Asphalt QC 2000 The Adventure Begins….

Topics Terminology Specifications Sampling and Testing Reporting/CQR Who Does What? Lube & Oil Change All in 20 Minutes!

In a Nutshell….. Payment based on Contractor’s (Quality Control) test data that has been verified Payment based on Contractor’s (Quality Control) test data that has been verified FDOT runs Verification tests at a lesser frequency FDOT runs Verification tests at a lesser frequency –Split-sample at plant by project personnel –Independent sample at District Lab Payment is based on density on the roadway and air voids, asphalt content and gradation at the plant Payment is based on density on the roadway and air voids, asphalt content and gradation at the plant –Percent Within Limits (PWL) – larger quantities –Pay Table – smaller quantities –Big Change!

General Details Include…. Initial lot size mandatory 2000 tons Initial lot size mandatory 2000 tons –Following lots may be 2000 or 4000 tons –Contractor’s option w/Engineer’s Approval –Deleted Initial Production Test Strip – No “Pause” Typical lot size 4000 tons Typical lot size 4000 tons –English and Metric the same 4 sublots per lot (1000 tons each) 4 sublots per lot (1000 tons each) Plant lot and roadway lots are the same Plant lot and roadway lots are the same All sampling performed by the Contractor All sampling performed by the Contractor FDOT establishes when to sample FDOT establishes when to sample – Several options available

Who’s on First? OldNewWho AcceptanceVerification Project Personnel (CEI) Quality Control Contractor Personnel Independent Assurance Independent Verification/ Independent Assurance District Materials Personnel Referee Testing Resolution System District Materials Laboratory

General Overview - Plant Engineer (VT) directs Contractor (QC) when to sample Engineer (VT) directs Contractor (QC) when to sample –Random basis – generated by Excel Spreadsheet –1/sublot (1/1000 tons or 1/500 tons) –QC splits out and boxes up Verification and Resolution Samples Tests include: Tests include: –Asphalt Content (FM only) –Gradation (FM 1-T 030) –Air Voids (AASHTO TP-4 & FM 1-T 209)

Verification - Plant Performed by Agency - FDOT or Consultant (CTQP Plant Level I) Performed by Agency - FDOT or Consultant (CTQP Plant Level I) –Tests run at plant Split-sample – randomly selected – 1/lot (1/4000 tons or 1/2000 tons) Split-sample – randomly selected – 1/lot (1/4000 tons or 1/2000 tons) –Same tests as QC Precision statement comparison with QC results Precision statement comparison with QC results –G mm, G mb, P b, P -200, P -8

Table Between-Laboratory Precision Values Property Maximum Difference G mm G mb PbPbPbPb0.44% P -200 FM 1-T 030 (Figure 2) P -8 FM 1-T 030 (Figure 2) Between-Laboratory Precision Values

Verification – Plant (Cont’d) If all results compare: If all results compare: –Accept material –Payment based on Contractor’s QC results If the results don’t compare: If the results don’t compare: –VT tests remaining sublot samples for property (or properties) in question. –If only initial unfavorable comparison: accept material and pay based on QC results –If two or more unfavorable: Resolution »Samples sent to District Lab

Independent Verification - Plant District Materials takes two samples per 12,000 tons District Materials takes two samples per 12,000 tons –Tested at District Lab Same tests as QC Same tests as QC Results have to meet requirements of Master Production Range Results have to meet requirements of Master Production Range –Go or no go….

Table Master Production Range CharacteristicTolerance Asphalt Binder Content (%) Target ± 0.55 Passing No. 8 Sieve (%) Target ± 5.50 Passing No. 200 Sieve (%) Target ± 1.50 Air Voids (%) 4.00 ± 1.50 Density, %G mm Density, %G mm : Coarse Graded (minimum) Fine Graded N/A Note: Density based on an average of 5 randomly located cores

Quality Control Sampling and Testing – Roadway Core locations identified by VT Core locations identified by VT –Tonnage basis Contractor cuts five cores per sublot Contractor cuts five cores per sublot –Example: 1000 ton sublot, 12 ft wide lane »150 lb/sy = 1 core/2000 feet »200 lb/sy = 1 core/1500 feet »250 lb/sy = 1 core/1200 feet »300 lb/sy = 1 core/1000 feet QC tests cores per FM 1-T 166 QC tests cores per FM 1-T 166 Retains cores for Verification/Resolution Retains cores for Verification/Resolution

Verification - Roadway Tests performed by Verification Technician Tests performed by Verification Technician –Tests run at plant Same-cores Same-cores –VT tests all five cores from a randomly selected sublot –Same test as QC Precision statement comparison with QC results Precision statement comparison with QC results –G mb = Compare favorably: Pay based on QC results Compare favorably: Pay based on QC results –If not: similar to plant Resolution

Independent Verification Roadway District Materials directs Contractor to take five additional cores from same sublot as plant IV sample District Materials directs Contractor to take five additional cores from same sublot as plant IV sample Results have to meet requirements of Master Production Range Results have to meet requirements of Master Production Range –Average density must meet minimum… –Go or no go….

Compensation If two or less sublots: use Small Quantity Pay Table based on average deviations from target If two or less sublots: use Small Quantity Pay Table based on average deviations from target If three or more sublots: use the estimated Percent Within Limits (PWL) for the lot, based on the following characteristics: If three or more sublots: use the estimated Percent Within Limits (PWL) for the lot, based on the following characteristics: –Density –Air Voids –AC Content –P-200 –P-8

Compensation (Cont’d) Pay factor for each characteristic is determined Pay factor for each characteristic is determined Composite Pay factor is based on: Composite Pay factor is based on: –35%Density –25%Air Voids –25%AC Content –10%P-200 –5%P-8 All calculations by Excel spreadsheet All calculations by Excel spreadsheet –Not by hand!

Reporting Contractor reports all QC test results, quantities, etc.: Contractor reports all QC test results, quantities, etc.: –Daily Asphalt Plant Quality Control Report –Daily Asphalt Roadway Quality Control Report –Inputs into CQR CEI reports all Verification test results and Verification activities: CEI reports all Verification test results and Verification activities: –Verify mix spread rate, tack spread rate, mix temperature, etc. –Asphalt Plant Verification Report –Asphalt Roadway Verification Report –Inputs into CQR Forms currently under development Forms currently under development CQR access through District Construction Office CQR access through District Construction Office

Other Related Issues Implementation date: July 2002 Letting Implementation date: July 2002 Letting –All projects No Type S/FC-3 projects No Type S/FC-3 projects –Specification only works with Superpave FC-9.5 & FC-12.5 (FC-6) accepted per 334 FC-9.5 & FC-12.5 (FC-6) accepted per 334 FC-5 specified in 337 FC-5 specified in 337 –Tolerances based on FC-5 construction data –Pay factors weighted differently –Criteria 3/8” No.4 & No. 8 sieve, and Binder Content Specification Refresher Course Specification Refresher Course

Thank You!

Upcoming Specification Changes July 2002 Letting

General The following Sections are “sunset” (but will still be in the book): The following Sections are “sunset” (but will still be in the book): –280 Asphalt Base Courses –331 Type S Asphalt Concrete, Quality Assurance and Acceptance Procedures –332 Type II Asphaltic Concrete –333 Type III Asphaltic Concrete –335 Sand-Asphalt Hot Mix

New Specs 234 Superpave Asphalt Base 234 Superpave Asphalt Base –Designated B-12.5 –SP-12.5 mix, »TL B or C »Fine Graded –May substitute an SP-12.5 in lieu of B-12.5 –Accepted per 334 (QC 2000) –Thickness determined by spread rate, not coring

Changes 300 Prime and Tack Coats for Base Courses 300 Prime and Tack Coats for Base Courses –Contractor measures application rate of prime and tack coats (twice per day) and provides basic QC –RA 500 replaces AC-5 »Can use in day or night 327 Milling of Existing Asphalt Pavement 327 Milling of Existing Asphalt Pavement –QC requirement to check cross-slope every 250’

More changes…. 330 Hot Bituminous Mixtures - General Construction Requirements 330 Hot Bituminous Mixtures - General Construction Requirements –Specific Contractor QC requirements »In addition to Section 105 –New temperature spec –No paving in the rain –Control of cross-slope

Still more changes…. 337 Asphalt Concrete Friction Courses 337 Asphalt Concrete Friction Courses –FC-2, FC-3 will sunset –FC-5 OGFC »Placement temp – down to 60 ⁰ F if good texture –FC-9.5 new 9.5 mm friction course mix »Placed 1” thick –FC-12.5 (FC-6) »Renamed FC-6 –FC-9.5 & 12.5 will require 100% polish resistant aggregate »Exception 60% granite

QC Asphalt Welcome… to the Real World.

Industry Perspective QC 2000 Asphalt Specifications Jim Warren Asphalt Contractors Association of Florida, Inc.

Contractor perspectives… Old: – –What good will this do? – –Oh No!, Not another new specification! – –Lets go back to S-1 Now: – –It’s no so bad… I see some positives. – –We’re trained, we’re equipped… Lets Roll! Opportunities

What's different from the old system? Same Superpave Mix as before Still going to test it the same way – no new tests More QC responsibilities than before Must change focus from average to uniformity about average (big change) Its still Hot, Black, and Sticky.

What’s in it for the contractor? More flexibility to run your operation. More responsibility and authority to make sure the job is done right. Less reliance of others for decisions of when to pave, adjustments to make, etc. Less rework, fewer call-backs, less wasted profits and opportunity costs. QC tests finally mean something. Finally, a payback for investing in QC personnel and equipment. Mo money (if you know what you’re doing).

What’s in it for the Industry? Levels the playing field for bidding. Improves the image of the Industry… Asphalt is State-Of-The-Art. Continuously improving our product – You want it? We can deliver on time, on budget. Eliminates lesser products from gaining a foothold in our market. Secures and protects the highway asphalt paving market due to superior performance and lower life-cycle cost.

What does Industry need to do to make it work? Educating your crews – “It’s not business as usual anymore” “This ain’t no S-1” Think P401. Stress the importance of attention to detail “Every ton counts!” Mgmt. Attitude – you can make this work! If you believe it, exude it… it will happen. Attend the refresher course – A Gotta! Get up to speed faster through a better understanding of the specification.

Making it Work! Schwartzkoff Rule #13: “When placed in command – take charge” Warren Corollary to Rule 13: “When placed in leadership, lead!” Mgmt. Attitude – you can make this work! If you believe it, exude it… it will happen. Every Ton Counts!

What’s in it for the Agency? Better, more reliable product. No need to look anywhere else for products. Flexibility to inspect where needed… Less $ spent on inspection means more $ for product (asphalt, bridges, etc.) Meets the National goal of “Get In, Do the Job, Get Out and Stay Out” Schwartzkoff “Rule #14: Do the Right Thing” Warren Corollary to Rule #14. Add “the First Time”

What does the Agency need to do make it work? Have some patience – change takes time – big changes don’t happen overnight. Cooperate during the transition Expect some mistakes, be willing to work them out Attend the refresher course – get up to speed faster through better understanding of the specification.

Refresher Course Objective: The objective of this 1-day program is to familiarize the participant with the new QC2000 asphalt specifications. Upon completion of this program, the participant will be able to: – –- Identify what’s different under these new specifications compared to current specifications, – –- Understand the respective roles and duties of the parties involved, and – –- Understand the acceptance process.

Refresher Course Agenda: Introduction Definitions Review Specifications – –(234, 285, 320, 330, 334, 337) The Matrix Walking through the Plant & Roadway Checks & Balances Calculations and Spreadsheet Forms, Case Studies, & Q&A Quiz

What’s in it for the Taxpayer? The Smooth Ride… Achievable Goals: – –No rutting – –No cracking – –No potholes Renewable Surface (roof) as part of entire paving system. A pavement that delivered the biggest bang for the buck that lasts. The Best Paving Product – second to none.