2017 INSTRUCTION MANUAL

[Pages:238]WEST VIRGINIA DIVISION OF HIGHWAYS

2017 INSTRUCTION

MANUAL

ASPHALT PLANT TECHNICIAN

WEST VIRGINIA DIVISION OF HIGHWAYS ASPHALT PLANT TECHNICIAN INSTRUCTION MANUAL

Contents

Chapter 1 - Background ...................................................................................................... 1 I HISTORY OF ASPHALT CONCRETE .................................................................. 3 II ASPHALT PLANT TECHNICIAN...................................................................... 4 III DEFINITIONS ...................................................................................................... 5 A) Asphalt Concrete ................................................................................................... 5 B) Bituminous Material .............................................................................................. 5 C) Mineral Aggregate ................................................................................................. 7 IV HIERARCHY OF SPECIFICATIONS................................................................. 9 A) Standard Specifications for Roads and Bridges..................................................... 9 B) Supplemental Specifications .................................................................................. 9 C) Project Plans/Notes ................................................................................................ 9 D) Special Provision Specifications.......................................................................... 10 E) Memorandums...................................................................................................... 10 V QUALITY ASSURANCE SYSTEM ................................................................. 10 A) Quality Control (QC) ........................................................................................... 10 B) Quality Acceptance (QA) .................................................................................... 10 C) Independent Assurance (IA) ................................................................................ 11

Chapter 2 - Material Fundamentals................................................................................... 13 I ASPHALT............................................................................................................... 15 A) Types of Asphalt.................................................................................................. 15 B) Performance Graded Binders ............................................................................... 15 C) Emulsions............................................................................................................. 23 D) Cutback Asphalt................................................................................................... 26 E) Asphaltic Products ............................................................................................... 27 II AGGREGATE .................................................................................................... 28 A) Storage/Handling ................................................................................................. 28 B) Gradation and Sizes ............................................................................................. 30 C) Key Properties...................................................................................................... 33

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III ASPHALT CONCRETE MIXTURES ............................................................... 37 A) Design Types ....................................................................................................... 37 B) Production ............................................................................................................ 39 C) Placement ............................................................................................................. 41 D) Sampling .............................................................................................................. 42

IV SUMMARY ........................................................................................................ 43 V REVIEW ............................................................................................................. 45 VI REVIEW ANSWERS ......................................................................................... 47 Chapter 3 - Materials Sampling ........................................................................................ 49 I INTRODUCTION .................................................................................................. 51

A) Make it Random ? The Importance of Random Sampling.................................. 51 II SAMPLING LIQUID ASPHALT....................................................................... 56

A) Safety Precautions ............................................................................................... 56 B) General Rules and Procedures ............................................................................. 57 C) Quality Control .................................................................................................... 60 III AGGREGATE .................................................................................................... 60 A) Stockpile Sampling .............................................................................................. 61 B) Mixing Plant Sampling ........................................................................................ 62 IV ASPHALT MIXTURES ..................................................................................... 63 A) Truck Sampling ................................................................................................... 64 B) Roadway Sampling .............................................................................................. 65 C) Sampling Size ...................................................................................................... 66 V SAMPLE IDENTIFICATION ............................................................................ 66 VI REVIEW ............................................................................................................. 67 VII REVIEW ANSWER ........................................................................................... 68 Chapter 4 - Mix Design and Testing................................................................................. 69 I INTRO / BACKGROUND ..................................................................................... 71 II PROPERTIES OF ASPHALT CONCRETE ...................................................... 71 A) Stability................................................................................................................ 72 B) Durability ............................................................................................................. 72 C) Impermeability..................................................................................................... 72 D) Workability .......................................................................................................... 72

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E) Flexibility ............................................................................................................. 73 F) Fatigue Resistance ................................................................................................ 73 G) Skid Resistance .................................................................................................... 73 III DESIGNING ASPHALT CONCRETE .............................................................. 73 A) Aggregates ........................................................................................................... 73 B) Aggregate Blending ............................................................................................. 80 C) Asphalt Binder Selection ..................................................................................... 89 D) Sample Prep/Compacting .................................................................................... 91 IV SPECIFIC GRAVITY......................................................................................... 95 A) Bulk Specific Gravity Tests................................................................................. 95 B) Maximum Theoretical Specific Gravity .............................................................. 96 V VOLUMETRIC ANALYSIS .............................................................................. 99 A) Percent Air Voids ................................................................................................ 99 B) Voids in the Mineral Aggregate (VMA)............................................................ 100 C) Percent Voids Filled With Asphalt (VFA)......................................................... 100 D) Dust to Binder Ratio .......................................................................................... 102 VI MIXTURE SPECIFIC REQUIREMENTS....................................................... 103 A) Marshall Stability and Flow............................................................................... 103 B) Superpave Moisture Sensitivity Testing ............................................................ 106 VII Plotting Test Results.......................................................................................... 106 A) Determining Asphalt Content ............................................................................ 109 VIII Quality Control TESTING ............................................................................ 111 A) Asphalt Content By The Ignition Method ......................................................... 112 IX Field Verification of Asphalt Concrete ............................................................. 124 X ADDITIONAL TESTING REQUIRED BY PLANT TECHNICIANS ........... 125 XI Review............................................................................................................... 129 XII Review Answer ................................................................................................. 134 Chapter 5 - Asphalt Mixing Plants.................................................................................. 139 I INTRODUCTION ................................................................................................ 141 II ASPHALT MATERIALS ................................................................................. 142 A) Aggregate Stockpiles ......................................................................................... 142 B) Asphalt ............................................................................................................... 143

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C) Mineral Filler ..................................................................................................... 143 III GENERAL MIXING PLANT COMPONENTS .............................................. 144

A) Cold Feed Bins .................................................................................................. 144 B) The Dryer ........................................................................................................... 145 C) Dust Collectors................................................................................................... 146 D) Surge and Storage Bins...................................................................................... 146 E) Truck Scales ....................................................................................................... 147 IV BATCH MIXING PLANT................................................................................ 147 A) Hot Bins and Screens......................................................................................... 147 B) Weigh Hopper .................................................................................................... 148 C) Asphalt Delivery ................................................................................................ 148 D) Pug Mill Mixer .................................................................................................. 148 E) Reclaimed Asphalt Pavement (RAP) In a Batch Plant ...................................... 150 V DRUM MIXING PLANT ................................................................................. 150 A) Cold Feed Bins .................................................................................................. 151 B) Dryer - Mixer ..................................................................................................... 151 C) Reclaimed Asphalt Pavement (Rap) In A Drum Plant ...................................... 152 D) Asphalt Delivery System ................................................................................... 152 VI PLANT INSPECTION...................................................................................... 152 A) Batch Plants Specific Inspection Items.............................................................. 153 B) Drum Mix Plants Specific Inspection Items ...................................................... 154 VII Avoiding Material and Equipment Problems.................................................... 154 A) Stockpiles........................................................................................................... 154 B) Asphalt Storage .................................................................................................. 155 C) Cold Feed ........................................................................................................... 156 D) The Dryer........................................................................................................... 156 E) Screens ............................................................................................................... 158 F) Hot Bins.............................................................................................................. 158 G) Surge and Storage Bins...................................................................................... 159 H) Trucks ................................................................................................................ 160 I) Observation of the Paving Mix ........................................................................... 160 VIII CALIBRATIONS .......................................................................................... 161

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A) Temperature Calibrations .................................................................................. 161 B) Scale Calibration ................................................................................................ 161 C) Aggregate Scale Calibration .............................................................................. 162 IX SUMMARY ...................................................................................................... 164 X REVIEW ........................................................................................................... 164 XI Review ANSWERS........................................................................................... 166 Chapter 6 - Job Mix Formula and Quality Assurance Testing ....................................... 167 I JOB MIX FORMULAS ........................................................................................ 169 A) Aggregate Master Range ................................................................................... 169 B) SELECTING A JOB MIX FORMULA ............................................................ 171 C) JOB MIX VERIFICATIONS ............................................................................ 175 II QUALITY ASSURANCE SYSTEM TESTING .............................................. 184 A) MOVING AVERAGE CALCULATIONS ....................................................... 184 B) QUALITY CONTROL TESTING .................................................................... 185 C) QUALITY CONTROL PLANS ........................................................................ 191 D) QUALITY ACCEPTANCE .............................................................................. 192 E) INDEPENDENT ASSURANCE ....................................................................... 192 Chapter 7 - Percent Within Limitations .......................................................................... 193 I INTRODUCTION ................................................................................................ 195 II DEVELOPMENT ............................................................................................. 195 III PROJECT LAYOUT OVERVIEW .................................................................. 196 IV LABORATORY TESTING .............................................................................. 196 A) Asphalt Content & Gradation ............................................................................ 197 B) Core Thickness................................................................................................... 197 C) Core Density ...................................................................................................... 197 D) Core Bond Strength ........................................................................................... 199 V PWL ANALYSIS.............................................................................................. 201 A) Penalty Structure................................................................................................ 203 Chapter 8 - Study Guide and Review ............................................................................. 207 I INTRODUCTION ................................................................................................ 209 II EXAMINATION .............................................................................................. 209 III PRACTICAL EXAMINATION ....................................................................... 209

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IV ADDITIONAL REFERENCE MATERIAL .................................................... 210 V REVIEW QUESTIONS .................................................................................... 212 VI REVIEW ANSWERS ....................................................................................... 223

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