401.19Contractor Quality Control The Contractor shall operate in accordance with the
approved Quality Control Plan (QCP) to assure a product meeting the contract requirements. The Contractor shall not begin paving operations until the Depa rtment approves the QCP in writing.
1 Quality Control - Method A, B & C The QCP shall meet t he requirements of
quality of the Hot Mix Asphalt Pavement including, but not limi ted to, the following:
will be met)
average contact pressure for pneumatic tired rollers
and free of debris or contamination that could adversely affect the finished pavement
avoiding paving in inclement weather, type of release agent to be used on trucks tools and rollers, compaction of shoulders, tacking of all joints, me thods to ensure that segregation is minimized, procedures to determine the maximum r olling and paving speeds based on best engineering practices as well as past expe rience in achieving the best possible smoothness of the pavement.
and delivery slip template for any plant to be utilized.
limitations. If a warm-mix technology is utilized, a proposed t arget production temperature range (not to exceed 50°F) will be provided for eac h mix design.
Policies and Procedures for HMA Sampling and Testing.
as well as a note detailing conditions under which the percent of RAP will vary from that specified on the JMF.
Acceptance testing results.
mingling of differing PGAB’s.
MaineDOT and deliver said samples to the designated acceptance laboratory.
personnel The QCP shall include the following technicians together with f ollowing minimum requirements:
Administrator must be a full-time employee of or a consultant e ngaged by the Contractor or paving subcontractor. The QCP Administrator shall have full au thority to institute any and all actions necessary for the successful operation of the QCP. The QCP Administrator (or its designee in the QCP Administrator’s absence) shall be available to communicate with the Department at all times. The QCP Administrator shall be certif ied as a Quality Assurance Technologist certified by the New England Transportation Techni cian Certification Program (NETTCP).
practices to assure the quality of aggregates and other mix com ponents and control proportioning to meet the JMF(s). The PCT shall inspect all eq uipment used in mixing to assure it is operating properly and that mixing conforms to the mix design(s) and other Contract requirements, and that delivery slips and plant record ation accurately reflects the mix being produced with all the required information. The QCP shall detail how these duties and responsibilities are to be accomplished and documented, and whether more than one PCT is required. The Plan shall include the criteria to be utilized by the PCT to correct or reject unsatisfactory materials. The PCT shall be certified as a Plant Technician by the NETTCP.
the job site to assure that delivered materials meet the requir ements of the JMF(s). The QCT shall inspect all equipment utilized in transporting, laydo wn, and compacting to assure it is operating properly and that all laydown and compaction co nform to the Contract requirements. The QCP shall detail how these duties and respon sibilities are to be accomplished and documented, and whether more than one QCT is r equired. The QCP shall include the criteria utilized by the QCT to correct or reject u nsatisfactory materials. The QCT shall be certified as a Paving Inspector by the NETTCP. The QCP shall detail the coordination of the activities of the Plan Administrator, the PCT and the QCT. The ProjectS uperintendent shall be named in the QCP, and the responsibilities for successful implementation of the QCP shall be outlined. The Contractor shall have a testing lab at the plant site, equi pped with all testing equipment necessary to complete the tests in Table 5. The Cont ractor shall locate an approved Gyratory Compactor at the plant testing lab. The Contractor sha ll generate QC sampling random numbers for each approved mix design. A copy of the rand om numbers shall be emailed to the QC.mainedot@maine.gov email address and remain o n-file (in print) and be
available for inspection at the QC laboratory. The Contractors hall sample, test, and evaluate Hot Mix Asphalt Pavement in accordance with the following minim um frequencies per each approved mix design:
TABLE 5: MINIMUM QUALITY CONTROL FREQUENCIES Test or Action Frequency Test Method Temperature of mix 6 per day at street and plant - Temperature of mat 4 per day - %TMD (In-Place Density - Surface) 1 per 125 ton AASHTO T355 or AASHTO T343 %TMD (In-Place Density - Base) 1 per 250 ton AASHTO T355 or AASHTO T343 Fines / Effective Binder 1 per 500 ton AASHTO T 312* Gradation 1 per 500 ton AASHTO T30 PGAB Content 1 per 500 ton AASHTO T164 or AASHTO T308 Voids at N design 1 per 500 ton AASHTO T 312* VMA at N design 1 per 500 ton AASHTO T 312* Rice Specific Gravity 1 per 500 ton AASHTO T209 Coarse Aggregate Angularity 1 per 5,000 ton ASTM D 5821 Flat and Elongated Particles 1 Per 5,000 ton ASTM D 4791 Fine Aggregate Angularity 1 Per 5,000 ton AASHTO T304 *Method A and B only
The Contractor shall monitor plant production on each approved mix design using running average of three control charts as specified in Section 106 - Quality. Control limits shall be as noted in Table 6 below. The UCL and LCL, shall not exceed the allowable gradation control points for the particular type of mixture as outlined in Table 1 of Section
703.09
TABLE 6: CONTROL LIMITS Property UCL and LCL Percent Passing 4.75 mm and larger sieves Target +/-4.0 Percent Passing 2.36 mm sieve Target +/-2.5 Percent Passing 0.075 mm sieve Target +/-1.0 PGAB Content Target +/-0.25 VMA at N design LCL = LSL + 0.2 Voids at N design JMF Target +/-1.2 Theoretical Maximum Specific Gravity JMF Target +/-0.020
The Contractor shall submit all HMA QC test reports, inspection reports and updated control charts to the Resident and QC.mainedot@maine.gov by ema il. The HMA QC test reports, inspection reports and updated control charts shall be signed by the appropriate technician and be submitted to the Department by 1:00 P.M. on t he next working day, except when otherwise noted in the QCP and approved by the Depa rtment. The Contractor shall also retain splits of the previous 5 QC te sts, with QC results enclosed for random selection and testing by the Department during inspections of the HMA production facility. Test results of splits that do not meet th e Dispute Resolution Variance
Limits in Table 14 shall trigger an investigation by the MaineD OT Independent Assurance Unit, and may result in that lab losing NETTCP certification an d the ability to request a dispute [Section 401.24 - Process for Dispute Resolution (Metho ds A, B and C only)]. The Contractor shall make density test results, including rando mly sampled densities, available to the Department onsite. Summaries of each day's re sults, including a daily paving report, shall be recorded and signed by the QCT and prov ided to the QC.mainedot@maine.gov email address and Resident in writing by 1:00 p.m. the next working day. The Contractor shall fill all holes in the pavemen t resulting from cutting cores by the Contractor or the Department with a properly compacted, acceptable mixture no later than the following working day. B efore filling, the Contractor shall carefully clean the holes and apply a coating of emulsified asphalt. The Contracto r may only cut additional cores for verification of the densometer, at a rate not to exceed 3 per day or 2 per 1000 ton placed.
If the Contractor’s control chart shows the process for a given mix design to be out of control (defined as a single point outside of the control limits on the running average of three chart) on any property listed in Table 6: Control Limits, the Contractor shall notify the Resident of all affected projects in writing of the corrective action by 1:00 PM the next working day. The written description shall detail what action i s being taken by the Contractor to bring the propert y in question back within contro l limits. Subsequent quality control results are expected to demonstrate an improvement and regression towards the aim. The Department reserves the right to take action, to includece ssation of production, in the case of repeated results outside the Table 6 control chart cont rol limits. On a daily basis, the Contractor shall perform density testing across the mat being placed, prior to being compacted by equipment at 12 in intervals. If the density values vary by more than 2.0% from the mean, the Contractor shall make adju stments to the screed until the inconsistencies are remedied. Failure to replace or repair defective placement equipment may result in a letter of suspension of work and notification o f a quality control violation resulting in possible monetary penalties as governed by Section 106 - Quality The Contractor shall cease paving operations whenever one of th e following occurs:
than 60 PWL.
requirements of Table 3: Aggregate Consensus Properties Criteri a in Section 703.07 for the design traffic level.
variable depth shim courses.
as the corrective action, by the end of the work day. Failure t o do so will be treated as a
second incident under 106.4.6 QCP Non-compliance. The Departmen t will only allow the continuation of paving operations when it is satisfied the corr ective action will result in an improvement in results. The Department may require the submitta l of a passing verification sample to allow further production. The Department retains the exclusive right, with the exception of the first day’s production of a new JMF, to determ ine whether the resumption of production involves a signifi cant change to the production p rocess. If the Department so determines, then the current lot will be terminated, a pay fact or established, and a new lot will begin. The Contractor may utilize innovative equipment or techniques n ot addressed by the Contract documents to produce or monitor the production of the mix, subject to approval by the Department.
2 Quality Control - Method D Unless otherwise noted in S ection 403 - Hot Mix
Asphalt Pavement, the Contractor shall submit a modified QC Pla n detailing, how the mix is to be placed, what equipment is to be used, and what HMA plant is to be used for Items covered under Method D. All mix designs (JMF) shall be approve d and verified by MaineDOT prior to use. Certified QC personnel shall not be req uired unless otherwise noted in Section 403 - Hot Mix As phalt Pavement. The Contracto r shall certify the mix and the test results for each item by a Certificate of Compliance.
401.20Acceptance Method A, B & C These methods utilizes Quali ty Level Analysis
and pay factor specifications. For Hot Mix Asphalt Pavement des ignated for acceptance under Quality Assurance provisions, the Department will sample once per sublot on a statistically random basis, test, and evaluate in accordance wi th the following Acceptance Properties:
TABLE 7: ACCEPTANCE PROPERTIES Properties Point of Sampling Test Method Gradation Paver Hopper AASHTO T30 PGAB Content Paver Hopper AASHTO T308 % TMD (In-Place Density) Mat behind all Rollers AASHTO T269 Voids at N design Paver Hopper AASHTO T 312 VMA at N design Paver Hopper AASHTO T 312 Fines to Effective Binder Paver Hopper AASHTO T 312 VFB Paver Hopper AASHTO T 312
The Department will obtain samples of Hot Mix Asphalt Pavement in conformance with AASHTO R 97, Sampling Asphalt Mixtures, and the MaineDOT Policies and Procedures for HMA Sampling and Testing. The Contractor shall transport the sa mples in containers provided by the Department to the designated MaineDOT Laboratory within 48 hours except when otherwise noted in the project specific QCP or as directed by t he Resident. Failure to deliver an acceptance sample to the designated acceptance laboratory will be considered the second incident under 106.4.6–QCP Non-Compliance.
Target values shall be as specified in the JMF. The Department will withhold reporting of the test results for the Acceptance sample until 7:00 AM, on the se cond working day of receipt of the sample, or after receipt of the Contractors results of the Acceptance sample split. Upon conclusion of each lot, where there is a minimum of four sublots, results shall be examined for statistical outliers, as stated in Section 106.7.2 - Statistica l Outliers.
TABLE 8: ACCEPTANCE METHODS Property USL and LSL Method A Method B Method C Lot Size* Entire production per item per contract up to 6000 ton Entire production per item per contract Entire production per item per contract up to 6000 ton Maximum Sublot Size – Mix 750 ton Lot quantity divided by three 750 ton Maximum Sublot Size – Density Surface Layers – 250 ton Base / Intermediate Layers – 500 ton Lot quantity divided by five Surface Layers – 250 ton Base / Intermediate Layers – 500 ton Minimum Number of Samples – Mix Four Three Four Minimum Number of Samples – Density Five *Unless otherwise agreed upon at the Prepave Meeting
If there is less than one-half of a sublot remaining at the end , then it shall be combined with the previous sublot. If there is more than one-half sublo t remaining at the end, then it shall constitute the last sublot and shall be represented by te st results. If it becomes apparent partway through a Lot that, due to an underrun, there will be insufficient mix quantity to obtain the minimum number of sublots needed, the Re sident may adjust the size of the remaining sublots and select new sample locations based on the estimated quantity of material remaining in the Lot. Unanticipated over-runs of up to 1500 ton shall be rolled into the last lot. Cases where the lot is terminated prior to reachi ng completion shall be handled in accordance with Section 106.7.3 Early Termination of Lots. I n cases where density incentive/disincentive provision apply, additional cores shall be taken to attain a minimum of three for the Lot. Isolated Areas During the course of inspection, should it appe ar that there is an isolated area that is not representative of the lot based on a lack of o bserved compactive effort, excessive segregation, a change in process or any other questio nable practice, that area may be isolated and tested separately. An area so isolated that ha s a calculated pay factor below 0.80 for Method A and C or below 0.86 for Method B, based on th ree random tests shall be removed and replaced at the expense of the Contractor for the f ull lane width and a length not to be less than 150 ft. Pavement Density The Department will measure pavement density using core samples tested according to AASHTO T 166. The Contractor shall cut 6-i nch diameter cores at no additional cost to the Department by the end of the working day following paving. Cores
shall be cut such that the nearest edge at least 9 inches from any joint. Pre-testing of the cores will not be allowed. If the Contractor and the Departmen t mutually determine that a core is damaged, the Contractor shall cut new core(s) at the sa me offset and within 3 ft of the initial sample. The Contractor and the Department will mut ually determine if underlying material is adhered to the core and if so will mark the core at the point where sawing is needed. The Department will place the cores in a secure contai ner and the Contractor shall transport the cores to the designated MaineDOT lab. The cores w ill be saw cut by the Department to remove underlying layers. No recuts are allowed at a test location after the core has been tested. Upon conclusion of each lot, density res ults shall be examined for statistical outliers as stated in Section 106.7.2.
On all sections of overlay with wearing courses designed to be 1 in or less in thickness, there shall be no pay adjustment for density otherwise noted in Section 403 - Hot Mix Asphalt Pavement. For overlays designed to be 1 in or less in t hickness, density shall be obtained by the same rolling train and methods as used on mainl ine travelway surface courses with a pay adjustments for density, unless otherwise di rected by the Department. There shall be no pay adjustment for density on shoulders unless otherwise noted in
same rolling train and methods as used on mainline travelway, u nless otherwise directed by the Department. Efforts to obtain optimum compaction will not be waived by the Department unless it is apparent during construction that local conditions make densification to this point detrimental to the finished pavement surface course.
TABLE 9: ACCEPTANCE LIMITS Property USL and LSL Method A Method B Method C Percent Passing 4.75 mm and larger sieves Target +/-7% Percent Passing 2.36 mm to 1.18 mm sieves Target +/-4% Target + /-5% Target +/-5% Percent Passing 0.60 mm sieve Target +/-3% Target +/-4% Target +/-4% Percent Passing 0.30 mm to 0.075 mm sieve Target +/-2% Target + /-3% Target +/-2% PGAB Content Target +/-0.4% Target +/-0.5% Target +/-0.4% Voids at N design 4.0% +/-1.5% 4.0% +/-2.0% N/A Fines to Effective Binder 0.9 +/-0.3 0.9 +/-0.3 N/A VMA at N design LSL from Table 1 LSL from Table 1 N/A VFB Table 1 plus a 4% production tolerance for USL Table 1 plus a 4% production tolerance for USL N/A % TMD (In-place Density) 95.0% +/- 2.5%
The Contractor shall cease paving operations whenever one of th e following occurs on a lot in progress: