Asphalt QC 2000 The Adventure Begins….
Topics • Terminology • Specifications • Sampling and Testing • Reporting/CQR • Who Does What? • Lube & Oil Change • All in 20 Minutes!
In a Nutshell….. • Payment based on Contractor’s (Quality Control) test data that has been verified • FDOT runs Verification tests at a lesser frequency • Split-sample at plant by project personnel • Independent sample at District Lab • Payment is based on density on the roadway and air voids, asphalt content and gradation at the plant • Percent Within Limits (PWL) – larger quantities • Pay Table – smaller quantities • Big Change!
General Details Include…. • Initial lot size mandatory 2000 tons • Following lots may be 2000 or 4000 tons • Contractor’s option w/Engineer’s Approval • Deleted Initial Production Test Strip – No “Pause” • Typical lot size 4000 tons • English and Metric the same • 4 sublots per lot (1000 tons each) • Plant lot and roadway lots are the same • All sampling performed by the Contractor • FDOT establishes when to sample • Several options available
General Overview - Plant • Engineer (VT) directs Contractor (QC) when to sample • Random basis – generated by Excel Spreadsheet • 1/sublot (1/1000 tons or 1/500 tons) • QC splits out and boxes up Verification and Resolution Samples • Tests include: • Asphalt Content (FM 5-563 only) • Gradation (FM 1-T 030) • Air Voids (AASHTO TP-4 & FM 1-T 209)
Verification - Plant • Performed by Agency - FDOT or Consultant (CTQP Plant Level I) • Tests run at plant • Split-sample – randomly selected – 1/lot (1/4000 tons or 1/2000 tons) • Same tests as QC • Precision statement comparison with QC results • Gmm, Gmb, Pb, P-200, P-8
Table 334-4 Between-Laboratory Precision Values Property Maximum Difference Gmm 0.019 Gmb 0.022 Pb 0.44% P-200 FM 1-T 030 (Figure 2) P-8 FM 1-T 030 (Figure 2) Between-Laboratory Precision Values
Verification – Plant (Cont’d) • If all results compare: • Accept material • Payment based on Contractor’s QC results • If the results don’t compare: • VT tests remaining sublot samples for property (or properties) in question. • If only initial unfavorable comparison: accept material and pay based on QC results • If two or more unfavorable: Resolution • Samples sent to District Lab
Independent Verification - Plant • District Materials takes two samples per 12,000 tons • Tested at District Lab • Same tests as QC • Results have to meet requirements of Master Production Range • Go or no go….
Table 334-5 Master Production Range Characteristic Tolerance Asphalt Binder Content (%) Target ± 0.55 Passing No. 8 Sieve (%) Target ± 5.50 Passing No. 200 Sieve (%) Target ± 1.50 Air Voids (%) 4.00 ± 1.50 Density, %Gmm : Coarse Graded (minimum) 93.00 Fine Graded N/A Note: Density based on an average of 5 randomly located cores
Quality Control Sampling and Testing – Roadway • Core locations identified by VT • Tonnage basis • Contractor cuts five cores per sublot • Example: 1000 ton sublot, 12 ft wide lane • 150 lb/sy = 1 core/2000 feet • 200 lb/sy = 1 core/1500 feet • 250 lb/sy = 1 core/1200 feet • 300 lb/sy = 1 core/1000 feet • QC tests cores per FM 1-T 166 • Retains cores for Verification/Resolution
Verification - Roadway • Tests performed by Verification Technician • Tests run at plant • Same-cores • VT tests all five cores from a randomly selected sublot • Same test as QC • Precision statement comparison with QC results • Gmb = 0.022 • Compare favorably: Pay based on QC results • If not: similar to plant Resolution
Independent Verification Roadway • District Materials directs Contractor to take five additional cores from same sublot as plant IV sample • Results have to meet requirements of Master Production Range • Average density must meet minimum… • Go or no go….
Compensation • If two or less sublots: use Small Quantity Pay Table based on average deviations from target • If three or more sublots: use the estimated Percent Within Limits (PWL) for the lot, based on the following characteristics: • Density • Air Voids • AC Content • P-200 • P-8
Compensation (Cont’d) • Pay factor for each characteristic is determined • Composite Pay factor is based on: • 35% Density • 25% Air Voids • 25% AC Content • 10% P-200 • 5% P-8 • All calculations by Excel spreadsheet • Not by hand!
Reporting • Contractor reports all QC test results, quantities, etc.: • Daily Asphalt Plant Quality Control Report • Daily Asphalt Roadway Quality Control Report • Inputs into CQR • CEI reports all Verification test results and Verification activities: • Verify mix spread rate, tack spread rate, mix temperature, etc. • Asphalt Plant Verification Report • Asphalt Roadway Verification Report • Inputs into CQR • Forms currently under development • CQR access through District Construction Office
Other Related Issues • Implementation date: July 2002 Letting • All projects • No Type S/FC-3 projects • Specification only works with Superpave • FC-9.5 & FC-12.5 (FC-6) accepted per 334 • FC-5 specified in 337 • Tolerances based on FC-5 construction data • Pay factors weighted differently • Criteria 3/8” No.4 & No. 8 sieve, and Binder Content • Specification Refresher Course
QC 2000 - Asphalt Welcome… to the Real World.
Industry Perspective QC 2000 Asphalt Specifications Jim Warren Asphalt Contractors Association of Florida, Inc.
Contractor perspectives… • Old: • What good will this do? • Oh No!, Not another new specification! • Lets go back to S-1 • Now: • It’s no so bad… I see some positives. • We’re trained, we’re equipped… Lets Roll! • Opportunities
What's different from the old system? • Same Superpave Mix as before • Still going to test it the same way – no new tests • More QC responsibilities than before • Must change focus from average to uniformity about average (big change) • Its still Hot, Black, and Sticky.
What’s in it for the contractor? • More flexibility to run your operation. • More responsibility and authority to make sure the job is done right. • Less reliance of others for decisions of when to pave, adjustments to make, etc. • Less rework, fewer call-backs, less wasted profits and opportunity costs. • QC tests finally mean something. • Finally, a payback for investing in QC personnel and equipment. • Mo money (if you know what you’re doing).
What’s in it for the Industry? • Levels the playing field for bidding. • Improves the image of the Industry… Asphalt isState-Of-The-Art. • Continuously improving our product – You want it? We can deliver on time, on budget. • Eliminates lesser products from gaining a foothold in our market. • Secures and protects the highway asphalt paving market due to superior performance and lower life-cycle cost.
What does Industry need to do to make it work? • Educating your crews – “It’s not business as usual anymore” “This ain’t no S-1” Think P401. • Stress the importance of attention to detail “Every ton counts!” • Mgmt. Attitude – you can make this work! • If you believe it, exude it… it will happen. • Attend the refresher course – A Gotta! Get up to speed faster through a better understanding of the specification.
Making it Work! • Schwartzkoff Rule #13: “When placed in command – take charge” • Warren Corollary to Rule 13: “When placed in leadership, lead!” • Mgmt. Attitude – you can make this work! • If you believe it, exude it… it will happen. • Every Ton Counts!
What’s in it for the Agency? • Better, more reliable product. • No need to look anywhere else for products. • Flexibility to inspect where needed… • Less $ spent on inspection means more $ for product (asphalt, bridges, etc.) • Meets the National goal of “Get In, Do the Job, Get Out and Stay Out” • Schwartzkoff “Rule #14: Do the Right Thing” • Warren Corollary to Rule #14. Add “the First Time”
What does the Agency need to do make it work? • Have some patience – change takes time – big changes don’t happen overnight. • Cooperate during the transition • Expect some mistakes, be willing to work them out • Attend the refresher course – get up to speed faster through better understanding of the specification.
Refresher Course Objective: • The objective of this 1-day program is to familiarize the participant with the new QC2000 asphalt specifications. Upon completion of this program, the participant will be able to: • - Identify what’s different under these new specifications compared to current specifications, • - Understand the respective roles and duties of the parties involved, and • - Understand the acceptance process.
Refresher Course Agenda: • Introduction • Definitions • Review Specifications • (234, 285, 320, 330, 334, 337) • The Matrix • Walking through the Plant & Roadway • Checks & Balances • Calculations and Spreadsheet • Forms, Case Studies, & Q&A • Quiz
What’s in it for the Taxpayer? • The Smooth Ride… • Achievable Goals: • No rutting • No cracking • No potholes • Renewable Surface (roof) as part of entire paving system. • A pavement that delivered the biggest bang for the buck that lasts. • The Best Paving Product – second to none.