Construction of Hot Mix *
Asphalt Pavements:
oe Se Wo.22
ee
ER EAE“”
‘This manual has been prepared to provide the essential information
required for the quality control of hot mix asphalt (HMA) pavements.
Emphasis has been placed on information which will benefit asphalt con-
struction inspectors, laboratory technicians, pkant personnel and paving crews.
Since the manual includes technical information on all aspects of HMA
pavement construction, it is an excellent reference for anyone involved
in asphalt paving operations.
‘This second edition has been largely rewritten. Chapter 1 has bee
rewritten as a different, but related, subject from the original version.
Chapters 7 and 8 on “Quality Control and Acceptance of Hot Mix
Asphalt” and “Segregation,” respectively, have been added. The writing
and editing of this manual has been a cooperative effort of the Asphalt
Institute field engineers, along with the help and cooperation of the
headquarters.
The standard practice of the Asphalt Institute is to utilize the
International System of Units (SD (metric), followed by U.S. customary
units.
The Asphalt Institute does not endorse products or manufacturers.
‘Trade or manufacturers’ names appear herein only where they give
credit for photos or other information and where it is necessary for the
purpose of this publication.
ASPHALT INSTITUTE
Research Park Drive
P.O. Box 14052
Lexington, Kentucky 40512-4052
(606) 288-4960
Fax (606) 288-4999 1” TQM for HMA Construction
Forward
‘Table of Contents eve eee eens peor
List of Figures even eens oo vii
List of Tables . teen eee eens eee
[ ehapter 4 1: Construction Project Management
Introduction ae eee
Purpose of Construction Project Management . .
Agency/Contractor Relationship
Sampling and Testing ..........
Safety
Conclusion
Chapter 2: |Materials ..
General Information
Asphalt... 0...
Aggregate
Chapter 3: Mix Design
Introduction . ae ee . ae
Mixture Characteristics and Behavior . + Bl
Properties Considered in Mix Design 2 BA
Evaluation and Adjustment of Mix Design . . ; 38
Applications of Mix Design Testing .
Objectives of Mix Design see seven ees BID
ee
Analyzing Marshall Test Results beo0 3-19
Hyeem Mix Design Method... coed eee eee 522
Superpive Mix Design 2.00.0... 005+ fee 3:30
Chapter 4: Plant Operations
Purpose and Objective
General Information
Material Handling
Aggregate Drying and Heatingjon Control Systems 06... eevee ee 4-20
Hot Mix Asphalt Storage . cece ee 42h
Quality Control and Observation of HMA Production... ...0ssss sss ss 0,427
Safety .....
Batch Plants .
Plant Guidelines .
Drum Mix Plants
[etapter 5: Piacing Hot Mix Asphalt |
Objectives . .
Introduction
Preparation for Paving :
Paving Equipment a
Delivery of Hot Mix Asphalt
Placing Procedures
Inspection of Mat .
Summary of Placing Procedure
Fume Recovery System . .
ietanter. 6: Compaction’ |
Introduction a
Compaction Principles
Equipment ...,.
Rolling Procedures .
Summary . .
67
6-19
Quality Control Testing :
Sampling and Testing Plan for Quality,Control_
Data Analysis
Acceptance Criteria . .
Density Specifications
Summary ...... .
740
7-3
7S
= 7-16
7-22Chapter 8: Segregation
Introduction
Segregation Defined
Avoiding Segregation in Production
Avoiding Segregation in Construction
Analysis of Segregation
‘Appendix |: Miscellaneous Tables |
Table A.01: Conversion Factors boven .
Table A.02; Types of Compacted Asphalt Pavements... cece eee Me?
‘Table A.03: Composition of Asphalt Concrete bevee ees
[ Appendix B: Glossary eacens
| Appendix Gr Random Number Tables . .
Appendix D D: AASHTO and ASTM Test ‘Methods .
‘Table D.01: AASHTO and ASTM Test Methods as Commonly Specified cece DA
[ Appendix E Superpave « oe
Superpave Performance Graded Asphalt Binder Specification ...... 6... Ela
isstotFigues a. : ;
Figure 2.01 ‘Typical Crude Oil Distillation Temperatures and Products .
Figure 2.02 Typical Refining Process. a
Figure 2.03 Asphalt Flow Behavior... . . . nae :
Figure 2.04 Asphalt Behavior at Varying Temperatures ee =
Figure 2.05 Variations of Three Viscosity-Graded Asphalts...... |,
Figure 2.06 Penetration Test. see bees ae
Figure 2.07 Capillary Tube Viscometer in Temperature-Controlled Water Bath.
Figure 2.08 Pouring Asphalt Cement Sample Into Viscometer .
Figuré 2.09” Flashpoint Tests. . pi
Figure 2.10 Thin Film Oven. .
. Figure 2.11 Rolling Thin Film Oven
Figure 212 Duciilty Test wes
Figure 2.13. Pressure Aging Vessel and Components . .
Figure 2.14 Rotational Viscometer. 5 ,
Figure 2.15 Dynamic Shear Rheometer Operation.
Figure 2.16 Bending Beam Rheometer
Figure 2.17 Direct Tension Tester . .
Figure 2.18 Sieve Analysis . .
Figure 2.19 Semi-Log Chart .
Figure 2.20 0.45 Power Chart.......- PeOEEEEE eT eeCer Tre
Figure 2.21 Typical 0.45 Power Chart and Example of Grading Band. __
Figure 2.22 VariouS Types of Aggregate Specific Gravities .
Figure 2.23 Los Angeles Abrasion Machine : .
Figure 2.24 Aggregate of Various Shapes and Surface Textures ; .
Figure 3.01 Voids in the Mineral Aggregate (VMA) in a Compacted Mix Specimen.
Figure 3.02 Maximum Density Curves Based on FHWA 0.45 Power Gradation Chart
Figure 3.03 Determining Specific Gravity of an Aggregate Sample
Figure 3.04 Preparing Test Specimen for Marshall Mold .
Figure 3.05 Marshall Drop Hammer Compacting Mix Specimen
Figure 3.06. Marshall Stability-Flow Apparatus... ......... 00002
Figure 3.67 Marshall Test Results: Mixture Properties vs, Asphalt Content
Figure 3.08 Saturating an Aggregate Sample with Kerosene (CKE Test).
Figure 3.09 Rodding Mixture Sample in: Mold. . :
Figure 3.10 Mechanical Compactor Conipacting Mixture Sample
Figure 3.11 Stabilometer Test . eens
Figure 3.12 Swell Test Apparatus oe . dasnneosees
Figure 3.13 Example Graphs Showing Unit Weight, Percent Air Voids
And Stabilometer Values for Hveem Mixture Specimens . 3-30
jure 3.14 Pyramid Chart Used to Determine Optimum Asphalt Content. _ 331
Figure 3.15 Example of Pyramid Procedures - 331
Figure 3.16 Superpave Gradation Limits, eevee eee : 333
Figure 3.17 Superpave Gyratory Compactor and Mold Configuration 3-34
Figure 3.18 Mixture Compaction Characteristics
From the Superpave Gyratory Compactor. 335
Figure 3.19 Air Voids, VFA and VMA vs, Asphalt Content _ . 3-36
Figure 4.01 Batch Plant... eee dietee eee 42’
“9
Figure 4.02
Figure 4.03
Figure 4.07
Figure 4.08
Figure 4.09
Figure 4.10
Figure 4.11
Figure 4.12
igure 4.13
Figure 4.14
Figure 4.15
Figure 4.16
Figure 4.17
Figure 4.18
Figure 4.19
Figure 4.20
Figure 4.21
Figure 4.22
Figure 4.23
Figure 4.24
igure 4.25
Figure 4.26
Figure 4.27
Figure 4.28
Figure 4.29
Figure 4.30
Figure 4.31
Figure 4.32
Figure 4.33
Figure 4.34
Figure 4.35
Figure 4.36
Figure 4.37
Figure 4.38
Figure 4.39
Figure 4.40
Figure 4.41
Figure 4.42
Figure 4.43
Figure 4.44
Figure 4.45
ure 4.46
igure 4.47
Drum Mix Plant we 42
Correct and Incorrect Methods for Storing Aggregate
Containing Large and Small Particles
Building a Horizontal Stockpile
Equipment Working on Top of a Stockpile.
Aggregate Sample Reduction, ... .
halt Storage Tanks
Asphalt Return Line
Sampling Valve in Delivery Line to Mixing Chamber .
Asphalt Sampling Device for Storage Tank . 4-10
Silo for Feeding Mineral Filler 4u>
Aggregate Cold Feed Bi : ce 414
Typical Types of Cold Feed Systems : 4-14
Typical Dryer Drum ween eee eee cee 416
Dryer Drum Flights and Function 4.16
Parallel Flow Dryer ...... eee pore see GIT
Counter Flow Dryer. . : 417
‘Types of Pryometers . - 418
Primary and Secondary dust Collectors. 421
Knockout Box (Primary Dust Collector) 422
Cyclone Dust Collector (Primary Dust Collector) 4-22
Baghouse (Secondary Dust Collector). 4-23
Wet Scrubber (Secondary Dust Collector) . wee 44
Storage Silos . = 425
Surge Bin : cites cee 425
A Batcher Above a Surge Bin sree 426
HUCK SCAG cece eee eee eee 4.27
Batch Plant : ee cece £33,
Screening Unit wo 485
Screening Unit Showing Aggregate Flowing Through Screens
And Into the Hot Bins 435
An Electronic Low Bin Indicator = 436
Segregation of Aggregates in Each of the Hot Bins... weet 437
Correct use of a Sampling Device . 438
How Cumulative Seale Settings Are Used
“To Control the Amount of Aggregate Drawn From the Hot Bins......... . 4-39
Asphalt Weighing and Delivery System in a Batch Plant. wee 4d
Under-Filled Pugmill Pence Md
Over-Filled Pugmill 4-42
Pugmill “Live Zone’ Ree eer ee a
Steps in a Typical Batch Plant Mixing Cycle . 443
Automated Batch Plant Controls . 2445;
Weigh Box Recycling Technique at a Batch Plant . ween = 4-46
Drum Mix Plants ~ Portable Type and ‘Stationary Type cece 450
Basic Drum Mix Plant. . . : en : cece ASI
Cold Feed Controls eee
Typical Sampling Device. 454
In-Line Belt Weigher (Weigh Bridge) +454
Parallel Flow Drum Mixer cone 456Figure 4.48
Figure 4.49
Figure 4.498
Figure 4.50
Figure 4.51
Figure 4.52
Figure 4.53
Figure 5.01
Figure 5.02
Figure 5.03
Figure 5.04
Figure 5.05
Figure 5.06
Figure 5.07
Figure 5.08,
Figure 5.09
Figure 5.10
Figure 5.11
Figure 5.12
Figure 5.13
Figure 5.14
Figure 5.15
Figure 5.16
Figure 5.17
Figure 5.18
Figure 5.19
Figure 5.20A
Figure 5.20B
Figure'5.21
Figure 5.22
Figure 5.23
Figure 5.24
Figure 5.25
Figure 5.26
Figure 5.27
Figure 5.28
Figure 5.29
Figure 6.02
Figure 6.03
Figure 6.04
Figure 6.05
Figure 6.06
Figure 6.07
Figure 6.08
Figure 6.09
Figure 6.10
Figure 6.11
Counter Flow Drum Mixer . 4-56
Parallel Flow Drum Dryer With a Coater 458
Counter Flow Dryer Drum With a Coater . 458
Double Barrel Drum Mixer . a bee . nee
Triple Drum Dryer/Mixer.... 5... ee 459
Double Drum Dryer/Mixer = 4-60
RAP Introduced Into a Drum Mix Plant . . 4-60
Typical Page From an Inspector's Diary 53
Milling Machine ............ cents 55
Correctly Placed Leveling’ Wedges Ensure Smoother Pavements 56
Limits for Multiple-Layer Leveling Wedges Should Be Determined by Level... 5-6
Correctly Placed Leveling Wedges for Overcoming Excessive Crown. ..... 56
Checking Subgrade Elevations... .. a . 59
A Typical Asphalt Distributor = 5-12
Proper Setting of Nozzles 513
Spray-Bar Height and Coverage 25-13
ATypical Paver 2.20.02... 5-16
Paver Power and Screed Units . = 516
Cedarapids Remix Paver 5-17
Self-Leveling Floating Screed. - 5-18
Forces Acting on the Screed 5-19
Vibratory Type Screed ....... Bagnosecti)
Mat Thickness and Crown Controls + 522
Autoimatic Screed Reference System 5-23
Ultra Sonic Grade Sensor . +524
Laser Grade Sensor . + 5:24
Pre-Strike-Off. . 5-26
Proper Setting cents . 5-26
Starting Blocks Under Screed + 5:28
Basic Requirements for Trucks 5-29
Types of Haul Trucks Peete cent 530
Material Transfer Vehicle. a peeeee penne 6 S31
Load Ticket......... 1 ae co . +533
Checking Mat Thickness With a Depth Gauge. ee oe ees
Taking Core Sample of Pavement and Measuring Mat Thickness of Core... 5-40
Bulkhead Transverse Joint and Papered Transverse Joint . . vee SA
Staggering Longitudinal Joints cee 5-43
Fume Recovery System (Courtesy of Cedarapids) 5-44
Durability Effects vs. In-place Air Voids . 62
Forces at Work During Compaction = 62
Time Allowed for Compaction ee peereceeer eeerpric6
Static Steel-wheeled Roller... coe pas posndeoe)
Forces Exerted on Mat by Steel-wheeled Rollers... 5... +68
Proper Direction of Roller Travel. -
Improper Direction of Roller Travel. .
Pneumatic (Rubber)-Tired Roller .:.......... +. - vs G1
Forces Exerted by Pneumittic-Tired Roller During Compaction 611
Single Steel-Wheeled Vibritory Roller. . weeeee es 613
Double Drum Vibratory Roller. . 6-14»
“
5
Figure 6.12 Illustration of Amplitude
Figure 6.13 Relationship Between Speed and Vibration
Figure 6.14 Different Modes of Vibration 1
Figure 6.15 Constructing a Test Strip :
Figure 6.16 Rolling a Hot Longitudinal Joint :
Figure 701 Percent Difference in Air Voids From Target Value .
Figure7.02 Percent Difference in Voids in the Mineral Aggregate From Target Value... 7-2
Figure 7.03 Percent of Total Sample Variance Attributable to Factors Shown, 75
Figuré 7.04 Curing Time Influence on Gam Determination... . . foe ee TB
Figure 7.05 Example Excerpt From a Random Number Table - 710
Figure 7.06 Random Sampling vs. Stratified Random Sampling a Mater - 710
Figure 7.07 Typical Quality Control Charts During Mixture Production cee TAA
Figure 7.08 Relationship Between Reference Density
‘And Air Voids for 5% Air Void Mix Design a 2.720
Figure 7.09 Relationship Between Reference Density
‘And Air Voids for 4% Air Void Mix Design... .... wees 7220
Figure 7.10 Relationship Between Reference Density
And Air Voids for 3% Air Void Mix Design 7-24
Figure 8.01 Segregated Hot Mix Asphalt Pavement ee
‘Typical VMA Curve 83
Figure 8.03 Gap-Graded Aggregate Gradation for HMA . 84
Figure 804 Cone Stockpile Segregation. . 5 cee BS
Figure 805 Cone Stockpile Built With Aggregate Ladder... 85
Figure 8.06 Buikding a Stockpile Properly : . 87
Figure 807 Tot Bins: Minimizing Segregation in tin No. 1 ce 88
Figure 8.08 Segregation During Drum Discharge 89
Figure 8.09 Uniformity During Drum Discharge by Fixing a Plow at Point of Discharge. . . 8-9
Figure 8.10 Uniformity During Drum Discharge by Turning Drag Chain 90° 89
Figure 8.11 Fine Aggregate Segregation of HMA on the Roadway 8-10
Figure 8.12 Plant Modifications to Avoid Segregation 8-10
Figure 8.13 Improper and Proper Methods of Loading ‘Trucks With HMA - 8:13
Figure 8.14 Chevron-Shaped Segregation on the Roadway. 8-14
Figure 8.15 terial Which Segregated Before Mi 817
Figure 8.16 Matcrial That Segregated After Mixing . . . 817
List of Tables al
‘Table 2.01 Guideline Temperatures for Storing Asphalts.
table 2.02 Guide for Loading Asphalt Products. :
‘Table 2.03 Temperature-Volume Corrections for Asphalt
Table 2.04 Aggregate Classifications.
Table 205 Typical Composition of Hot Mix Asphalt
Table 2.06 - Typical Sieve Sizes
Table 2.07 eve Analysis Data Converted to Aggregate Gradation . BaH6
‘Table 3.01 fects of Pavement Instability . oo
‘Table 3.02 Causes and Effects of Lack of DurabilityTable 3.03
Table 3.04
Table 3.05
‘Table 3.06
Table 3.07
Table 3.08
Table 3.09
Table 3.10
‘Table 3.11
Table 3.12
Table 4.01
‘Table 4.02
Table 5.01
Table 5.02
Table 6.01
Table 6.02
‘Table 7.01
Table 7.02
Causes and Effects of Permeability :
Causes and Effects of Workability Problems .
Causes and Effects of Poor Fatigue Resistance
Causes and Effects of Poor Skid Resistance
Marshall Mix Design Criteria .
‘Minimum VMA Requirements
Surface Area Factors... ... a
Example of Calculation of Surface Area...
Suggested Test Report Form Showing Test Data
For a Typical Mix Design by the Hveem Method.
Hveem Mix Design Criteria eee
Size of Samples Adequate for Routine Grading
And Quality Analysis per AASHTO T2. eee
Possible Causes of Deficiencies in Hot Mix Asphalt.
Spraying Temperature Range for Prime and Tack Coat.
Typical Problems and Their Probable Cause... . .
for Setting Vibratory Compactor Controls
In Relation to Layer Thickness.
Factors Influencing Compaction.
Mix Design Verification Results by Mix Number and Designer
Sample Quality Control and Acceptance Procedures .”
C Introduction __ | 3b ye2". billions of dollars are spent on hot
- ree mix asphalt (HMA) construction projects in the
United States. Achieving good performance of these pavements does not just
happen, but is the result of many hours of effort and project management by
pavement design and construction professionals. Fach phase of a project,
from the drawing board to the laboritory 0 the field; contains important
steps'and procedures that must be followed to ensurg a long lasting, well
performing pavement
Project management has evolved as a tool to plan, coordinate and ~
control the complex and diverse activities of current HMA construction pro-
jects. Factors leading to new project management techniques include:
‘= Economic pressures within the transportation industry.
Competition between rival contractors.
‘A much higher regard for the value and well-being of the workforce
and environment.
Implementation of stringent quality control standards
Safety for the construction workforce and public transportation users.
As the title indicates, this manual is devoted to the principles of
“Construction of Hot Mix Asphalt Pavements.” It is the intent of the manual to
provide the technical information necessary to carry out sound construction
project management for HMA pavements. The manual has been written for
two distinct, yet similar groups of individuals: those employed by the owner
‘or agency of the construction project, and those employed by the construc-
tion contractor. Not all personnel from both groups need to know all the
information contained in this manual. Obviously, it is necessary to be familiar
with the portion directly related to an individual’s job, However, an under-
standing of the entire design and construction process will often provide an
appreciation for where a specific task fits into the overall project management
process, and thereby ultimately improve in-service pavement performance.
a Fs = ‘The primary purpose of HMA construction
Purpose of Construction | project management is to foresee and pre-
Project Management dict as many of the dangers and problems
La ————] as possible and to plan and control activi-
ties so the project may be completed successfully in spite of all the risks. This
process starts before any resources are committed, and must continue until all
work is finished, The objective is for the final result to satisfy the project
owner within the promised time period and without using more dollars and
other resources than those originally established by a contract agreement.
Planning and control must be exercised over all the activities and
resources involved in the HMA construction project. ‘This can only be accom-
plished through effective communication. The communication process
requires an understanding of the project documents by both the owner repre-
sentatives and the contractor personnel. It embodies :t whole framework of
logical and progressive planning and decisions, perceptiveness, a liberalapplication of common sense, proper organization, painstaking attention to documentation, and
a clear grasp of proven and long-established principles of construction project management
HMA construction projects have in common the fact that the accomplishment phase must be
conducted on a site exposed to the elements and remote from the contractor's faclty, These
Crear uction Projects incur special risks and problems of organization and communication. They
often require massive capital investment and deserve (but do not always yet) rigorous manage-
ment of progress, finance and quality.
Construction Project Management is carried out to ensure quality work in compliance with
the Project requirements. This entails employing active communication in organizing, planning
and executing HMA construction projects in accordance with the written instructions detailed en
the formal project documents.
First and foremost, both agency and contractor personnel must address the importance of
communication concerning the project contract. The contract is the agreement between the
agency and the contractor. It states the obligations of both parties including criteria for labor,
‘materials, performance and payment. While there are many documents that make up the HMA
Sonsttuction contract, the agency's project manager is concerned primatily with the plans and
Specifications. Together, the plans and specifications explain requirements that the contractor
must fulfil to construct a satisfactory product and be paid in full for the work. Special provi,
sions within the contract normally relate to addenda or supplemental specifications that are Pro-
ject specific.
Plans are the contraéct documents that show the location, physical aspects and dimensions of
the work to be accomplished. They include layouts, profiles,
Specifications are the written technical
method and manner of executing the work. These specifications normally describe quantities
and the quality of materials and labor to be provided under the contract. Material specifications
and test procedures from the American Society for Testing and Materials (ASTM) ant che
American Association of State Highway ahd Transporation Officials (AASHTO) are listed in the
sandard specifications and are legally part of the contract documents by reference only. Other
documents, such as the Manual on Uniform Traffic Control Devices (MUTCD) and the
Occupational Safety and Health Administration (OSHA) regulations are also included in the stan-
Gard specifications and become a legal part of the contract documents by reference only
Specifications are the means of communication among the contractor and the construction pro-
ject manager. Specifications are particularly important to the agency and contractor representa
tives, as they constitute the rules by which the HMA project is managed and accomplished.
> CONSTRUCTION PROJECT MANAGEMENT”
£
i The 2ist Century ushers in a new relationship with
[ Agenay/Con entractor Relationship ll the agency/contractor in the HMA construction
industry. The new relationship is based upon an increasing recognition of the importance of
quality during the 1990's. Asa result, the Total Quality Management (TQM) concept is being
adopted as the key to the HMA industry's ability to Compete in today’s environment. Partnering,
training programs, certification requirements, etc. are integral parts of the overall TQM concept,
which involves the following key elements:
+ Top management must he committed to the TQM process.
© Quality is derived from the identification, improvement, and control of those processes
essential to HMA construction,
* Statistical analysis is necessary to achieve TQM.
+ Teamwork and cooperation of all involved is necessary to produce total quality.
+ Continual improvement in quality is the focus for TQM
+ Agency/owner satisfaction is the ultimate goal
In the past, many state and other agencies have performed all of the sampling, testing and
approval of materials and processes that were incorporated into the project. In the current envi-
ronment, many agencies utilize Quality Assurance (QA) type specifications. Under this type of
specification, the contractor furnishes the HMA mix designs performed either by its technicians
or those of a qualified firm. The contractor is further required to accomplish the quality control
(QO) testing on the HMA production and densification. The agency will have a program of
acceptance sampling and testing normally performed either by its personnel or 4 qualified test-
ing firm. In some acceptance programs, the agency will use a combination of contractor test
results along with verification tests. The acceptance program confirms the test results of the con-
trictor and gives the sigency the documentation necessary for final acceptance and payment for
the product. The use of QA/QC speci resulted in an improved HMA product.
Maintaining and improving the quality of construction will achieve a substantial increase in the
pavement life for future HMA construction,
In addition to contractor QC activities, practically all asphalt binder suppliers and many
aggregate suppliers conduct extensive testing of their products prior to shipping them to HMA
facilities. Virtually all asphalt binders are shipped under certification programs controlled by
staté agencies. Various programs are employed by aggregate suppliers in cooperation with state
agencies to control and verify the quality and gradation of aggregates used in HMA production.
[roa er for HMA Goi anstruc ction.) Te 8*° key TOM processes for HMA construction are
hot mix plant production and on-site HMA placement.
important to the control of a process to establish those characteristics that will lead to a
fii product. It would be desirable if a single important characteristic could be chosen for a
selected process; however, in the case of LIMA construction the processes are too complicated
to be properly controlled with just one characteristic. The difficulty of controlling a process dras-
tically increases with the number of measurement characteristics. Therefore, it becomes neces-
sary to minimize the number of chosen characteristics. In addition, there should be precise test
methods for each measurement characteristic. The selection of processes, test characteristics and
ity program, which is only as good as their selection.
CONSTRUCTION PROJECT MANAGEMENT