department will pay 75 percent of the contract price for mixture and asphaltic material if the engineer allows the mixture to remain in place. The engineer will determine the quantity of material subject to pay reduction based on the testing data and an inspection of the completed pavement Optional Contractor Assurance General (1) CA testing is optional and is conducted to further validate production testing. The contractor may offer CA data to provide an additional piece of information for the following: 1. Process control decisions. 2. Troubleshooting possible sampling, splitting, or equipment problems. Effective with the December 2014 Letting Standard Specifications

174 3. Limiting liability, as defined in CMM 8-36, for nonconforming product as a result of department verification testing. These provisions do not supersede department's rights under Personnel Requirements (1) Ensure that an HTP-certified HMA technician certified at a level appropriate for mixture production control testing performs all CA testing and data analysis. Personnel performing CA testing cannot perform QC testing for the same materials Laboratory Requirements (1) Conduct CA testing in a facility conforming to the department's laboratory qualification program. Furnish and maintain a laboratory fully equipped for performing selected CA tests. If the a single laboratory is providing CA and QC data for the same materials, ensure that a separate set of equipment is used to prepare CA samples and run CA tests Testing (1) For the CA program, use the test methods enumerated here in , other engineer-approved methods, or other methods the industry and department HMA technical team recognizes. The contractor may select tests at its option. If using tests in limiting liability, as provided in CMM 8-36, data must exist for the property in question. (2) Perform selected testing as follows: - Bulk specific gravity (Gmb) of the compacted mixture according to AASHTO T166 based on the average of 2 specimens. - Maximum specific gravity (Gmm) according to AASHTO T Air voids (Va) by calculation according to AASHTO T VMA by calculation according to AASHTO R35. (3) There is no specified frequency for CA testing. (4) The department will compare CA samples to QC samples. Obtain CA samples by retaining a QC split portion conforming to the "rule of retained" requirements, as provided in CMM Alternatively the contractor may have CA personnel take an additional sample during production Documentation (1) Report CA test results to the engineer and the contractor's field staff within 2 business days after receiving the samples Allowable Differences (1) Differences between the QC and CA split sample test results are acceptable in limiting liability, as provided in CMM 8-36, if within the following limits: ITEM ALLOWABLE DIFFERENCES Percent passing 12.5 mm sieve 6.0 Percent passing 9.5 mm sieve 6.0 Percent passing 4.75 mm sieve 5.0 Percent passing 2.36 mm sieve 4.0 Percent passing 600-µm sieve 3.5 Percent passing 75-µm sieve 2.0 Bulk specific gravity of the compacted mixture Maximum specific gravity Department Testing Quality Verification Program General (1) The engineer will conduct QV tests to determine the quality of the final product and measure characteristics that predict relative performance. Not for Contract Administration Personnel Requirements (1) The department will provide at least one HTCP-certified HMA technician, certified at a level appropriate for sampling and mixture production control testing, to observe QV sampling of project mixtures. Effective with the December 2014 Letting Standard Specifications

175 (2) An HMA technician certified at a level appropriate for sampling and mixture production control testing, or an HMA ACT working under the HMA certified technician, will split samples and do the testing. An HMA technician certified at a level appropriate for sampling and mixture production control testing must coordinate and take responsibility for the work an ACT performs. No more than one ACT can work under a single certified technician. (3) An HMA technician certified at a level appropriate for sampling and mixture production control testing will ensure that all sampling and testing is performed correctly, analyze test results, and post resulting data. (4) The department will make an organizational chart available at the testing laboratory and to the contractor before mixture production begins. The department's chart will include names, telephone numbers, and current certifications of all QV testing personnel. The department will update the chart with appropriate changes, as they become effective Laboratory Requirements (1) The department will furnish and maintain a facility for QV testing conforming to the department's laboratory qualification program requirements and fully equipped to perform QV testing. In all cases, the department will conduct testing in a separate laboratory from the contractor's laboratory Department Verification Testing Requirements (1) HTCP-certified department personnel will obtain random samples by directly supervising HTCP-certified contractor personnel sampling from trucks at the plant. The department will sample according to CMM Sample size must be adequate to run the appropriate required tests in addition to one set of duplicate tests that may be required for dispute resolution. The engineer will split the sample for testing and retain the remaining portion for additional testing if needed. (2) The department will verify product quality using the test methods enumerated here in (2), other engineer-approved methods, or other methods the industry and department HMA technical team recognizes. The department will identify test methods before construction starts and use only those methods during production of that material unless the engineer and contractor mutually agree otherwise. (3) The department will perform all testing conforming to the following standards: Bulk specific gravity (G mb ) of the compacted mixture according to AASHTO T166. Maximum specific gravity (G mm ) according to AASHTO T209. Air voids (V a ) by calculation according to AASHTO T269. VMA by calculation according to AASHTO R35. (4) The department will randomly test each design mixture at the following minimum frequency: FOR TONNAGES TOTALING: Less than 501 tons... no tests required From 501 to 5,000 tons... one test More than 5,000 tons... add one test for each additional 5,000-ton increment Documentation Not for Contract Administration (1) The engineer will document all observations during QV sampling, and review QC mixture adjustments and QC/CA test results daily. The engineer will note results of observations and inspection records in a permanent field record as they occur Acceptable Verification Parameters (1) The engineer will provide test results to the contractor within 2 mixture-production days after obtaining the sample. The quality of the product is acceptably verified if it meets the following limits: - Va is within a range of 2.7 to 5.3 percent. - VMA is within minus 0.5 of the minimum requirement for the mix design nominal maximum aggregate size. (2) If QV test results are outside the specified limits, the engineer will investigate immediately through dispute resolution procedures. The engineer may stop production while the investigation is in progress if the potential for a pavement failure is present. (3) If production continues for that mixture design, the engineer will provide additional retained sample testing at the frequency provided for in CMM This supplemental testing will continue until the material meets allowable differences or as the engineer and contractor mutually agree. Effective with the December 2014 Letting Standard Specifications

176 Dispute Resolution (1) When QV test results do not meet the specified limits, the bureau's AASHTO accredited laboratory and certified personnel will referee test the retained portion of the QV sample and the retained portion of the nearest available previous QC sample. (2) The department will notify the contractor of the referee test results within 3 business days after receipt of the samples. (3) The department will determine mixture conformance and acceptability by analyzing referee test results, reviewing mixture project data, and inspecting the completed pavement all according to CMM Corrective Action (1) Remove and replace unacceptable material at no additional expense to the department. (2) The department will reduce pay for the tonnage of nonconforming mixture, as determined during QV dispute resolution, if the engineer allows that mixture to remain in place. If production of that mixture design continued during the investigation, the department will also adjust pay for that mixture forward to the next conforming QV or QC/CA point. The department will pay for the affected mixture at 50 percent of the contract price. The department will adjust pay for both the mixture and the asphaltic material Independent Assurance Testing (1) The department will evaluate both the contractor and department testing personnel and equipment as specified in Construction General (1) Construct HMA pavement conforming to the general provisions of Thickness (1) Provide the plan thickness for lower and upper layers limited as follows: NOMINAL MINIMUM LAYER MAXIMUM LOWER MAXIMUM UPPER MAXIMUM SINGLE SIZE THICKNESS LAYER THICKNESS LAYER THICKNESS LAYER THICKNESS [3] in inches in inches in inches in inches 37.5 mm mm mm mm [1] [2] mm [1] [2] 2 3 [1] SMA mixtures use nominal size 12.5 mm or 9.5 mm. [2] SMA mixtures with nominal sizes of 12.5 mm and 9.5 mm have no maximum lower layer thickness specified. Not for Contract Administration [3] For use on cross-overs and shoulders HMA Pavement Density Maximum Density Method Minimum Required Density (1) Compact all layers of HMA mixture to the density table shows for the applicable mixture, location, and layer. Effective with the December 2014 Letting Standard Specifications

177 ReviseTable footnote 5 to specify minimum density for SMA mixtures according to CMM LOCATION LAYER TABLE MINIMUM REQUIRED DENSITY [1] PERCENT OF TARGET MAXIMUM DENSITY MIXTURE TYPE E-0.3, E-1, and E-3 E-10, E-30, and E-30x SMA [5] TRAFFIC LANES [2] LOWER 91.5 [3] 92.0 [4] UPPER SIDE ROADS, CROSSOVERS, TURN LANES, & RAMPS SHOULDERS & APPURTENANCES LOWER 91.5 [3] 92.0 [4] UPPER LOWER UPPER [1] The table values are for average lot density. If any individual density test result falls more than 3.0 percent below the minimum required target maximum density, the engineer may investigate the acceptability of that material. [2] Includes parking lanes as determined by the engineer. [3] Minimum reduced by 2.0 percent for a lower layer constructed directly on crushed aggregate or recycled base courses. [4] Minimum reduced by 1.0 percent for lower a layer constructed directly on crushed aggregate or recycled base courses. [5] The minimum required densities for SMA mixtures are determined according to CMM Pavement Density Determination Revise (1) to eliminate density testing of sawed or cored samples. (1) The engineer will determine the target maximum density using department procedures described in CMM The engineer will determine density as soon as practicable after compaction and before placement of subsequent layers or before opening to traffic. (2) Do not re-roll compacted mixtures with deficient density test results. Do not operate continuously below the specified minimum density. Stop production, identify the source of the problem, and make corrections to produce work meeting the specification requirements. Revise (3) to use the linear sublot or the nominal tonnage system to determine nuclear density tests per lot. (3) A lot is defined in CMM 8-15 and placed within a single layer for each location and target maximum density category indicated in table The lot density is the average of all samples taken for that lot. The department determines the number of tests per lot according to either the linear sublot system or the nominal tonnage system defined in CMM Not for Contract Administration (4) A certified nuclear density technician, or a nuclear density ACT working under a certified nuclear density technician, will locate samples and perform the testing. A certified nuclear density technician must coordinate and take responsibility for the work an ACT performs. No more than one ACT can work under a single certified technician. The responsible certified technician will ensure that sample location and testing is performed correctly, analyze test results, and provide density results to the contractor weekly Waiving Density Testing (1) The engineer may waive density testing for one or more of the following reasons: 1. It is impracticable to determine density by the lot system. 2. The contract contains less than 750 tons of a given mixture type placed within the same layer and target maximum density category. (2) If the department waives density testing notify the contractor before paving. The department will accept the mixture by the ordinary compaction procedure as specified in (3) If HMA QC testing is waived under , density testing is also waived. Effective with the December 2014 Letting Standard Specifications

178 460.4 Measurement (1) The department will measure the HMA Pavement bid items acceptably completed by the ton as specified in Payment General (1) The department will pay for measured quantities at the contract unit price under the following bid items: ITEM NUMBER DESCRIPTION UNIT HMA Pavement Type E-0.3 TON HMA Pavement Type E-1 TON HMA Pavement Type E-3 TON HMA Pavement Type E-10 TON HMA Pavement Type E-30 TON HMA Pavement Type E-30X TON HMA Pavement Type SMA TON Incentive Density HMA Pavement DOL HMA Pavement General (1) The department will pay for the HMA Pavement bid items at the contract unit price subject to one or more of the following adjustments: 1. Disincentive for density of HMA pavement as specified in Incentive for density of HMA pavement as specified in or Reduced payment for nonconforming smoothness as specified in Reduced payment for nonconforming QMP HMA mixtures as specified in (2) Payment for HMA Pavement Type E-0.3, E-1, E-3, E-10, E-30, and E-30x is full compensation for providing HMA mixture designs; for preparing foundation; for furnishing, preparing, hauling, mixing, placing, and compacting mixture; for QMP testing and aggregate source testing; for warm mix asphalt additives or processes; and for all materials except asphaltic materials. (3) Payment for HMA Pavement Type SMA, is full compensation for providing HMA mixture designs; for preparing foundation; for furnishing, preparing, hauling, mixing, placing, and compacting the mixture; for QMP testing and aggregate source testing; and for all materials including asphaltic materials and warm mix asphalt additives and processes; for stabilizer, hydrated lime, and liquid antistripping agent if required. (4) If provided for in the plan quantities, the department will pay for a leveling layer, placed to correct irregularities in an existing paved surface before overlaying, under the pertinent paving bid item. Absent a plan quantity, the department will pay for a leveling layer as extra work. Not for Contract Administration (5) Except for SMA mixes, the department will pay for asphaltic materials separately under the Asphaltic Materials bid items as specified in Except for SMA mixes, hydrated lime or liquid antistripping agent, when required, is included in the contract price for the asphaltic material. (6) If the department waives density testing under , the department will not adjust pay under either or (7) Restore the surface after cutting density samples as specified in (1) at no additional cost to the department Disincentive for HMA Pavement Density (1) The department will administer density disincentives under the Disincentive Density HMA Pavement and the Disincentive Density Asphaltic Material administrative items. If the lot density is less than the specified minimum in table 460-3, the department will reduce pay based on the contract unit price for both the HMA Pavement and Asphaltic Material bid items for that lot as follows: DISINCENTIVE PAY REDUCTION FOR HMA PAVEMENT DENSITY PERCENT LOT DENSITY PAYMENT FACTOR BELOW SPECIFIED MINIMUM (percent of contract price) Effective with the December 2014 Letting Standard Specifications

179 From 0.5 to 1.0 inclusive 98 From 1.1 to 1.5 inclusive 95 From 1.6 to 2.0 inclusive 91 From 2.1 to 2.5 inclusive 85 From 2.6 to 3.0 inclusive 70 More than 3.0 [1] [1] Remove and replace the lot with a mixture at the specified density. When acceptably replaced, the department will pay for the replaced work at the contract unit price. Alternatively the engineer may allow the nonconforming material to remain in place with a 50 percent payment factor. (2) If the engineer directs placing HMA mixtures between October 15 and May 1 for department convenience as specified in (5), the department will not assess a density disincentive on pavement the department orders the contractor to place when the temperature, as defined in (2), is less than 36 F Incentive for HMA Pavement Density (1) If the lot density is greater than the minimum specified in table and all individual air voids test results for that mixture placed during the same day are within +1.0 percent or percent of the design target in table 460-2, the department will adjust pay for that lot as follows: INCENTIVE PAY ADJUSTMENT FOR HMA PAVEMENT DENSITY PERCENT LOT DENSITY ABOVE SPECIFIED MINIMUM PAY ADJUSTMENT PER TON [1] From -0.4 to 1.0 inclusive $0 From 1.1 to 1.8 inclusive $0.40 More than 1.8 $0.80 [1] The department will prorate the pay adjustment for a partial lot. (2) The department will adjust pay under the Incentive Density HMA Pavement bid item. Adjustment under this item is not limited, either up or down, to the bid amount the schedule of items shows. (3) The department will restrict incentive payment for shoulders paved integrally with the traffic lane, if the traffic lane does not meet incentive requirements, the department will not pay incentive on the integrally paved shoulder. Not for Contract Administration Effective with the December 2014 Letting Standard Specifications

180 HMA-IPT Laboratory Exam Page 1 Student Date HIGHWAY TECHNICIAN CERTIFICATION PROGRAM THE UNIVERSITY OF WISCONSIN-PLATTEVILLE TECHNICIAN CERTIFICATION PROGRAM HMA TECHNICIAN IPT QUALIFYING LABORATORY EXAM Area of Qualification Pass/Fail Instructor A. Sampling B. Bulk Specific Gravity C. Maximum Specific Gravity D. Sawed or Cored Pavement E. WisDOT 1560 Solvent Extraction Comments:

181 HMA-IPT Laboratory Exam Page 2 EXPLANATION The practical laboratory examination for the Hot-Mix Asphalt Technician IPT consists of a combination of oral and hands-on presentations to the laboratory instructor. The instructor will use the attached checklist to verify fine and key points in any given test. In the practical examination, the student will be given an actual sample. The student will do the hands-on tests on his/her own under the observation and questioning of the instructor and present the results to the instructor. Successful Completion Successful completion of examination includes the satisfactory completion of the following: 1. The instructor will engage the student in oral discussion on any of the attached areas which the student must be thoroughly familiar with. The student should satisfactorily explain any part of the hands-on training included in Asphalt Technician I, including purpose of test and how the data is used. 2. The student must demonstrate acceptable skill in performing the laboratory procedures presented in Asphalt Technician I. Parts where the student shows lack of full comprehension must be repeated. HMA TECHNICIAN-IPT Practical Laboratory Examination Oral Examination Instructions: 1. The instructor may choose one or more of the following sub-categories to test the student s understanding of the laboratory procedures. 2. If the instructor is in doubt of the student s understanding, the number of testing categories may be increased.

182 HMA-IPT Laboratory Exam Page 3 A. Sampling COMPLETED A.1 A.2 A.3 A.4 Responsibility for sampling Location for sampling Sampling procedure Sample reduction procedure B. Bulk Specific Gravity (G mb ) Procedure COMPLETED B.1 Specimen molds and equipment pre-heated in an oven at 300 F. B.2 B.3 B.4 Each specimen (enough material to attain a final specimen height of 115 mm 5 mm) placed in a flat pan and placed for a maximum of one hour at F to bring mix standard compaction temperature. Place a paper disc in the bottom of heated specimen. Place full contents of flat pan into the mold in one lift action (additional funnels or scoop chutes may be used in order to accomplish this). B.5 Ensure a compaction temperature of about F. B.6 B.7 B.8 B.9 B.10 Perform compaction. How many gyrations are required? Where do you find that information? After compaction is completed, extrude the specimen. Remove protective paper discs and label briq. Cool briq by fan on a flat surface for one hour and 45 minutes. Why is this important? Water temperature for G mb should be 77 2 F (25 C). Why this temperature? B.11 Sample should be submerged for three to five minutes in water before weighing.

183 HMA-IPT Laboratory Exam Page 4 B.12 B.13 SSD weight in air is determined after blotting specimen quickly with a damp towel. Compute individual specimen G mb. Determine average G mb of four specimens. Check for specified uniformity with standard. Explain what to do if they don=t. C. Maximum Specific Gravity COMPLETED C.1 C.2 C.3 C.4 C.5 C.6 C.7 C.8 C.9 Cure sample in 300 F oven to 30 minutes to one hour. Sample broken up and let cool to room temperature, care being taken not to fracture the mineral particles or having remaining conglomerates of fine aggregate greater than ¼ inch. Place sample in pre-calibrated container Weigh container and sample. Add water at 77 2 F (25 C) to cover sample. Wetting agent may be added. Apply required partial vacuum for 15 2 minutes. Agitate container every two minutes to assist in air removal. After completion of vacuum, fill container with controlled temperature water. Place lid, adjust water level, and weigh. Drain water from sample, decanting water through a towel or a #200 sieve held over top of container to prevent loss of fine particles. Back dry the sample. While drying, intermittently stir the sample. Break conglomerations by hand.

184 C.10 Weigh at 15 minute intervals until loss in weight is less than 0.5 g for a given interval. Sample is then considered SSD. D. Sawed or Cored Pavement COMPLETED D.1 D.2 Obtaining pavement samples is contractor=s responsibility. Explain normal condition of field samples as received. Describe core preparation before testing. D.3 Testing procedure for G mb : S S S Immerse in water at 77 o F (25 o C) for three to five minutes and determine submerged weight. Surface dry the sample by blotting with damp cloth and determine weight. Oven dry the sample at o F and determine weight. D.4 Compute G mb of cores as required by contract. E. Extraction Using Solvent WisDOT 1560 COMPLETED E.1 E.2 E.3 E.4 E.5 Obtain a representative sample of asphaltic mixture according to the latest copy of the department=s procedure manual. Dry sample for 10 to 20 minutes in oven at F (RAP stockpile samples shall be heated until dry, approximately 30 to 60 minutes). Weigh sample to the nearest 0.1 gram. Determine the percent asphalt being added to the mixture at the time the sample was obtained from the settings of the asphalt plant for produced mixtures (RAP stockpile samples, use the asphalt content shown for the RAP on the mix design). Place mixture in the pan, pail, or bowl and cover with solvent (agitate the sample gently with spatula).

185 E.6 Soak plant produced mixtures 15 to 30 minutes and RAP stockpile samples for 30 to 60 minutes. Note: Excess soaking time in the solvent will require more water washed and cause more smoke during the drying period. E.7 Decant the solvent, pouring over a No. 8 sieve nested over a No. 200 sieve. Dispose of solvent by an approved method. Continue rinsing with water until the wash water is clear. Material retained on either of the two sieves shall be washed back into the sample. E.8 E.9 E.10 Decant off any excess water (care should be taken to avoid the loss of particles for the AASHTO Test Method T 27). Dry the sample to a constant weight in an oven or on a hot plate (avoid excessive temperature in the drying process). Conduct a gradation test on the aggregate according to the procedures of AASHTO Test Method T 27.

186 APPENDIX: QMP Award Nomination Form The Quality Management Program Award recognizes outstanding certified highway materials technicians who have displayed exceptional leadership roles in developing quality materials used in highway construction projects. These winners are chosen from contractors, consultants, and the Wisconsin Department of Transportation. It is this industry support and joint partnering that makes this program a success. Some of the qualities attributed to the award winners include HTCP certification, HTCP promotion, development of cost savings, development of time savings, quality improvement, being a team player and possessing a positive attitude.

187 Quality Management Program Award Nomination Application This Outstanding Individual or Team is Nominated to Receive this Year s Quality Management Program Award Individual/Team: Address: City/State/Zip: Telephone: Employer: Work Address: City/State/Zip: Telephone: Fax : List individual or team nominated: Identify outstanding individual or team achievement(s) that exemplify this nomination for the Quality Management Program Award : *Application submitted by: Do you wish to remain anonymous? Yes No (* Required for nomination) Date: Please fax (608) or send completed application before November 1 of each year to Highway Technician Certification Program, University of Wisconsin-Platteville, 049 Ottensman Hall, 1 University Plaza, Platteville, WI

188 Quality Management Program Award Nomination Application This Outstanding Individual or Team is Nominated to Receive this Year s Quality Management Program Award Individual/Team: Address: City/State/Zip: Telephone: Employer: Work Address: City/State/Zip: Telephone: Fax : List individual or team nominated: Identify outstanding individual or team achievement(s) that exemplify this nomination for the Quality Management Program Asphalt Award : *Application submitted by: Do you wish to remain anonymous? Yes No (* Required for nomination) Date: Please fax (608) or send completed application before November 1 of each year to Highway Technician Certification Program, University of Wisconsin-Platteville, 049 Ottensman Hall, 1 University Plaza, Platteville, WI

189 Corrections

190 OOPS! Found an error? Course Title: Please describe the error and the page or topic where you found it: We might have questions. How can we reach you? Name: Phone: Note to Development Team: Send updates to or call , or mail to HTCP, 1 University Plaza, University of Wisconsin-Platteville, Platteville, WI THANK YOU!

191 Course Evaluation

192 HIGHWAY TECHNICIAN CERTIFICATION PROGRAM (HTCP) EVALUATION The HTCP would appreciate your thoughtful completion of all items on this evaluation. Your comments and constructive suggestions will be carefully studied and will serve as a valuable resource to improve our course presentations: Course: Date: 1. Overall rating of this program: Outstanding Above Average Average Below Average Unacceptable Did the course meet your expectations? How well were you satisfied with the quality and quantity of the course materials? Comments about course materials/visual aids: 2. Instructor: Outstanding Above Average Average Below Average Unacceptable Effectiveness of course presentation: Responsiveness and interaction with students: Ability to communicate: Knowledge of course content: Please fill in and rate overall effectiveness of laboratory instructor(s)/guest lecturer(s): Outstanding Above Average Average Below Average Unacceptable Comments: Please make additional comments about individual laboratory instructor(s)/guests lecturer(s) quality of instruction: