Hot Mix Asphalt Level I Technician Course

694 Pages·2013·28.39 MB·English

Hot Mix Asphalt

Level I

Technician Course

2012-2013

Illinois Department of Transportation
Bureau of Materials & Physical Research

Hot Mix Asphalt Level I Course Manual Revised January 2013

TABLE OF CONTENTS

PAGE
INTRODUCTION

Course Outline ............................................................................................................................. 1
Hot Mix Asphalt Course Testing Requirements ........................................................................... 3
Nuclear Density Tester Course Testing Requirements ................................................................ 5
Instructors and Course Evaluation Form ...................................................................................... 7

CHAPTER 1 – SPECS., SPECIAL PROVISIONS & NUCLEAR CORE CORELATION

Materials .................................................................................................................................... 1-1
Job Mix Formula (JMF) Limits ................................................................................................... 1-3
Volumetric Requirements .......................................................................................................... 1-5
Quality Control/Quality Assurance documents ........................................................................... 1-6
Start of HMA Production ............................................................................................................ 1-7
Hot-Mix Asphalt QC/QA Start-Up Procedures (MTP - Appendix B4) ......................................... 1-9
Determining Growth Curve during Start-up ................................................................................. 1-14
Completing a Nuclear Core Correlation during Start-up ............................................................. 1-21
Nuclear Core Correlation Layout ............................................................................................... 1-33
Example of Completed Nuclear Core Correlation ...................................................................... 1-35
Laboratory Requirements .......................................................................................................... 1-40
Annual Quality Control Plan & Addenda .................................................................................... 1-40
Quality Personnel ...................................................................................................................... 1-41
Plant Tests ................................................................................................................................ 1-42
Dust to Asphalt Ratio & Moisture Content .................................................................................. 1-43
Asphalt Binder Sampling ........................................................................................................... 1-44
HMA Sampling ........................................................................................................................... 1-44
Required Field Tests ................................................................................................................. 1-45
Control Limits ............................................................................................................................. 1-46
Control Charts ........................................................................................................................... 1-46
Corrective Action for Required Plant Tests ................................................................................ 1-47
Corrective Action for Required Field Tests ................................................................................ 1-48
Quality Assurance by the Engineer ............................................................................................ 1-49
Acceptance by the Engineer ...................................................................................................... 1-51
Documentation .......................................................................................................................... 1-51

CHAPTER 2 – CONTROL CHARTS AND CALCULATIONS

Definitions .................................................................................................................................... 2-1
Moving Average Calculation ........................................................................................................ 2-2
Control Chart Legend .................................................................................................................. 2-3
Examples of Scales for QC/QA Control Charts ............................................................................ 2-4
Hot-Mix Asphalt QC/QA Control Charts/Rounding Test Values – Appendix B8 ............................ 2-5
Hot-Mix Asphalt Design Example ................................................................................................ 2-9
Asphalt Binder Content Control Chart Example ........................................................................... 2-11
Hot-Mix Asphalt -200 Sieve Control Chart Example .................................................................... 2-13
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CHAPTER 3 – INGREDIENTS OF HOT MIX ASPHALT

Aggregates
Introduction ........................................................................................................................... 3-1
Sources ................................................................................................................................. 3-3
Properties .............................................................................................................................. 3-6
General .................................................................................................................................. 3-10
MISTIC Designations ............................................................................................................. 3-11
Descriptions of Mixtures ......................................................................................................... 3-12
Friction Requirements of Coarse Aggregates ......................................................................... 3-14
Specific Requirements ........................................................................................................... 3-17
Performance Graded Binders
An AC Graded System .......................................................................................................... 3-19
Changing Times ..................................................................................................................... 3-20
Performance Driven Binders .................................................................................................. 3-20
What Does PG 54-22 Mean? ................................................................................................. 3-20
PG Certified Program ............................................................................................................. 3-21
Conclusion ............................................................................................................................. 3-21
Tips on Handling Asphalt Binders .......................................................................................... 3-22
Specification for Asphalt Binders ............................................................................................. 3-23
Petroleum Asphalt Flow Chart ................................................................................................ 3-25

CHAPTER 4 – PLANTS AND SAMPLING

Drier-Drum Plants ........................................................................................................................ 4-1
Batch Plants ................................................................................................................................ 4-2
Stockpiles .................................................................................................................................... 4-3
Illinois Specification 201 IDOT Aggregate Gradation Sample
Size Table & Quality Control Sieves
Coarse Aggregate Gradation Table ...................................................................................... 4-3
Fine Aggregate Gradation Table ........................................................................................... 4-4
Cold Aggregates Bins and Feeders ............................................................................................. 4-5
Collector Weigh Belt .................................................................................................................... 4-6
Drier.............................................................................................................................................. 4-7
Screen Deck Arrangement .......................................................................................................... 4-8
Segregation and Sampling .......................................................................................................... 4-9
Hot Bin Sample Sizes ................................................................................................................... 4-10
Drag Slat Conveyor ..................................................................................................................... 4-11
Batcher (Gob Hopper) ................................................................................................................. 4-12
Surge Versus Storage ................................................................................................................. 4-12
Segregation ................................................................................................................................. 4-13
Guidelines for Hot-Mix Sampling from Trucks QC/QA ................................................................. 4-14
Guidelines for Hot-Mix Sampling from Job-Site (PFP & QCP) ...................................................... 4-14
Blending ...................................................................................................................................... 4-14
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CHAPTER 4 – PLANTS AND SAMPLING (Continued)

Visual Observation ...................................................................................................................... 4-15
Hot-Mix Asphalt QC/QA Initial Daily Plant and Random Samples (Appendix B6) ......................... 4-17
Example of Hot-Mix Asphalt QC/QA Initial Daily Plant and Random Samples .............................. 4-21
Truck Sample Splitting Diagram (Appendix B14) .......................................................................... 4-23
Asphalt Splitting Flow Chart .......................................................................................................... 4-25
Testing Sequence for Bulk Specific Gravity (G ) ........................................................................ 4-27
mb
Testing Sequence for Maximum Specific Gravity (G ) .............................................................. 4-29
mm

TESTING PROCEDURES FOR HOT MIX ASPHALT (CHAPTERS 5-10)

Chapters 5 through 10 provide the various test procedures which are performed on hot mix asphalt as
part of the design process and the Contractor’s quality control.

The Illinois procedure for performing each test can be found at the end of the respective sections. These
procedures have been adopted to provide accurate and consistent test results. Deviation from these
procedures may result in unreliable results.

CHAPTER 5 – ASPHALT CONTENT

Ignition Oven
Alternative Method needed to replace Trichloroethylene ...................................................... 5-1
How Does the Ignition Oven Work? ...................................................................................... 5-1
History of the Ignition Oven ................................................................................................... 5-2
Accuracy of the Ignition Test .................................................................................................. 5-3
Calibration (Barnstead/Thermolyne Furnace) ........................................................................ 5-4
Test Procedure (Barnstead/Thermolyne Furnace) .................................................................. 5-11
Gradation (Barnstead/Thermolyne Furnace) ........................................................................... 5-14
Safety Issues ......................................................................................................................... 5-14
Example (Barnstead/Thermolyne Furnace) ........................................................................... 5-15
Barnstead/Thermolyne Tester Asphalt Content Determination Worksheet ............................. 5-17
Calibration (Gilson Furnace) .................................................................................................. 5-19
Test Procedure (Gilson Furnace) ........................................................................................... 5-23
Gradation (Gilson Furnace) .................................................................................................... 5-26
Gilson Ignition Tester Asphalt Content Determination Worksheet ........................................... 5-27
Hot-Mix Asphalt Mix Design Procedure for Dust Correction Factor Determination ................. 5-29

Calibration of Equipment for Asphalt Binder Content Determination
(Nuclear Gauge and Ignition Oven) Appendix B11 ....................................................................... 5-37

Standard Method of Test for Determining the Asphalt Binder Content of
Hot-Mix Asphalt (HMA) by the Ignition Method (AASHTO T 308-09) ............................................ 5-40

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CHAPTER 5 – ASPHALT CONTENT (continued)

Extraction Test
Purpose of test ....................................................................................................................... 5-55
Equipment .............................................................................................................................. 5-55
Split Sample ........................................................................................................................... 5-56
Weights Necessary To Begin Extraction ................................................................................. 5-56
Accuracy ................................................................................................................................ 5-56
Prepare Sample for Extraction ................................................................................................ 5-57
When Fluid Dripping from the Sample is Clear ...................................................................... 5-57
Unload Sample from Baskets .................................................................................................. 5-58
Drying the Extracted Aggregate ............................................................................................. 5-58
Washed Gradation ................................................................................................................. 5-58
Calculations ........................................................................................................................... 5-58
Differences between IDOT and AASHTO Procedures ........................................................... 5-59
Extraction Worksheet ............................................................................................................. 5-61

Standard Method of Test for Quantitative Extraction of Bitumen from Bituminous
Paving Mixture (AASHTO T 164-94) ..................................................................................... 5-63

Nuclear Asphalt Content Gauge
Purpose of test ...................................................................................................................... 5-87
Equipment .............................................................................................................................. 5-87
Troubleshooting ..................................................................................................................... 5-88
Determination of Weight for Calibration and Testing - W ....................................................... 5-90
o
Calibration ............................................................................................................................... 5-93
Testing the plant mixture for asphalt content .......................................................................... 5-97
Report .................................................................................................................................... 5-98

Nuclear Asphalt Content Gauge Power Point Presentation .......................................................... 5-99

Standard Method of Test for Asphalt Cement Content of Asphalt Concrete Mixtures by
The Nuclear Method (AASHTO T-287-97) ................................................................................... 5-129

CHAPTER 6 – BULK SPECIFIC GRAVITY (G )(d)
mb

Definitions ..................................................................................................................................... 6-1
Purpose of Test ........................................................................................................................... 6-1
Superpave Gyratory Compaction
Purpose of Gyratory Compaction ............................................................................................ 6-1
Gyratory Compactive Efforts ................................................................................................... 6-3
Overview of Compaction Procedure ....................................................................................... 6-4
Specimen Compaction ........................................................................................................... 6-5
Illinois Method for Field Control .............................................................................................. 6-8
Specific Gravity ............................................................................................................................ 6-9
Field VMA .................................................................................................................................... 6-9
Lab Calculation Exercise ............................................................................................................. 6-10
QC/QA Worksheet for Bulk Specific Gravity ................................................................................ 6-11
Compacting an SGC Specimen to a Specified Height and Air Void Level ................................... 6-14
Hamburg Wheel Test ................................................................................................................... 6-15
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CHAPTER 6 – BULK SPECIFIC GRAVITY (G )(d) (Continued)
mb

Hot Mix Asphalt – Mixture Design Verification and Production (BMPR) ....................................... 6-17
Compaction Using Marshall Test Method .................................................................................... 6-19
Specific Gravity and Density for Hot-Mix Asphalt ......................................................................... 6-20

Standard Method of Test for Preparing and Determining the Density of Hot-Mix Asphalt
(HMA) Specimens by Means of the SHRP Gyratory Compactor (AASHTO T 312-04) ................ 6-23

Standard Method of Test for Bulk Specific Gravity of Compacted Bituminous Mixtures
Using Saturated Surface-Dry Specimens (AASHTO T 166-07, Methods A and C) ...................... 6-33

Standard Method of Test for Superpave Volumetric Design for
Hot-Mix Asphalt (HMA) ( AASHTO R 35-04) .............................................................................. 6-45

Standard Method of Test for Resistance to Plastic Flow of Bituminous Mixtures Using
Marshall Apparatus (AASHTO T 245-94) ..................................................................................... 6-63
Hamburg Wheel-Track Testing of Compacted Hot Mix Asphalt (HMA) (AASHTO 324-11) .......... 6-75

CHAPTER 7 – MAXIMUM SPECIFIC GRAVITY (G )(D)
mm

Definition ...................................................................................................................................... 7-1
Weigh-In-Water Method
Calibrate Pycnometer.............................................................................................................. 7-2
Examples of Pycnometer Calculations .................................................................................... 7-2
Sample Preparation ............................................................................................................... 7-2
Testing ................................................................................................................................... 7-3
Maximum Specific Gravity (G ) Worksheet – Weighing-In-Water Method ............................ 7-5
mm
Weigh-In-Air Method
Calibrate Pycnometer.............................................................................................................. 7-7
Examples of Pycnometer Calculations .................................................................................... 7-7
Sample Preparation ............................................................................................................... 7-7
Testing ................................................................................................................................... 7-8
Maximum Specific Gravity (G ) Worksheet – Weighing-In-Air Method ................................. 7-9
mm
Procedure for Mixes with High Absorptive Aggregate ................................................................... 7-11
Specific Gravity and Density for Hot-Mix Asphalt ......................................................................... 7-13

Standard Method of Test for Maximum Specific Gravity of Bituminous
Paving Mixtures (Reference AASHTO T 209-05) ......................................................................... 7-15

CHAPTER 8 – CORE DENSITY DETERMINATION

Purpose of Test ............................................................................................................................ 8-1
Core Specimen Removal From The Pavement ........................................................................... 8-1
Prepare Core Specimens for Testing ........................................................................................... 8-2
Equipment ................................................................................................................................... 8-3
Procedure to Determine Density .................................................................................................. 8-3
Calculations ................................................................................................................................. 8-4
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CHAPTER 9 – STRIPPING TEST

Standard Method of Test for Resistance of Compacted Bituminous Mixture to
Moisture-Induced Damage (AASHTO T 283-07) .......................................................................... 9-3

Tensile Strength Ratio (TSR) Steps ............................................................................................. 9-17
Formulas for TSR ........................................................................................................................ 9-19
Stripping Test Worksheet ............................................................................................................ 9-21

CHAPTER 10 – NUCLEAR DENSITY TEST

Introduction ................................................................................................................................... 10-1
Nuclear Gauge Operation ............................................................................................................ 10-1
General .................................................................................................................................. 10-1
Standard Count ...................................................................................................................... 10-1
Test Count ............................................................................................................................. 10-2
Test Procedure ...................................................................................................................... 10-4
Clean Gauge .......................................................................................................................... 10-5
Correlation ................................................................................................................................... 10-6
Test Sites .................................................................................................................................... 10-6
Report Form and Instructions ...................................................................................................... 10-6
Material Codes ............................................................................................................................ 10-7
Field Worksheet ........................................................................................................................... 10-10
MI 303N QC/QA Nuclear Density Report ..................................................................................... 10-11
MI 303N QC/QA Nuclear Density Report Instructions ................................................................... 10-15

Standard Test Method for Determination of Density of Bituminous Concrete
In Place by Nuclear Methods (ASTM D 2950-91) ......................................................................... 10-25

Determination of Random Density Test Site Locations (Appendix B7) ........................................ 10-37
Example Problem of Hot-Mix Asphalt Random Density Locations ............................................... 10-39
Hot-Mix Asphalt – Density Testing of Longitudinal Joints (BDE 80246) ....................................... 10-43
Random Test Determination Layout ....................................................................................... 10-45
Random Test Determination Layout for Two Confined Edges (Inlay) ..................................... 10-46
Random Test Determination Layout for One Confined Edge .................................................. 10-47
Random Test Determination Layout for Two Unconfined Edges ............................................ 10-49

HOMEWORK

Chapter 2 ..................................................................................................................................... HM-1
Chapter 4 ..................................................................................................................................... HM-5
Chapter 5 ..................................................................................................................................... HM-9
Chapter 9 ..................................................................................................................................... HM-13
Chapter 10 ................................................................................................................................... HM-17
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HOMEWORK SOLUTIONS

Chapter 2 ..................................................................................................................................... SOL-3
Chapter 4 ..................................................................................................................................... SOL-5
Chapter 5 ..................................................................................................................................... SOL-9
Chapter 9 ..................................................................................................................................... SOL-13
Chapter 10 ................................................................................................................................... SOL-17

APPENDICES

Suggested Laboratory Equipment/Suppliers App-3

Hot-Mix Asphalt QC/QA Laboratory Equipment (MTP-Appendix D4) App-9

Model Annual Q/C Plan for Hot-Mix Asphalt Production (MTP-Appendix B1) App-15

Model Annual Q/C Plan for Hot-Mix Asphalt Production
Addendum (MTP-Appendix B2) App-25

Hot-Mix Asphalt Mix Design Verification
Procedure (MTP-Appendix B9) App-27

Development of Gradation Bands on
Incoming Aggregates at Mix Plants (Appendix-A1) App-33

Hot-Mix Asphalt QC/QA QC Personnel
Responsibilities and Duties Checklist (MTP-Appendix B5) App-35

Standard Test Method for Correlating Nuclear Gauge
Densities with Core Densities (MTP-Appendix B3) App-45

Hot Mix Asphalt QC/QA Start-Up Procedures (MTP-Appendix B4) App-53

Bureau of Materials and Physical Research Policy Memorandum, “Minimum Private
Laboratory Requirements for Construction Materials Testing or Mix Design App-59

Ignition Oven Aggregate Mass Loss Procedure (MTP-Appendix B18) App-75

Procedure for Internal Angle Calibration of Gyratory Compactor (SGCs)
using the Dynamic Angle Validator (DAV-2) (MTP – Appendix B19) App-77

QC/QA Document –
Segregation Control of Hot Mix Asphalt (MTP – Appendix B20) App-83

Off-site Preliminary Test Strip and
Modified Start-up Procedure (MTP – Appendix B23) App-85

MTP = Manual of Test Procedures for Materials
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SPECIAL PROVISIONS

PFP – Plant Sampling SP - 2
PFP – Jobsite Sampling SP - 7
QCP SP - 12
PFP – Quality Level Analysis SP - 16
PFP – Random Plant Samples SP - 28
PFP & QCP – Random Density Procedure SP - 32
PFP & QCP – Random Jobsite Sampling SP - 36
PFP – Pay Dispute Resolutions SP - 48
QCP – Pay Calculation SP - 50
PFP & QCP – Implementation SP - 56

PFP = Payment For Performance
QCP = Quality Control for Payment

BMPR = Bureau of Materials and Physical Research
MoTP = Manual of Test Procedures

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