ITEM 403 ASPHALT CONCRETE QUALITY ASSURANCE
403.01 Description. This specification outlines the asphalt concrete quality assurance program
including the contractor requirements for controlling asphalt concrete mixtures during production and construction through Contractor provided quality control (QC) testing and the Department Verification Acceptance (VA) program.
403.02 General. The Contractor is responsible for all aspects of process control and QC needed
to ensure quality of the specified material, including but not limited to sampling, testing, inspecting, assessing, and corrective action to ensure the quality of the final product. The Department is responsible for all aspects of quality assurance (QA) and independent assurance (IA) to ensure and verify the quality and acceptability of the final product. Independent (non -split) random samples are required for Contractor QC when those results are used in the acceptance decision, and for Department VA. The Department will verify Contractor QC results by QC monitoring reviews and by Department VA sampling and testing. If the Contractor results cannot be verified, Department results will be used for acceptance and payment. If the Contractor fails to operate according to their Department-accepted Quality Control Program (QCP), the Department will accept asphalt mixtures by Restricted Acceptance. Restoration of Contractor QC sampling and testing used for acceptance will be by the Department’s Quality Control Review Group (QC Review Group) based on District recommendation and review of the Contractor problems, resolutions, and QCP. The QC Review Gr oup consists of the Asphalt Materials Engineer, Office of Materials Management (OMM); the Administrator, OMM; and the Pavement Engineer, Office of Construction Administration. Acceptance does not relieve the Contractor of responsibility for supplying and installing a finished product conforming to all requirements of the Contract. Supplement 1041 outlines the responsibilities and requirements for Contractor and Consultant employees engaged in all aspects of asphalt concrete production at any level, including, but not limited to, management, supervision, quality control (QC), plant operations, materials management, paving operations, and hauling truck drivers.
403.03 Quality Control Program (QCP). For each paving season create and execute a QCP.
In the QCP cover processes conducted to provide an asphalt mixture at the paving site that is uniform in composition, conforms to the specification requirements and that when placed is free of any defect (ex. segregation, lack of mixture and texture uniformity, raveling, rutting, holes, debris etc.) within the Contractor’s control at project completion. The intention of the QCP is not to copy and paste or paraphrase what is already in the specifications. It is expected that contractors that only place asphalt mix (i.e., paving contractors) also submit a QCP. A minimum of four weeks before mix production and placement, but no later than second Friday in January, submit a hard copy of the proposed QCP to OMM for review and acceptance. Provide digital copies in a searchable formatted PDF, such as Optical Character Recognition. Convert files from Microsoft Office documents (printed or saved as a PDF) and other computer programs (e.g., plant control systems), including all appendices, as a single document with page numbering. Documents that are unable to be converted digitally without printing can be scanned into a PDF, however, the results must be digitally readable. Save digital files with the date of revision in the file name. Keep a cop y of the Department’s acceptance letter and the QCP in both the Contractor plant laboratory and the plant operation control room. A digital copy of the QCP and acceptance letter may be kept in each location provided that the QCP file icon is labelled with a descriptive file name that includes the revision date and is on the computer’s desktop in each area. Remove out-of-date QCPs from the computer desktop. Updates to the QCP will require the entire QCP to be submitted with the updates and a summary of the changes. Send a hard copy and a digital copy of the acceptance letter and QCP to OMM and District Testing in every District in which work is performed. Execute and comply with the Department accepted QCP. Failure to comply with the accepted QCP may result in removal of personnel in accordance with Supplement 1041, removal from VA, and adversely affect the Contractor’s Prequalification rating. For Contractors who produce and place material, include all sections in the order below and include the bold titles. For Contractors who only produce mix include sections A through M, S, and T. For Contractors who only place mix include sections A through C and M through T. As a minimum, include in the following in the QCP: Make the first page of the QCP a front cover with the Company name(s) and logo, the construction year, a statement that this is their Quality Control Plan, and the revision date. Start the second page with the Table of Contents listing all the required sections below in the same order with page numbers and including Appendices. Name Appendices with letter and title of each section and include after the revision sheet.
A.Quality Control Personnel: Provide the Contractor’s full name including main address, mailing address if different, phone number(s), email(s), and other information as deemed fit. Provide a table of organization (can be a hierarchy list) including company president, vice president, superintendents, Quality Control, Plant, and Paving Managers including area managers, and supervisors and note their designated responsibilities to meet QCP requirements. Include office and cell phone numbers, emails, office location if different than the main office, and Department approvals (e.g. Asphalt Level 2 or 3 and FQCS). Provide the name of the Quality Control Manager holding a Supplement 1041 Level 3 approval for production and the names of FQCS for placement and who are company employees. Provide lists of approved Asphalt Level 2 and 3 technicians and FQCS technicians in Appendix A that includes expirations and a date showing when the lists were put together. Note any technicians that are consultants and the company that employs them.
B.Training: Document means for annual training including in ethical conduct according to company expectations of all company employees and consultants who are responsible for the mix design, production, testing, and placement of asphalt mix and their supervisors. Doc ument how and when training is given, what the expectations are, how expectations are communicated and list the personnel classifications being trained. Describe the QC Manager’s and supervisor’s responsibilities and methods to ensure personnel are trained and ethical conduct is maintained throughout the year.
C.Review of QCP: Procedure for ensuring that every Contractor employee involved in the testing of asphalt mix, operation of the asphalt plant facility, and placement has read the QCP and has on site access to all applicable Department specifications, supplements, proposals, policies, and the current approved JMF.
D.Level 2 Lab Calibration: Procedures for equipment calibration and documentation for Level 2 lab equipment including calibration record storage. Ensure calibration intervals meet or exceed the Department requirements (Supplements, AASHTO, ASTM standards, and AASHTO R 18). Provide documentation that all Level 2 lab equipment has been calibrated at the time of the Level 2 lab approval inspection.
E.Asphalt Mixture Quality Control Sampling and Testing: E1. QC Technicians: Assign Level 2 technicians for all Level 2 QC testing duties. Provide a list designating Level 2 technician responsibilities and expected actions. A list of technician names is not required in the QCP but shall be included in AWP. Ensure only approved personnel handle and test samples at all times. If Level 2 consultant technicians are used, include a document in the QCP listing designated responsibilities and expected actions (if di fferent from employee expectations). Provide a copy of the document to the Level 2 consultant technician. E2. Random Numbers: Provide and follow the procedure for determining random numbers for asphalt mix QC sampling and testing including additional sampling and full testing at the start of production. Track random numbers used. Include how random numbers are tracked and the frequency that they will be monitored and that processes are being done correctly (that they have an approximately equal distribution of results across the entire Lot or Sublot). Document how any misuse of the random number procedure is corrected and ensure future compliance. E3. Labeling: Document and follow the procedure for labeling QC, calibrations, sublots, and split samples and testing done on the TE-199, TE-448, and TE-125. Include procedures for saving samples, including duration, and how samples will be destroyed and removed from the lab that are not required by specification (e.g., heat up pills in oven and bust open). E4. Extra Testing: Provide and follow procedures, frequencies, and expectations (e.g., how will the extra testing help with ensuring the mixture conforms to the specification requirements) for extra testing (e.g., responses to poor test results or field mix problems, aggreg ate stock testing, reclaimed asphalt concrete pavement checks, additional moisture checks) and any other testing necessary to control materials not already defined in these Specifications. Include how these will be labeled on the Quality Control Report. If extra testing procedures do not follow Department procedures, provide step- by-step instructions for each test in Appendix E4. Note: District Testing may observe, review, and approve or disapprove the procedures at any time according to 403.06.E. E5. Warning Band & Control Charts: Provide and use warning bands for all tests and give specific instruction how the warning bands and control charts will be used for tests in concert with
403.06 E, 403.06.F, Table 403.06.G-1 specification requirements. Include an example control chart
according to 403.06.E in Appendix E5. E6. QC Test Result Issues: Provide and follow step -by-step procedure of how QC technicians will handle mix that is in the warning band, out of specification including when multiple failures happen, and how these issues will be resolved (e.g., when air voids are out what adjustment(s) will be made, etc.). Flow charts may be used and provided. E7. Recording: Provide how results will be accurately and correctly recorded and reported and who will be responsible for sending daily results to District Testing. If the role for sending daily results to District Testing is the QC technician, indicate QC technician (a specific name is not required). Provide copies of all test reports and forms used in the quality control process including any forms that would be used for handwritten data in Appendix E7.
F.Record Retention: Provide and follow methods to maintain all worksheets, including all handwritten records, and other test and sample records from all plant(s) and, or project(s) for a minimum of eight years. Define the test record retention process. Define company records retention requirements.
G.Asphalt Binder QC: Provide and follow procedures for handling and testing of the mix plant asphalt binder QC samples and subsequent corrective action of binder test failures of any sample (QC or Department). Include how samples will be labeled and stored. Failure to perform QC of asphalt binder samples is at the Contractor ’s risk. Any Department binder sample failures will result in penalties according to Supplement 1102. These include remove and replace, pay deductions, or other penalties for the asphalt mix represented by the Department’s sample. The Department may take as few as one sample representing the entire course being placed according to C&MS 700.00.
H.Mix Plant Info: List of each mix plant name, mix plant number, AWP Facility ID, plant operator(s), phone number(s), email address(es) (if applicable), county the plant is located, physical address, mailing address (if different), and if plant is portable. For each mix plant also include the mix plant type including drum type (e.g., counter -flow, parallel flow, double barrel, mini drum, uni - counterflow), if applicable, plant operating system, the high and low operating tons per hour, number and size of storage silos, number and size of liquid asphalt binder silos or tankers, RAP processing method used, if the plant has the capabilities to in -line blend chemical additives (e.g. chemical WMA and liquid antistrips), if plant has WMA water injection system, RAP bin sizes and number of bins, and if RAS will be used. Provide copies of 5 -minute printouts with labels showing the minimum criteria required according to Supplement 1101 with each computerized system used in Appendix H.
I.Quick Calibrations: Provide expectations on when quick calibrations will be performed according to S upplement 1101 outside of the minimum frequency (e.g., mix production issues). Provide example quick calibration documentation forms in Appendix I.
J.RAP/RAS Processing: Provide and follow procedures to meet the processing, testing and documentation requirements for RAP and RAS in 402.04 including test forms, record keeping, technician responsibilities, and the following. J1. RAP Processing: Include in the QCP methods of validating RAP properties when using concurrent project RAP. Include additional methods and procedures to dictate how the processing of RAP by means of fractionation or by additional in line processing will be accomplished for mix plants using Method 2. Specify documentation method for RAP pile measurements. Include any additional information about RAP or RAS processing and pile maintenance (e.g., if RAP piles are moved to other or shared between plants). J2. RAS Processing: If RAS is used, include RAS usage methods before using RAS and include what Contractor requirements apply to the RAS processor. Include the Contractor’s blending equipment type and operation and uniformity testing requirements for preblended RAP and RAS or RAS and virgin aggregate. If methods are different based on the mix plant, specify what plants follow what methods. Other methods must be approved by OMM prior to use on a project.
K.Material Verification & Handling: Provide and follow procedure and frequency for ensuring aggregates, RAP, and RAS piles, and asphalt binder source and PG grade (bill of lading and BOL load number) are reviewed against the running JMFs and record of review listing the above information be kept in the plant lab for the duration of the project. Means to meet the handling and storage requirements of 402.06 and asphalt binder suppliers for all asphalt binders.
L.In-Line Blending of Additives: Provide and follow processes outside of Supplement 1053 for in- line blending for chemical WMA additives and liquid antistrip additives (e.g., storing and handling additive during cold weather). Include procedure(s) to calibrate in -line additive pumps. Inc lude a description of what chemical WMA additives and antistrip additives will be used at each facility (may be included in 403.03.H). Include example weight tickets with chemical WMA used according to
402.05 B and forms for dosing rate verification in Appendix L.
L1. 401.05 Cold Temp Production: Provide and follow procedure and processes for producing mix with chemical WMA for cold temperature paving according to 401.05 including how it will be communicated with District Testing when it will be used, how the target dosage will be determined, and corrective actions when mix issues occur (e.g., chunking or low density in the field). Address communication efforts and checks with paving company. L2. Dosage Verification: Provide and follow procedures to ensure proper dosing rates are within tolerance according to Supplement 1053 and a corrective action plan when rates do not meet requirements.
M.Haul Vehicles & Mix Quality: Define who is responsible at each mix plant and at the paving site to meet delivered mixture uniformity/coating. Provide and follow specific methods for ensuring all haul vehicles meet all Department requirements including procedures for ensuring haul veh icles not meeting requirements are not used, that proper bed release products are used and checks to ensure non- approved release agents or products (i.e., diesel) are avoided, and that tarps completely cover all loads. Include immediate notification to the Department of non -compliance. Detail procedures of loading mixture to minimize thermal and material segregation.
N.Field Quality Control Supervisor (FQCS): Provide a Supplement 1041 approved FQCS who is a company employee that is routinely and usually at the paving site during placement of any permanent asphalt concrete pavement. Define the roles and responsibilities of the FQCS including how the FQCS will be determined when more than one person on the paving crew is a FQCS and what position on the crew (e.g., paving foreman) would likely be the FQCS.
O.Misc. Equipment for Paving: Provide and follow details on calibration and verification of asphalt distributors, tar kettles, and other equipment used for applying emulsions and hot applied materials (e.g., tack coats, longitudinal joint adhesive, VRAM).
P.401.05 Cold Temp Paving: Describe and follow the extra steps (e.g., additional rollers, extra monitoring of density) planned for cold temperature paving, including any communication.
Q.Mix Paving Issues: Provide and follow a detailed description of how the FQCS will handle and correct all paving issues including segregation, tenderness, mat tears, debris, holes, low density, bleeding/flushing, not straight joints, poor tack coat, longitudinal joint sealant, VRAM application, and milling/planing irregularities like scabbing, etc. Include that the FQCS is to immediately communicate all issues to the Department.
R.Field Sampling & Coring: Provide and follow procedures for sampling, tracking, handling and documentation method for all sampling and testing at the project paving site including taking of all cores used for density determination or density gauge correlation. Describe the process for Supplement 1055 cores including who will run the cores for the Contractor and how the results will be reported back to the Supplement 1055 gauge operator. Ensure personnel obtaining and handling cores at the project site are approved Asphalt Level 2 technicians, FQCS or personnel approved by OMM or Office of Construction Administration.
S.Signatures: Provide the signature of the Quality Assurance Manager for both production and placement and, if different, the person in authority to enforce all operations covered by the QCP as outlined in this subsection.
T.Revision Sheet: Provide a revision sheet with the last 8 years of records. In the revision sheet include three columns: the first column being the date of the revision (matching with the revision sheet date); the second column is to list the section and page number being updated; and the third column is to provide a short description of what was revised, added, or removed. Highlight all revisions from the previous version to make clear to the Department what was revised or added. Stone-Matrix Asphalt (SMA) Mixes: For 443 mixes, develop and follow a separate project specific QCP with the following additional information beyond the above sections in a single QCP and submit to OMM, District Testing, and the Engineer at least 3 weeks before the start of production for acceptance. Include production and placement. activities for the SMA. If separate companies produce and place the mix, collaborate to develop a single pro ject specific QCP. Also, submit the already accepted QCP outlined above along with the project specific QCP. Provide a front cover for the project specific QCP that clearly indicates its use for SMA; the construction project number; the Company names(s) and logo(s); and the revision date. Provide a Table of Contents as the second page including page numbers and sections in the order below.
U.Quality Control: U1. Manager and Technicians: List the QC Manager that will oversee production and their experience with SMA. Provide a list of approved Asphalt Level 2 and 3 technicians that will be present during production of the SMA and their experience with SMA sampling and testing. U2. Testing Equipment: Provide additional equipment and calibrations to test SMA. U3. Additional Testing for SMA: Describe what additional testing will take place. Include special testing worksheets to calculate the additional tests required for SMA in Appendix U3. U4. Troubleshooting Production of SMA: Provide step-by-step details on what adjustments will be made if mix issues happen (e.g., segregation, draindown, fiber stabilizer clumps in mix, etc.)
V.Production: Provide the plant(s) that will produce the SMA and the experience the plant operator(s) has with SMA production. Include additional calibration procedures for the fiber stabilizer and verifying rates.
W.Placement of SMA: W1. FQCS: Provide the FQCS that will oversee the placement of the SMA and their experience with placing SMA. W2. Hauling: Provide any additional steps on hauling of the asphalt mix including special considerations related to haul distance, air temperature, etc. W3. Project Specific Paving: Provide any additional steps that are specific to paving SMA for this project that will need special considerations (e.g., gore areas, hand work, pavement geometry, etc.). W4. Test Strip: Provide details on placement of the test strip including any changes needed compared to non-443 mix placement. W5. Troubleshooting: Provide step -by-step details on what adjustments will be made if mix issues happen (e.g., segregation, fat spots, bleeding/flushing, etc.)
X.Signatures: Provide signatures and dates of the QC Manager, Asphalt Level 3, Plant Operator, and FQCS so that they understand the SMA specification, their duties, and have read this project specific QCP and company QCP.
403.04 Testing Facilities. Provide testing facilities at the plant site conforming to Supplement
1041. Provide testing facilities and sufficient testing equipment and qualified staff that can handle the production at the plant, including multiple projects being produced during the same production day.
403.05 Asphalt Mixture Sampling. Sample and provide enough material to perform all required
and requested testing by the Department. Follow sampling requirements as outlined below. The District may require sampling and testing from the roadway according to AASHTO R 97, Subsection 5.9 (Sampling from Roadway before Compaction). Report all sampling and testing on the Quality Control Report, as applicable (TE -125 for 301, 302, and 424 Type A or TE 199 for all other mixes) and when applicable the 448 and 449 Sublot Report (TE-448).
A.Quality Control (QC) Sampling & Testing. For QC sampling and testing, the Contractor ’s technician will randomly select the truck in which to take a sample by using a Department provided random number generator. For 448 and 449 sublots, the Department will provide the random number immediately prior to each sublot. The Contractor’s technic ian will give no indication to anyone other than the Department of the time that the sample is to be taken. Include the random number, sample tonnage location, and time of sampling on the daily Quality Control Report with each test. with each test. Random independent (not split) sampling and testing is required by Federal regulation. A single pattern of non -randomness will be a minor event as indicated in Supplement 1041 and a continued pattern of non-randomness will trigger a major event and Restricted Acceptance according to 403.11. For QC 446, 447, and non-449 sublot samples, sample and test a minimum of one time for each 750 tons (680 metric tons) of asphalt concrete produced, or for any portion of 750 tons, for every production day. For 448 and 449 sublot sampling and testing, the sublot sample will be the QC sample as described below. For low production days where a sublot sample is not generated, sample and test one random QC sample. A production day includes the period of time from when mix production begins to the time the last load of asphalt leaves the asphalt plant, either from the mix drum or from any storage silo. Any planned break in plant production to accommodate a new work shift triggers a new production day. Perform random additional sampling and full testing beyond the minimum specified for QC during the first three days of production. These samples will be called ‘Additional Tests’ and are required. All tests are required to be reported on the Quality Control Report. Extra sampling and testing are at the Contractor ’s discretion according to their QCP and are considered process control. All tests are required to be reported on the Quality Control Report. Contractor process control sampling and testing do not need to be random and cannot be used for acceptance. If samples are split, test all samples taken. Split samples are for process control or troubling shooting differences in Department and Contractor results and cannot be used for acceptance. When split samples are requested, provide a clean area of suffici ent size and a hard surface to perform sample splitting at the testing facility. Split samples by quartering and recombining only as described in AASHTO R 76, Method B for hard surfaces for the Department and Contractor’s sample. Alternately, use a mechanical splitter according to AASHTO R 47 , Type A, followed by the quartering method. The split sample size required is generally 22 to 27 pounds (10,000 to 12,000 g). A mechanical quartering device approved by OMM may be used in lieu of the above but only split according to the procedure outlined in the Contractor QCP. Wrap and label split samples as process control, the Lot Sublot, time, location (tonnage), and accompanying Contractor test identification. The Moni toring Team will pick up all Department samples within four work days. Sample mishandling (careless identification, changing sample size, consistency, or pre -testing) will result in a change to Restricted Acceptance.
B.Sublot Sampling and Testing. For 448 and 449 acceptance mixes not including 301, 302, and 424 Type A mixes, conform to the procedures of Supplements 1035, 1038, 1039, and 1043. Use 3000 tons (3000 metric tons) Lots and 750 tons (750 metric tons) Sublots. However, when production is limited to less than 3000 tons (3000 metric tons), the quantity produced will be considered a partial Lot, unless otherwise approved by District Testing or OMM. For partial Lots of 1500 tons (1500 metric tons) or less sample and test at least two sublot sa mples regardless of the tons produced. The Department will provide the random number for the sublot immediately prior to each sublot sample. It is the responsibility of the QC technician to ensure they have the sublot sample and immediately notify the Monitoring Team if they do not have one. Sublot samples will be considered QC samples and will have full testing performed as outlined in
403.06 The test results will apply for both QC and sublot requirements.
Test all sublot samples from locations selected by the Monitoring Team or Engineer . A change in the location of the Sublot sample must be approved by the Monitoring Team and be reasonably close to the original location. This location allowance does not apply to any other samples including Department VA sample locations selected by the Monitor. Record all sublot test data on form TE-448 in addition to the Quality Control Report.
C.Small Quantity. Small Quantity (SMQ) sampling and testing will be allowed for Contractors with an accepted QCP according to 403.03 and for facilities not on Restricted Acceptance. SMQ is only allowed for JMF’s that have been properly offset according to Supplement 1043, show documented acceptable comparison testing according to 403.06 and 403.10, and do not represent a 448/449 sublot sample location. Notify District Testing a minimum of 24-hours prior to testing of any SMQ material unless otherwise authorized by District Testing. The total production per project for each mix type is not to exceed 750 tons or 20 percent of the mix type bid quantity tonnage, whichever is less. District Testing can sample, test and reject any material received under this procedure. Material may be rejected by visual inspection by the Department or rejected through Department verification testing. Poor plant or mix control, poor mix performance, poor mix quality, failure to submit the required forms as required, or ongoing District sample failures can result in disallowing further use of this procedure on the project and future projects. This procedure may be disallowed by the Department for any Contractor’s facility when documented premature SMQ mix failure in any application has occurred on the Contractor's previous project(s). When material is being produced under this procedure and has a quantity of less than 150 tons per production day for each mix type, no QC sampling or testing is required, and the acceptance is by Contractor certification as outlined below. A Department Lev el 2 or 3 technician must be present to verify the mix in the haul trucks is acceptable, not visually segregated, well coated, and is within an acceptable mix temperature. Any mixture sent to the paving site greater than 150 tons that does not have adequate QC testing will be considered non-specification material and subject to removal. A quick check plant calibration must have been performed in accordance with the Contractor's QCP as outlined in 402.03. Computerized plant operation tickets, a copy of the dated and signed quick check calibration(s), and a TE 199 SMQ form must be submitted. The required SMQ information must be submitted by the Contractor to District Testing by the end of each production day unless otherwise authorized by District Testing. The TE -199 SMQ form will be signed by an employee of the Contractor having authority to represent the Contractor as outlined in the Contractor's QCP. The TE-199 SMQ form will be sent to the Project Engineer and District Testing. Failure to follow the procedures outlined above may result in the removal of SMQ use for the mix plant facility. Ongoing issues occurring company-wide may result in the removal of SMQ acceptance for the company.
403.06 Quality Control Tests. Prior to each production day, determine the moisture content of
each aggregate, RAP, and RAS stockpile to be used in the JMF according to AASHTO T 255 and ensure the moisture contents are entered into the mix plant controls. Retest stockpiles after weather event prior to resuming production day and as outlined in the Contractor’s QCP. Perform process and QC tests on all samples to control the asphalt concrete mix within the specifications and report each test result according to Table 403.08-1. As a minimum and as required by mix type, ensure that these QC tests measure the asphalt binder content, gradation, air voids, Maximum Specific Gravity (MSG), and any additional testing according to the Contractor ’s accepted QCP. Perform only asphalt binder content and gradation testing for 301, 302, and 424 Type A. Ensure QC tests for asphalt binder content and air voids are not consistently on the low side or high side of JMF and adjust the mix within the tolerances allowed by the specification. Perform additional process testing, QC sampling and testing, or both, over the minimum required, during production when the QC tests show the asphalt concrete being produced is outside the warning bands in the Contractor ’s QCP. Immediately resolve problems indicated by any test result exceeding the warning bands and immediately retest a sufficient number of samples to validate corrections have returned the materials to within the warning band limits. The Contractor may determine the method of testing the asphalt concrete beyond the minimum specified contractually according to the details and the methods technicians will follow in the Contractor’s accepted QCP. Should additional testing as required above not be performed, District Testing, after consultation with OMM, will require the testing frequency to be increased for the remainder of the project. If this occurs, District Testing will request an opinion from the QC Review Group for action(s) against the technician, Contractor, or both including but not limited to warning, removal, or a change of the facility to Restricted Acceptance. Record the results of every test performed, including failed tests. Perform the required QC tests, control charts, and test requirements as follows:
A.Asphalt Binder Content. Determine the asphalt binder content of a sample of asphalt concrete by performing an Asphalt Content (AC) Gauge test according to Supplement 1043. Make all printouts available for review by the Monitoring Team at any time. Offset the AC Gauge for each JMF on each project at the start of the project. Perform the offset using the solvent extraction method for every QC sample according to Supplement 1038 and the AC Gauge Verification and Offset Record until the offset is established. Use solvent extraction according to Supplement 1038 when an AC Gauge problem exists and for testing cooled samples that cannot adequately be tested in an AC Gauge test. Total, for each day’s production, the flow meter printouts for SBR polymer added at the asphalt concrete mixing plant. Calculate the percent of polymer versus neat asphalt binder in the mix each day and record values on the Quality Control Report. Provide calculation worksheets and printouts in the plant laboratory for review by the Monitoring Team. A +/- 0.2 percent tolerance from the target amount of SBR polymer will be used as a guide for an acceptable amount of SBR polymer, but consistently low values will not be acceptable. Only take SBR PG-Modified Binder samples using a five-gallon (19 L) bucket. Take 1 gallon (4 L) of binder to clean the valve port and discard it. Take 2 gallons (7.5 L) of binder, stir its contents and transfer it to the required sample containers. Determine the moisture content of the asphalt concrete for each AC Gauge test according to Supplement 1043. Maintain the moisture content at 0.80 percent or less.
B.Gradation. Perform the gradation test on aggregate remaining after removing the asphalt binder with a solvent from an asphalt concrete sample used in an AC Gauge test (solvent sample) or on aggregate remaining after removing the asphalt binder with a preapproved asp halt ignition oven according to Supplement 1054 and from an asphalt concrete sample used in an AC Gauge test (ignition oven sample). For asphalt concrete samples with polymer modified PG Binder use only an asphalt ignition oven to obtain aggregate gradation results. District Testing may make an exception to this for SBS polymer if no issues arise. Correct each solvent sample for ash. Perform all other gradations on solvent samples, ignition oven samples, or on samples obtained according to the Contractor’s accepted QCP. The gradation results of all the sieves must be representative of the JMF. If the Contractor fails to control the entire gradation, the Department may require a redesign according to 440. When the F-T value is specified for a mix, calculate it for each gradation analysis. Maintain the F- T value at +4 percentage points or less for these mixes during production. Calculate the F/A ratio for every solvent sample or ignition oven sample analysis. Maintain the F/A ratio so no F/A ratio is greater than 1.2 for all mixes. Use the effective asphalt binder content determined by the AC Gauge for calculating the F/A ratio. For 302 mixes, use total asphalt content determined by the AC Gauge. Calculate the effective asphalt binder content according to the Department’s Asphalt Level 2 procedures. Use MSG from the production mix test. Use the combined Gsb value based on bin percentages during the time the sample was taken. Calculate the effectiv e asphalt binder content on the calculation sheet using the asphalt binder content determined by the AC Gauge and attach it to the Quality Control Report. If the F/A ratio is greater than 1.0 for ignition oven samples, calculate the F/A ratio using the per cent passing the No. 200 (75 µm) sieve from a washed gradation of the ignition oven sample according to AASHTO T 30.
C.Air Voids and MSG. Determine the air voids of the asphalt concrete by analyzing a set of compacted specimens and a corresponding MSG determination according to Supplement 1036. Use a Marshall or gyratory compactor meeting the requirements of Supplement 1041 to compact specimens. If the compactor was moved to the plant before production, calibrate it and present the results to District Testing for acceptance. Ensure that the cure temperature and specimen compaction temperature are the same. Use a 1 -hour cure for all mix samples used in air voids analysis. The Contractor may use a 2 - hour cure time if voids are consistently near the low air void warning band. When a 2-hour cure is used, notify District Testing and OMM and use the 2-hour cure for all air voids testing through the remainder of the project, and record the cur e time and temperature on the Quality Control Report. Use the approved JMF lab compaction temperature. Do not reduce lab compaction temperature for warm mix asphalt. Use a compaction temperature tolerance of +/ - 5.0 ºF (3.0 ºC). Compact specimens to design blows or Ndes. Record on the Quality Control Report if the mixture produced was run at the asphalt plant as a hot mix asphalt (HMA) or as a warm mix asphalt (WMA) produced according to 402.05 or another approved method. Calculate the Voids in Mineral Aggregate (VMA) value for every set of compacted specimens according to Supplement 1037. Calculate the average of all the MSG determinations performed each production day and report this average on the Quality Control Report. When the range of three consecutive daily average MSG determinations is equal to or less than 0.020, average these thre e average MSG determinations to determine the Maximum Theoretical Density (MTD). Exclude the MSG in the daily average MSG if the sample did not meet the requirements in Table 403.06.G-1. After the MTD is established, compare all individual MSG determinations to the MTD.
D.Other Requirements. Perform an APA test once each day for the first 3 days according to Supplement 1057 if the produced mixture requires an APA test. Compact the sample the same day the sample was taken, cure it overnight, and test it the following day. Give the test result and sample density to District Testing the day of the APA test. Report the APA data on the Quality Control Report. Retain all QC samples for each AC Gauge test and MSG test and all compacted specimens for review by the Department for at least two days for AC Gauge tests and at least seven days for MSG and compacted specimen samples unless directed otherwise. Maintain M SG samples in the state described in AASHTO T 209, Section 7.3 and keep sample at room temperature. Measure the temperature of the mixture and record the value. Validate the results on the load tickets at least once during each hour of production. The Contractor may conduct extra process control testing of any type. Record all extra testing along with all other quality control records and have these records readily available for the Monitoring Team’s review. District Testing may observe, review, and approve or disapprove the procedures at any time.
E.Control Charts. Maintain up to date control charts showing each individual test result and the moving accumulative range as follows for all mixes:
1.Plot tests showing the percent passing for: 1/2 inch (12.5 mm), No. 4 (4.75 mm), No. 8 (2.36 mm), and No. 200 (75 µm) sieves, the percent asphalt binder content, the MSG, percent air voids, the VMA, the Gmb, the produced mixture Gsb, the effective specific gravity of combined aggregate blend (Gse), and aggregate bin percentages, including baghouse fines.
2.Show the out of specification limits specified in 403.06.F and Table 403.06.G-1 and QCP Warning Band Limits on the control charts. Additionally, for MSG show the established MTD range limits.
3.Label each control chart to identify the project, mix type and producer.
4.Record the moving accumulative range for three tests under each test point on the chart for air voids, MSG, and asphalt binder content. Accumulative range is defined as the positive total of the individual ranges of two consecutive tests in three consecuti ve tests regardless of the up or down direction tests take. If more than the minimum required testing (i.e. 750 tons per sample per production day, 403.05.A) is performed do not include the result in accumulative range calculations. Regularly calculating and tracking Percent -Within-Limits (PWL) is suggested to assist in determining process control and QC effectiveness and for identifying potential areas that need additional attention (e.g., low PWL values for any material characteris tic). For PWL calculations reference AASHTO R 9 or the Federal Highway Administration’s Standard Specifications for the Construction of Roads and Bridges on Federal Highway Projects ("FP -24"), Section 106.05, and use the material characteristic specification limit(s) for upper limits, lower limits, or both. Make all charts available for review by the Department.
F.Test Requirements for 301, 302, and 424 Type A. Control mixes as follows:
1.If a single asphalt binder content is more than ±0.50 percent beyond the JMF, immediately take and test an additional sample.
2.If the Range difference in any three consecutive asphalt binder content tests is greater than 0.70 percent for 302 mixes or 0.60 percent for 301 and 424 Type A mixes immediately notify the Monitoring Team. Range is defined as the difference between the largest and the smallest test result.
3.If the Range difference in any three consecutive gradation tests for the No. 4 (4.75 mm) sieve is greater than 10.0 percent, immediately notify the Monitoring Team.
4.Maintain gradations within design limits of mix type.
5.Maintain a minimum of 7 percent retained on the 1 inch (25.0 mm), ¾ inch (19.0 mm), ½ inch (12.5 mm), and 3/8 inch (9.5 mm) for 302 mix. Stop production and immediately notify the Monitoring Team when either 6 or 7 occurs:
6.If two consecutive asphalt binder content tests are more than 0.50 percent beyond the JMF, notify the Monitoring Team and cease production until the problem is corrected.
7.If Range deviations as specified in 2 or 3 continue, cease production. Any mixture sent to the paving site without stopping production and notifying the Monitoring Team, when required by this specification, will be considered non-specification material.
G.Test Requirements for all other mixes. Control all other mixes of Table 403.06.G-1 and as follows: TABLE 403.06.G-1 Mix Characteristic Out of Specification Limits[5] Asphalt Binder Content[1] -0.30% to 0.30% 1/2 inch (12.5 mm) sieve[1] -6.0% to 6.0% No. 4 (4.75 mm) sieve[1][8] -5.0% to 5.0% No. 8 (2.36 mm) sieve[1] -4.0% to 4.0% No. 200 (75 m) sieve[1] -2.0% to 2.0% Air Voids[2] 2.5% to 4.5% Air Voids[3] 3.0% to 5.0% MSG[4] -0.012 to 0.012 F/A 1.2 max F-T +4 max[6] VMA Design – 0.5%[7] [1] Deviation from the JMF [2] For Design Air Voids of 3.5% [3] For Design Air Voids of 4.0% [4] Deviation from the MTD [5] Unless otherwise restricted by mix type specification [6] When specified for mix type [7] Reduce VMA production minimum 0.5% from minimum design VMA (e.g., minimum design VMA for a 442 19.0 mm is 13.0 and the minimum during production will be 12.5%). [8] For 442 12.5 mm mixes do not exceed 63% max during production Stop production and immediately notify the Monitoring Team when either 1, 2, or 3 occurs:
1.Any two tests in a row or any two tests in two days are outside of the specification limits of Table 403.06.G-1. Do not shut down during the first three days of production for VMA unless two VMA tests in a row are outside specification limits. 2 Any two tests in a row or any two tests in two days (QC and 448 and 449 sublot) exceeding 63 percent passing the No. 4 sieve for 442 12.5 mm mixes. 3 Any four consecutive moving accumulative ranges greater than specification limits of 2.50 percent for air voids or 0.60 percent for asphalt binder content occur. Any mixture sent to the paving site without stopping production and notifying the Monitoring Team, when required by this specification, will be considered non-specification material.
H.Load-and-Hold Testing and Restart of Production . Perform a load -and-hold procedure by producing the mix and performing full testing if production is stopped due to a plant shutdown from failing test results. Demonstrate to the Department that the plant can produce the JMF conforming to the appropriate mix specifications. Provide notification of the date and time of the scheduled load and hold testing that is mutually agreed upon by the Contractor and the Department. Provide full test results to the Department including any plant or mix changes to correct all deficiencies. The Department will review the results to determine if production may continue. Do not restart production until an adequate correction to remedy problems is in place and the Monitoring Team is satisfied. Determine root - cause(s) for proble m(s) and take immediate action to resolve when there is a lack of Department satisfaction with mix quality or control. When production problems cannot be solved within one day after a plant shut down a contractor’s representative holding Level 3 Asphalt De partment approval is required to be at the asphalt plant until a full production day is achieved with results satisfactory to the Monitoring Team. If deficiencies cannot be corrected, the Department may opt to rescind the JMF according to 403.09. Multiple load-and-holds at a mix plant facility may result in the Department requiring the Contractor to prove that the mix can be produced and meet specifications on non -Department and non -LPA projects at the cost to the Contractor before being permitted to proceed producing for the Department or LPA projects.
403.07 JMF Field Adjustments. During the first three days of production the Contractor may
adjust the JMF gradation within the below limits without a redesign of the mixture. For projects with less than 3 days of production, give District Testing written notice of any JMF gradation adjustments within 1 workday following the last day of prod uction. Limit adjustments of the JMF to conform to actual production, without a redesign of the mixture, to 3 percent passing each of the 1/2 inch (12.5 mm), No. 4 (4.75 mm), and No. 8 (2.36 mm) sieves and 1 percent passing the No. 200 (75m) sieve. Do not exceed the limits in Table 424.02-1, Table 441.02-1, Table 442.02-2, and Table 443.03-1 in the adjusted JMF . Do not exceed five percent adjustment for each individual aggregate. RAP may be reduced up to five percent (virgin AC would go up to meet total AC) and maintain the original JMF virgin PG grade (e.g., going from 30 percent to 25 percent would still require a PG 58-28). Determine the need for any JMF gradation adjustments in the time specified. Should no adjustments be made, the Department will base acceptance on conformance to the original JMF. After the time period specified, the Department will allow no further adjustment of the JMF. Should a redesign of the mixture become necessary, submit a new JMF according to the requirements for the initial JMF. A new acceptance lot will begin when a new JMF established by a redesign of the mixture becomes effective. Make any adjustment of this ne w JMF as provided for the original JMF. Record both the design JMF and the adjusted JMF in effect during production of an acceptance lot on the Quality Control Report for that lot. In the event that a new JMF is proposed and approved, also make a notation on the ticket for the first load produced under the new JMF.
403.08 Quality Control Reports. Record all test results and sample identification on the Quality
Control Report including the random number, sample tonnage location, and time of sampling with each test. Record on the Quality Control Report if the mixture produced was ran at the asphalt plant as a hot mix asphalt (HMA) or as a warm mix asphalt (WMA) produced according to 402.05 or another approved method. Also record if antistrip additives were used, dosage rate, the daily quantity used, and copies of the yield checks according to S upplement 1053. After startup adjustments, report any plant operation changes on the Quality Control Report. Ensure that these documents contain technician comments as to production quality, input materials received and condition, and include any other process or QC activities as specified in the QCP. Document all decisions regarding responses to test results on the Quality Control Report. (referring to the particular test), including reasons why a particular problem may exist, what action was taken to correct the problem (plant operation or testing), and what communication with Department personnel took place. Attach computerized plant printouts representing samples tested to that day’s report, if desired by the Monitoring Team, or otherwise keep them with the quality control records. Ensure that the technician records the test results for the AC content and percent passing the No. 4 (4.75 mm) sieve on the plant printout from the tonnage the quality control sample was taken. Keep remaining printouts and a copy of all QC reports in the plant laboratory for the duration of the project after which they may be transferred to an office location for records retention. and a copy of all QC reports in the plant laboratory for the duration of the project after which they may be transferred to an office location for records retention. Deliver (fax, e-mail, hand) completed Quality Control Reports to District Testing by the end of each day in which testing is conducted. If desired by District Testing and always for unsigned E -mail versions, mail the originals. Ongoing problems with submitting reports on time may also result in the plant not being able to produce until the report is submitted with adequate time for review by District Testing. Ongoing problems with inadequate, incomplete, or illegible reporting w ill result in a change to Restricted Acceptance. The Contractor’s technician must sign each Quality Control Report. Retain copies of all records documenting the quality control inspections and tests as outlined in the Contractor’s QCP according to 403.03.F and furnish them to District Testing on request. Provide delivery tickets of liquid or hydrated lime antistrip additive, if used, to District Testing at the end of the project and at the end of each construction year on a multiple year project. Provide the following information for each shipment: Letter of certification, Production date, Shipment date, Shipment destination, Batch or lot number and Net weight. The District Testing will verify the weight (in pounds) of antistrip additive used is within 10 percent of the calculated amount of antistrip additive required for the total weight of asphalt binder, based on the produced JMF. The Department may obtain samples of the hydrated lime at any time to verify quality. If the quality. If the quality of the hydrated lime is in question, the Department may require independent laboratory testing. Report test results to the accuracy of the following decimal places. When the figures to be dropped in rounding off are exactly one-half of unity in the decimal place to be retained, round the value up to the nearest number in the decimal place to be retained. TABLE 403.08-1 REPORTING ACCURACY Single Test Average Asphalt Binder Content Effective Binder Content (PBE) 0.01 0.01 No. 200 (75 µm) sieve 0.1 0.1 Other sieves Whole number 0.1 BSG, MSG, MTD, GSB, GSE 0.001 0.001 Air Voids 0.1 0.1 VMA 0.1 0.1 F/A 0.1 0.1 F-T Whole number Whole number Mix Moisture Percent 0.01 0.01 APA, inch (mm) 0.0004 (0.01) 0.004 (0.1) Additionally for 448 and 449 acceptance mixes (excluding 301, 302, and 424 Type A), track the Sublot and Lot tonnages through the project and identify on the Quality Control Report each random Sublot test as to Lot number and Sublot tonnage location . In addition to the Quality Control Report , submit form TE-448 with lot identification and actual sieve weights for each Sublot sample from the technician’s gradation worksheets.
403.09 Mixture and Placement Deficiencies . The Contractor is responsible for controlling all
production processes to assure the Engineer that the mixture delivered to the paving site is uniform in composition, within the specification requirements and limits, conforms to the JMF, and that the placed mixture is free of any defect (ex. segregation, tenderness, lack of mixture and/or texture uniformity, raveling, flushing, rutting, holes, debris etc.). Correct pavement problems according to 401.08. If the Department has any suspicion that other mixture composition or pavement problems exist, the Monitoring Team will conduct an initial investigation through review of data, sampling of the asphalt pavement, or both. Should a Department investigation determine that the Contractor’s QCP is not controlling the mixture in a manner to achieve mixture quality as described above, the Contractor’s QC test results, and corresponding pavement quality may be rejected. In that case the Department will conduct a thorough investigation by testing samples from the roadwa y and use those test results in determining disposition of the non-specification material. A mixture is not uniform in composition if multiple non -specification individual tests or any four consecutive non -specification moving accumulative ranges exist. The mixture can be rejected, production can be stopped or a redesign can be required by the D epartment. OMM will not approve any redesign it determines is unsatisfactory to provide acceptable mix performance. Submit this new design for approval according to 440 and at no additional cost to the Department. When any Contractor QC tests are out of specification and not within the limits of 403.06.F and Table 403.06.G-1, material that is sent to the paving site, the Engineer in conjunction with District Testing or OMM will determine disposition of the material according to Supplement 1102.
403.10 Verification Acceptance (VA). The Code of Federal Regulation 23 CFR 637, requires
independent random sampling and testing for acceptance through verification sampling and testing; and requires evaluation with an independent assurance (IA) program. District Testing will perform VA by testing independent random samples. If the independent random Department VA sampling and testing verifies the accompanying Contractor tests, the individual and average of the Contractor’s quality control tests will be used to determine acceptance as follows: • For 449 acceptance mixes (301, 302, and 424 Type A) according to 449.04.A - Each production day; • For 448 and 449 acceptance mixes - Average of the Contractor’s tests for each Lot according to
448.04 and 449.04 B, respectively;
• For 446, 447, 448, or 449 acceptance mixes - Daily average MSG (other than 301, 302, and 424 Type A).
A.Monitoring. The Department will establish District Monitoring Teams for the purpose of verifying all Contractor mixture production processes. Verification will be accomplished by obtaining independent random samples from the plant or roadway. Split samples may be use d to help isolate differences in test results resulting from a technician performing the test or equipment but cannot be used for verification of Contractor QC results or acceptance.
B.Sampling. The Department will perform VA by sampling and testing independent samples a minimum of one in every four production days to verify Contractor sampling, testing, and mix control. The Department will determine where the sample is taken. One day may be added to the above Department sample testing frequency for each production day that is less than 500 tons (450 metric tons). In addition to the above, for 446 and 447 acceptances, the Department may take a daily sample for asphalt content and the sample may also be utilized for gradation and MSG. The Department can require samples from the plant or project site (hopper, plate or truck). The Department may take additional samples including split samples, to determine plant operation and equipment, and personnel process control functionality, effectiveness, proficiency, and isolating variability and for additional verification of Contractor QC or as desired. Other properties can be tested by the District as desired. The Department will sample or require the Contractor to sample with the Monitor witnessing sufficient material to perform all the tests. If the Contractor desires, enough material will be taken or provided to obtain three split samples: one is the Contractor split for information purposes only; one is the Department split for verification acceptance; and one is the referee split for dispute resolution. If requested, provide the Monitor access to split the sample at the plant facility. If the Contractor tak es the sample for the Monitor, the Monitor or Department must witness the entire sampling process and must take immediate possession of the Department’s verification and referee samples. The Department will take immediate possession of the Department and r eferee splits and deliver them to District Testing. District Testing or OMM will also perform independent assurance (IA) monitoring and testing of QC technicians and for projects from independent assurance samples (IAS) or split samples. The Contractor’s portion of the Department’s VA split sample or IAS results are for informational purposes only and cannot be used for quality determination, verification, acceptance, or payment (Federal regulation 23 CFR 637).
C.Department Verification Testing and Monitoring. All Department VA or IAS samples will be prepared by the Monitor (e.g., material for nuclear gauge pans or MSG) and tested at District Testing or OMM using Department equipment. All VA samples will be tested for asphalt content and gradation. The Department will also perform MSG testing on VA samples on all mixes other than 301, 302, and 424 Type A. Record the results, date tested, and technician performing the testing, and include in District Testing project record. The Contractor may test the split of the VA sample with the Monitor witnessing The Department will use its VA test results and the Contractor’s production day QC individual and average test results or sublot tests in the comparison for the Department VA testing. The Department can use QC split samples to investigate contractor data but they cannot be used as VA samples. The results will be compared to the Contractor split using tolerances in Table 403.10-1. TABLE 403.10-1 DEPARTMENT VERIFICATION ACCEPTANCE Percent Asphalt Binder[1] [2] Percent Passing No. 4 (4.75mm) [1] [2] MSG Comparison [3] ± 0.30 ± 4 0.010 [1] District VA mix test deviation from the approved JMF. [2] District VA mix test deviation from that production day QC test result and/or individual and average lot testing results. [3] Deviation of District MSG VA compared to QC MSG daily average for all asphalt pavement mixture types except 301, 302, and 424 Type A. mixtures. If the Department VA tests confirm Contractor testing is within the verification tolerances, but a pattern of high or low results exist that suggests mix control is not at the approved design JMF, then investigate with the Monitoring Team to correct the pr oblem to the Monitoring Team’s satisfaction. Direct any questions regarding interpretation of circumstances to OMM in writing. . If the Monitor witnesses the Contractor’s portion of the Department’s VA split sample being tested, the results may also be utilized as an IAS sample.
D.Contractor QC Tests are Acceptable are Verified. Production is acceptable if:
1.The Monitoring Team verifies the Contractor’s QCP is being fully followed; and
2.The Department VA tests are within the limits specified in 403.10.C; and
3.For 301, 302, and 424 Type A mixes, the remaining sieves do not exceed the limits of the applicable specification. Failure on the Contractor’s part to respond and resolve Monitoring Team concerns may result in a change to Restricted Acceptance. Acceptance is per 446, 447, 448, or 449.
E.Contractor QC Tests Not Acceptable or Verified . If the Department VA test is not within specification, tolerance limits, or does not verify the accompanying Contractor QC tests within the verification tolerances of Table 403.10-1, immediately cease production until resolved. Investigate to the Department’s satisfaction. The Monitoring Team, District Testing, or OMM may choose to participate in determining the cause of non -verification or out of specification results. Until fully resolved, the Department results will be utilized for acceptance. The Contractor may dispute the results within seven calendar days with written notification to the Department as to why the Contractor believes the Department’s VA results may be erroneous with supporting documentation and testing (which could include hist orical test data). If Contractor documentation and testing adequately supports their tested results as determined by OMM, the referee sample will be sent to OMM. for dispute resolution. The Department will deliver the referee sample to OMM. The results closest to the referee sample results will be used in acceptance. If the Contractor’s written request for referee testing is accepted The Department may allow District Testing to investigate a non -comparison or out -of-specification material issue by testing the Department’s VA sample at the Contractor’s mix plant lab to determine if the non-comparison is from Contractor testing (technician or equipment). If this material is found to verify the original Department’s VA results, the referee sample will be sent to OMM for dispute resolution. If this material does not compare with the Department’s VA results, then the Department’s initial results will be utilized for acceptance. If a Contractor’s MSG test result is not verified by Department MSG VA testing according to the tolerance in Table 403.10-1, the Department’s corresponding MSG for that production day and every day back to when the Contractor’s MSG was verified by the Depa rtment’s MSG VA will be used for each 446, 447, 448, or 449 acceptance mixes (other than 301, 302, and 424 Type A Day/Lot density and QC air void determination). If an independent VA plant sample is not available, the Department may test MSG from a random independent field sample or road cut sample for Department VA testing. The Contractor may occasionally request a review with the Department for the purpose of determining the cause of a verification comparison problem. Department decisions upon review are final. If a Contractor is requesting a review of every occurrence of lack of comparison and the Department test is predominantly found correct, the Department may deny that Contractor further reviews until the Contractor has determined the root -cause of the problem and made corrections to prevent it from recurring. TABLE 403.10-2 DEVIATION LIMITS Property Mix Limits Asphalt Binder Content All ±0.5 % No. 4 (4.75 mm) sieve All, except 302 ±6.0% 302 ±7.0% Additionally, stop production and perform additional tests to aid in problem solving if ongoing Department VA tests do not verify. . Document the resolution and root cause. If needed, contact OMM for assistance in resolving problems.
F.Contractor Department VA Removal and Restoration . For 446 and 447 MSG, for a given Contractor facility, if in a series of eight or more Contractor/ Department MSG comparison tests (VA, Monitoring tests) the Contractor MSG is lower than the Department MSG by more than 0.002 or low MSG comparisons that occu r more than 65 percent of the time, the facility will be removed from Department MSG Verification Acceptance and operate under 403.11. The District will request an opinion from the QC Review Group before notifying the Contractor of removal from Department VA if repeated problems occur with: poor comparison of tests originating from Contractor sampling or testing (not the District); poor comparison of Contractor tests to the JMF; plant operation; source materials; or any of the other requirements of Department specifications regardless of whether they occur in a single project or successive projects. The District will immediately notify the Contractor of the removal with a follow up letter from District Testing. Once notified, acceptance of asphalt mixtures is by Restricted Acceptance. Restoration of the VA procedures may occur on a future project with a District recommendation to the QC Rev iew Group based on consistent improved plant operation and mix control, a review of the Contractor problems and resolutions, and a review of the QCP by the QC Review Group.
G.Dispute Resolution for 446 and 447 cores . The Contractor may dispute the results of District Testing core results within seven calendar days with written notification to the Department as to why the Contractor believes the Department’s results may be erroneous with supporting documentation and testing (which could include historical test data). If Contractor documentation and testing adequately supports their information as determined by OMM, the Department’s core(s) will be delivered to OMM by District Testing. Do not cut more cores unless the D epartment feels the cores were damaged prior to the original District Testing core results. If OMM BSG core test results differ by more than 0.010 from District Testing results, OMM results will be used in the calculation of the pay factor. If not, then the original District Testing core results will be used. The Contractor may occasionally request a review of District Testing results. However, if a Contractor frequently requests a review of District Testing core results and the District Testing results are predominantly found correct, the Department may deny that Contractor further reviews. Department decisions upon review are final.
403.11 Restricted Acceptance. If the Contractor is removed from Department VA, the following
will occur. The Contractor must bring its QCP and operation to a level acceptable to the District, OMM, and QC Review Group before production continues. District Testing will ensure that the project C -95 (Contractor’s Prequalification Rating survey) reflects the change to Restricted Acceptance in all of the appropriate C-95 categories. The Department will accept all material for Department projects from the facility under Restricted Acceptance. SMQ acceptance while the facility is under Restricted Acceptance will not be permitted. Quality control testing requirements specified in 403.06 are modified as follows:
A.Sampling and testing once every 90 minutes during the production day using a random number to determine the time to sample for each JMF produced. Ensure the sample is within five minutes of the random time. If no trucks are being loaded, sample the next truck to be loaded. Do not discuss sampling times with anyone other than the Department. This requirement does not apply to 446 and 447 MSG Restricted Acceptance according to 403.10.F. If the sampling and testing exceeds the capacity of the testing facility according to 403.04, immediately notify the Engineer and District Testing, then stop production until the testing facility can handle the capacity. The Department may limit the number of JMF’s being produced at a mix plant facility if more than one is being produced and sampling and testing becomes an issue while on Restricted Acceptance.
B.For 301, 302, and 424 Type A mixes, if the variation from the JMF for one test is 8 percent passing the No. 4 (4.75 mm) sieve or 0.3 percent asphalt binder content, investigate and correct the problem, then resample and test. Maintain the moving average of three tests within 4 percent passing the No. 4 (4.75 mm) sieve and 0.2 percent asphalt binder content. In addition to the Quality Control Report, maintain control charts according to 403.06.E for asphalt binder content and the No. 4 (4.75 mm) sieve. If the Range difference in any three consecutive tests is greater than 0.6 percent for asphalt binder content or 10.0 percent passing the No. 4 (4.75 mm) sieve, notify the Monitoring Team. If Range deviations as specified continue, cease production. For 446 and 447 MSG, the Department will test a single daily MSG for each corresponding 446 and 447 Day/Lot density determination from the facility. The facility can be returned to Department MSG VA when the 65 percent criteria (see 403.10.F) are not exceeded in a series of 30 comparison tests.
C.Report each day’s testing on a Quality Control Report, according to 403.08. Report all testing performed by the Contractor ’s technician on the Quality Control Report. After startup adjustments, report any plant operation changes on the Quality Control Report. Ensure that each Quality Control Report contains technician comments as to production quality, input materials received and condition, and includes any other quality control activities required in the QCP. The Contractor’s technician must sign each Quality Control Report. Attach each day’s computerized plant printouts to that day’s report. The technician must note on the accompanying printout from which tonnage the quality control sample was taken with accompanying test results for asphalt binder content and percent passing the No. 4 (4.75 mm) sieve. Keep a copy of all Quality Control Reports for a project in the Contractor’s plant laboratory. The District will monitor according to 403.10, except notification for ceasing production does not have to be in writing. Additional samples may be obtained for Department testing at any time. For 301, 302, and 424 Type A mixes, if the average of the Lot or partial Lot acceptance tests for any sieve other than the No. 4 (4.75 mm) sieve exceeds the specification limits, the pay factor is determined as follows: TABLE 403.11-1 301, 302, 424 TYPE A PAY FACTORS Number of Tests 1 2 3 4 Pay Factor 0.98 0.97 0.96 0.95 For 448 and 449 Sublot acceptance mixes, the Department will perform acceptance sampling and testing according to 403.05, 448.04, and 449.04 except the Lot size will be 5000 tons (5000 metric tons) with 1250 ton (1250 metric tons) Sublots. Sublots and acceptance samples may be taken from the roadway or plant at the Districts discretion. Department testing under Restricted Acceptance will receive a lower testing priority than other VA projects.
Referenced in this section
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Source: Construction and Material Specifications, 2023 (rev. 7/17/2026) Edition. Pages 171–191 of 892. View official source ↗