Acceptance Control Asphalt Layers

63
Volume 2
Chapter 17 Revision 0
Acceptance Control Asphalt Layers
Surfacing Base Subbase Selected Subgrade
Materials Manual
Western Cape : Provincial Administration Department of Transport and Public Works Roads Infrastructure Branch
Materials Manual
First Edition
Chapter 17
Acceptance Control Asphalt Layers
Western Cape Provincial Administration Department of Transport and Public Works Roads Infrastructure Branch
Western Cape Provincial Administration 2008 by the Western Cape Provincial Administration. All right reserved First Edition revision 0 published 2008. Printed in the Republic of South Africa
SET: ISBN 0-620-29823-5 CHAPTER: ISBN 1-920158-18-9
WCPA Department of Transport and Public Works
Materials Manual Volume 2 Chapter 17
ACCEPTANCE CONTROL: ASPHALT LAYERS

Contents page 17-
INTRODUCTION .................................................................................................. 1 SOURCE ........................................................................................................... 2

Introduction ...................................................................................................................................2 Sampling Plan ...............................................................................................................................2 Tests..............................................................................................................................................2 Time Schedule To Obtain Acceptance .........................................................................................3 Applicable Forms ..........................................................................................................................3 Assessment...................................................................................................................................4
Coarse Aggregate ............................................................................................................................ 4 Fine Aggregate ................................................................................................................................. 4 Filler.................................................................................................................................................. 4 Bituminous Binder ............................................................................................................................ 4
DESIGN MIX ...................................................................................................... 5

Introduction ...................................................................................................................................5 Tests..............................................................................................................................................5 Time Schedule To Obtain Acceptance .........................................................................................5 Applicable Forms ..........................................................................................................................5 Assessment...................................................................................................................................5 Approval Of Design .......................................................................................................................6
T A B L E O F C O N T E N T S
TRIAL SECTION ................................................................................................. 7

Introduction ...................................................................................................................................7 Sampling Plan ...............................................................................................................................7 Tests..............................................................................................................................................8
Laboratory ........................................................................................................................................ 8 Field.................................................................................................................................................. 8
Time Schedule To Obtain Acceptance .........................................................................................9 Applicable Forms ..........................................................................................................................9 Assessment...................................................................................................................................9

Grading............................................................................................................................................. 9 Compaction .................................................................................................................................... 10 Other Properties ............................................................................................................................. 10
Approval Of Trial Section ............................................................................................................10
CONSTRUCTION LOTS ...................................................................................... 12

Introduction .................................................................................................................................13 Sampling Plan .............................................................................................................................13 Tests............................................................................................................................................13
Supply Control Of Mix..................................................................................................................... 13 Asphalt Mix..................................................................................................................................... 14 Layer Thickness ............................................................................................................................. 14
Time Schedule To Obtain Acceptance .......................................................................................14 Applicable Forms ........................................................................................................................14 Assessment.................................................................................................................................15

Compaction .................................................................................................................................... 15 Binder Content ............................................................................................................................... 19 Voids .............................................................................................................................................. 19 Grading........................................................................................................................................... 20 Shape ............................................................................................................................................. 20 Stability and Flow ........................................................................................................................... 20 Dynamic Creep and ITS ................................................................................................................. 20
17 Acceptance Control: Asphalt Layers
20 October, 2008
page 17-i
General .......................................................................................................................................20
Compaction .................................................................................................................................... 21 Slippage ......................................................................................................................................... 21 Early Trafficking.............................................................................................................................. 21
Submission of Acceptance Control Forms..................................................................................22 As-Built Data Sheets ...................................................................................................................22
FIGURES
Figure 17-1: Figure 17-2: Figure 17-3: Figure 17-4: Figure 17-5: Layout of the Materials Manual....................................................................................................1 Example of design form for verification for asphalt layers .........................................................11 Example of design form for verification for asphalt layers .........................................................12 Example of completed form E-ASS-ACB1-E .............................................................................17 Example of completed form E-ASS-ACA1-E .............................................................................18
TABLES
Table 17-1: Example of Typical Compaction Window Reductions for Thin Mats ...........................................21
T A B L E O F C O N T E N T S
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ACCEPTANCE CONTROL: ASPHALT LAYERS INTRODUCTION

This chapter gives the background required to adequately apply the acceptance control process for asphalt layers, as well as identifying some problems, and the means to address the problems to provide an acceptable product. This chapters part in the overall layout of the Materials Manual is shown in Figure 17-1. The Western Cape Provincial Administration has over the years constructed the bulk of its heavily trafficked road network using deep granular flexible pavements. The accelerating growth of heavy axles on the network has led to more frequent use of asphalt layers for
asphalt surfacing, and asphalt base, where larger aggregate

sizes have been introduced in mixes, commonly known as large aggregate mixes for bases (LAMBS).
INPUTS
ACTIVITIES
Chapter 8
QUALITY ASSURANCE
7 Construction equipment control
I N T R O D U C T I O N
ACCEPTANCE CONTROL
Chapter 9
Chapter 13
Chapter 17
BASIC CONCEPTS
Chapter 10
SELECTED LAYERS
Chapter 14
ASPHALT LAYERS
Chapter 18
ROADBED
Chapter 11
SUBBASE LAYERS
Chapter 15
SEALS
Chapter 19
STOCKPILED MATERIAL
Chapter 12
CHEMICALLY TREATED LAYERS

Chapter 16
GRAVEL WEARING COURSE

Chapter 20
FILL
BASE LAYERS
CONCRETE
Figure 17-1: Layout of the Materials Manual
20 October, 2008
page 17-1
SOURCE
INTRODUCTION
Asphalt is usually purchased from a commercial source. The aggregates used to manufacture the asphalt are delivered to the asphalt plant and control is exercised through sampling from the hot bins or the aggregate stockpiles. For fixed commercial plants and new or mobile plants quality control of the aggregates is exercised through Surfacing - Hot-mix Asphalt, Unmodified Bitumen Binder and table for Component conformance control - asphalt surfacing - unmodified bitumen binder Surfacing - Hot-mix Asphalt, Modified Bitumen Binder and table for Component conformance control - asphalt surfacing bitumen-rubber asphalt
SAMPLING PLAN
The sampling plans for aggregates, bitumen and rubber are provided in Chapter 4, Field Sampling Methods, under the headings listed below: Sampling Plan, Processed Materials Sampling of Natural Materials Sampling of Bituminous Binders Sampling of Processed Materials (Untreated) and Sampling of other commodities
sampling of the stockpiles at the crusher

site, cold feed and/or hot bins of the asphalt plant, especially in the case of asphalt batch plants, sampling the binder quality and testing of specific properties.
S O U R C E
In the case of new aggregate sources for projects remote from a commercial asphalt plant, the new sources shall be adequately explored and on completion, rehabilitated as outlined in Chapter 5, Materials Investigations and Reporting. The proposed site and rehabilitation plan for borrow pits shall be approved by the Regional Director, Minerals and Energy, in accordance with the procedures outlines in Chapter 5, Materials Investigation and Reporting, Environmental Assessment Report, and Inspection and Approvals prior to proceeding with any mining activities. Guidelines for sourcing material and the developing, operating and closing of borrow pits/quarries is covered in the Departments Operations Manual 1 . The conformance control requirements of materials and mixes shall be in accordance with Chapter 8, Quality Assurance, under the following sections: Asphalt Bases and table for Component conformance control - asphalt base
1. Operations Manual, Manual for the Identification, development, operation and closure of gravel material sources, Western Cape Provincial Administration, Department of Transport, Cape Town, September 2006.
Further information can be obtained from Chapter 11, Stockpiled Material.
TESTS
Refer to Chapter 8, Quality Assurance for tests to be carried out on the materials and type of mixes as indicated under Component Conformance Control for Base, Asphalt Bases and table for Component Conformance Control asphalt base, Surfacing - Hot-mix Asphalt, Unmodified Bitumen Binder and table for Component Conformance Control - asphalt surfacing - unmodified bitumen binder, and Surfacing - Hot-mix Asphalt, Modified Bitumen Binder and table for Component Conformance Control asphalt surfacing - bitumen-rubber asphalt.
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Refer to SABITA Manual No. 3, Test methods for bitumen-rubber 2 . The properties measured in this phase of quality control are normally the following: Aggregate (coarse and fine)
Resilience Compression-recovery Ductility
Grading Strength (hardness) by virtue of its geo

logical origin Durability (resistance to environmental weathering) Shape and texture (flakiness, elongation, crushed faces) Absorption (water and type binder) Abrasive resistance (polishing under traffic) Atterberg Limits (active clay) Binder adhesion (stripping) Filler
TIME SCHEDULE TO OBTAIN ACCEPTANCE

The time schedule to obtain acceptance for the product is governed by the time to obtain the required samples and the duration of specific tests. A schedule is outlined in Chapter 3, Commentary on Test Methods, Time Schedule for Duration of Testing.
APPLICABLE FORMS
STAGE Sampling FORM CODE S-SOU-GRA-E DESCRIPTION Field samples of Material for Pavement Layers Borrow Pits Field samples of material for surfacing Bitumen-rubber binder spray/mixing grade component and blending control Test data: aggregate for bituminous surfacing and layers Acceptance Control Constructed Base Continuously Graded Asphalt Acceptance Control Constructed Wearing Course - Continuously Graded Asphalt Acceptance Control Constructed Wearing Course - Semi Gap Graded Asphalt Acceptance Control Constructed Wearing Course Porous (Open Graded) Asphalt Acceptance Control Constructed Wearing Course Stone Mastic Asphalt DESCRIPTION page 17-3
Type (active, e.g., lime, cement; nonactive, e.g., cyclone dust, etc.) Grading Density in toluene for fineness Binder (conventional or modified)
S-SOU-SUR-E
Testing
T-DAT-BRB-E
S O U R C E
Type (normally unmodified bitumen) Grade viscosity and penetration Softening Point (ring and ball) Ductility Composition (saturates, aromatics, resins, asphaltences) Ageing of bitumen before and after use (Rolling thin film oven test [RTFOT]) Modifier
T-DAT-SUR1-E
Evaluation
E-ASS-ACB1-E
E-ASS-ACA1E
Type and grade (rubber, polymer) Grading of crumbed rubber Resilience of crumbed rubber Extender oil in the case of crumbed rubber Blend (Bitumen rubber binder)
E-ASS-ACA2-E
E-ASS-ACA3-E
Softening point Flow Viscosity

2. Test methods for bitumen-rubber. SABITA, Manual 3, Cape Town, 1992.
E-ASS-ACA4-E
STAGE
FORM CODE
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WCPA Department of Transport and Public Works E-ASS-ACF-E Acceptance Control Constructed Friction Course Thin and Ultra Thin Asphalt
FINE AGGREGATE
The shape and texture of particles significantly affects the workability of the mix as well as the resistance to deformation. The sand equivalent value (which is computed as a ratio of the sand to clay height readings, using a flocculating test procedure), shall be at least 50 as per COLTO Standard Specifications 3 , Clause 4202 (b) (vi). The binder and water absorption greater than 1,5 percent should be evaluated carefully to avoid long term drying out, i.e., poor durability.
ASSESSMENT
COARSE AGGREGATE
The coarse aggregate in an asphalt mix should be uniform in quality, especially as regards grading, free from deleterious matter, weathered and disintegrating particles. The particles should ideally be cubical and shall conform to the flakiness index criterion. The texture and shape will also influence the stability of the mixture, and therefore, an angular shape is preferred to rounded and/or elongated particles. In the case of natural gravel, only the clean, hard material, preferably more than 40 mm in diameter, which is free from any organic matter and clay lumps (which could make it more susceptible to binder stripping), should be crushed. The crushed particles must conform to the criterion for crushed faces. Aggregates with a high binder or water absorption (>1,0 percent) should be carefully evaluated since such material can result in the long term drying out of mixtures with corresponding poor durability, shrinkage, cracking and even disintegration.
FILLER
Active filler shall consist of milled blast furnace slag, hydrated lime, ordinary portland cement, portland blast furnace cement, fly-ash, or a mixture of any of the above materials as specified or determined during design verification stages. Acceptance will be based on appropriate certification of the product offered, or on appropriate tests being performed to verify such certification.
S O U R C E
BITUMINOUS BINDER
The bituminous binder must comply with standards given in Chapter 2, Materials Standards, COLTO Standard Specifications3 and the project specifications. For bitumen-rubber blends, the rubber crumb shall comply with the requirements of COLTO (Section 4200, Standard Specifications3 Clause 4202 (a) (2) and Table 4202/1). It should be noted that the natural rubber content of different sources may differ, thus requiring the addition of different percentages of rubber crumb to produce an equivalent blend.
3.Standard Specification for Road and Bridge Works for State Road Authorities, COLTO, Pretoria, 1998
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DESIGN MIX
INTRODUCTION
The laboratory design method adopted can be either according to Marshall or, in the case of LAMBS design, according to Hugo (Modified Kentucky) procedure 4 . It is a means of selecting and proportioning materials, within the limits of the project specifications, to obtain a mix with the desired qualities and properties by determining the most economical blend. This is done by: optimising the grading of the coarse aggregate, fine aggregate and fillers, and the addition of a suitable binder in sufficient quantities. In the case of high performance layers the Bayley method should also be consulted.
TESTS
Refer to Chapter 8, Quality Assurance for the appropriate tests to be carried out as indicated under Design Verification for the following layers and types of mixes: Basecourse, Asphalt Base and table for Design Verification (laboratory) - Asphalt Base Surfacing - Hot-Mix Asphalt, Unmodified Bitumen Binder and table for Design verification (laboratory) - asphalt surfacing unmodified binder Surfacing - Hot-Mix Asphalt, Modified Bitumen Binder and table for Design verification (laboratory) - bitumen-rubber asphalt
The method should yield a mix having the following properties:
thorough coating of the aggregate particles and bonding them together to ensure a durable pavement layer under desirable compaction; sufficient mix stability and resistance to flow, to satisfy the long term service requirements and demands, especially under heavy traffic, without distortion and displacement; and for continuously graded mixes, sufficient unconnected voids in the mix to prevent flushing and permeability The laboratory compacted mix must provide a reservoir of space for the expansion of binder even after additional compaction due to traffic, bleeding, or loss of resistance to plastic deformation, but limit the space to keep harmful air and/or moisture out, and have sufficient workability to permit efficient placing of the mix without the segregation of aggregate, especially in the case of coarse graded mixes.
4. LAMBS - The design and use of large aggregate mixes for bases. SABITA, Manual 13, Cape Town, 1993.

The duration of the relevant tests can be assessed using Chapter 3, Commentary on test methods, Time schedule for duration of test.
S O U R C E
APPLICABLE FORMS
STAGE Testing FORM CODE T-BEN-ASP-E DESCRIPTION Test Data: As Built Test Results Asphalt mixes Asphalt Mix Design
Evaluation
FORM D3 (TMH 10)
ASSESSMENT
The use of modified binders, such as bitumenrubber blends, should be a well controlled process to ensure the required properties. For further details of the blending of the various constituents, i.e., bitumen, crumbed rubber and extender oil, refer to Chapter 6, Materials Selection, Constraints and Design Procedures,
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Bitumen-Rubber Asphalt. Charts showing the resilience, flow, softening point (ring and ball) and viscosity with time should be obtained and submitted during the Mix Design stage.
temperature and reaction time, should all be substantiated by behaviour curves for the required properties` and be submitted at least two weeks prior to the commencement of the blending operation.
FORM CODE E-DET-ASP-E APPLICATION Design Verification Trial Section Asphalt Layers
APPROVAL OF DESIGN
For the approval of the proposed design the following form must be submitted to the Materials Engineer at the earliest stage, well before the trial sections commence with an accompanying letter recommending the design parameters. The form is the same as that to be used later for the trial section, but has the specification for the proposed design inserted. In addition for asphalt using a nonhomogeneous modified binder (bitumenrubber) the requirements of COLTO3 (Section 4200, Clause 4202 (a) (4) and /or such other Project Specifications shall be complied with. The information, which includes a
A copy of the letter and also of the forms to the Manager: Pavement Technology, Materials Testing Laboratory, Cape Town. See Chapter 1, Management Procedures For Monitoring And Control, Proposed Designs and Trial Sections.
S O U R C E
method statement, details of the proposed plant, component details, blending / reaction
page 17-6 20 October, 2008 17 Acceptance Control: Asphalt Layers
TRIAL SECTION
INTRODUCTION
Once the source materials and laboratory design has been approved, it is necessary to timeously assess and verify construction procedures and processes (e.g., plant mixing, stockpiling procedures, compaction techniques, etc.) applied to satisfy the criteria outlined in Chapter 2, Materials Standards, HotMix Base, Surfacing, Conventional Hot-Mix Asphalt, Surfacing, Bitumen-Rubber Asphalt, and/or COLTO Standard Specifications3, before proceeding with full production. The constraints that have been imposed are based on extensive research, constructability considerations and ultimately verified with the Heavy Vehicle Simulator. Unless substantive historic data is available verifying all relevant parameters, a length of asphalt base or surfacing shall be constructed as a trial section: at the start of any asphalt base or surfacing, or on the introduction of asphalt base or surfacing from a new source, or when crusher modification and/or other processes need to be introduced to attain the required grading, or when compaction problems are experienced with a previous trial section. verify the adequacy of the crushing arrangement, stockpiling techniques and plant capability, or to make appropriate corrections to the production plant, or where the situation warrants a laboratory re-design and re-evaluation; agree on binder content and characteristics of modified binder where applicable; assess constructability issues such as the paver performance (being a function of settings/adjustments such as auger box/ auger height, automatic level control devices; maintenance management of components especially those subject to a high rate of wear such as tamper bars, screed plates etc.); and do a compaction study in order to agree on the use of the most suitable type of roller, or combination of rollers, the minimal roller passes, rolling pattern for each roller to obtain the maximum or desired compaction at the most desirable temperature at the minimal compaction cost, and compaction window temperatures
T R I A L S E C T I O N
After a mix design is approved, a trial mix should be run through the asphalt plant and tested for conformance, before a trial section is paved with the material The construction of a trial section provides the opportunity to calibrate the dynamic properties of the mix design; verify the laboratory target grading before and after placement by the paver in order to agree to a target grading for the construction lots; assess the variability of the grading;
SAMPLING PLAN
The sampling requirements for a trial section are given in Chapter 4, Sampling Methods, Asphalt Pavement Layers, and/or project specifications, and covers the position of test points for core samples to be tested in the laboratory. The sampling plan and procedures to obtain field samples of the mix before compaction are given in Chapter 4, Sampling Methods, and respectively Sampling Plan, Asphalt Pavement Layers and Sampling of Pavement Layers, Asphalt Layers, or in the project specification. The following issues are covered:
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Location of such a trial section
Size of trial section (usually 150 tons minimum but preferably 200 tons) The number of samples Position of test points
sity (Rice) stability, flow, dynamic creep, indirect tensile strength, VIM, VMA, VFB, immersion index, etc., determined on laboratory compacted specimens. Cantabro abrasion loss (only porous asphalt).
Procedure for obtaining a field sample of the mix Procedure to obtain specimens for density determination A minimum of six duplicate samples (a minimum of 10 kg per sample) of the mix and six layer specimens (core or cut specimens) may be required by the Manager: Pavement Technology, Materials Testing Laboratory, Cape Town.
MODIFIED BINDER
The following tests shall be carried out: Ball penetration and resilience Compression-recovery Flow Dynamic viscosity Softening Point (ring and ball)
TESTS
Determination of the digested rubber for correction factor to adjust to actual binder content
Refer to Chapter 8, Quality Assurance for the appropriate tests to be carried out, as indicated under Design Verification (trial section), for the following layers and types of mixes: Basecourse, Asphalt Base and table for Design Verification (trial section) - Asphalt Base Surfacing - Hot-Mix Asphalt, Unmodified Bitumen Binder and table for Design verification (trial section) - asphalt surfacing unmodified binder Surfacing - Hot-Mix Asphalt, Modified Bitumen Binder and table for Design verification (trial section) - bitumen-rubber asphalt
FIELD
MIXTURE
The temperature of mixture
at the plant, in the load truck arriving at site, before unloading in hopper, either in
truck or hopper, and after placement by paver but prior to compaction shall be recorded on the Form R-LOG-ASP1-E with all other information, such as samples taken, weather conditions, etc. In addition, for bitumen-rubber, the temperature of the blend shall be carefully controlled and monitored during blending operations, with random checking by the Engineer.
LABORATORY
MIXTURE
Samples of the asphalt mix before compaction shall be taken for the following laboratory tests: Binder content
LAYER
For continuously graded mixes, the compaction operation can be monitored by means of a nuclear density apparatus, but it must be calibrated against cores. For acceptance control compaction shall be measured on cores. Core samples shall be obtained prior to opening the layer to traffic and should be cut at low
Grading, flakiness and fractured faces (only fractions equal to or greater than 6,7 mm) Marshall or Hugo (Modified Kentucky) properties such as maximum theoretical denpage 17-8
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surface temperatures. For a layer thickness greater than 35 mm, and a normal mean aggregate size (NMAS) up to 26,5 mm a core sample with a diameter of 100 mm is suitable. For NMAS > 26,5 mm diametric cores are preferable. Marvil permeability tests shall be done prior to coring at each test point. The following tests shall be carried out on the cores: Bulk relative density (all cores) Dynamic creep (6 cores minimum) Resilient modulus (6 cores minimum)
ment Procedures for Monitoring and Control, Administrative Procedures, Correspondence, Proposed Design And Trial Sections), which could delay the final approval of the various parameters/criteria proposed for construction control. Also note the time constraints in Section 8000 of the COLTO Standard Specifications for Road and Bridge Works3.
APPLICABLE FORMS
STAGE Sampling FORM CODE S-SOU-SUR-E DESCRIPTION Field samples of material for surfacing Testing T-DAT-BRB-E Bitumen-rubber binder - spray/mixing grade component and blending control T-DAT-ASP-E Test Data: Asphalt Layers T-DAT-SUR1-E Test data: aggregate for asphalt surfacing or layers T-BEN-PERI-E Test Data: Permeability Water: Method Marvil Evaluation E-ASS-MAR-E Field Test: Water permeability Marvil E-DET-ASP-E Design Verification Trial Section - Asphalt Layers
Indirect Tensile Stress (6 cores minimum),being the same cores as used for the determination of the resilient modulus Binder determination as well as grading if so directed (normally only required when minimum dynamic properties not achieved) These tests will normally apply to all proposed new designs prior to proceeding with any production runs. For proven designs using conventional binders, the Engineer may relax this requirement subject to still having the cores extracted and tested by an approved laboratory if so required by the Materials Engineer. These tests will be performed on a random basis as the project progresses, with a higher frequency of testing being applicable to new designs. In addition, the frequency of testing shall relate to risk of environmental factors (temperature levels, heavy axle intensity, steep gradients/ intersection areas, grading and aggregate shape variability, and binder variability).
ASSESSMENT
GRADING
The procedure to assess the grading obtained from a trial section in order to arrive at a target for construction lots is as follows: Record the values of percentage passing each sieve obtained for each sample on Form E-DET-ASP-E and compare the mean grading with the laboratory design target grading limits. See example Figure 17-2 on page 17-11 for asphalt bases and wearing courses and Figure 17-3 on page 17-12 for friction courses Plot the grading envelope. This is the mean value obtained for each sieve plus twice the standard deviation (2Sn) on either side of the plotted mean value. On the same figure,
page 17-9

The duration of the relevant tests can be assessed using Chapter 3, Commentary on test methods, Time Schedule For Duration Of Testing. Duplicate samples will be required by the Control Laboratory (refer to Chapter 1, Manage17 Acceptance Control: Asphalt Layers
20 October, 2008
plot the required asphalt grading envelope. It should be critically assessed with respect to the asphalt mix specifications and requirements for properties such as stability, creep etc.
APPROVAL OF TRIAL SECTION

For approval of the trial section and mix design the following forms must be submitted to the Materials Engineer at the earliest stage, long before the construction sections commence, with an accompanying letter stating the motivation for changing the approved design.
FORM CODE E-DET-ASP-E APPLICATION Design Verification - Trial Section - Asphalt Layers (base & wearing courses) Design Verification Trial Section Friction Courses Acceptance Control - Asphalt Surfacing - Continuously Graded Acceptance Control - Asphalt Surfacing - Semi-Gap Graded Acceptance Control - Asphalt Surfacing - Open Graded Acceptance Control - Friction Courses (Thin and Ultra Thin) Acceptance Control - Asphalt Base - Continuously Graded
COMPACTION
The typical standard deviations for compaction are between 1 and 2 percent. See Chapter 9, Acceptance Control: Basic Concepts, for more details. The specified minimum compaction, expressed as a percentage of the maximum theoretical density (Rices Method), is given in Chapter 2, Materials Standards. The mean value of the maximum theoretical density shall be used for calculating compaction. Typically asphalt base placed in a 55 to 75 mm single compacted layer, using double-drum vibratory roller and a 25 ton pneumatic tyre roller (tyre pressure 7 to 8 bars), should be capable of obtaining compaction in the range of 93 to 97 percent (Maximum Theoretical Relative Density) when Marshall Vims are of the order of 4,0 to 4,5 percent. For small projects it may sometimes not be appropriate to assess the proper use of compaction equipment in order to arrive at a meaningful type of roller and roller pattern. In this case, the mix properties and/or proven mixtures may give an indication of constructability.
E-DET-AFC-E E-ASS-ACA1-E
E-ASS-ACA2-E E-ASS-ACA3-E E-ASS-ACF-E E-ASS-ACB1-E
A copy of the letter and the forms shall be sent to the Head: Materials Support Services, Cape Town. See Chapter 1, Management Procedures For Monitoring And Control, Proposed Designs and Trial Sections. The outcome of the tests done by the Manager: Pavement Technology, Materials Testing Laboratory will verify the proposed target settings for acceptance, or adjustment for an additional trial section.
OTHER PROPERTIES
The shape of the aggregate, stability, flow, dynamic creep, etc., should be assessed with regard to the approved design.
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WCPA Roads & Traffic Administration Branch
C O N S T R U C T I O N L O T S
Figure 17-2: Example of design form for verification for asphalt layers
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page 17-11
Figure 17-3: Example of design form for verification for asphalt layers
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WCPA Roads & Traffic Administration Branch
CONSTRUCTION LOTS
INTRODUCTION
The quality of the asphalt layer is judged by means of construction lots. The construction lots shall satisfy the criteria outlined in Chapter 2, Materials Standards, and is usually based on minimum tons or on a days production specification. The following issues are covered: Size of construction lot The number of samples Position of test points
Procedure for obtaining a field sample of the mix Procedure to obtain specimens for density
Hot Mix Asphalt Base, or Surfacing, Conventional Hot-Mix Asphalt, or Surfacing, Bitumen-Rubber Asphalt, or the appropriate project specifications. The test section representing the construction lot shall be visually homogeneous. Any isolated, non-homogeneous areas (e.g., coarse patches) must be excluded from the test section and treated separately. The use of a statistical judgement plan applicable to certain parameters, such as degree of compaction, binder content, voids-in-mix and grading in certain cases, involves a random sampling procedure. This approach provides for
TESTS
The requirements are given in Chapter 8, Quality Assurance, Construction Layer Control, tables for the appropriate asphalt mix: Asphalt base
Asphalt Surfacing - unmodified bitumen binder Asphalt Surfacing - modified binder
SUPPLY CONTROL OF MIX

The Form R-LOG-ASP1-E shall be used to record the following: The particulars of truck loads Time of arrival at site Time of off-loading into hopper Section covered by the specific load Temperature of
the appropriate corrections to be made at

the plant to ensure that the mix properties will not violate the target limits set; the verification of the target limits to ensure that engineering properties required are being met; and a low level of risk to the client authority of accepting a poor quality product, or a low, fixed risk to the contractor of rejection of a good quality product.
the truck load at site (ensure that a

tarpaulin cover and not hessian is being used to cover body of truck in order to maintain supply temperature level with minimal loss, especially during transport, or while standing at the site of the works), the asphalt in paver hopper surface (note tilting of hopper required at regular intervals), the layer after placement by paver, but prior to first breakdown compaction, Particulars of field samples taken with regard to test point position, etc.
page 17-13
SAMPLING PLAN
The sampling plan and procedures to obtain field samples of the mix before compaction are given in Chapter 4, Sampling Methods, and respectively Sampling Plan, Asphalt Pavement Layers and Sampling of Pavement Layers, Asphalt Layers, Sampling of Bituminous Treated Materials, or in the project
20 October, 2008
These particulars may be useful in the assessment of lots not fully complying with the project specifications and must be submitted in such cases. The Form T-DAT-BRD-E must be submitted in the case of modified bitumen-rubber asphalt binder with the appropriate graphs displaying time versus viscosity, etc.
termining the layer density using a nuclear device. In the case of lots not fully complying with the project specifications with regard to compaction and/or high voids-in-mix, MARVIL permeability tests shall be mandatory to determine what steps must be taken for payment purposes and/or remedial actions.
ASPHALT MIX
Samples shall be taken at test points for the following laboratory tests: Binder content Grading Flakiness Fractured faces (where applicable) Bulk relative density of compacted specimens and maximum theoretical density (Rice density) Stability and flow (where applicable, not for FC) Indirect Tensile Strength, (ITS) for high performance mixes. Gyratory Refusal Densities for high performance mixes.
LAYER THICKNESS
Layer thickness is obtained from cores taken for density determination.

The duration of the relevant tests can be assessed using Chapter 3, Commentary on test methods, Time Schedule For Duration Of Test.
APPLICABLE FORMS
STAGE Sampling Testing FORM CODE S-SOU-SUR-E T-DAT-BRB-E DESCRIPTION Field samples of material for surfacing Bitumen-rubber binder - spray/mixing grade component and blending control Test data: aggregate for asphalt surfacing or layers Acceptance Control Asphalt surfacing - continuously graded Acceptance Control Asphalt surfacing semi-gap graded Acceptance Control Asphalt surfacing - porous (open graded) Acceptance Control Asphalt base - continuously graded Acceptance Control Friction Courses (Thin and Ultra Thin)
The bitumen-rubber binder is sampled after blending, but before mixing to determine the following properties: Compression-recovery Softening point (ring and ball) Resilience Flow Dynamic viscosity Homogeneity, i.e., content of saturates, aromatics, resins and asphaltines The voids-in-mix and effective relative density of each sample shall be calculated. The effective relative density determines if the binder content and Rice density obtained from each sample is realistic for the type of aggregate blend and binder content specified. During the compaction of the mix, the roller passes and patterns must be controlled by de-
T-DAT-SUR1-E
Evaluation E-ASS-ACA1-E
E-ASS-ACA2-E
E-ASS-ACA3-E
E-ASS-ACB1-E
E-ASS-ACF-E
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ASSESSMENT
COMPACTION
The assessment of compaction of the layer shall comply with the requirements of a statistical judgement plan. The actual variability of the work obtained by the measurements of in situ density from cores shall be used. The range of standard deviations obtained when statistically assessing compaction is a useful measure of process control applied by the Contractor during the compaction phase, provided that a consistent product is being supplied by the manufacturer (which includes temperature on arrival at paver). Based on past experience a deviation for compaction is typically 1,5. A value of say 2,9, will require further investigation regarding compaction procedures, such as the extent to which process control is being applied, the control of roller movements (including number of passes), care taken during core extraction procedures etc. See Figure 17-3 on page 17-17 for Form EASS-ACB1-E (Constructed Base-Continuously Graded Asphalt) and Figure 17-4 on page 1718 Form E-ASS-ACA1-E (Constructed Wearing Course - Continuously - Graded Asphalt ). For friction courses form E-ASS-ACF-E is used, which is similar to E-ASS-ACA1-E used for wearing courses, other than the recording of density which is optional. Outliers are to be dealt with as in Chapter 9, Acceptance Control: Basic Concepts, and/or Project specifications. For critical values for asphalt materials see Appendix C, Table of critical values (C0,99;n) for outlier test for asphalt layers. In the case of an outlier, the kr values for =15 percent will be for {n-1} test values. The outlier shall be further investigated to identify any possible problems with the asphalt layer, etc. In the case of non-compliance with the specification, retesting of any test point is not permissible. If the decision is in question due to the credibility of the test values, the whole construction lot shall be retested with a new set of random test points.
If a test lot is re-tested, the second set of values shall be compared with the first set of values (a minimum of six values for each set) to determine if they belong to the same population. Form E-ASS-COM2-E is used for the comparison between two sets of values. The statistical data from the second set of values shall be taken as final. In the case of non-compliance, the section represented by the lot shall be rejected and the contractor or construction unit shall propose an appropriate remedial action. This remedial action shall first be approved by the Materials Engineer. Conditional acceptance may be applied at the sole discretion (see COLTO Standard Specifications3, Clause 8208(a)(i))of the Materials Engineer unless otherwise specifically allowed for in the Project Specifications. Before considering conditional acceptance for compaction in the case of lots not fully complying with the specification, the MARVIL permeability test shall be carried out. If the mean value is:
3 /m2/hr, and single values are <5 /m2/hr, ACCEPT but effect payment in accordance with calculated reduced payment >3 /m2/hr, use a diluted mineral filled emulsion to waterproof the layer and then RETEST Reduced payment will normally be the outcome of conditional acceptance. When considering conditional acceptance for lots with outcomes OUTSIDE the specifications with respect to compaction, (but having all other parameters complying with the specifications), no more than 50% payment will be considered. Such reduced payment will always be subject to the Contractor being allowed to offer an acceptable alternative, such as:
milling and reinstating with a totally acceptable product for which he will qualify for 100% payment,
page 17-15
20 October, 2008
recycling the in-situ material using a proven

and approved technique,
providing a suitable overlay subject to the

total structural configuration and satisfying the design requirements as verified and agreed to by Materials Engineer.
page 17-16
20 October, 2008
Figure 17-4: Example of completed form E-ASS-ACB1-E
20 October, 2008
page 17-17
Figure 17-5: Example of completed form E-ASS-ACA1-E
page 17-18
20 October, 2008
Normally conditional acceptance at 50 percent payment, will be subject to a diluted mineral filled emulsion (preferably also modified with a synthetic Styrene Butadiene Rubber (SBR) latex) being applied over the full affected surface area with soft brooms. The payment reduction factor is as follows:
A binder content that is too high can lead to unacceptable deformation characteristics at intersections or on steep grades, as well as bleeding/flushing and resultant in unacceptable skid resistance values. In the case of UTFC and TFC mixes which have Agremnt (or other approved) certification, the licence holders approved design and quality system shall be applicable for the specific property product.
x Lr fr = 0,67 + 0,3 n La Lr
Normally this points towards a need for improved process control regarding compaction equipment, assuming grading to be acceptable. Should this situation persist, a detailed investigation shall be carried out.
VOIDS
The inter-granular spaces occupied by the bituminous binder and air in a compacted mix, are called the voids in the mineral aggregate (VMA). Problems experienced with low air voids in the mix (VIMs), can often be attributed to a mix not satisfying the minimum VMA specified (COLTO Standard Specifications Table 4203/1), or too much binder overfilling the VMA. Gradings that follow the maximum density grading (0,45 exponent line) often have inadequate voids in the mineral aggregate (VMA). The impact of the minus 0,075 mm fraction on the VIM is clearly demonstrated by the results obtained in an experiment carried out on a medium continuously graded wearing course mix:
Minus 0,075mm Fraction 6,8 8,1 9,0 VIM Marshall compaction -75 blows 5,6 4,5 3,7
BINDER CONTENT
The type binder (including test method to determine binder content for modified binders) and asphalt mix type (open graded, semi-gap graded or continuously graded) will have a bearing on risk related tolerances permitted as indicated in the notes to Table 8206/3 of the COLTO Standard Specifications2, or the Project Specifications as appropriate. The applicable tolerance will normally be plus or minus 0,2 percent (while 0,3 percent is preferable), whilst for gap graded mixes and mixes using non-homogeneous modified binder, a more relaxed tolerance of plus or minus 0,4 percent will normally apply. If the acceptance control yields an uncertain or outside specification outcome for binder at the upper limit, the following discretionary approaches by the Engineer are recommended: Pay in full subject to the application of a bitumen-rubber porous asphalt wearing course (minimum thickness 25 mm) overlay. This will be required to cover the full extent of the problem area plus adjoining sound areas to keep a consistent road surface. Apply partial payment, subject to review after at least two full summer periods of trafficking.
These aspects need to be investigated at an early stage of a production run, and, if necessary, the design revised. The following strategies should be considered to assess completed asphalt. Lower than specification voids in the mix, together with high in situ density, but within the tolerance binder content (statistically assessed for compliance), may give adequate performance:
20 October, 2008
page 17-19
Pay in full if VIMS only marginally low

(uncertain outcome when statistically assessed), If the VIMs are substantially low, apply partial payment, subject to review after at least two full summer periods of trafficking. Low voids in the mix together with high in-situ density, but binder content at upper limit:
/ACA4/ACF/ACB1-E) shall be used to record the test values for the appropriate sieves. The standard deviations of the constructed lot can be compared with the standard deviations of the statistical data provided in Chapter 9, Basic Concepts, to assess the quality of processing and placing control being exercised. During the production stage a specific trend may appear which may justify a small adjustment to the target grading. Any adjustment shall be kept to the absolute minimum and shall only be done after approval of the Materials Engineer. The slope of the grading curve is an indication of problems that may arise in the proper placement of the mix, especially in the case of the percentage passing the 4,75; 2,36 and 0,075 mm sieves.
Treat as for high binder content

Higher than specification voids in the mix (which is a mix characteristic and does not reflect on the in situ voids) and all other measured parameters complying with the specifications:
Do permeability tests to assess potential for a mineral-filled treatment. ment satisfy the criteria provided under compaction, then consider full payment.
Should such tests with or without treat-
SHAPE
The flakiness on the +6,7 mm fraction and the percentage crushed faces may indicate a trend towards low compaction or low stability.
If conditions are not conducive to such treatment, such as at intersection areas, steep grades or having a high volume of heavy vehicles in the traffic mix, apply calculated partial payment factors. Where the design of a mix has included gyratory tests, the sensitivity of the mix to the environmental factors (traffic, temperature etc.) will be better understood and may influence engineering decisions involving noncomplying lots. For UTFC and TFC mixes the specified voids and acceptance criteria for the (Agremnt or similar) certification for the specific propriety product should be applicable.
STABILITY AND FLOW

Stability and flow shall be measured on laboratory specimens to determine the trend that may develop during the production stage.
DYNAMIC CREEP AND ITS

If the results of the samples randomly cored do not comply with the criteria given in Chapter 2, Materials Standards and/or the Project Specifications, then additional cores shall be tested and the mean value shall be greater than the criterion. In the event of non-compliance, the mix design shall be revised and another trial section ordered.
GRADING
The statistical scheme is used to assess the production of a consistently good product and to assess the quality of the grading in order to control the contractual engineering properties. The scheme is not used for payment purposes. The applicable form for evaluating the specific asphalt mix (E-ASS-ACA1/ACA2/ACA3
page 17-20
GENERAL
Any tests carried out during the approval stage for the source may be repeated for any construction lot. Durability tests, etc., shall be carried out at specific production intervals to verify the source. Such test samples may be
20 October, 2008
Materials Manual Volume 2 Chapter 17 Table 17-1: Example of Typical Compaction Window Reductions for Thin Mats
MAT THICKNESS (mm) COMPACTION WINDOW (MIN) BASE TEMP 45 C AIR TEMP 30 C BASE TEMP 16 C AIR TEMP 13 C
drawn from stockpile, dumped heaps, and/or completed layer. Visual acceptance of the surface of the completed asphalt layer is also required. The completed layer shall have a closely knit surface and be free from areas of segregated material.
25
11 (8) 26 (20) 38 (28)
9 (7) 21 (16) 32 (24)

150C 135C Nil
COMPACTION
PROCESS CONTROL
Appropriate process control during compaction of an asphalt layer includes the monitoring of:
40 50
Asphalt Delivery Temperature Temperature at screed Wind Speed
quality of asphalt mix mixing temperature prior to and during

paving operations the mechanical condition of the paver and compaction equipment the agreed rolling pattern usually established during the trial section.
(Impact of Wind speed 17km/h; 25% window reduction)
SLIPPAGE
Slippage of an asphalt layer may occur during compaction due to inadequate tacking (refer Chapter 6, Materials Selection, Constraints and Design Procedures, Surfacing, Tack Coat) or due to a phenomena known as chilling of the base 7 as a result of a cold wind. Other causes of slippage include old polished surface not giving mechanical key, dust, or excessive prime. During slippage the wearing course moves horizontally relative to the base when the shear stress (developed by traffic) between the layers is greater than the shear or bond strength holding them together. Slippage is most likely to occur when wearing courses are tolled at elevated temperatures on chilled bases founded on pavements of inadequate stiffness. An uncured tack-coat, covered too soon, may also contribute to flushing.
WINDOW FOR COMPACTION

Work done by Wise 5 identified a practical window for placing and compaction thin-layer hot mix asphalt. Guidelines for determining the appropriate window for placement are included in SABITA Manual 22 6 . Under cooler (winter) conditions the window time to achieve acceptable compaction is significantly reduced, particularly for thinner asphalt mat thicknesses. For thin mats (40 mm and less) very rapid cooling occurs through the entire thickness. This window period is further reduced by wind6. See example in Table 17-1 on page 17-20.
EARLY TRAFFICKING
Bleeding/flushing of a sounds asphalt mix can occur under extreme ambient temperatures when a newly paved wearing course is subjected to early heavy trafficking. The manifestation of the problem is usually associated
5. Wise J, Lorio R A practical guide for estimating the compaction window time for thin-layer hot mix asphalt, Proceedings 8th Conference on Asphalt Pavements for Southern Africa (CAPSA) Sun City, September 2004. 6. Hot Mix Paving in Adverse Weather, SABITA, Manual 22, Cape Town, August 2006.
7. Kennedy and Lister, Proceedings the Performance of Rolled Asphalt Road Surfacings, London, October 1979.
20 October, 2008
page 17-21
trafficking immediately after the compaction process is completed.
lots not fully complying with the specification, but accepted by the Material Engineer without removal or reworking of the material.
SUBMISSION OF ACCEPTANCE CONTROL FORMS

For the final approval of completed work, the appropriate acceptance control forms shall be forwarded, under cover of a letter, to the Head: Pavement Technology, Materials Testing Laboratory, Cape Town, every two weeks, or at more frequent intervals, if required by the Materials Engineer. The letter shall state in list form whether each construction lot complies with the specificationsee Chapter 1, Management Procedures for Monitoring and Control. In addition to the appropriate acceptance control forms, the following forms shall also be submitted:
FORM CODE T-DAT-BRB-E T-DAT-SUR1-E R-LOG-ASP1-E APPLICATION For bitumen-rubber blends Test Data: Aggregates for bituminous surfacing and layers Report on as-built test results for all asphalt layers
AS-BUILT DATA
The data of completed work which has been accepted, suitably replaced and tested, or other remedial measures applied and accepted, shall be recorded electronically on the As-Built Acceptance Control Utility System (ABACUS). A project data base, containing the specific project specifications needs to be set up in advance with the Head: Pavement Technology, Materials Testing Laboratory. The submission of copies of the acceptance control reports (A4 size) with the data of at least the first three lots must be submitted at the beginning of the project for scrutinising. As part of the final submission of the As-Built Data both electronic and in book form, a list of all construction lots not fully complying with the specifications, but accepted by the Materials Engineer, shall be included.
A copy of the letter shall be sent to the Materials Engineer. If a lot or lots do not fully comply with the specification, and should there be any doubt as to the appropriate actions regarding acceptance or rejection, or remedial actions, the matter should immediately be referred to the Materials Engineer with all the relevant data recorded on the forms mentioned in the previous paragraph. Copies of the forms shall be sent to the Head: Pavement Technology, Materials Testing Laboratory, Cape Town. Tests done on duplicate samples by the Pavement Technology, Materials Testing Laboratory shall determine the course of action and final decision of the Materials Engineer. Data from each lot shall only be recorded on the As-Built Data Sheet after the final decision of the Material Engineer with regard to:
lots fully complying with the specification, or

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Acceptance Control Asphalt Layers

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Surfacing Base Subbase Selected Subgrade

SET: ISBN 0-620-29823-5 CHAPTER: ISBN 1-920158-18-9

WCPA Department of Transport and Public Works

Materials Manual Volume 2 Chapter 17