Quality Control (QC) and Asphalt Mix Quality = ???

Topics
Quality Assurance (QA) in
Bituminous Road Construction
By
Prof. Prithvi Singh Kandhal
Associate Director Emeritus
National Center for Asphalt Technology
Auburn University, Alabama USA
pkandhal@gmail.com
Kandhal
Introduction of Quality Control and Quality
Assurance (QC/QA) Concepts
Testing Components of Asphalt Mix
Testing Asphalt Mix (Composition; Volumetrics;
Mix Strength)
Testing Roadway Density
Quality Control by Contractor
Quality Assurance by Owner (PWL and Pay Factors)
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QC/QA Testing Asphalt Mix

QUALITY
Quality Control Contractors Mix Component Source Approval
Responsibility Properties or Specifications

Meets or exceeds the [Also called process control]

Mix Design
expectations or needs of the Quality Assurance Owners Mix Composition
customer Responsibility
[Making sure the quality of a Mix Volumetric
Properties
product is what it should be]
Mix Mechanical
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Testing Mix Component - Aggregate Testing Mix Component - Aggregate

MIXTURE DESIGN Coarse Aggregate Properties
Fine Aggregate
- Flat & Elongated Particles
- Los Angles Abrasion - Sand Equivalent Value
- Soundness (Sodium or Magnesium Sulphate) - Plasticity Index (PI)
- Aggregate Impact Value
- Polished Stone Value Mineral Filler
- Water Absorption - Gradation
- Stripping - Plasticity Index (PI)

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 Centrifuge Extraction Test
Testing Mix Component - Binder Testing Mix Composition
Viscosity Graded Bitumen (IS:73) Bitumen Content (Design +/- 0.3 %)
- Viscosity at 60 C and 135 C - Centrifuge Extraction Method
- Penetration at 25 C - Ignition Oven Method Ash Correction
- Flash point
- Solubility
Gradation of Extracted Aggregate (Job-mix
- Softening point Formula Gradation +/- Specified
- TFO Residue (Viscosity Ratio and Tolerances)
Ductility)
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Job-Mix Formula Tolerances

Ignition Oven Test
Temperature - 578 C
Test time - 30 to 40 minutes
Testing
gradation of
extracted
Troxler
aggregate

Thermolyne

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Testing Compacted Mix Volumetrics Testing Mix Mechanical

Properties
Determine Bulk Specific Gravity of
Compacted Specimen, Gmb
Marshall Stability
Determine Theoretical Maximum Specific
Marshall Flow
Gravity of Loose Mix, Gmm
Calculate % Air Voids; % VMA; % VFA

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 Marshall Stability and Flow Test Checking Density With
60oC
40 Minutes in Asphalt Mix Roadway Density Nuclear Gauge
Water Bath
50mm/min Proving Measured by Nuclear Gauge
Loading Rate Ring
Stability = Measured by Cores
Flowmeter
Maximum Load Permissible In-place Air Voids: 8 % Max.
Flow =
Deformation at Breaking
Head
Maximum Load

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Quality Control (QC) by Contractor Frequency of Testing (Example)

Should develop and implement QC Plan for
inspection and testing to ensure asphalt mix meets
the specification
QC Plan should include frequency of testing
QC Plan should include steps:
- to keep the process under control
- to quickly determine when process has gone out
of control
- to respond adequately to bring the process back
into control
Asphalt binder 1 test per 1500 tons of
binder
Binder content and gradation 1 test per
400 tons of asphalt mix (minimum 2/day)
Mix volumetrics, stability and flow 1 test
per 400 tons of asphalt mix (minimum
2/day)

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Control Charts for

Benefits of Control Charts Control Chart for Air Voids
Process Control 6

Action Limit (UCL)

Early detection of trouble
Upper Spec. Limit 5
Warning Limit
Decrease variability
% Air Voids

Establish process capability 4

Reduce price adjustment costs

3

Decrease inspection frequency

Lower Spec. Limit Action Limit (LCL)
2
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50

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Quality Assurance by Owner Sampling location

Quality assurance based on LOTS
LOT Generally one days production
SUBLOTS Generally 5 sublots in a lot
Stratified random sampling plan is preferred
Use random numbers from table
Sublot 1
Sampling mix from trucks leaving asphalt
LOT plant (based on time or tonnage)
Sampling loose mix behind the paver at
predetermined random locations
Obtain cores after compaction for checking
Sublot 2 Sublot 3 Sublot 4 Sublot 5 mat density at random locations

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Loose HMA

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Loose HMA Sample Splitting Examples of tests to be

performed

Bitumen content
Laboratory air voids in Marshall specimens
Field air voids in compacted mat

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 Bitumen Contents of 5 Sublots STATISTICS Statistical Tools
Bitumen Content as per Job Mix Formula Measures of Variability
6.1 +/- 0.4 % (Range of 5.7 to 6.5 %)
A tool for helping to make
informed decisions and Percent Within Limits (PWL)
Bitumen Contents in 5 sublots: resolve disputes.
6.0, 5.6, 6.2, 5.8, 6.1 Pay Factors

What does it mean? Comparison of Data Groups

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Specifications and Variability

Minimum
Standard Deviation
s = standard deviation Specification X = 93.5
Limit S = 0.75
No. of Samples

No. of Samples

X = 96.0
S = 2.0
Percent Within Limits (PWL)

-3s -2s - 1s 1s 2s 3s
68%
96% 90 92 95 100
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99.7%

Percent Within Limits Percent Within Limits

PWL and PD Concept
PWL = 100 - (PDU + PDL) Target Value 5.0 Lot X s PWL Target Value 5.0 Lot X s PWL
PD = Percent Defective Limits 0.4 1 5.0 0.20 100 Limits 0.4 target 1 5.0 0.20 100
target
Lot 1 2 5.0 0.40 67 2 4.8 0.20 84
(in terms of area of the distribution) Lot 2 Lot 2
Lot 1

Upper limit Upper limit

PDL Lower limit
PDU
Lower limit Target

PWL

Bitumen contentKandhal
% 4.2 4.6 5.0 5.4 5.8 4.2 4.6 5.0 5.4 5.8
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Bitumen Content Bitumen Content

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 Payment Based on PWL
Small number of test results outside the PWL Pay Factors
specification limits is normal and not
necessarily detrimental to performance What if the contractor disputes
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Payment is based on PWL and allows for both agencys test results ?
90-95 PWL + 10
potential penalty or bonus
60-89 0.5 PWL + 55
Commonly requires 90% PWL for full Retesting can be conducted in
payment Below 60 Reject presence of the contractor
>90% giving bonus
<90% gives reduction in payment
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RETEST
Bitumen contents in sublots
1 2 3 4 5
Original 6.0 5.6 6.2 5.8 6.1
Retest 6.1 5.4 6.4 5.7 6.1

Determine mean and std. dev. of both lots and

conduct t-test to determine if the two sets of
results came from the same population Kandhal

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KANDHAL

Questions
does it all
make
sense?

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