Raising the Quality Bar- Everyone Wins!

Quality in the Concrete Paving Process Raising the Quality Bar- Everyone Wins! Jim Grove, PE Federal Highway Administration/Global Consulting Inc. Office of Infrastructure Virginia Concrete Conference March 8, 2013 Richmond, VA Introduction - 1

What? Quality Assurance We test and inspect to insure pavement meets specifications We have quality procedures to insure long life pavements These are not the same! Introduction - 2

Testing vs. Quality Testing does not insure quality Testing is a tool to achieve quality Testing and inspection allow us to anticipate and avoid problems We use test results to achieve quality Introduction - 3

Quality in the Concrete Paving Process Workshops Alaska Hawaii Workshops to date Upcoming Workshops Introduction - 4

Agenda Workshop Introduction Module 1: Quality Assurance Concepts Module 2: Materials and Characteristics for Quality Pavement Why Module 3: Pre-Paving and Mix Production Module 4: Paving Module 5: Utilizing Quality Concepts Module 6: Quality in Field Practice What How Both contractors and agency personnel! Introduction - 5

Reference Materials Participant Workbook All the presentation slides Class exercises Quality in the Concrete Paving Process Richmond, Virginia 2013 Introduction - 6

Testing Guide Reference Materials Identified concrete tests for critical concrete properties What to test Purpose How to test What does it mean? Implication Introduction - 7

Quality Manual What to inspect How to inspect Reference Materials Format of the Workshop QC Plan Checklists Both contractors and agency Introduction - 8

Flash Drive Reference Materials National Concrete Pavement Technology Center: Integrated Materials and Construction Practices for Concrete Pavement Manual (IMCP Manual) ACPA : Concrete Pavement Field Reference: Pre- Paving ACPA : Concrete Pavement Field Reference: Paving NHI Course 134064: Transportation Construction Quality Assurance Example QC Plan Example spreadsheets for control charts Introduction - 9

Contractor Benefits Contractors who consistently meet specifications have an advantage at the bidding table Reduce Penalties Done right the first time Reduced Re-Work QC costs are typically a fraction of re-work costs Increase Incentives Know you will get full incentive Use incentive to reduce bid amount Allows energy for monitoring the process, not wasting it on fixing problems Introduction - 10

Agency Benefits Agency receives improved quality without additional cost Finish project sooner Frees up personnel sooner Open to the public sooner Avoids time needed to assess re-work and determine penalty Creates a better working environment Public gets a longer lasting pavement Introduction - 11

Core Elements of a QA Program Quality Assurance Quality Control Agency Acceptance Independent Assurance Dispute Resolution Qualified Labs Qualified Personnel Introduction - 12

Acceptance Plans that Recognize Inherent Variability Based on proven mathematical probability (MIL 414) Take into account the sources of inherent variability Provide a more realistic assessment of degree of conformance Introduction - 13

Quality Measurement Tools Two principal tools used to measure conformance with requirements: Inspection Testing Introduction - 14

Inspection Components Equipment Materials Workmanship Environmental Conditions Introduction - 15

Measuring Quality with Testing Three criteria must be identified to assess Quality through testing: Quality Characteristics Quality Measures Quality Limits Introduction - 16

Sampling The process of selecting one or more samples from a population (Lot). Key elements of sampling system: Lots Statistical Samples Minimum of 3 samples Ideally 8 to 20 random samples Sublots Samples Introduction - 17

Removes bias Random Sampling All materials have an equal probability of being sampled Appropriate for acceptance testing Appropriate for statistical process control Introduction - 18

Sources of Variability Material Process Sampling Testing Composite Variability Introduction - 19

Validity of Sampling Data The principles associated with Normal Distribution can be applied to determine the Quality of a Lot of Material, assuming: 1) Multiple (n > 3) samples are used 2) All samples are Randomly obtained 3) Samples are obtained from the same Lot under Controlled Conditions Introduction - 20

Re-Sampling vs. Re-Testing Re-sampling Take a new material sample Replace the original sample with the new Re-testing Perform another, separate test Perform the test on the split from the original sample II - 21 Introduction - 21

Analysis and Application of QC Test Results Control charts Unit Weight, pcf Used to plot and monitor consecutive QC test results Results can be tracked against a process target/limits Can help to identify whether the process is in control 148May indicate that adjustments process is necessary 146 144 142 140 138 1-1 1-2 2-1 2-2 2-3 3-1 3-2 3-3 4-1 5-1 5-2 6-1 6-2 7-1 7-2 Unit Weight Mixture Design Upper Limit Lower Limit Introduction - 22

Control charts do not Eliminate variability Control Charts Tell you where your problem lies Tell you how to correct the problem Some control charts Help distinguish between the inherent chance causes of variability and assignable causes Introduction - 23

Acceptance Function Acceptance is not focused on directing the methods used to achieve conformance The primary objectives of agency acceptance are: Measure the Quality of all materials produced and placed by the contractor Determine the corresponding payment the contractor should receive Introduction - 24

Acceptance Function Quality measurement is achieved through three general acceptance activities: Monitoring the adequacy of contractor QC activity Performing acceptance inspection to identify visually deficient work Performing Acceptance sampling and testing for key quality characteristics Agency is obtaining information to confirm that all products meet the specified quality level Introduction - 25

Module 2: Materials and Characteristics for Quality Pavement Introduction - 26

Concrete Materials Cements / Supplementary cementitious materials Aggregates Water (Admixtures) Introduction - 27

Cement How SCM s Work Calcium Silicate Hydrate Secondary Reaction Causes => Stuff to Harden Calcium Hydroxide Calcium Silicates + Water CSH + CH Calcium Carbonate Fly Ash / Slag Supplemental Cementitious Material + Water + CH Begins after the cement reaction CSH Introduction - 28

Chemical Admixtures Air entraining admixtures (AEA) Water reducers Set modifying admixtures To make good concrete better, not to fix bad concrete!! Introduction - 29

Strength Affects fatigue cycles Controlled by w/cm Other factors are indirect Strength and durability are not the same Introduction - 30

Permeability Test (Surrogate tests for durability) Rapid Chloride Permeability Test (Indirectly) Wenner Probe/Surface Resistivity Test (Indirectly) Rapid Chloride Permeability Test Surface Resistivity Test Introduction - 31

Unit Weight Test Unit Weight Quality Indicator for: Uniformity Batching tolerances Air Content Introduction - 32

Calorimetry Test Calorimetry (heat signature) Quality Indicator for: Cementitious system Strength development Time of set Sawing window Uniformity Introduction - 33

Air Content Test Air Content Quality Indicator for: Freeze-thaw damage Strength Air 1% Strength 5% Introduction - 34

Air Void System Why? Water expands when it freezes What are we looking for? Expansion of 9% Small bubbles close together Air void system is more important than total air content Introduction - 35

Quality Control Stage Monitor mixture quality during production and react to changes Gradation Slump Unit weight Air content Microwave water content Strength Permeability Introduction - 36

Incompatibility All materials meet specification, yet the mixture is unsatisfactory Early stiffening Air entrainment Strength development Due to chemical reactions between materials Change mix temperature, SCM dose and/or admixture type Refer to page 9 of the Testing Guide Introduction - 37

Volume Shrinkage Introduction - 38

Pre-Paving Activities Introduction - 39

Load transfer Why? Dowel Basket Placement Introduction - 40

Paver Preparation Extrusion process Check slab dimensions and cross-slopes Introduction - 41

Aggregate Stockpile Management Minimize segregation Build long and wide-not high! Build stockpiles in tiers to avoid segregation Fines at the top Coarse at the bottom Picture courtesy of Martin Marietta Materials Introduction - 42

Aggregate Stockpile Management Uniform Moisture Stable and well drained foundation underneath stockpiles Place a separation layer on top of soil Draw from areas of known moisture content Introduction - 43

Aggregate Stockpile Management Mud balls Introduction - 44

Recommended Practices Adequate mixing time Uniformity Air entrainment Strength Workability Introduction - 45

Transporting Concrete Maintain haul route Introduction - 46

Paving Activities Refer to the Field Reference Manual for Quality Concrete Pavements for details on steps shown in italics Introduction - 47

Spreading Concrete Continuous supply of concrete to the paver Consistent head => smoothness Introduction - 48

Consolidation Match vibrator frequency to workability and paver speed Electronic vibrator monitor Introduction - 49

Key Inspection Items One contactor example Tape QC Inspection list on the paver Stringline constant Edge slump every 50 Offset alignment every 50 Slab width every 50 Introduction - 50

Key Inspection Items Check dowel location Real-time NDT Core verification after first day Depth Alignment Position relative to sawn joint Introduction - 51

QC Measurements Verify dowel bar location behind the paver Introduction - 52

Key Inspection Items Periodically verify steel location behind the paver Cover meter (pachometer) GPR after hardened MIT-SCAN-2 Pachometer GPR Introduction - 53

MIT-SCAN-2 Cut the tie wires Key Inspection Items Introduction - 54

Recommended Practices Identify bumps and dips overlap straightedge by 1/2 Correct bumps and dips Introduction - 55

Texturing Macro Texture Wet weather skid resistance Reduce hydroplaning Introduction - 56

Group Activity Why do we Cure? Introduction - 57

Recommended Practices Adequate number of saws on the project Introduction - 58

Module 6: Quality in Field Practice Introduction - 59

Slump Measure of consistency Quick and easy Introduction - 60

Air Void Analyzer Air void system Initially to verify a good air void system For QC, not for specification compliance Higher total air => lower spacing factor 0.020 Spacing Factor, in 0.01 in Limit 0.015 in Limit Spacing Factor, in 0.016 0.012 0.008 At the plant 0.004 0.000 5.2% 6.5% 6.0% 6.5% 5.0% 5.3% Total Air 3-1 3-2 3-3 4-1 5-1 6-1 Introduction - 61

Cementitious system Heat Signature Strength development Time of set Sawing window Incompatibilities Uniformity Introduction - 62

Permeability Surface Resistivity Test Easy and quick test Rapid Chloride Permeability Test Takes more time and effort- old stand by Surface Resistivity, KOhm-cm 25 20 15 10 5 0 Low Moderate High 56 Days 2-1 2-2 2-3 3-1 3-2 4-1 5-1 5-2 6-1 6-2 7-1 7-2 Sample ID Introduction - 63

Heat Signature vs. Surface Resistivity 25.0 56 Day Surface Resistivity, Ohm-cm 23.0 21.0 19.0 17.0 15.0 13.0 11.0 9.0 7.0 5.0 y = 1351.9e -0.046x R² = 0.9141 90 92 94 96 98 100 102 104 106 Maximum Temperature of the Heat Signature Curve, F Introduction - 64

HIPERPAV [Example] Software tool for assessing cracking risk Tensile Strength Critical Tensile Stresses - Top Critical Tensile Stresses - Bottom Introduction - 65

HIPERPAV Software tool for assessing cracking risk Placement on the night of 5/21/12 @ 1:00 5:00 9:00 A.M. P.M. Introduction - 66

HIPERPAV Software tool for assessing cracking risk Placement on the night of 5/22/12 @ 12:00 8:00 4:00 A.M. P.M. Introduction - 67

Maturity curve Maturity Temperature and time factor can be used to determine in-place pavement strength 800 Maturity Curve - Standard Cured Beams Flexural Strength, PSI 700 600 500 400 300 200 100 0 820 C-Hrs Specimens Cast on 5/16/12 0 500 1000 1500 2000 2500 3000 3500 4000 Maturity, C-Hrs Opening strength= 550 psi MOR Introduction - 68

Maturity curve Maturity ( C-Hrs) Maturity Temperature and time factor can be used to determine in-place pavement strength 1000 900 800 700 600 500 400 300 200 100 0 0 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 Time(hrs) Maturity number = 820 C-Hrs Field Maturity (5/18/12) Field Maturity (5/21/12) 22 hrs Opening strength= 550 psi MOR Introduction - 69

MIT-SCAN-T2 Thickness example Design thickness = 11 Average thickness (T2)= 12.3 T2 Pavement Thickness, in 14.0 13.5 13.0 12.5 12.0 11.5 11.0 10.5 10.0 Thickness Design Average 294+05 296+00 297+00 299+00 301+00 697+16 698+10 700+20 702+14 704+08 706+00 708+00 710+00 713+00 715+00 Introduction - 70

Air/Unit Weight Normally they will run parallel Unit weight changes if air content changes Unit weight changes if water (slump) changes When they diverge Unit Weight, pcf Change in materials or proportions 143 142 141 140 139 138 137?? Unit Weight Air Content 1-1 2-1 2-2 2-3 3-1 3-2 3-3 3-4 Sample ID 5% 6% 7% 8% 9% 10% Air Content, % Introduction - 71

Agenda Workshop Introduction Module 1: Quality Assurance Concepts Module 2: Materials and Characteristics for Quality Pavement Why Module 3: Pre-Paving and Mix Production Module 4: Paving Module 5: Utilizing Quality Concepts Module 6: Quality in Field Practice What How Both contractors and agency personnel! Introduction - 72

Jim Grove Federal Highway Administration/Global Consulting Inc. Office of Infrastructure 2711 South Loop Drive Suite 4502 Ames, Iowa 50010 Phone: 515-294-5988 Mobile: 515-450-3399 jim.grove@dot.gov Introduction - 73