Course Slides - robvos.orgrobvos.org/docs/edu/aaps/AAPS-slides-v7.02x3LD.pdfV0.3 March 2015 November 2015 draft v7.02 These notes are in DRAFT form and under review Course Slides Administration

V0.3 March 2015

November 2015 draft v7.02 These notes are in DRAFT form and under review

CourseSlides

AdministrationofAsphaltPavementsSpecification

Acknowledgments These slides are based on training material prepared by Roads and Maritime Services (RMS) Pavement Surfacings Section, NSW. Amendments to the course slides reflect changes to the specification, the release of new research outcomes and best asphalt supply and placing practices.

All photographs have been supplied by RMS, NSW unless otherwise specified.

Disclaimer These course slides have been produced to assist in the provision of consistent interpretation and application of the asphalt specifications for dense graded asphalt.

The slides have no contractual standing and it should be noted that the approved interpretations of the specification are included in guide notes attached to the specification. Specific local circumstances may warrant specification application or interpretation other than described in these slides.

The information contained in these slides reflects current thinking and is based on contemporary literature, research and experience. The slides are not a controlled document and updates will not be issued.

These slides are intended to focus on the Queensland technical specification for asphalt and do not address issues of health, safety and environment. Whilst this information is important to the success of the delivery of asphalt paving, course participants must obtain separate suitable training and advice on such matters.

The slides have been prepared for Queensland use and AAPA does not accept any liability arising from the unauthorised use of these slides.

Further information For further information about this course contact:

The AAPA Training Centre Email: [email protected] Phone: 03 9853 3595

robvos

Typewritten Text

Australian Asphalt Pavement Association Administration of Asphalt Pavements Specification

Version 7.02 November 2015 AAPS 1

Administration of Asphalt Pavements Specification

Course outline

• Safety• Toilets• Mobile phones• Special dietary needs• Sign training sheet

Housekeeping

Course OutlineRelevant TMRMRTS30 Clauses

1.0 – 4.0 Module1 Introduction toasphalt5.0 Module2 QualitySystemRequirements7.0 Module 3 Materialsforasphalt7.2 Module 4 Mixrequirements7.3 Module 5 TheMixSubmission7.4 Module 6 Production8.0 Module 7 Placement9.0 Module8 FinishedPavementPropertiesMRS30 Module9 Non-conformance ofasphalt11.0 Module10 Annexure



Assignment / Examination

§ Available§ Questionsandassignmentscover

understandingandinterpretation§ Readinstructionsandensureyouhave

answeredallthequestions.§ Completedassignment/examinationscripts

tobereturnedbyduedate.§ Satisfactorycompletionofthecourseis

necessaryforacertificate.§ CertificatestobeissuedbyAAPA

What’s new?MajoroverhaulofAsphaltspecification

Newmaterialsupplyspecifications:§ MRTS101AggregatesforAsphalt§ MRTS102ReclaimedAsphaltPavementMaterial§ MRTS103FillersforAsphalt

Neworupdatedsystems:§ QuarryRegistrationSystem§ AsphaltMixDesign&Registration§ PrequalifiedAsphaltContractors

MRS&MRTS30AMRS&MRS31A

MRTS30MRS30

Includes SMA & OGVoids replace density24 month warranty

Guiding principals?

§ Fundamentalchangeinphilosophy

§ Greater responsibilityoncontractor§ Contractorsqualityplanakeydocument§ SeekadvicefromE&Tifindoubt§ Engineeringapproach



Roles and Responsibilities

| 15 March 2016

AsphaltContractor

Engineeringand

TechnologyTMRRegion/Administrator

Everyone has a part to play

Prequalified Asphalt Contractor

§ Develop and implement quality plans§ Aggregate production § RAP management (where applicable)§ Asphalt production & paving§ Pavement construction

§ Certify their own asphalt mix designs§ Production mix not laboratory mix

§ Provide a two year warranty§ Outcome driven specification with greater flexibility§ Extends beyond contract into Prequalification System -TIPDS

| 15 March 2016


Details A1 A2 A3 A4

Asphaltpaving ✅ ✅ ✅ ✅

Asphaltmanufacture ✅ ✅

Asphalt - types DG DG,OG DG,OG DG,OG,EME,SMA+

Asphalt- tonnage <200 < 2000 Nolimit Nolimit

ManagementSystems– Quality,Environmental, OHS

ISO9001Extaudit

3rd partycert

ISO9001

3rd partycert

ISO9001

3rd partycert

ISO9001

Technicalcapacity– increasingrequirements ✅ ✅✅ ✅✅✅ ✅✅✅✅

WarrantyDeed ✅ ✅ ✅ ✅

Company FinancialLevelF1-F150 F? F? F? F?

Reference: Manual – Transport Infrastructure Project Delivery SystemVolume 3 (Prequalification System) July 2015




§ Warranty Deed in Prequalification§ Delivering performance commitment beyond the contract§ Is a legal undertaking to remedy performance defects§ Asphalt must not ravel, rut, shove, strip or bleed for first 24

months and meet specified surface shape criteria § Obligations on Principal / Administrator

§ Asphalt must be used within specification limits§ Design & selection details to be provided to PAC§ Deviation from fit-for-purpose use to be stipulated pre-tender

§ Register for work that is not warrantied§ Captures details of areas excluded from warranty – before &

during contract§ Register is part for prequalification system and contract

| 15 March 2016

TMR Regions / Administrator

§ Embed change in approach in administration processes§ Ensure asphalt is used within fit-for-purpose limits§ Review and comment on quality plans (optional)

§ Administrator§ Construction processes

§ Surveillance and audit against asphalt supplier’s quality plan(s)

§ Compliance of mix produced (mix design)§ Production audits

| 15 March 2016

Engineering & Technology

§ Registration of mix designs (changed role)§ Certification by asphalt supplier§ ‘Paper’ check only§ Verification testing no longer undertaken

§ Assess suitability of high RAP content mix designs§ History of ‘proven performance’

§ Support/undertake production and construction audits (on request)

Technical Note 148Asphalt Mix Design Registration System

July 2015

| 15 March 2016



Forthebest chance ofachieving expectations

§ Befamiliarwithrequirementsofspecifications§ Bethereandbeproactive§ Listentoimprovementproposals§ Seekadviceifnotsure

This training assumes:

§ Thespecificationshavebeenread§ Thereisanunderstandingoftheasphaltmanufacturingprocessandlayingofasphalt

§ AbasicunderstandingandknowledgegainedfromtheAAPAcourses:§ WorkingSafelywithBitumen§ BituminousSurfacing– PrinciplesandPractices§ AsphaltPlacementandCompaction§ PolymerModifiedBindersandEmulsions

§ Thiscourseislimitedtoadministrationofasphaltcontracts



1. Introduction to Asphalt

Administration of Asphalt PavementsSpecification

Asphalt to suit the application§ Achieving performance is about customising the mixture to suit the

application

!

What’s new?

§ Combinedintoonespecification§ Medium duty dense graded§ Heavydutydense graded§ Open graded§ Stonemastic

Guidanceonselectionofmixandbinder



What’s new?Clause 1.1 overview

Guidanceonselectionofmixandbinder

Application

Traffic Volume

(average daily ESAs in the design lane in the year of

opening)

Dense graded asphalt mix type Typical Binders

Free Flowing High Shear1

As phal t loc ated wi th in 100mm of

the pav ement s urfac e

< 1000 < 300 Medium duty C320

< 3000 < 1000 Medium duty C6002,3

Al l < 3000 Medium duty A5S4

Al l 300 to < 3000 Heav y duty C6002,3

≥ 3000 ≥ 1000 Heav y duty A5S4,5

As phal t loc ated more than 100 mm below the

pav ement s urfac e

< 3000 < 1000 Medium duty C320

Al l < 3000 Medium duty C6006

≥ 1000 300 to < 3000 Heav y duty C320

≥ 3000 ≥ 1000 Heav y duty C6006

What’s new?

Application

Traffic Volume

(average daily ESAs in the design lane in the year of

opening)

Dense graded asphalt mix type Typical Binders

Free Flowing High Shear1

As phal t loc ated wi th in 100mm of

the pav ement s urfac e

< 1000 < 300 Medium duty C320

< 3000 < 1000 Medium duty C6002,3

Al l < 3000 Medium duty A5S4

Al l 300 to < 3000 Heav y duty C6002,3

≥ 3000 ≥ 1000 Heav y duty A5S4,5

As phal t loc ated more than 100 mm below the

pav ement s urfac e

< 3000 < 1000 Medium duty C320

Al l < 3000 Medium duty C6006

≥ 1000 300 to < 3000 Heav y duty C320

≥ 3000 ≥ 1000 Heav y duty C6006

Average equivalent standard axles in lane per day

High shear areas • signalized intersections and

approaches• very slow moving heavy

vehicles• roundabouts

Asphalt purchase specifications

§ MRTS30

§ MRTS30.1

§ MRS30

§ Related Specifications§ Bitumen(MRTS17)

§ Polymer Modified Binder (MRTS18)

§ Aggregates for Asphalt(MRTS101)

§ Reclaimed Asphalt Pavement Material (MRTS102)

§ Fillers (MRTS103)



Fillers

§ What are fillers?§ What are added fillers?

§ Passing 0.075mm Australian Standard sieve§ Free of organic material or other deleterous material (ie clay)

Binder types in asphalt

§ Class 320§ Polymer modified binders A5S

– SBS modified for crack and rut resistance impvement§ Class 600 (not in surfacings)§ Sometimes specified

§ Class 170 Low volume urban roads (cul-de-sacs)§ A2V – improved deformation resistance and petrochemical

resistance

Exercise No.1Selection oftheasphaltmixtype?

§ Equivalent Standard Axle§ Traffic Volume

§ What do you need?§ AADT

§ CV Content

§ ESA’s / CV

§ For a road requiring resurfacing, calculate for a s ingle lane in each direction the

ESA’s for the following open road speed 90kph

§ AADT 13000

§ 25% CV

§ 1.7 ESA’s / CV surfacing layer

§ Nominate mix type and typical binder to be used



Exercise No.1

Calculate ESA’s

§ 13000 x 0.25 x 1.72

= 2762.50

Nominate type and typical binder to be used§ Medium duty typical binder A5S

Why not C600?

Sprayed seal under asphaltAggregate with the low spread rate

Two types• Waterproofing seal

– No longer needed under dense graded?– Under OG and SMA– Prevent stripping in underly ing asphalt– C170 binder with 7mm aggregate

• SAMI seal– Under any asphalt to prevent cracks from

pavement reflecting through– PMB with 10mm aggregate

The aggregate is for protection of the binder membrane.



Administration of Asphalt Pavements Specification

2. Quality System Requirements

Quality Relationship

Based on trust and customer/supplier relationship – focused on product that meets the specification

Topics in this module

§ Quality manuals and plans

§ Surveillance

§ Parallel testing

Asphalt for Roads

• To procure asphalt we need a• pavement design• site specif ic detail• a technical specif ications for asphalt

• To place asphalt we need• procedures and plans• to address specif ication requirements



The technical specifications

§ Are the primary technical content documents

§ Are part of a broader contract document

§ Sit inside the procurement framework

§ Must be tailored to suit the contract type & procurement system (without compromising product performance)

Quality System Requirements

Hold Point 1

§ Nonconforming tensile strength ratio§ Incorporation of Asphalt into works§ Acceptance of nonconfirming mix

design into the Works§ Approval to place asphalt at a non-

conforming layer thickness§ Approval to place asphalt at a non-

conforming pavement temperature§ Placing of Nominated mix after trial

placement

§ TSR testing frequency 7.2.3 nominated by contractor in ITP

§ TSR limits Table 7.2.5§ Read in conjunction with in-situ

voids§ Indicator of moisture sensitivity



Hold Point 2

§ Non – conforming tensile strength ratio

§ Incorporation of Asphalt into works§ Acceptance of nonconfirming mix




placement

§ Confirmation of registered asphalt supplier

§ Mix design certificate§ Asphalt Quality plan§ Aggregate Production plan§ RAP management plan§ Submit to Administrator 7 days

before work starts

Hold Point 3






placement

§ Pretender if project specific§ Mix designs with current

registration with TMR§ Not meeting minimum standards§ Administrator considers

§ Costs – savings / additional§ Performance impacts:

serviceability, durability, functional

§ Whole of life & maintenance§ Construction programme§ Safety

Hold Point 4






placement

§ Lay at thickness not complying with Table 8.6.1

§ Shape correction layers§ Aim for smoothness

§ Works methods to achieve dense layer

§ Submitted by contractor 3 days prior



Hold Point 5






placement

§ Lay at temperature not complying with Table 8.7

§ Demonstrate bond & compaction§ Coring§ Double testing frequency for air

voids§ Provide additional compaction

equipment

Hold Point 6





conforming pavement temperature§ Placing of nominated mix after trial

placement

§ Trial run§ New mixes, large jobs, high risk§ Confirm ability to meet spec§ Contractor to submit verification

checklist & results

Asphalt Quality Plan (Clause 5.2)

§ How work is to be performed to achieve specification and quality requirements

§ Specific to the contract and contains detailed procedures§ Minimum requirements Table 5.2 and MRTS50§ Administrators should check the contractors Asphalt Quality Plan against

specifications.



Asphalt Quality Plan

Clause Planning Documents

5.4 & 5.6

Inspection and test plan (ITP), including methods and frequencies ofsampling, methods and frequencies of testing, verification checklists, and timeframe for submission of test results

MRTS50Clause 7

Asphalt materials – for each constituent material, lot/stockpile size, method of defining each lot and allocating a unique lot number.

7.1

Procurement, handling and storage of each constituent material

Nominated particle size distribution and tolerances for each constituent aggregate

7.3 Development, certification and registration of the nominated mix design

Table 5.2 lists minimum requirements

Traceability of Constituent Materials

§ Traceability: ability to trace materials up or down the supply chain

§ Lot size a function of:§ Specification requirements§ Suppliers quality plan§ Production processes§ Level of variability in raw materials

§ Lot numbers§ Unique identifier§ Determined by contractor§ Reference for testing and delivery documentation

Sampling Locations

§ Sampling locations within a lot What size is a lot?§ Same mix size§ Same mix design§ Same asphalt plant§ Same shift§ Same conditions

Sub-lots § Isolate areas that skew results§ Avoid rejecting sound material

Q050 test method



Inspection & Test Plan

Shall also include as per MRTS50:§ the work process and associated inspection and test points§ the allocation of responsibilities for carrying out the inspections

and testing§ the required frequency of the inspections and testing§ the methods to be used for measurements and tests§ the criteria for acceptance§ measurements or tests which involve use of calibrated equipment§ all Witness and Hold Points.

TMR Registration Systems

§ Assess providers of high cost specialised products§ Quarries –supply of aggregates for asphalt§ Asphalt contractors – manufacture & paving of

asphalt

§ Meets broad materials quality and capability requirements

§ Listed on TMR website§ Monitoring of conformance is still at project level§ Performance reports feed into registration

system

Surveillance

§ Collaborative and proactive. § Knowledge of processes§ Observe and report immediately

§ Surveillance officer will need:§ Quality System documents§ Relevant Specifications§ Contractors project quality plan§ Surveillance Checklist



Surveillance

Possible responses for a non-compliance with respect to project quality plan:

- Mention to the contractor in passing- Issue a formal CAR - Issue a formal CAR with a hold point - Formal intervention by the Principal’s

representative- Emergency action- Default of contract

Contract Administration System Revised: 19/03/2010

FORM - Corrective Action Request CAF031M

Page 1 of 1

Forms are to be identified by a sequential number.

Contractor {Enter Text} Notice of Test No.

{Enter Text}

Contract No.

{Enter Text} Project No.

{Enter Text} Project Name

{Enter Text}

Lot No. {Enter Text} Chainage {Enter Text} CAR No. {Enter Text}

Non conformance Details:

Issued By: (name) Signature: Date:

Received By: (name) Contractor’s Representative: Date:

Contractor’s Comments: (Immediate action to fix the problem and, if required, actions to correct cause to prevent reoccurrence. Records / analysis to be attached as appropriate.)

Name: Signature: Date: / /

Superintendent’s Comments: (Verification of effectiveness of actions taken.)

Name: Signature: Date: / /

Parallel testing

§ Acceptance is based on contractors testing§ Witnessing contractors testing if in doubt

§ Parallel testing§ Verify compliance§ Trigger joint investigation if results unacceptable




3. Materials for Asphalt

Materials for Asphalt (Cl. 7.1)MRTS30 Asphalt Pavements requires:

§ Coarse & fine aggregates (MRTS101)

§ Recycled Asphalt Pavement (RAP) (MRTS102)

§ Added fillers (MRTS103)

§ Bitumen (MRTS17) & PMB’s (MRTS18)

§ Additives

§ Adhesion agents

§ Warm Mix Additives

§ Emulsion tack coat (AS1160)

Material sources – Quarries and sandpits

Quarries (coarse & fine aggregates)§ Clean, dry, hard, tough, sound§ Free from clay, dirt and other deleterious materials§ Specified test properties

Sandpits (fine aggregates)§ Clean, hard, tough, sound, moderately sharp grains§ Free from coatings, particles of clay, other

deleterious materials § Specified test properties



Weak Particles Limit

§ Removed from specification§ Controlled by TSR and MRTS 101 Aggregate requirements

§ Wet / Dry strength variation§ Degradation factor§ Wet ten percent fines value

Quarry Registration System

§ Quarry Assessment covers§ Production processes§ Source rock properties§ Does not cover conformance

forprojects

§ MRTS101 covers§ Production and quality details

at time of works

Aggregate Production Plan

Area of quarry§ Which face§ Properties can

change with a quarry§ MRTS101

Production methods§ Extraction and

processing§ Will affect aggregate

shape

Quality control§ Stockpile management§ At the quarry and plant§ Lots sizes and number§ Traceability



Museum samples of constituents used at design

Sealed bottles preferredRetain for the duration of the work

Visually check against deliveries during production

Aggregate

§ Property requirements are largely unchanged except for

§ Coarse aggregate (Clause 7.1 MRTS101)§ Water absorption limits relaxed to ≤ 2.5%

§ Fine aggregate (Clause 7.2 MRTS101)§ Water absorption limit ≤ 3.0% (quartz sands ≤ 1.5%)§ Aggregate soundness (sodium sulphate solution) ≤ 12%

| 15 March 2016

Coarse Aggregate

Minimum frequency of testing§ Particle Size Distribution

§ Normal and reduced testing level§ 1 per 1,000 tonnes

§ Flakiness Index§ Normal testing level

§ 1 per 2500 tonnes§ Reduced testing level

§ 1 per 5000 tonnes



Nominated Aggregates (MRTS 101 Clause 8)

§ Nominated aggregates§ For mix design submission§ Registered quarry§ Evidence of compliance with Clause 7

§ Grading limits§ Target grading§ Contractor to nominate § For each aggregate fraction

(e.g. 20mm, 14mm 10mm…)§ Tolerance in MRTS30 Table 7.4.3.2 applied for production

| 15 March 2016

Cons ti tuent Materia ls

Geolog ic al Typeof Materia l Suppl ier Sourc e / Location

Mas s of Tota l

As phal t Mix . (%)

28mm20mm14mm Rhy o-dac ite Bora l Peppertree 24.2

10mm Rhy o-dac ite Bora l Peppertree 13.5

7mm Rhy o-dac ite Bora l Peppertree 21.45mm

G Sand Manufac tured Sand Bora l Peppertree 24.4

Hy drated L ime Hy drated L ime Bora l Cement Maru lan 1.5

RAP RAP Bora l Enfie ld 15.0

RAP Management Plan

§ Procedures for meeting requirements of MRTS102

§ Free from foreign material

§ Crushed and screened§ Traceable to a stockpile§ Aggregates must

conform to MRTS101

§ Coarse and fine fractions

§ Free flowing§ Homogenous§ Control moisture

Added fillers in asphalt

§ May be naturally occurring in the aggregate feed and/or separately imported & added to the process

§ General test properties:- Dry compacted voids (AS 1141.17)- Methylene blue value

§ Specific tests covered in MRTS103 for the following added fillers:- Fly ash- Hydrated Lime & Ground Limestone- Cement Works Flue Dust- Cement



Added fillers in asphalt - Dry compacted voids (AS 1141.17)

§ Applies to the combined filler fraction.§ Minimum - 40%§ Impacts on stiffness of the binder/filler mastic§ Facilitates higher binder contents

Combined fillers in asphalt - Methylene Blue Value

§ Applies to the combined filler fraction excluding§ Hydrated Lime§ Dust from clean coarse aggregates.

§ Maximum§ 18 mg/g (without lime)§ if 18 to 10mg/g (without lime)

triggers a maximum of

§ 10 mg/g (with lime added)

Bitumen traceability

• Producers certificate• Batch Number• Lot size

• What’s in storage tank• New lot when topped up

• Sampling frequency• Varies• MRTS 17 & MRTS18



Additives – Clause 7.1.7

Bitumen adhesion agents• Used to improve moisture sensitivity

Warm mix additives• Allow reduced asphalt manufacturing temperatures (~ 30°C)• Used to improve compaction• Separately registered mixWarm Mix Asphalt may be used on any project subject to the requirements of this Technical Specif ication being met.

Bitumen Emulsion Tack Coat– Clause 7.1.8

• Used to provide a bond between layers• Typical emulsion is CRS 170/60 (Cationic Rapid Set)• Must comply to AS1160




4. Mix Requirements

Quality Requirements for Asphalt

§ Proportions of constituents (Cl. 7.2.1)§ Volumetric Characteristics (Cl. 7.2.2)§ Moisture Content (Cl. 7.2.3)§ Moisture Sensitivity (Cl. 7.2.5)§ Resilient modulus (Cl. 7.2.6)§ Deformation resistance (Cl. 7.2.7)

§ Combined particle size distribution § Binder in asphalt§ RAP and RAP progression criteria§ Hydrated Lime§ Adhesion Agent§ Warm Mix Asphalt additive

Constituent Materials – Clause 7.2

› Combined particle size distribution (Grading)› Binder in asphalt› RAP› Hydrated Lime› Adhesion Agent› Warm Mix Asphalt additive

- Binder content (Cl. 7.2.1.2)- Ratio filler to binder (Cl. 7.2.2 b)- Binder film thickness (Cl. 7.2.2 d)

Related to volumetric characteristics

- SMA fixed binder fraction ≤ 0.55 (Cl. 7.2.1.2 c)- OG binder film thickness ≥ 15.0 microns (Cl. 7.2.2 d)



SMA Fixed Binder Fraction

§ Fixed Binder Fraction

The workability of stone mastic asphalt mixes at placement temperatures reduces as the fixed binder fraction of the binder-filler mastic increases. Although the maximum specification limit is set at 0.55, mixes with a fixed binder fraction exceeding 0.50 may also exhibit poor workability.

Binder Content – Cl. 7.2.1.2

Nominal SizeofAsphalt

AC7 AC10 AC14 AC20

EffectiveBinderVolume(%)

≥ 11.5

(≥11.0)

≥ 11.0

(≥10.5)

≥ 10.5

(≥10.0)

≥ 10.0

(≥9.5)

When absorbed binder is determined using relationship referenced in Q311

Nominal Size ofAsphalt

10 mm(OG10)

14 mm(OG14)

10 mm(SMA10)

14 mm(SMA14)

EffectiveBinderVolume(%)

≥ 9.0(≥8.5)

≥ 8.0(≥7.5)

≥ 14.5(≥14.0)

≥ 13.5(≥13.0)

Binder in asphalt

AIR VOID

AGGREGATE

ABSORBED BINDERWATER PERMEABLE POROSITYNOT FILLED WITH ABSORBED BINDER

AGGREGATE VOLUME(BULK S.G.)

AGGREGATE VOLUME(EFFECTIVE S.G.)

AGGREGATE VOLUME(APPARENT S.G.)

EFFECTIVE BINDERCONTENT

VOLUME OF WATERPERMEABLE POROSITY

BINDER FILM THICKNESS



Proportion of Constituents – Clause 7.2.1.3

› Combined particle size distribution (Grading)› Binder in asphalt› RAP (Reclaimed Asphalt Pavement)› Granulated Glass Aggregate› Hydrated Lime› Adhesion Agent› Warm Mix Asphalt additive

RAP Approval Level

Maximum Percentage(1)

(%) Testing Required (Table 7.2.1.3-B)

Performance Period

Surfacing Course

1S 15 Section A N/A

2S 20 Section B 3 years

Other than Surfacing Course

1 15 Section A N/A

2 25 Section B 2 years

3 30 Section C 3 years

4 40 Section C 5 years 1 Determined as percentage by mass of RAP material to mass of total mix.

Reclaimed Asphalt Pavement Material (RAP)Clause 7.2.1.3 – RAP

• RAP permitted in all courses of dense graded (not SMA, not OG)

• Mix design valid for 2 years

• Approval levels

Reclaimed Asphalt Pavement Material (RAP)

Must comply with pre-requisite requirements

• Performance testing (Table 7.2.1.3-B)

• Evidence of proven performance to progress from level 1 & 1S

Ahistory of ‘proven performance’ would typically involve demonstrating the following:

a) Performance testing demonstrating that the resilient modulus, fatigue, deformationresistance and moisture sensitiv ity are notadversely affected by the inclusion of theproposed RAP content and

b) Field investigation involv ing condition monitoring for the duration of the performance periodand sampling and testing cores from the pavement at the end of the performance period.

The approval level applies to s imilar designs suppliedfrom the same asphalt plant using thesame binder grade.



Warm Mix Asphalt Additive

§ Validation through national trials § Many advantages§ No adverse affects§ Table 7.2.1.6

Additive Maximum Proportion

Wax 2.0% by mas s of b inder

Surfac tants L imi t to be nominated by Contrac tor

Water (e i ther d i rec tly , or in the form ofwater c onta in ing c ry s ta ls )

3% by mas s of the b inder

Quality Requirements for asphalt

§ Proportions of constituents (Cl. 7.2.1.4)§ Volumetric Characteristics (Cl. 7.2.2)§ Moisture Content (Cl. 7.2.3)§ Moisture Sensitivity (Cl. 7.2.5)§ Resilient modulus (Cl. 7.2.6)§ Deformation resistance (Cl. 7.2.7)

Asphalt volumetrics

Total Volume of compacted

specimen(Bulk Density)

Effective Binder

Impermeable Portion of Combined Aggregate

Air Voids

Absorbed Binder

Voids in Mineral Aggregate (VMA)Total

Volumeof

Binder

Total volume of

aggregate

Voids filled with Binder

Volume ofcompacted specimenless air voids(Maximum Density)



Mix design – Clause 7.2.2 (Volumetric Characteristics)

Asphalt Type Laboratory Compaction MethodAir Voids in LaboratoryCompacted Specimens

Medium duty densegraded asphalt

Marshall compaction (50 blowsperface) or gyratory compaction(120 cycles )

≥3.0%

Heavy duty dense

Marshall compaction (50 blowsper face) or, ≥3.0%

≥3.0%Marshall compaction (75 blowsper face) or,

graded asphalt Gyratory compaction

(120 cycles )and(350 cycles )

≥3.0%≥2.0%

Stone mastic asphalt Marshall compaction (50 blows perface)

≥ 1.5%

Open graded asphalt Marshall compaction (50 blows perface)

≥ 20.0%

Mix design – Clause 7.2.2 (Volumetric Characteristics)

Air voids in laboratory compacted samples below the minimum values may lead to rutting, flushing, bleeding, mix instability.

Isolated non-conformances for air voids are typically accepted subject to:• The Contractor taking corrective action to prevent a recurrence of the non-

conformance• The asphalt complying with the performance standards listed in Clause 1.2, and• The Contractor agreeing to remove and replace the nonconforming asphalt (as

well as any overlying asphalt) if the performance standards listed in Clause 1.2 are not met.


§ Proportions of constituents (Cl. 7.2.1)§ Volumetric Characteristics (Cl. 7.2.2)§ Moisture Content (Cl. 7.2.3)§ Moisture Sensitivity (Cl. 7.2.5)

§ Minimum tensile strength ratio 80%§ Freeze/thaw group > 600kPa§ AG:PT/T232

§ Resilient modulus (Cl. 7.2.6)§ Deformation resistance (Cl. 7.2.7)



Visible surface evidence of moisture damage

Hold Point 1: Non-conforming TSRCondition Action Required

70% ≥ TSR < 80% and previous result ≥ 80%

a) Promptly implement corrective action andb) Test after implementing corrective action and report

results to the Administrator within 4 working days70% ≥ TSR < 80% and previous result < 80% Observe Hold Point 1

TSR < 70% Observe Hold Point 1

Tests not carried out at required frequency ortests results not reported within specifiedtimeframe or corrective action not promptlyimplemented

Observe Hold Point 1


§ Proportions of constituents (Cl. 7.2.1.4)§ Volumetric Characteristics (Cl. 7.2.2)§ Moisture Content (Cl. 7.2.3)§ Moisture Sensitivity (Cl. 7.2.5)§ Performance tests

§ Resilient modulus (Cl. 7.2.6)§ Deformation resistance (Cl. 7.2.7)§ Fatigue resistance (Cl. 7.2.8)§ Asphalt binder drain off (Cl. 7.2.9)§ Asphalt particle loss (Cl. 7.2.10)§ Mix Volume Ratio (Cl. 7.2.11)§ Marshall Stability, Stiffness and Flow (Cl. 7.2.12)



Performance Tests

§ Deformation Resistance – Clause 7.2.7§ Wheel tracking

§ > 15% RAP§ Warm mix

§ Mix design submission§ May be requested on

production mix when….




5. The Mix Submission

Mix design Submission Timeline

If approved,thePACandAdministratoradvisedinwritingwithlistingonthemixdesignregister

SubmissionreviewedPACtoallownotlessthan14daystobeadvisedonsuitability

AsphaltMixDesign Register(TMR nomineethroughDeputyChief Engineer,PMG)

Nominatedasphaltmixdesign submission(refertoTN148AsphaltMixDesignRegistration)Submitnotlessthan28daysbeforeasphaltbeingincorporatedintotheworks

Submission for Nominated mixes (Clause 7.3)

Constituentmaterials(Cl. 7.3.2.1)

Mix design(Cl.7.3.2.2)

WarmMixAdditives

(Cl.7.3.2.4)

Productiontrial

(Cl.7.3.2.3)

Asignedstatement(Cl.7.3.2)

DesignRegistration(Cl.7.3.3)TN148



Asphalt Panel Cont r act 11. 2637. 0494

Dense Gra ded Hea v y Duty Asphalt Mix Submissio n AOS R116

Asphalt Pr oducer Bor al

Plant Locat ion Enf ield

Plant Type Dr um Pr oduct ion Tr ial Validit y Requir em ent s.Conf ir m at ion

( Yes/ No) Const it uent M at er ials G eological Type of M at er ial Supplier Sour ce / Locat ion

M ass of Tot al Asphalt M ix. ( %) See not e below

I dent if icat ion Num ber of Plant 01 All t est ing car r ied out wit hin 3 m ont hs of Subm ission dat e yes

Nom inal M ix Size ( m m ) 14m m Test s of Const it uent M ater ials repr esent s m at er ials used in pr oduct ion t rial. yes 28m m

Supplier M ix Code 01- 016430 20m mM ix Design Dat e 11/ 04/ 2014 All phases of each t est was com plet ed at one

labor at or y wit h t he exception of com pact ion of br iquet t es of asphalt .

yes14m m Rhyo- dacit e Bor al Pepper t r ee 19. 2

Dat e of Subm ission to RTA 5/ 05/ 2014 10m m Rhyo- dacit e Bor al Pepper t r ee 13. 3Plant Tr ial Test Repor t Ref er ence ENF14/ 0665 7m m Rhyo- dacit e Bor al Pepper t r ee 21. 4Plant Tr ial Dat e 11/ 04/ 2014 5m m

Q ualit y Requir em ent Nom inat ed Value Test Met hod Lower Lim it Upper Lim it Plant Tr ial Result s Accept able as per R116 Ed8 Rev0

G r ading Passing AS sieve (m m) AS 2891. 3. 1 G Sand M anuf act ur ed Sand Bor al Pepper t r ee 24. 4

53. 0 Hydr at ed Lim e Hydr at ed Lim e Bor al Cem ent M ar ulan 1. 5

37. 5 RAP RAP Bor al Enf ield 15. 0

26. 5 Binder Type C 450 Pum a Bot any 5. 2

19. 0 100 100 100 100 YES Baghouse Filler Baghouse Filler Bor al Enf ield

13. 2 91 84 98 98 YESBit um en Adhesion

Agent

9. 50 81 74 88 85 YES War m M ix Addit ive6. 70 65 58 72 70 YES

4. 75 53 46 60 54 YES Not e : M ix Design percentages based upon const ituent m at er ials and not plant hot bin input s

2. 36 38 33 43 34 YES

1. 18 28 23 33 25 YES RAP Appr oval LevelRequir ed Appr oval Level. Please

Tick.

Have You Com plet ed Requir ed Test ing in Annexur e R116/ F and At t ached AO S For m 3153. ? Yes or No

0. 600 20 16 24 19 YES 10. 300 13 9 17 14 YES 1W þ

0. 150 8. 0 5. 5 10. 5 9. 1 YES 20. 075 5. 5 4. 0 7. 0 5. 9 YES 2W

Binder Cont ent % 5. 2 AS 2891. 3. 1 4. 9 5. 5 4. 9 YES 3

Binder Film Thickness ( um )AG : PT/ T237 or AS2891. 8 > 7. 5 9 YES 4

Filler t o Binder Rat io AS 2891. 3. 1 ≥ 0. 8 ≤ 1. 2 1. 2 YES

Tensile St r engt h Rat io ( %)RTA T640

≥ 80 87 YESAver age Tensile St r engt h of Fr eeze/ Thaw gr oup ≥ 600kPa 757 YES

Bulk Densit y at 120 cycles

RTA T662, AS 2891. 7. 3, AS 2891. 8, AS 2891. 9. 2

2. 409

Bulk Densit y at 350 cycles 2. 473 Addit ional I nf or m at ion CO NFO RM ANCE STATEM ENTS YES O R NO

Voids in asphalt m ix 120 cycles ≥ 3. 0 ≤ 6. 0 4. 6 YES

M ass of Asphalt f or G yr at or y Compact or M ould ( g) 1260. 0

T h is a s p h a lt & a ll th e c o n s titu e n t m a te ria ls m e e ts th e re q u ire m e n ts o f C la u s e 2 .1 a n d 2 .2 o f R 1 1 6 E d 8

R e v 0 . YES Voids in asphalt m ix 350 cycles ≥ 2. 0 2. 1 YES Bulk Densit y of Combined

Aggr egat es ( AS 2891.8) 2. 713A ll a p p lic a b le te s t c e rtific a te s fo r th is a s p h a lt m ix a n d its c o n s titu e n ts a re h e ld b y th e a s p h a lt p ro d u c e r fo r

re v ie w a n d a u d it b y R T A YES

Voids in M iner al Aggr egat e ( %) 15. 0 15. 0 YES Dr y Com pact ed Voids ( DCV %) AS 1141. 17 47. 1

M axim um Densit yAS 2891. 7. 3

2. 526M ETHYLENE BLUE VALUE ( mg/ g) RTA T659 ( Result < 10m g/ g) 3. 0

M oist ur e Cont ent of Asphalt ( %) . Test f or Dr um plant s or War m m ix

RTA T660<0. 5 0. 1 YES

Resilient Modulus at 5. 0% +/ - 0. 5% as per AS 2891. 13. 1 5700

NSW RMS example




Productiontrial

(Cl.7.3.2.3)

WarmMixAdditives

(Cl.7.3.2.4)



Production trialValidity requirements§ For each mix design § Tests of the constituent materials must represent

the materials used in the trial batch§ Trial batch produced by the mixing plant from

which the asphalt is to be supplied§ All tests must be from one trial batch§ Testing of the constituent materials - refer:

§ TMR Quarry Registration System § MRTS50 Specific Quality System Requirements § MRTS101 Aggregates for Asphalt

clause 9.3 Testing§ Mix Design Registration

within 12 months of submission



As phal t Panel Contract 11.2637.0494 Dense Gra ded Hea v y Duty Aspha lt Mix Submissio n AOS R116

Asphalt Pr oducer Bora lPlant Locat ion Enfie ldPlant Type Drum Pr oduct ion Tr ial Validit y Requir em ent s. Conf ir m at ion ( Yes/ No)

I dent if icat ion Num ber of Plant 01 All t est ing car r ied out wit hin 3 m ont hs of Subm ission dat e y esNom inal M ix Size ( m m ) 14mm Test s of Const it uent M at er ials r epr esent s m at er ials used in

pr oduct ion t r ial. yesSupplier M ix Code 01-016430M ix Design Dat e 11/04/2014 All phases of each t est was com plet ed at one labor at or y wit h

t he except ion of com pact ion of br iquet t es of asphalt . yesDat e of Subm ission t o RTA 5/05/2014Plant Tr ial Test Repor t Ref er ence ENF14/0665Plant Tr ial Dat e 11/04/2014

Q ualit y Requir em ent Nom inat ed Value Test M et hod Lower Lim it Upper Lim it Plant Tr ial Result s Accept able as per R116 Ed8 Rev0

G r ading Passing AS sieve ( m m ) AS 2891. 3. 1

53. 0

37. 5

26. 5

19. 0 100 100 100 100 YES13. 2 91 84 98 98 YES9. 50 81 74 88 85 YES6. 70 65 58 72 70 YES4. 75 53 46 60 54 YES2. 36 38 33 43 34 YES1. 18 28 23 33 25 YES

0. 600 20 16 24 19 YES0. 300 13 9 17 14 YES0. 150 8.0 5.5 10.5 9.1 YES0. 075 5.5 4.0 7.0 5.9 YES

Binder Cont ent % 5.2 AS 2891. 3. 1 4 .9 5.5 4.9 YESBinder Film Thickness ( um )

AG : PT/ T237 or AS2891. 8 > 7.5 9 YES

Filler t o Binder Rat io AS 2891. 3. 1 ≥ 0 .8 ≤ 1.2 1.2 YESTensile St r engt h Rat io ( %)

RTA T640≥ 80 87 YES

Aver age Tensile St r engt h of Fr eeze/ Thaw gr oup ≥ 600k Pa 757 YESBulk Densit y at 120 cycles

RTA T662, AS 2891. 7. 3, AS 2891. 8, AS 2891. 9. 2

2 .409Bulk Densit y at 350 cycles 2 .473Voids in asphalt m ix 120 cycles ≥ 3 .0 ≤ 6.0 4.6 YESVoids in asphalt m ix 350 cycles ≥ 2 .0 2.1 YESVoids in M iner al Aggr egat e ( %) 15.0 15.0 YESM axim um Densit y AS 2891. 7. 3 2 .526M oist ur e Cont ent of Asphalt ( %) . Test f or Dr um plant s or War m m ix RTA T660 <0.5 0.1 YES

Production Trial Validity Requirements. Confirmation (Yes/No)

Al l tes ting c arried out wi th in 3 months of submis s ion date yes

Tes ts of Cons ti tuent Materia ls repres ents materia ls us ed in produc tion tria l .

yes

Al l phas es of eac h tes t was c ompleted at one laboratory wi th the ex c eption of c ompac tion of briquettes of asphalt.

yes

Plant Trial Test Report Reference ENF14/0665

Plant Trial Date 11/04/2014

NSW RMS example




Productiontrial

(Cl.7.3.2.3)

WarmMixAdditives

(Cl.7.3.2.4)



Asphalt Mix Design Register

| 15 March 2016

Valid for:§ Two years§ Prequalified

Asphalt Construction responsible to resubmit new design before expiry



Nomination of Mix Design (Cl. 7.3.3)

All docs submittedarecheckedforconformance

Ifok then

At least 7 days before asphalt is to be incorporated into the Works, the Contractor shall submit to the Administrator a copy of one mix design registration certificate for each nominal size of asphalt mix to be incorporated into the Work Milestone




6. Production

Hold point 2: Production of Asphalt (Cl. 7.4.1)

§ Which registered supplier ?§ Mix design certificate§ Aggregate production plan§ RAP management plan

§ At least 7 days before work

§ Incorporation of asphalt into the works is a hold point

Hold point 3: Production of Asphalt

Non conforming mix designs that hold current registration with TMR§ Incorporation only if accepted in writing by the Administrator

§ Provision is made in the guide notes for the designer of the works to seek advice from the Principal Engineer (Asphalt & Surfacings) considering:§ Cost savings / additional costs§ Performance impacts to road users and pavement durability§ Whole of life considerations§ Construction program impacts§ Safety impacts



Method of Production (Clause 7.4.2)

The method of production must: § Control the process § Target the nominated mix

within applied tolerances§ Supply a homogeneous

product

Process Control

§ Means of monitoring level of variability

§ Mix properties plotted on control charts

§ Wider impression of process§ Avoid reacting to single point in

time § Assists to identify unique causes

of variation

Aust roads AGPT04B- 14

!

Method of production (Clause 7.4.2)

Target the nominated mix

Combined Particle Size Distribution

0

10

20

30

40

50

60

70

80

90

100

AS Sieve Size (mm)

Perc

enta

ge P

assi

ng

0.075 0.150 0.300 0.600 1.18 2.36 4.75 6.70 9.50 13.2 19.0

R116 Control Point l Contract ID:

Mix Code:

Binder Content:

VMA:

Cont r ol point



Method of production (Clause 7.4.2)

Supply homogeneous product

Tight controls on raw materials§ Uniform distribution of RAP§ Attention to mixing times

Production Tolerances (Clause 7.4.3)Apply production Tolerances in Table 7.4.3.2

Description Tolerance

Permissible variation to nominated combined particle sizedistribution during production (% by mass of total aggregate,Q308A or AS 2891.3.1) for each mix size:

Pass 4.75 mm AS sieve and larger ± 7

Pass 2.36 mm and 1.18 mm ± 5

Pass 0.600 mm and 0.300 mm ± 4

Pass 0.150 mm ± 2.5

Pass 0.075 mm ± 1.5

Permissible variation to the nominated binder content during production (% by mass of total mix, AS 2891.3.1) ± 0.3

Permissible variation to the nominated maximum density during production (t/m³, Q307A or AS 2891.7.1)

± 0.0351

Asphalt manufacturing plant (Clause 7.4.4)

§ Sufficient capacity to supply for continuous operation of paver.§ Affects rideability§ Affects compaction

§ Auditable records of key process parameters§ Raw materials quality§ Temperature of mix§ Grading§ Binder content§ Mixing times (batch plant)§ Constituent proportions



Asphalt StorageCl 7.4.5.2

Dense mix§ 30 hour maximum storage time§ Longer times may be possible§ Check with supplier

Open grade and SMA§ More prone to drain down & segregation§ Max 4 hours storage + transport§ Longer if approved by Administrator

Asphalt TemperatureAAPA Advisory Note 7

§ Too high - damage asphalt§ Too low - affects ability to achieve

compaction

§ Maximum temperatures§ 175°C for conventional binders§ 185°C for PMBs§ As recommended in AAPA advisory note 7

§ Recorded when§ Leaves pugmill or drum§ Leaves hot storage &/or In truck before

departure§ Up to contractor to nominate where

Asphalt TemperatureAAPA Advisory Note 7



Case Study 1

Temperature of asphalt exceeded maximum during client audit

CS1: Audit Results – temperature exceeded

§ Temperature in delivery exceeded maximum allowable temperature§ What are the options?

CS1: Temperature exceeded

§ Old system§ Reject – no discretion, limited judgment allowed.

§ New system§ Audit against Asphalt Quality Plan procedures§ Outcomes:

§ Assessment of performance implications§ Conditional acceptance / reject with consideration to warranty criteria

Changes will lead to increased focus on Process Audits of the Asphalt Quality Plan




7. Placement

Transport of asphalt (Clause 7.5)

Uniform light application of release agent (not diesel)

Timer

Transport of asphalt (Clause 7.5)

The vehicle:§ Vehicle must follow vehicle movement plan§ No oil or fuel leaks which may damage asphalt§ Truck bodies must be covered§ Consider insulated truck bodies for long hauls

Operations:§ Haulage operations to facilitate continuous placing§ No spillage of asphalt during tipping operation§ Smooth engagement with receiving hopper.



Delivery Docket

Plant Mix type

Mix code

Placing of Asphalt Clause 8

Aim to produce§ Homogeneous product§ Tightly bound surface§ Uniform bond with substrate§ Specified surface properties

Placing asphalt to Specification

§ This module will focus on :› Pavement preparation (Clause 8.2)› Method of placement (Clause 8.3)› Protection of Work (Clause 8.4)› Course & layer thickness (Clause 8.6)› Pavement temperature & weather (Clause 8.7)› Paving & Compaction temperature (Clause 8.8)› Tack coat (Clause 8.9)› Joints (Clause 8.10)› Placement Trial (Clause 8.11)› Temporary ramps (Clause 8.12)



Pavement Preparation (Clause 8.2.2)

• Cleaning– Dry– Swept

• To help create an effective intra-layer bond

Bond failure due to surface contamination

Existing pavement markers must be removed prior to paving



Pavement Preparation (Clause 8.2)

Pavement repairs

Crack Sealing (Clause 8.2.3)

Strain Alleviating Fabric Strips (Clause 8.2.4)



Placing Asphalt

§ Pavement preparation (Clause 8.2)§ Method of placement (Clause 8.3)

Placing asphalt

› Pavement preparation (Clause 8.2)› Paving equipment (Clause 8.3)

Asphalt to be placed by:- self-propelled paving machine - with automatic level control

Level control

Is the type of level control effective?If not what measures taken to rectify?Can levels be rectified by next layer?



Method of Placement (Clause 8.3)

§ Asphalt to be placed by machine § Hand placement only for:

§ minor correction of existing surface§ where use of paver is impracticable§ Broadcasting or overworking asphalt leads to segregation

Method of Placement (Clause 8.3)

§ Asphalt to be placed by machine§ Hand placement § Material Transfer Vehicle (MTV)

Material Transfer Vehicle

Benefits§ Buffer between trucks and paver§ Acts as surge bin§ Remixing ability to prevent

temperature and mix segregation

Limitations§ May exceed weight restrictions on

structures when loaded§ Maneuverability – avoid confined

areas e.g. tapers, turning lanes, roundabouts < 50m radius

§ Consider the additional cost of MTV



Placing Asphalt

§ Pavement preparation (Clause 8.2)§ Method of placement (Clause 8.3)§ Protection of work (Clause 8.4)

Protection of Works (Clause 8.4)

It is the Contractor’s responsibility to ensure the asphalt has cooled sufficiently prior trafficking to minimise deformation of the asphalt. …

Clause 8.1§ The application of water to induce rapid cooling in the asphalt shall not

be used at any stage in the process, including preparation for trafficking, unless approved by the Administrator.

Placing Asphalt

§ Pavement preparation (Clause 8.2)§ Method of placement (Clause 8.3)§ Protection of work (Clause 8.4)§ Protection of services and road fixtures (Clause 8.5)



Protection of services and road fixtures (Clause 8.5)

Quality plan Handwork around pits and bridge joints

Placing Asphalt

§ Pavement preparation (Clause 8.2)§ Method of placement (Clause 8.3)§ Protection of work (Clause 8.4)§ Protection of services and road fixtures (Clause 8.5)§ Course & layer thickness (Clause 8.6)

Course and layer thickness (Clause 8.6)

What is a course?§ Specified thickness of

one type of mix

§ Can be made up multiple layers

What is a layer?§ Asphalt laid in a single

pass of the paver

AC10- Layer2

AC10- Layer1Cou

rse

AC10Course

AQP to nominate thickness of each layer



Course and layer thickness requirements

What is Specif ied or Nominated What is placed

Clause 8.6.1 – Nominated Layer Thickness• Course depth will be specif ied in drawings• Layer thickness may be specif ied otherwise

nominated by contractor

• Thickness limits (Table 8.6.1), range asphalt which may be effectively laid & compacted

• Approximately 3.0-5.0 times the nominal mix size for dense mix

Clause 9.4.2 – Tolerance on average and individual layer thickness as laid.• Affect pavement life• Drainage

• Inf luence adjoining structures

Corrective courses and tie-ins

§ May need to lay outside thickness limits§ Reduce risk of differential compaction§ Match into existing levels

§ Contractor will submit work method to achieve dense and homogenous layer

Quality Checklist- Placement

§ Are the Contractors Checklists and ITPs available and being used?

§ Staffing levels as per Contractor’s Project Quality Plan § Suitable action to protect and maintain fixtures and Services

within work area. (cover grates, hydrants etc) § Pavement temperature is suitable to proceed with works§ Asphalt is placed and compacted within temp. range

according to binder manufacturers recommendations.§ Thickness correct (allow for compaction)



Placing Asphalt

§ Pavement preparation (Clause 8.2)§ Method of placement (Clause 8.3)§ Protection of work (Clause 8.4)§ Course & layer thickness (Clause 8.6)§ Pavement temperature and weather conditions (Clause 8.7)§ Paving and compaction temperatures (Clause 8.8)

Pavement Temperature and Weather

Pavement Temperature and Weather Conditions Clause 8.7§ Pavement must not be wet § Rain must not appear imminent (contractors call).§ Measure pavement temperature on a regular basis

Definitions• Wet• regular basis

Paving and Compaction Temperature (Clause 8.8)

Quality plan must include:• Minimum temperature asphalt is to be delivered to the pavement• Minimum temperature of mat when initial compaction will commence• How this will be measured (probe, infrared surface thermometer)



Temperature Measurement

Surveillance of mix temperature and traceability records

Compaction temperatures AC7 & OG

Asphalt Mix Type (Asphalt Designation )

Minimum Mix Temperature (°C)

Dense graded asphalt (AC7 & AC7H) 115°C

Open graded asphalt (OG10, OG14) 120°C

For opengradedasphaltanddensegradedasphaltwitha nominalsizelessthan10mm in-situair voids is nottypicallytested.

MRTS30 Table 8.8

Infrared Thermometers

§ Must be accurate to ± 2°C§ Verification of accuracy daily ?

§ Compare against reference device e.g. calibrated infrared thermometer with NATA certificate

§ Range of temperatures e.g. one pavement and one mix temperature reading

§ Use difference as temperature offsetProduct specifications

Infrared temperaturerange

566: -40 °C to 650 °C (-40 °F to 1202 °F)568: -40 °C to 800 °C (-40 °F to 1472 °F)

Infrared accuracy < 0 °C (32 °F): ± (1.0 °C (± 2.0 °F) + 0.1°/1 °C or °F);> 0 °C (32 °F): ± 1 % or ± 1.0 °C (± 2.0 °F), whichever is greater

Display resolution 0.1 °C / 0.1 °F

Infrared spectral response 8 µm to 14 µm

Infrared response time < 500 msec

Thermocouple Type-Kinput temperature range

-270 °C to 1372 °C (-454 °F to 2501 °F)

Thermocouple Type-Kinput accuracy

-270°C to-40°C:

± (1 °C + 0.2 °/1 °C) (-454 °F to -40 °F: ± (2 °F + 0.2 °/1 °F))

-40°C to1372°C:

± 1 % or 1 °C (-40 °F to 2501 °F: ± 1 % or 2 °F), whichever isgreater

D:S (distance tomeasurement spot size)

566: 30:1568: 50:1

Laser sighting Single-point laser < 1 mw output Class 2 (II) operation, 630 nm to 670 nm

Minimum spot size 19 mm (0.75 in)

Emissivity adjustment By built-in table of common materials or digitally adjustable from 0.10 to 1.00by 0.01

Data storage with

Date/Time stamp

566: 20 points

568: 99 points

PC Interface and cable 566: None568: USB 2.0 with FlukeView® Forms software

Hi/Low alarms Audible and two-color visual

Min/Max/Avg/Dif Yes

Display Dot matrix 98 x 96 pixels with function menus

Backlight Two levels, normal and extra bright for darker environments

Trigger lock Yes

Switchable Celsius andFahrenheit

Yes

Power 566: 2 AA/LR6 Batteries568: 2 AA/LR6 Batteries and USB when used with a PC

Battery life If usedcontinuously:

laser and backlight on,12 hours; laser and backlight off,100 hours

Operating temperature 0 °C to 50 °C (32 °F to 122 °F)

Storage temperature -20 °C to 60 °C (-40 °F to 140 °F)

Bead thermocouple Type-Krange

-40 °C to 260 °C (-40 °F to 500 °F)

Bead thermocouple Type-Kaccuracy

± 1.1 °C (2.0 °F) from 0 °C to 260 °C (32 °F to 500 °F), typically within 1.1 °C(2.0 °F) from -40 °C to 0 °C (-40 °F to 32 °F)

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Uniform compaction

Uniform compaction temperatures = uniform density

§ Aim for§ Constant supply of asphalt to the paver § Uninterrupted paving.

§ Variation in density (air voids) leads to premature distress.

§ Areas may be sub-lotted and tested separately to confirm they comply with the specification requirements for air voids.

Case Study 2

Unexpected rain event

Application of engineering judgment

CS2: Review correspondence

§ Rain increased from light drizzle to heavy downpour§ Paving continued throughout rain event§ Initial decision for removal subjected to engineering judgment and

appealed.§ What are the options under the old system?§ What additional options exist for the new system?



CS2: Unexpected rain event

§ Old system§ A process existed to allow the use of engineering judgment but outcome was

limited to a black/white response due to the constraints of the specification.

§ New system§ The approach increases the use of engineering judgment and experience

allowing greater risk to be transferred to the contractor through the 24 month performance warranty.

Compaction

Method of achieving compaction§ Roller type§ Number of passes§ Rolling pattern

May need to vary for§ Temperature§ Layer thickness§ Paving speed

Up to contractor

Typical surveillance checks - Compaction

§ Temperatures§ Warm up§ No oil leakage§ No pick up on tyres or drum§ Even rolling patterns§ Smooth speed and direction change



Exercise No.2

§ Scenario§ 3 rollers on project, one roller breaks down and is parked

up at 3:00pm§ 150 tonnes en route to project. You know this is the final

round for the trucks for the day.§ Based on your experience you believe you can achieve

compaction with the 2 working rollers§ What action should you take?

§ In regards to the paver?§ In regards to testing?

Placing Asphalt

§ Pavement preparation (Clause 8.2)§ Method of placement (Clause 8.3)§ Protection of work (Clause 8.4§ Course & layer thickness (Clause 8.6)§ Pavement temperature and weather conditions (Clause 8.7)§ Paving and compaction temperatures (Clause 8.8)§ Tack coat (Clause 8.9)

Is this tack coating acceptable ?



Tack Coat Application rate (Clause 8.9)

• Typically 0.1 to 0.2 l/m2 of residual bitumen (Not emulsion – nominate in AQP)

• Even application with mechanical applicator• Strong bond is achieved

Tack Coat Application rate

• Approximately double application rate for joints, kerb faces, etc.• Hand work where mechanical applicator impractical

Tack coat

§ Endorsed daily record or quantity sheet§ Binder content – amount of bitumen as a %

LotNo. Volume(L)

BinderContent(%)

Area(m2)

ApplicationRate(L/m2)

1 720 30 1200 0.18

2 360 60 1200 0.18

(720 x 0.3 ) ÷ ( 1200 ) = 0.18 L/m2



Placing Asphalt

§ Pavement preparation (Clause 8.2)§ Method of placement (Clause 8.3)§ Protection of work (Clause 8.4§ Course & layer thickness (Clause 8.6)§ Pavement temperature and weather conditions (Clause 8.7)§ Paving and compaction temperatures (Clause 8.8)§ Tack coat (Clause 8.9)§ Joints (Clause 8.10)

Joints (Clause 8.10)§ Implement procedures to maximise joint density§ Mechanised edge compaction or trimming§ Loose or cracked material removed before placing adjacent run

Joints (Clause 8.10)

Finish surface smooth, planar and coinciding with the surface of the rest of the mat. Refer to Cl 9.6.2 and Q712



Longitudinal Joints (Clause 8.10)

§ Coincident with final traffic markings in surface layers§ 150mm from the line of change of cross fall§ Offset by 150mm from joints in underlying layers

§ On/Off Ramps – joints not on lane lines but outside wheel paths

Dense graded asphalt

Minimise broadcasting of material

Remove excess and segregated material

Transverse Joints (Clause 8.10)

§ Where§ Minimum 25m apart§ Offset 1m from joint in underlying layer§ Consider if practical for road location and geometry

§ When§ Commencement of each paving run§ When mix has cooled below initial compaction temperatures

Transverse joints



Placing Asphalt

§ Pavement preparation (Clause 8.2)§ Method of placement (Clause 8.3)§ Protection of work (Clause 8.4§ Course & layer thickness (Clause 8.6)§ Pavement temperature and weather conditions (Clause 8.7)§ Paving and compaction temperatures (Clause 8.8)§ Tack coat (Clause 8.9)§ Joints (Clause 8.10)§ Placement Trial (Clause 8.11)

Placement Trial (Clause 8.11) – Hold Point 6

Demonstrate conformance with the specification, covered in AQP

Where to use it§ Major projects§ High production volumes§ High risk projects§ Crew inexperienced with mixes/plant

Where not to use it§ Minor works§ Maintenance activities§ Proven mixes§ Experienced crew

What is being trialed§ Nominated mix§ Plant capability§ Crew competency

Minor non-conformances not a reason to repeat trial

Placing Asphalt

§ Pavement preparation (Clause 8.2)§ Method of placement (Clause 8.3)§ Protection of work (Clause 8.4)§ Course & layer thickness (Clause 8.6)§ Pavement temperature and weather conditions (Clause 8.7)§ Paving and compaction temperatures (Clause 8.8)§ Tack coat (Clause 8.9)§ Joints (Clause 8.10)§ Placement Trial (Clause 8.11)§ Temporary Ramps (Clause 8.12)



Temporary Ramps and Tie-ins (Clause 8.12)Transverse joints - ramp length for every 50mm of height

50mm

50mm

2.5m

1.5m

≤

≥

Temporary Ramps and Tie-ins (Clause 8.12)Longitudinal joints - 1.0m ramp length for every 50mm of height

§ Avoid ramp encroaching into wheel path§ Ravelling along edge of ramp, loose stone§ Assess if delineation to prevent travel over joint and omission of ramp is safer.

50mm

1.0m

Surface gritting of SMA (Cl 8.13)

§ Improve initial skid resistance§ Applied

§ As part of compaction process§ At rate in kg/m2 in Cl 8.13

§ Table 8.13 for grading



Case Study 3

Binder for SAMI not conforming asphalt placed

CS3: Review test results and details

§ Results from point of delivery tests on SAMI binder out of specification§ Asphalt wearing course had been place on the SAMI§ Appears that the S4.5S binder had changed in property from previous test

results§ Contract consideration and implications impacted on the ability to transfer

the performance risk onto the Principal§ Decision taken to reject the SAMI and require the removal of the wearing

course.§ Was the decision considered as “harsh”?§ What alternatives exist for the new system?

CS3: Out of specification binder for SAMI

§ Old system§ Engineering judgment on basis of weaker

binder than specified§ Significant deviations from specification make

performance judgments difficult§ Contract & project requirements have variable

risk acceptance§ Rejected on basis on not meeting later service

expectations§ New system

§ Performance is included in warranty which allows for ongoing assessment

§ Principal owns the 24 month warranty and can operate beyond the contract

§ Appeal by Administrator to TMR PMG possible for technical guidance

Test Min Max ResultVisc 0.800 0.348TR 54 85 40SP 82 100 58.5



Administration of Asphalt PavementsSpecifications

8. Finished Pavement Properties

Finished Pavement Properties

Homogeneity

Layerdensity(In-situairvoids)

Surfacetexture

Courselayer&thickness

Courseposition

Surfaceshape

Ridingquality

Homogeneity (Clause 9.1)

Cracking Ravelling




FattyBoney


Damage during construction

In-situ Air Voids

§ Why is density so important? § Impact of segregated product § Verify conformance before covering§ Effective compaction process

§ Structural stiffness§ Moisture sensitivity§ Permeability



In-situ Characteristics

§ Verify conformance and establish records before covering work.§ Do not cover nonconforming work unless disposition accepted and

implemented.§ Clauses 9.2.2 and 9.4.4

§ In-s itu air void and layer thickness

§ Acceptance is on the basis of cores.

or§ Nuclear density testing in lieu of cores if in accordance with Q306E.

§ Layer thickness based on dip records during paving

In-situ Air Voids (Clause 9.2)

Dense graded asphalt

§ Joints

§ boundary between two paver runs, testing straddle joint expect where different mixes§ Administrator can direct testing

§ Air voids not measured where stated nominal thickness less than 30mm§ Potential for interconnected voids§ Greater risk of damaging sample during extraction and trimming§ Insuffic ient material to determine density

LocationLimits of Character istic Values of In situ Air Voids

Specified layer thickness> 30 mm and< 50 mm

Specified layer thickness≥ 50 mm

Mat VL = 3.0% and VU = 8.0% VL = 3.0% and VU = 7.0%

Joints (1) VL = 3.0% and VU = 11.0% VL = 3.0% and VU = 10.0%

Determination of in-situ air voids (Clause 9.2.2)



Core Hole Restoration

ü

û


§ In-situ air voids (Clause 9.2)§ Surface texture (Clause 9.3)§ Course and layer thickness (Clause 9.4)§ Course position (Clause 9.5)

Surface Texture (Clause 9.3)

§ Only measured on SMA

§ Sand patch test

§ 0.7mm for SMA10

§ 1.1mm for SMA14

§ After gritting

§ Seek advice from if texture outside limits



Course & Layer Thickness

Clauses 8.6 & 9.4

Course & layer thickness (Clause 9.4)

Finished surface level not specified§ Single layer

§ Average layer thickness = nominated thickness ± tolerance

AC10- Layer2

AC10- Layer1Cou

rse

Course & layer thickness (Clause 9.4)

Finished surface level not specified§ Subsequent layers

Average layer thickness = nominated thickness ± average value tolerance

+Individual value thickness = nominated thickness ± individual value tolerance

AC10- Layer2

AC10- Layer1Cou

rse



Determining layer thickness (Clause 9.4.4)

§ Average compacted layer thickness

𝐴𝑣𝑔𝑐𝑜𝑚𝑝𝑎𝑐𝑡𝑒𝑑𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠TA=1000𝑥M(DxA)

§ TA = average thickness of compacted layer, in mm. § M = the mass of asphalt in the lot, in tonnes.§ D = the average compacted density of the lot, in t/m3. § A = area of the lot, in m2.


Layer thickness at any one point

AC10- Layer2

AC10- Layer1Cou

rse

or


Compacted layer thickness at a point

§ Cores – prior to trimming

§ Dipping - 𝑇𝑇 = =>?>𝑥𝑈𝑇

TT = compacted layer thickness at a specific test location, in mm.TA = average thickness of the compacted layer in mm.UA = average thickness of the uncompacted layer to achieve TA above, in mm.UT = uncompacted layer thickness at a specific location, in mm.

Compaction factor



Course thickness (Clause 9.4)

Finished surface levels specified§ Average compacted thickness

§ By survey vs. By calculation (9.4.4a) must be consistent

§ Within 10% of nominated thickness for surface course by survey

§ Individual thickness

§ Within 20% of nominated thickness for surface and intermediate courses by survey

Total asphalt thickness no longer a compliance requirement

Levels v Thickness

§ Laying to levels§ laying relative to a datum

§ Laying to thickness§ laying relative to base

In a perfect world these are the same

Levels v Thickness

§ Laying to levels§ laying relative to a datum

§ Laying to thickness§ laying relative to base

• Thickness can be reduced• Chasing levels can affect smoothness

• Allow self levelling action of paver to smooth out undulations

• Still match into existing structures




§ Layer density (In-situ air voids) (Clause 9.2)§ Course and layer thickness (Clause 9.4)§ Surface texture (Clause 9.3§ Course position (Clause 9.5)§ Surface Shape (Clause 9.6)

Surface shape (Clause 9.6)

§ Must not pond water

§ Must not deviate from the bottom of a 3 m straightedge by more than the specified tolerance

Course Maximum Deviation from a ThreeMetreStraight-Edge (mm)

Through Carriageway< 70 km/h Traffic Speed

Through Carriageway≥ 70 km/h Traffic Speed2

At Actual Completion Date

Surfac ing c ourse 5 3

Cours e immediately be low the surfacing c ours e

101 5

Al l o ther courses 15 10

12 months after Date ofPractical Completion

As phal t surface 8 6

Surface shape (Clause 9.6)

Determine surface shape for:§ All trafficked lanes

§ Longitudinal joints

§ Transverse joints

Correct nonconformities before a subsequent course is placed



3m Straightedge


§ Layer density (In-situ air voids) (Clause 9.2)§ Course and layer thickness (Clause 9.4)§ Surface texture (Clause 9.3§ Course position (Clause 9.5)§ Surface Shape (Clause 9.6)§ Ride quality (Clause 9.7)

Riding quality (Clause 9.7)

• Assessed for each 100m lane interval

• Final layer, running lanes only

• Laser vehicle must get up to 30km/hr

• Allow enough room for it to get up to speed and stop

• Roundabouts, railway lines … will affect ride measurement

• Contractor to include ride measurement in inspection and test plan



Ride quality (Clause 9.7)

Clause 9.7 Ride Quality• NAASRA counts/km unit • Multiple layers

• Annexure MRTS30.1 or 50 counts/km

• One layer over pavement constructed by others:• Ra = 0.6 x Rb + 5 • Rb – ride quality before overlay, determined by contractor

Correction layers for Low Areas

Mill to remove localised high spots

One option to rectify shape



Supplying for good ride quality

Continuous supply to achieve compaction

Asphalt delivered at a rate that allows roller access to mat to compact before mat cools

Paver may need to stop on occasion




9. Non-conformance of asphalt

Non-conformance of asphalt

§ Conformance Requirements (Clause 5.3)§ Compliance Testing (Clause 5.4)

§ Sampling (Clause 5.4.2)§ Nonconformities (Clause 5.8)§ Homogeneity (Clause 9.1)§ Performance requirements (Clause 1.2)

Conformance requirements (Clause 5.4.1)

Verify conformity to the specification by § Sampling§ Testing§ Providing records of process control





§ Sampling (Clause 5.4.2)§ Nonconformities (Clause 5.8)§ Homogeneity (Clause 9.1)

Lots and Sub-lots

Random stratified selection for § in-situ air voids§ core thickness§ deviation from

straight edge within lane

§ Method

§ Dry (dry ice)

§ Wet Coring (cores have to be air dried)

§ Must be extracted undamaged

§ Distortion or damage to cores can affect results

Coring



Non-conformance (Clause 5.8)

If a lot fails to conform to the specification, such failure will constitute a “Nonconformity” under the Contract.

Addressing a non-conformance§ Pre-established dispositions (MRS30)§ Contractors disposition (e.g. accepts as is or extended

warranty)§ Remove and replace

Pre-established dispositions

TMR may accept asphalt for utilisation at a reduced level of service based on the requirements of Clause 3.2 being satisfied. However, it may not be appropriate to apply these pre-determined dispositions for specific high risk / high profile projects. Where it is determined that application of these pre-determined dispositions is not appropriate, it will be stated elsewhere in the Contract that the requirements of MRS30 Clause 3.1 do not apply.

Pre-established dispositions – MRS 30 (Clause 3.1)

Outlines acceptance of non-conformances for:

§ Combined particle size distribution & binder content§ In-situ air voids§ Riding quality



Combined PSD & binder content Table 3.2

Combined Partic le Siz eDistribution Element% by which Nonconformanceexceeds

Production Tolerance(Clause 7.4.3.2 ofMRTS30) Deductions (in percentof schedule rate)(% by mass oftotal aggregate)

Pas s ing 37.5 mm Eac h 2 or part thereof 1











Pas s ing 0.150 mm Eac h 0.5 or part thereof 2

Pas s ing 0.075 mm Eac h 0.5 or part thereof 2

Binder Content (% by mass of total asphalt mix)

Al l as phal t mix Eac h 0.1 or part thereof 3

Combined PSD & binder content

Combined Partic le Siz eDistribution Element

% by which nonconformity exceeds production tolerance(Clause 7.4.3.2

of MRTS30) Deductions (in percentof schedule rate) P roduction To le rance (Tab le 7 .4 .3 .2 )(% by mass oftotal aggregate)

Pas s ing 37.5 mm Eac h 2 or part thereof 1 ± 7











Pas s ing 0.150 mm Eac h 0.5 or part thereof 2 ± 2 .5

Pas s ing 0.075 mm Eac h 0.5 or part thereof 2 ± 1 .5

Binder Content (% by mass of total asphalt mix)

Al l as phal t mix Eac h 0.1 or part thereof 3 ± 0 .3

Case Study 4

PSD & Bitumen content deficiency



CS4: Review results

CS4: Penalty & design revision

Old system§ Penalty applied§ Mix design locked in

New system§ < 20% total§ Penalty applied§ Possible mix design

revision in hands of PAC

In-situ Air Voids

MRS30Table3.3– DeductionsforNonconformingIn-situAirVoids



Ride quality (Clause 3.4)

Ride Quality in Excess of Specified Limitby (counts/km)

Deduction (in % of Lot Value)

≤ 5 2

6 – 10 4

11 – 15 8

16 – 20 16

Ride quality is average over the lot

What will affect ride quality?

Was ride affected by influences outside of contractors control?

§ Work by others e.g. joints at start and end of works

§ Service covers

§ Bridge joints

§ Railway lines

§ Roundabouts

Roughness calculationsCalculation of surface roughness shall accurately represent the ride quality of the complete pavement. It is generally accepted that the inclusion of other road features within the pavement are likely to reduce ride quality.

In accordance with the test method adopted, these features are required to be noted during roughness testing. In accordance with MRTS30, the following features are allowed to be excluded from ride quality assessment:

§ Roundabouts§ Railway lines§ Bridge joints§ Inspection pit covers (for example, drainage manholes)

The Contractor shall nominate a methodology and provide calculations on ride quality for the Administrators acceptance, showing how each feature has been excluded from the assessment and the subsequent lot structure.

Under no circumstances should pavement features including joints, or s ignalised/unsignalised intersections be excluded from the ride quality assessment without the express agreement of the Administrator.



Ride quality incentives (MRS30 Clause 4)

a. The Lot conforms to all requirements of MRTS30

Ridequalitybelowspecifiedlimitby(counts/km)

Incentive(inpercentofvalueofLot)

≤10 011– 15 116– 20 2>20 3

Case Study 5

Compaction Deficiency

CS5: Review correspondence & results

§ Annexure Clause 13 – NO reduced level of service for rejected lot§ Density 91.6% below required 92% § Rejection was appealed § Lot accepted at a reduced value

§ What outcome and approach is expected for the new system?



CS5: Compaction deficiency

§ Old system§ Annexure: Acceptance of a rejected lot for utilisation at a reduced level of

service. NO§ Outcome: Reject without compensation§ Appealed: With client engineering judgment – accept at reduced value

§ New system§ Now using airvoids in place of density§ Clause 3 possible to include with deduction and optional warranty extension§ Annexure does not include tick box for non-acceptance of reduced level of

service. Does remain an option based on project specific requirements.

Contractor’s disposition

§ Is the disposition covered by pre-established dispositions?§ What is the effect on the overall life of the project?

§ Seek advice from Engineering & Technology§ Will the disposition result in increased operating and/or

maintenance costs?§ Will the disposition delay the completion of the project and

will that cause problems?§ Does the disposition have relevant supporting evidence?

Review of contractor’s disposition (Cont’d)

§ Are there previous non-conformances of a similar nature?§ Is corrective action required to eliminate or minimise the

cause of the non-conformance?§ Was the cause of the non-conformance within the

contractors control?§ Will remove and replace have other consequences e.g.

additional joints, ride, disruption





§ Sampling (Clause 5.4.2)§ Nonconformities (Clause 5.8)§ Homogeneity (Clause 9.1)§ Performance requirements (Clause 1.2)

Performance Requirements (Clause 1.2)

Comply with surface shape requirements for first 12 months

Performance Requirements (Clause 1.2)24 month warranty against

• Raveling

• Bleeding

• Shoving

• Stripping



Boney and Segregated

What are some of the possible causes of segregation ?

What was the pavement condition?

§ Base condition§ Type and quality of repairs§ Extent of preparation works




10. Specific Contract Requirements Annexure

Annexure MRTS30.1

1. Binder2. Crack Filling3. Strain Alleviation Fabric Strips4. Material Transfer Vehicle5. Bridge Structures 6. Placement Trial7. Ride Quality8. Supplementary Requirements

Binder selection (Clause 1)

§ Specify binder type for each mix size§ Must be filled out

§ Pavement Design Supplement provides guidance on binder selection

Lo cation Nominal M ix Size B inder C lass B inder Speci fication

Wearing courseCh.100- 500

AC14 A5S MRTS18



Surface Preparation (Clause 2 & 3)

§ Crack Filling§ Isolated cracking§ > 2mm wide§ Widespread cracking consider SAMI

§ Strain Alleviating Fabric Strips§ Joints in concrete pavements§ Where large movements expected§ Difficult to place on milled surface

Material Transfer Vehicle (Clause 4)

Considerations:• Not for every job• Not for every layer• Size and location of work site• Safety• Manoeuvrability• Weight

Structures (Clause 5)

Load limits apply on structures within the Work as follows:

STRUCTURE CHAINAGES DETAILS

Can also apply to large culverts Safety implications for contractor



Placement trial (Clause 6)

Consider:• Size and risk of the works

– For major construction works• History with mixes nominated• Is it a ‘Value for money’ decision• Interruption to asphalt works

Ride Quality Measurement (Clause 7)

Consider:• Is the asphalt being placed in more than one layer• Is a single layer being placed over a pavement constructed by others• Length of works (Ride is measured in 100m sections)• Any constraints on ability measure

A better ride quality (i.e. lower roughness count) costs more to achieve than a lower ride quality. Therefore it is important that an appropriate ride quality requirement is specified for the particular project involved.A maximum roughness count of 50 counts per kilometre typically applies on TMR roads. However, a lower maximum roughness count of 40 counts per kilometre may be specified in some instances (e.g. for heavily trafficked, high speed roads such as motorways, arterial roads and national highways).

Supplementary Requirements (Clause 8)

§ Timing of works§ Staged construction§ Level control is not specified elsewhere§ Access to site§ Milling required§ Pavement repairs required§ Limitations on paving and compaction (e.g. vibration near structures)§ Any other requirement not covered by the specification

Created March 2013, replaces Jan 2013 version. Page 1

Guide to the heating and storage of binders for sprayed sealing This is a general guide to heating temperatures and storage times of bituminous binders used in sprayed sealing applications. Although the information provided in the table was correct at the time of publication, users of bituminous products are advised to contact suppliers for current information and Material Safety Data Sheets prior to using any particular product.

Binder Supplier Sealing Binder Austroads binder class

Recommended spraying

temperature range (°C)

Recommended maximum

holding time at spraying

temperature

Recommended medium-term

storage temperature (°C)

Recommended medium-term storage time

(AG:PT/T190) (Note 1) (Notes 2 & 3) (Notes 2 & 3) PAVING GRADE BITUMEN

AS2008 bitumens Class 170 175 - 185 7 days 130 - 150 30 days

Class 320 175 - 185 7 days 130 - 150 30 days

MODIFIED SPRAYED SEALING BINDERS

Bituminous Products Pty Ltd Bitulastic S10E S10E 180 - 190 2 days 130 - 140 14 days

Bitulastic S20E S20E 180 - 190 2 days 130 - 140 14 days



Bitulastic S45R S45R 180 - 200 3 days 140 - 160 14 days

Bitulastic Multi 600/170 M500/170 180 - 190 7 days 140 - 160 30 days

BP Australia Pty Ltd OLEXOBIT SP 180 - 190 2 days 120 - 160 60 - 7 days

OLEXOBIT HSS 180 - 190 2 days 120 - 160 60 - 7 days

OLEXOBIT SAM S35E 180 - 190 2 days 120 - 160 60 - 7 days

OLEXOBIT MAX S15E 185 - 190 1 day 120 - 160 14 - 7 days

OLEXOBIT S30 S10E 180 - 190 1 day 120 - 140 14 - 7 days



OLEXOBIT CR45 S45R 185 - 195 1 day(Note 4) 120 - 140 14 - 7 days

Downer Australia Downer S10E S10E 180 - 190 1 day 130 - 150 5 - 7 days

Downer S15E S15E 180 - 190 1 day 130 - 150 5 - 7 days




Downer S45R S45R 190 - 200 1 day 140 - 160 5 - 7 days

Fulton Hogan Industries Pty Ltd SPRAYflex S5E 170 - 180 1 days 130 - 150 7 - 5 days

SPRAYflex S10E S10E 170 - 180 1 days 130 - 150 7 - 5 days




SPRAYflex S30E 180 - 190 1 days 140 - 160 7 - 5 days


SPRAYflex S0.3B 170 - 180 1 days 135 - 160 7 - 20 days

SPRAYflex S45R S45R 185 - 195 1 days 140 - 160 10 - 7 days (Note 4)

SPRAYflex S15RF S15RF 185 - 195 1 day 140 - 160 7 -5 days (Note 4)

SPRAYflex S18RF S18RF 190 - 200 1 day 140 - 160 7 -5 days (Note 4)

advisory note 7

http://austroads.com.au/images/stories/T190_Framework_specification_Dec_2010.pdf


Binder Supplier Sealing Binder Austroads binder class

Recommended spraying


Recommended maximum

holding time at spraying

temperature




(AG:PT/T190) (Note 1) (Notes 2 & 3) (Notes 2 & 3) SAMI Bitumen Technologies Pty Ltd SAMIseal S10E S10E 175 - 185 2 days 120 - 140 14 days

SAMIseal S15E S15E 175 - 185 2 days 120 - 140 14 days



SAMIseal S45R S45R 185 - 195 3 days (Note 4) 120 - 140 14 days (Note 4)

Polyseal HSS S35E 175 - 185 7 days 120 - 160 30 days

Polyseal SAM S35E 175 - 185 7 days 120 - 160 30 days

Shell Company of Australia Multiphalte 600/170 M500/170 175 - 190 3 days 70 - 155 30 - 5 days

Cariphalte S25E S25E 185 - 195 1 day 140 - 160 10 - 7 days





Cariphalte S5E 175 - 190 3 days 140 - 160 14 - 7 days

Sprayline 15% Crumb Rubber S15RF 175 - 200 5 days 130 - 150 10 days

18% Crumb Rubber S18RF 185 - 200 5 days 140 - 160 10 days

Notes:

1. Adjustment of the spraying temperature may be required to allow for prevailing conditions, such as pavement temperature and wind speed, but should not exceed the recommended maximum spraying temperature. The listed temperature ranges apply to the binder before the addition of cutter or additive. For further information, refer to the Austroads Bituminous Materials Safety Guide.

2. All polymer modified binders must be stirred prior to use and regularly circulated during storage due to the possibility of polymer segregation. Refer to binder manufacturer/supplier for advice on storage of binders for periods longer than shown.

3. Longer storage times apply to lower storage temperatures.

4. These products require continuous agitation during storage.

Guide to the heating and storage of binders for asphalt manufacture This is a general guide to heating temperatures and storage times of bituminous binders used in asphalt applications. Although

the information provided in the table was correct at the time of publication, users of bituminous products are advised to contact

suppliers for current information and Material Safety Data Sheets prior to using any particular product.

Binder Supplier Asphalt Binder Austroads binder class

Recommended mixing


Recommended maximum

holding time at Mixing

temperature




(AG:PT/T190) (Note 1) (Notes 2 & 3) (Notes 2 & 3) PAVING GRADE BITUMEN

AS2008 bitumen grades Class 170 140 - 165 14 days 130 - 150 30 days

Class 320 150 - 170 14 days 130 - 150 30 days

Class 600 160 - 180 14 days 130 - 150 30 days

RMS bitumen grades AR450 155 - 175 14 days 130 - 150 30 days

MODIFIED ASPHALT BINDERS

Bituminous Products Pty Ltd Bitulastic A35P A35P 165 - 175 4 days 140 - 150 30 days

Bitulastic A25E A25E 165 - 175 4 days 130 - 140 14 days




Bitulastic Multi 1000/320 M1000/320 165 - 175 30 days 140 - 150 30 days




Binder Supplier Asphalt Binder Austroads binder class

Recommended mixing


Recommended maximum

holding time at Mixing

temperature




(AG:PT/T190) (Note 1) (Notes 2 & 3) (Notes 2 & 3) BP Australia Pty Ltd OLEXOBIT AOG A25E 145 - 155 7 days 120 - 150 60 - 7 days

OLEXOBIT AB4 A20E 155 - 165 2 days 120 - 140 14 - 7 days



OLEXOBIT SMA+ A25E 145 - 160 7 days 120 - 150 60 - 7 days

OLEXOBIT A35P A35P 160 - 175 4 days 140 - 150 14 - 7 days

Downer Australia Downer A10E A10E 160 - 175 2 days 120 - 140 14 - 7 days

Downer A15E A15E 160 - 175 2 days 120 - 140 14 - 7 days



Downer A35P A35P 160 - 175 4 days 140 - 150 14 - 7 days

Fulton Hogan Industries Pty Ltd PAVEflex A5E 165 - 175 3 days 140 - 160 7 - 5 days

PAVEflex A10E A10E 165 - 175 3 days 140 - 160 7 - 5 days




PAVEflex A35P A35P 160 - 175 7 day 140 - 160 14 - 10 days

PAVEflex A35PH A35P 160 - 175 7 day 140 - 160 14 - 10 days

SAMI Bitumen Technologies Pty Ltd SAMIfalt A10E A10E 165 - 175 4 days 120 - 140 14 days

SAMIfalt A15E A15E 165 - 175 4 days 120 - 140 14 days



SAMIfalt B380 A25E 160 - 175 7 days 120 - 140 14 days

SAMIfalt A35P A35P 160 - 175 7 days 120 - 140 14 days

SAMIfalt Multigrade Plus M1000/320 160 - 175 7 days 120 - 140 14 days

Shell Company of Australia Multiphalte 1000/320 M1000/320 160 - 180 5 days 70 - 155 30 - 5 days

Cariphalte A10E A10E 165 - 180 4 - 3 days 140 - 160 10 - 7 days



Cariphalte A35P A35P 155 - 170 5 days 140 - 160 10 - 7 days

Notes:

1. The recommended mixing temperature range and the recommended holding time at mixing temperature refer to the binder prior to its introduction to the asphalt mixing process. Adjustment of the temperature of mixing may be required to allow for prevailing conditions, such as pavement temperature, wind speed, asphalt mix type and haulage distance, but should not exceed the recommended maximum mixing temperature. For further information, refer to the Austroads Bituminous Materials Safety Guide.

2. All polymer modified binders must be stirred prior to use and regularly circulated during storage due to the possibility of polymer segregation. Refer to binder manufacturer/supplier for advice on storage of binders for periods longer than shown.

3. Longer storage times apply to lower storage temperatures.

It is recommended that reference is made to the AAPA website for the most current version of this document.

Disclaimer: Although the information contained in this Advisory Note is believed to be fundamentally correct, the Australian Asphalt Pavement Association Does not accept any contractual tortious or other form of liability for its contents or for any consequences arising from its use. Advice should be sought from suppliers prior to handling, applying or storing products outside the recommended ranges. Date of Issue: March 2013

Level 2, 5 Wellington Street, KEW Victoria 3101

Tel: (03) 9853 3595 Fax: (03) 9853 3484 E-mail: [email protected] Web: www.aapa.asn.au


pavement work tips are produced by AUSTROADS in conjunction with AAPA

continued on reverse

Key Summary

This issue of

“pavement work

tips” outlines the

influence of

temperature and

binder viscosity

on handling

properties of

asphalt using

various binders.

INTRODUCTION

The viscosity (or flow) characteristics of bituminous binders have a significant influence on the handling properties of asphalt mixes, including:

• mixing • cohesion • binder drain-down during storage and

transport • compaction.

Binder viscosity varies with temperature and different binders require different temperatures to achieve the same handling properties. Polymer modified binders, in particular, increase in viscosity at a much faster rate on cooling than normal paving grade bitumens.

Flow characteristics of binders can also be altered using ‘warm mix’ technologies such as foaming of binder during mixing or flow modifying additives. This ‘pavement work tip’, however, refers only to conventional asphalt manufacture and placing.

Figure 1 shows typical relationships between viscosity and temperature for three different binders and the ranges of viscosity for mixing and effective compaction.

Table 1 provides a ready reference of the

temperature, and associated viscosity, for

various binders to enable effective mixing and

placement of asphalt.

MIXING

The binder is heated to enable it to flow so as to achieve proper coating and “wetting” of aggregates. It must not be so fluid as to cause binder drain-down or lead to segregation or inadequate cohesion of the mix. Overheating or extended mixing times can also cause hardening of the binder due to oxidation or breakdown of polymers.

Good mixing can generally be achieved within a binder viscosity range of 0.08 to 0.2 Pa.s with a target value of 0.1 Pa.s preferred.

Binder drain-down is not generally an issue

with dense graded asphalt but may need to be

considered with the higher binder contents

associated with open graded and stone

mastic asphalt mixes.

In open graded asphalt it is common practice to limit the maximum temperature of the mix to prevent drainage by providing a minimum binder viscosity of about 0.12 Pa.s. Increased resistance to binder drain-down can be obtained with fibres and polymer modified binders.

Stone mastic asphalt is often handled at slightly higher temperatures than open graded asphalt in order to achieve workability, in which case fibres are nearly always used to reduce binder drain-down.

ASPHALT COMPACTION

Compaction of asphalt while it remains workable is a vital requirement for placement of all hot mix asphalt.

Compaction should not commence unless the mix has sufficient cohesion to support rollers and avoid excessive displacement. Generally this relates to a minimum binder viscosity of about 0.25 Pa.s.

Steel-wheeled rolling has greatest effectiveness in the range 0.25 to 10 Pa.s, while multi-tyre rolling can continue up to about 100 Pa.s. Multi-tyred rolling cannot generally commence until viscosity has increased to about 2 Pa.s to avoid excessive pick-up. The minimum compaction temperature in Table 1 is based on a viscosity of 10 Pa.s, beyond which the effectiveness of compaction falls rapidly.

POLYMER MODIFIED BINDERS (PMBs)

It is important to appreciate that the stiffness of

PMBs can increase more rapidly than unmodified

bitumen on cooling and, consequently, influence

the required compactive effort and time available

for compaction. In some instances, they may also

be handled at marginally higher viscosities than

unmodified bitumen and the temperatures in

Table 1 have been adjusted to reflect that

practical experience.

pavement work tips - No 13 November 2010

For more

information on any

of the construction

practices discussed

in "pavement work

tips'', please

contact either your

local AUSTROADS

representative. or

AAPA:

tel (03) 9853 3595;

fax (03) 9853 3484;

e-mail:

[email protected].

A complete list of

“pavement work

tips” issues is

available on

AAPA’s website:

www.aapa.asn.au

Issues may be

downloaded using

Adobe Acrobat

Reader. Copies may

also be obtained

from AAPA.

Material may be

freely reproduced

providing the

source is

acknowledged.

This edition was

prepared by

members of the

Austroads Asphalt

Research Reference

Group.

Austroads and AAPA believe this publication to be correct at the time of printing and do not accept responsibility for any consequences arising from the use of the information herein. Readers should rely on their own skill and judgement to apply information to particular issues.

page 2

FIGURE 1: BINDER VISCOSITY/TEMPERATURE RELATIONSHIP

TABLE 1: TYPICAL BINDER TEMPERATURE/VISCOSITY RELATIONSHIPS

Binder Class

Temperature (°C)1

Softening Point

(1200 Pa.s)

Minimum for final rolling

(100 Pa.s)

Minimum for effective

compaction2

(10 Pa.s)

Maximum for Compaction (Cohesion)

(0.25 Pa.s)

Maximum to prevent drainage in

OGA4

(0.12 Pa.s)

Optimum Mixing

2

(0.1 Pa.s)

Bitu

me

n 170 45 65 90 140 150 160

320 48 70 95 150 160 165

600 52 75 100 160 n.a. 170

Mu

ltig

rad

e M500/

170 55 75 100 165 165 170

M1000/320 60 75 100 165 170 170

PM

Bs

A35P 62 85 105 150 155 170

A25E 58 80 105 150 150 155

A20E 77 95 115 155 155 160

A15E 94 110 120 160 160 1653

A10E 97 115 125 160 160 1653

Notes: 1. Temperatures are typical of relevant binder classes in about middle of classification range. 2. Refer comments on polymer modified binders in text.

3. A maximum temperature of 165°C is generally recommended in the AAPA Guide to safe use of SBS binders to avoid fuming, unless otherwise recommended by the binder supplier (refer AAP Advisory Note 7).

4. Fibres can inhibit drainage at higher temperatures.

REFERENCES

AAPA (1998) HS&E Guide No 5 – Guide to safe use of SBS.

AAPA Advisory Note 7 – Guide to the Heating and Storage of Binders for Sprayed Sealing and Hot Mixed Asphalt.

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Asphalt StatisticalProcess Control

Key Summary

This issue of'pavement worktips' provides aguide to theapplication ofstatistical processcontrol charts to themanufacture ofasphalt

AUSTROADS

pavement work tips is produced by AUSTROADS in conjunction with AAPA

BACKGROUNDIn 1997, AAPA published a guide to asphalt

plant process control. The purpose of theguide is to provide an introduction to the useof statistically based process control charts forcontrol of asphalt production.

Control charts can provide:

� the producer with tools to analyse andimprove the consistency and quality of theasphalt production

� the purchaser with increased assurance ofquality.

The underlying premise is that quality isimproved, not by inspection and testing, butby determining causes. The application ofsuitable process control procedures andeffective use of statistically based measuresof quality should also allow a reduction in theamount and type of traditional tests used toaudit the quality of outputs.

INTRODUCTION TOCONTROL CHARTS

Control charts come in a variety of typesbut have a number of common features.

The types of charts referred to here can onlybe used when there is measurable data that isrecorded in a time sequence. Data points areplotted on a chart that normally shows, as aminimum, the process average and upper andlower control limits. Such charts allow analysisof system changes over time.

Charts are used to minimise making twokinds of mistake:

� acting as though something out of theordinary happened when nothing did(overcontrolling); and

� failing to act when something out of theordinary did happen (undercontrolling).

Variations due to error or process change,detected by statistical methods, are termedassignable causes.

Control limits oraction limits areupper and lowerb o u n d a r i e sestablished bystatistical analysis ofthe process. They areused to identifyassignable causes asan outcome ofproduction goingoutside the controllimits.

It is important to understand the distinctionthat control limits are not the same asspecification limits although specificationlimits and target values can also be shown onthe chart for comparison with specificationcompliance.

A capable process is generally one where thecontrol limits lie within the specification limits.Where the control limits are outside one ormore of the specification limits there is greaterrisk of falsely reacting to chance or randomcauses. Corrective action, when there is noclear evidence of a process problem, is likelyto increase, rather than decrease, processvariability.

Further data on a chart can include warninglimits established within the upper and lowercontrol limits to warn of possible problemsand need for corrective action.

SELECTING CONTROLCHARTS

There are four main types of control chartapplicable to asphalt work. The followingdescriptions are somewhat abbreviated andmore detailed information can be obtainedfrom the references.

Individual /Moving Range

This is one of the simplest of all controlcharts. It plots results of individual samples

Asphalt Statistical Process Control page 2For more informationon any of theconstruction practicesdiscussed in"pavement work tips",please contact eitheryour localAUSTROADSPavement ReferenceGroup representativeor AAPA �tel (03) 9853 3595;fax (03) 9853 3484;e-mail:[email protected]

A complete list of"pavement work tips"issues is available onAAPA's web site:www.aapa.asn.au

Issues may bedownloaded usingAdobe AcrobatReader. Copies mayalso be obtained fromAAPA.

Material may befreely reproducedproviding the sourceis acknowledged.

This edition wasprepared byJohn Rebbechi inconsultation withmembers of theNational AsphaltResearchCoordinationGroup (NARC).

and a moving range that is the simpledifference between two consecutive results.

Moving Average /Moving Range

This is a variation of the individual movingrange chart and is used to plot the results ofsingle samples as a rolling average of a number(e.g. 5) of consecutive results and the rangeof that group of results. By averaging the data,it reduces the risk of reacting to false out ofcontrol conditions when the process has notchanged.

This type of chart is particularly applicableto monitoring routine production where datais obtained from single samples.

Average/Range

This chart plots the average of groups ofresults and the range of results in thosegroups. As it uses more data, it is considereda more powerful tool for analysing whether aprocess is stable and predictable than theabove chart types. The AAPA Guide providesan example of this type of analysis inestablishing control charts for asphaltproduction.

Average/Standard Deviation

This is a variation of the average/rangechart. It uses the standard deviation ratherthan range to provide a better guide to processvariability. It requires more calculation but canbe applicable, for example, to the analysis ofcompaction testing where results are obtainedfrom groups of samples and the standarddeviation of the sample group is generallycalculated and recorded.

USING AND INTERPRETINGCONTROL CHARTS

As well as the recording of test resultsundertaken for assurance inspection purposes,control charts can be used for monitoring anumber of processes, particularly thoseupstream of the assurance inspection process.Examples of applications other than assuranceinspection include:

� Grading of incoming aggregates

� Aggregate and filler batch weights

� Binder batch weight

� Temperature of mixed asphalt.

Charts based on assurance inspection testresults of manufacture can include:

� Grading (e.g. one sieve below nominal size,2.36 mm and 0.075 mm sieves)

� Binder content

� Maximum density.

Setting Control Limits

Control limits are commonly set at ± 3 timesthe standard deviation (σ) for single samplesor 3σ/√n where n is the number of samplesin a group.

Warning limits are commonly set at ° thecontrol limits.

Decision Rules

Control charts require decision rules.Following are typical examples of decisionrules for action indicated by assignable causes.

Determine and correct assignable cause if:

� One point lies outside control limits

� Two out of three points lie outside warninglimits.

Investigate for possible assignable cause andneed for corrective action if:

� Nine points in a row are on one side ofthe central line

� Six points in a row are steadily increasingor decreasing

� Two out of three points lie outside thewarning line.

CONCLUSIONMost of the data required for process

control charts is already available in productionfacilities. Some effort is required to set up,maintain, and interpret systems to improveboth efficiency and quality of asphaltproduction.

REFERENCESAAPA (1997) Implementation Guide IG-3,

Asphalt Plant Process Control Guide

AS 3942 Quality Control � Variables charts� Guide.

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Asphalt shape correction

Key Summary

This issue of'pavement work tips'provides a guide toimprovement ofpavement ridequality throughasphalt shapecorrection andregulation

AUSTROADS


INTRODUCTIONThis Work Tip provides a guide to correction

of shape of asphalt surfaces and is supplementaryto two previous work tips:

Work Tip No. 3: Asphalt Riding Quality providesadvice on achieving smooth riding asphaltpavements through job planning, skilled operationof paver level controls, achievement of smoothconsistent paving and materials flow though theasphalt paver, proper construction of joints anduniform surface compaction.

Work Tip No 10: Asphalt Paving with AutomatedLevel Control provides a guide to the selection anduse of automated level control systems.

GENERALTwo important factors in planning of asphalt

shape correction and regulation are:

� The effect of differential asphalt compactionon varying depths of material.

� The ability of the paver and level controlsystem to place asphalt to the desired surfaceprofile.

INFLUENCE OF ASPHALTCOMPACTION

The density of asphalt spread by the paver isaround 80 to 85% of the design compacteddensity. This will vary slightly depending on thescreed system and mix characteristics but, as ageneral rule, a 15 to 20% reduction in volume(thickness) will occur under rolling.

Asphalt placed in depressions will thus compactmore under rolling due to the greater depth ofloose material. For example, a local 10 mmdepression could result in a depression of up to2mm in the finished work. A 50 mm depressioncould result in a depression of up to 10mm infinished level unless regulated beforehand (seeFigure 1) or compensated for by altering thethickness of asphalt being spread).

To obtain good surface shape and ride qualityit is therefore necessary to make allowance forvariations in compacted thickness whendetermining loose levels for spreading, or to

correct surface shapeby preliminaryregulation or coldplaning.

Shape correction isparticularly importantwhen placing thinsurfacing layers andwhere there are rapidchanges in surfaceshape.

Rapid changes suchas isolated mounds,hollows, sunken service trenches and potholes cancause:

� Dragging on high spots

� Reflection of the shape of depressions in thefinished surface.

Figure 1. Shape correction

INFLUENCE OF LEVELCONTROL SYSTEM

Where longitudinal shape correction is involved,the surface profile achieved by the paver screedwill be influenced by the level control system.

The floating screed asphalt paver ensures asmooth transition between changes in pavingthickness and correction over short lengths of

Finished level after compaction

Finished level after compaction

(a) Without shape correction

(b) With shape correction

Correction course

Finished level before compaction

Finished level before compaction

Asphalt shape correction page 2For moreinformation on anyof the constructionpractices discussedin "pavement worktips", please contacteither your localAUSTROADSPavement ReferenceGrouprepresentative orAAPA �tel (03) 9853 3595;fax (03) 9853 3484;e-mail:[email protected]

A complete list of"pavement worktips" issues isavailable on AAPA'sweb site:www.aapa.asn.au

Issues may bedownloaded usingAdobe AcrobatReader. Copies mayalso be obtainedfrom AAPA.

Material may befreely reproducedproviding the sourceis acknowledged.

This edition wasprepared by IanCossens and JohnRebbechi inconsultation withmembers of theNational AsphaltResearchCoordinationGroup (NARC).

Austroads and AAPAbelieve this publication tobe correct at the time ofprinting and do not acceptresponsibility for anyconsequences arising fromthe use of the informationherein. Readers should relyon their own skill andjudgement to applyinformation to particularissues.

minor shape variation in the underlyingpavement. Shape correction over a greaterlength can be improved by using a mobilereference device or levelling beam that averagesthe surface shape over the length of the beam.

Where shape or thickness correction isrequired over a length greater than that spannedby the paver or levelling beam, it is necessary tomake adjustments to the thickness of asphaltbeing spread. Adjustment should be based onsurvey information and applied by:

� manual adjustment of thickness controls

� string line, or

� computerised level control.

Figure 2 shows the combined effect ofdifferential compaction and level controlmethod on effectiveness of shape correctionwhen no compensation is made for loosethickness of spread material.

This effectiveness varies with the length ofthe bump or depression being corrected andfalls off rapidly once the length of the variationexceeds the length of the paver (around 4 m)or the length of the levelling beam, if used.

For example, a little over 20% of the effectof a 10 m long shape variation will be reflectedif a 9 m levelling beam is used but some 55%of the existing variation will be reflected by apaver.

Placing by stringline is not affected by thelength of the bump or depression, althoughabout 20% of the existing variation will bereflected in the new surface due to differentialcompaction unless compensation is applied tothe loose thickness of asphalt being spread.

Computerised level control systems usuallyapply a factor to compensate for loose thickness.

Figure 2. Effectiveness of level control system inreducing shape variation

CORRECTING SURFACERUTTING

The need for some form of correction prior toplacing a new wearing course is influenced by thepotential differential compaction, the thickness oflayer and depth of rutting. The followingguidelines are provided to minimise the effect ofrutting being reflected in a new asphalt surface.

a) Rut depth less than 10mmRegulation not generally required except whenrequired to ensure free drainage of opengraded materials or to avoid significantthickness variation in ultra thin surfacing.

b) Rut depth 10�30 mmRegulate with suitable asphalt mix providedthat existing asphalt is stable.

c) Rut depth greater than 30 mmGenerally the surface should be planed backto a uniform surface. Rutting of this depth isoften an indicator of unstable asphalt materialsthat should be completely removed to reducerisk of further rutting. This may involveremoval of up to 50 mm or more of asphalt,or removal of a complete layer, to ensureelimination of all unstable materials.

SELECTING MATERIALS FORREGULATION

Where separate regulation layers are to be placedprior to resurfacing, the size and type of asphaltshould be selected in accordance with theperformance properties required and the thicknessof material being spread. Normally a dense gradedasphalt is used with a binder type suitable to theperformance application.

The size of asphalt may need to comply withconflicting aims. Generally, the larger the size, thegreater the stability of the mix, but smaller sizesprovide greater workability and ease of taperingto thin layers. Table 1 gives an indication of sizeof dense graded asphalt suitable for mostapplications.

Table 1. Suggested asphalt sizes for regulation

40

20

5 10 15 200

% r

efle

ctio

n of

exi

stin

g va

riatio

n

Length of bump or depression (m)

60

0

String line

Pav

er o

nly

9 m

leve

lling

beam

Thickness of shapecorrection

Asphalt size

Isolated areas and rut depth<20mmExtensive areas or rutting20–30mm depthExtensive areas, >30mmdepth

7mm

10mm

14 or 20mm



Key Summary This issue of “pavement work tips” provides a guide to asphalt tack coating, including rationale for its use and guidelines to good practice.

INTRODUCTION

Tack coating is the light application of a bituminous material to promote adhesion

between an existing surface and a new asphalt layer.

Obvious effects of poor bond between asphalt layers and underlying pavements are seen as premature failures such as delamination and slippage. Less obvious effects of poor bonding between layers are reduced structural performance and reduced long term serviceability. Recent research suggests that the effectiveness of this bond plays an even greater part in pavement performance than that commonly accepted in the past.

A further specialty role of asphalt tack coating is in paving of ultra-thin asphalt surfacings where a heavy application of tack coat is used for both bonding of the surface layer and as an aid to waterproofing the underlying surface.

Figure 1 Slippage failure

TACK COAT BINDER TYPES

Bitumen emulsions are preferred as tack coat binders. Cutback bitumens or bitumen emulsions containing cutter oils should not be used as the oils can remain trapped in the binder and cause softening of the asphalt.

Generally, either cationic or anionic bitumen emulsions complying with AS1160 can be used. The type of bitumen emulsion should suit the conditions of use, e.g. climate, required emulsion break time, available spray equipment, etc.

Rapid setting cationic emulsions provide the most versatile binder for use in cooler regions where damp conditions may be encountered.

In warmer or drier conditions, slower setting cationic emulsions and anionic emulsions may combine satisfactory performance with greater ease of handling and stability in storage and dilution.

Emulsions may be diluted with clean, potable water before application to improve spraying properties. Contaminants that can cause premature breaking of the emulsion must be avoided. Where emulsion is diluted, the water must be added gradually to the total quantity of the emulsion. Addition of emulsion to water will cause the emulsion to break. An alternative to field dilution of emulsions is the manufacture of tack coating emulsions with a lower (e.g. 30%) binder content.

Further guidelines for storage and handling of bituminous emulsions are provided in Work Tip No. 2.

In some specialty bituminous emulsions, the use of harder base bitumens can reduce tackiness and pick-up under the tyres of delivery trucks, thus reducing the incidence of tracking of emulsions onto other surfaces or loss of tack coat within the wheelpath area.

Tack coating materials used in conjunction with the placing of ultra-thin asphalt surfacings usually employ a high bitumen content, polymer modified emulsion specifically developed for that purpose. These emulsions require special handling due to their high binder and polymer contents.

TACK COAT APPLICATION RATES

Residual binder application rates are specified in some specifications. Where no minimum is specified, a minimum rate of 0.15 L/m² residual bitumen binder (at 15°C) is recommended.

Actual rates of spraying of binder must take into account the water content of bitumen emulsions. For example, an ASS/170-60 diluted 50:50 with water will require a total spray rate of 0.5 L/m² to achieve a residual binder application rate of 0.15L/m2, i.e. 0.5 L/m² × 0.6 binder content of the emulsion × 0.5 dilution factor = 0.15 L/m² residual binder.

pavement work tips – No 51 March 2013

For more information

on any of the

construction practices

discussed in

"pavement work

tips'', please contact

either your local

Austroads Pavement

Task Force rep. or

AAPA:

tel (03) 9853 3595;

fax (03) 9853 3484;

e-mail:

[email protected].

A complete list of

“pavement work tips”

issues is available on

AAPA’s website:

www.aapa.asn.au

Issues may be

downloaded using

Adobe Acrobat

Reader. Copies may

also be obtained from

AAPA.

Material may be

freely reproduced

providing the source is

acknowledged.

This edition was

prepared by members

of the Asphalt

Research Working

Group.

Austroads and AAPA believe this publication to be correct at the time of printing and do not accept responsibility for any consequences arising from the use of the information herein. Readers should rely on their own skill and judgement to apply information to particular issues.

page 2

Increased tack coat binder application rates may be required on aged, porous or very textured surfaces, particularly milled surfaces or sprayed seals that have received little or no traffic. If uncertain, a suitable application rate may be determined by visual assessment of trials of different spray rates on measured areas of the existing surface.

Some specifications allow the tack coat to be omitted where asphalt is to be spread over clean, freshly laid asphalt. Generally, this should only be allowed where successive asphalt layers are placed on the same or following day and have not been subjected to trafficking.

PREPARATION

Unbound and lightly bound granular bases

Unbound and lightly bound (stabilised or modified) granular base materials require a prime or primerseal prior to asphalt surfacing. Cutback bitumen primerseals require a curing period, generally a minimum of three months of warm weather, before surfacing with asphalt. No minimum curing period is required for primerseals constructed with bitumen emulsions that contain little or no cutter oil.

A tack coat cannot be used as a substitute for priming or primersealing. Bitumen emulsion tack coats provide very little penetration of the granular base and, being both tacky and poorly bonded to the underlying surface, provide a high risk of pick-up on the tyres of delivery trucks and paving equipment.

Cured primed and primersealed surfaces should be tack coated immediately prior to placing asphalt.

Existing bituminous surfaces and concrete pavements

Existing surfaces must be clean and dry prior to tack coating. Particular care is required in removing dust from freshly milled surfaces. Figure 2 shows excessive pick up of tack coat applied to a poorly cleaned, milled surface.

Figure 2 Pick-up of tack coat on dusty milled surface

Very dense and hard surfaces may require milling to achieve an additional mechanical key in areas of high surface shear. For example, Figure 3 shows slippage of asphalt placed on a smooth concrete surface on a heavily trafficked freeway exit ramp.

Figure 3 Asphalt slippage failure on concrete pavement

APPLICATION PROCEDURES

Application procedures must ensure a uniform distribution of binder across the entire width of the area to be paved. For large areas, the emulsion should be applied through a pressurised spray bar and purpose built tack coat spray system or calibrated sprayer. A hand sprayer or lance may be used for small areas.

Heating of tack coat emulsions to a maximum of 60°C, prior to spraying, can improve the flow through the spray nozzles and help with the breaking of the emulsion. Heating is generally not necessary with diluted emulsions or application through pressure sprayers.

The emulsion tack coat must be allowed to break and be dry to the touch before applying asphalt. ‘Break’ is achieved when the water separates and leaves only the bitumen, and is generally distinguished by a change in colour from brown to black. Breaking time will depend mainly on the prevailing weather and existing surface conditions.

Breaking of the emulsion reduces the risk of pick-up of fresh tack coat binder onto the tyres of delivery vehicles and paving equipment. Pick-up must be avoided as it reduces the effectiveness of bond between old and new surfaces, particularly in critical wheelpath areas, as well as creating a nuisance by tracking on to nearby surfaces. Where pick-up is an issue, a light mist of water sprayed on the tyres of delivery vehicles may assist in reducing pick-up. Care should also be taken to ensure that tyres of delivery vehicles remain clean and uncontaminated by pick-up of material from unpaved shoulders, etc.

A special application of tack coating is the use of an asphalt paver with integrated emulsion application. This is particularly applicable to ultra-thin asphalt paving applications where a high binder application rate of modified bituminous emulsion is required. When applied in this manner, there is no contact of vehicle tyres with the tack coat and the asphalt may be applied directly to the unbroken emulsion. The heat of the asphalt causes rapid breaking and vaporisation of the water in the bituminous emulsion.

REFERENCES

Pavement work tips No 2: Storage & handling of bituminous emulsions.

AS 1160: Bituminous emulsions for construction and maintenance of pavements.

Technical Note 148

Asphalt Mix Design Registration January 2016

Transport and Main Roads Technical Note, January 2016

Copyright

http://creativecommons.org/licenses/by/3.0/au/

© State of Queensland (Department of Transport and Main Roads) 2016

Feedback: Please send your feedback regarding this document to: [email protected]

TN148 Asphalt Mix Design Registration

Technical Note, Transport and Main Roads, January 2016 1

1 Purpose and scope

This Technical Note has been prepared to assist Prequalified Asphalt Contractors (PAC) with

registering asphalt mix designs with the Department of Transport and Main Roads (TMR). However,

registration does not attest to the production, delivery, placement or compaction of the mix and does

not guarantee the handling properties or performance of the mix.

2 Registration intent

The intent of the asphalt mix design registration process is to ensure asphalt mixes are designed and

can be produced by a particular manufacturing plant to comply with the requirements of the relevant

asphalt specification. A mix design will be registered if the requirements of MRTS30 Asphalt

Pavements are satisfied, and the mix design submission contains all required details as described in

MRTS30 and this Technical Note. Registration of a mix design will result in the mix being listed on the

asphalt mix design register located on the TMR website http://www.tmr.qld.gov.au.

Where the PAC is unable to provide a demonstrated history of compliance with the requirements of

MRTS30 for a particular mix type, TMR reserves the right to undertake an audit of the asphalt plant

prior to registration of the asphalt mix design.

3 Submission of asphalt mix design

3.1 General

Asphalt mix design submissions shall contain all details in accordance with the requirements of

Clause 7.3.2 of MRTS30 Asphalt Pavements. Mix design submissions must be sent to the Asphalt Mix

Design Registrar at the following email address: [email protected].

3.2 Mix design submission spreadsheet

TMR has developed a mix design submission spreadsheet to assist PACs to demonstrate their mix

design complies with all of the requirements of MRTS30 Asphalt Pavements.

The PAC must complete the relevant sections of the asphalt mix design submission spreadsheet for

each mix design submission and attach all corresponding test reports and supporting documentation

pertaining to the submission. Failure to complete all relevant sections and attach all test reports will

lead to the mix design not being registered.

The mix design submission spreadsheet can be obtained from the TMR website.

3.3 Asphalt mix design certificate

3.3.1 General

The PAC must include in the asphalt mix design submission a mix design certificate, signed by the

PAC’s mix designer, certifying that the mix design complies with the requirements of MRTS30 Asphalt

Pavements.

The mix design certificate shall be based on the mix design certificate template found on the TMR

website and shall contain the following information:

a) PAC’s company name

b) plant location and identification number

c) mix design code



d) Technical Specification that the mix design complies with

e) description of all constituent materials, their sources, grade/class (for binder) and proportions

within the mix

f) target grading, binder content and maximum density as well as their job limits for the mix

design

g) method of compaction used to determine air voids in laboratory compacted specimens (i.e.

Marshall compaction (75 blows), Marshall compaction (50 blows), or Gyratory compaction),

and

h) specification requirements (if any) that the mix design does not comply with.

3.3.2 Mix design code

The mix design code is specific in its structure and shall be comprised of three distinct parts as

follows:

a) Part 1

i. Part 1 identifies the manufacturer and the type of asphalt using the abbreviations

designated in Appendix A e.g. "MAN : AC10M".

b) Part 2

i. Part 2 is a two digit number representing the year of the asphalt mix design registration

e.g. "15".

c) Part 3

i. Part 3 comprises a unique four digit number followed by the applicable binder type/s for

the mix design in brackets e.g. “1234(320,600,A5S)”. Each PAC has been allocated a

unique set of four digit numbers to use for their mix designs. These numbers are listed on

the Asphalt Mix Design Register.

ii. Part 3 may also contain additional components to further indicate specific elements of the

mix design (see Appendix A). Each additional component shall be presented in individual

brackets between the unique four digit number and the binder type/s. Refer to the

complete example below.

The mix design code is structured Part 1 / Part 2 / Part 3. For example, an AC10M mix design

submitted in 2015, with a unique four digit number of 1234 that contains Class 320 bitumen binder,

15% (max) RAP and a water-based warm mix asphalt additive would have the following mix design

code:

MAN: AC10M/15/1234(15R)(F)(320)

3.3.3 Material sources

The material source for all mix components must be noted on the mix design certificate. A specific

naming convention is employed to facilitate a consistent approach to identifying sources. The following

list provides details on how to identify sources for different mix components:

aggregate sources: the name utilised in the Quarry Registration System (QRS), for example -

Moy Pocket Quarry



crusher dust sources: the name utilised in the QRS. If the quarry has multiple rock types, the

rock source that shall be incorporated into the mix shall be placed in brackets, for example -

Narangba Quarry (Hornfels)

sand sources: the company or quarry name followed by location in brackets, for example -

Metalia Sands (Maryborough)

hydrated lime sources: the company name followed by location in brackets, for example -

Sibelco (Tamaree/Attunga)

binder sources: binder supplier followed by location in brackets, for example - BP (Pinkenba) /

SAMI (Port of Brisbane).

Multiple sources of hydrated lime may be listed on the mix design certificate provided the PAC submits

documented evidence demonstrating that:

Each source complies with the specification requirements.

Different filler source(s) will not affect the properties of the mix. Evidence would include

evaluating the differences between voids in dry compacted filler and apparent particle density

test results for the filler sources, and then assessing the effect of these differences on mix

properties.

The combined filler, for each listed hydrated lime source, complies with the voids in dry

compacted filler minimum specification requirement.

More than one binder grade/class may be listed on the mix design certificate for the following mix

types:

Medium duty dense graded asphalt

Heavy duty dense graded asphalt where gyratory compaction or Marshall compaction

(75 blows per face) is used to demonstrate conformance with Table 7.2.2 of MRTS30, and

Heavy duty dense graded asphalt where Marshall compaction (50 blows per face) is used to

demonstrate conformance with Table 7.2.2 of MRTS30, and conformance with Table 7.2.7 of

MRTS30 is demonstrated:

For each grade / class of binder, or

Where a harder (i.e. more deformation resistant) binder is proposed, deformation

resistance testing of the mix containing this binder is not required where a softer (i.e. less

deformation resistant) binder has already demonstrated the performance required of the

harder binder.

e.g. For an AC14H design with both C320 and A5S binder:

Testing of the mix with A5S binder is required where the final rut

depth of the mix with C320 binder is > 2.0 mm and ≤ 3.5 mm

Testing of the mix with A5S binder is not required where the final rut

depth of the mix with C320 binder is ≤ 2.0 mm.

Compliance of the mix design with the specified Marshall stability, stiffness and flow (Marshall

designed mixes only) and moisture sensitivity requirements with binder classes/grades not used for

the production trial will be demonstrated during the first production lot for the works.



Where a registered mix design is varied by the inclusion of a warm mix asphalt additive, registration of

the mix design (with the warm mix asphalt additive included) may be granted without the need for a

production trial provided the PAC can demonstrate a history of compliance with the requirements of

MRTS30 for the particular warm mix asphalt additive and mix type.

Where a PAC requests registration of a mix design for production from more than one plant, testing for

resilient modulus, deformation resistance, asphalt binder drain-off, asphalt particle loss, mix volume

ratio and Marshall stability, stiffness and flow (where applicable) only needs to be completed on mix

from one of the plants.

Registration of a mix design may also be granted for production from an additional plant (without the

need for a production trial at this plant) provided the PAC can demonstrate:

the plants are essentially identical in their configuration, and

there is a proven history of compliance with the requirements of MRTS30 for the particular mix

type at the additional plant’s current location.

3.4 Mix design submission and review timeframes

The PAC shall allow not less than 14 days for the mix design to be reviewed (provided the mix design

submission complies with the requirements of this Technical Note). If the initial mix design submission

is assessed by the Registrar as not complying with the requirements of this Technical Note and the

relevant technical specifications, the PAC will be advised and the mix design review period will

recommence on the date of resubmission by the PAC. For the above reason, it is recommended that

the mix design submission be received by the Asphalt Mix Design Registrar not less than 28 days

prior to the commencement of asphalt production.

4 Review of mix design submissions and registration

Prior to the end of the mix design review period, the Asphalt Mix Design Registrar will advise the

following parties in writing whether or not the mix design will be registered:

PAC, and

Administrator for the TMR project where the mix design will be used.

The mix design register is updated fortnightly to include newly registered asphalt mix designs.

An existing mix design, that holds current registration, can be revised at any time without the need for

a full mix design submission. Only the mix design certificate and test results relating to the design

revision need be included as part of the revised mix design submission.

Mix designs are registered for a period of two years from the date of initial submission. A full mix

design submission is required to renew the registration of an existing mix design.

Not more than one mix design may be registered for a specific plant, constituent materials, mix type,

nominal size, and binder grade/class combination at any one time.



Appendix A - Mix design code designations

The following tables contain descriptions of abbreviations to be used in a mix design code.

Table A1 - Mix design code designations

Mix Designation

Description

Part 1

AC#M1 Medium duty dense graded asphalt mix, as defined in MRTS30 Asphalt Pavements, ranging in nominal aggregate size from 7 mm to 20 mm.

AC#H1 Heavy duty dense graded asphalt mix, as defined in MRTS30 Asphalt Pavements, ranging in nominal aggregate size from 7 mm to 20 mm.

OG#1 Either 10 mm or 14 mm open graded asphalt mix, as defined in MRTS30 Asphalt Pavements.

SMA#1 Either 10 mm or 14 mm stone mastic asphalt mix, as defined in MRTS30 Asphalt Pavements.

Part 3

R Indicates the mix contains RAP. The percentage of RAP in the mix shall also be identified e.g. (15R) for 15% RAP.

W Indicates the mix contains a wax-based warm mix asphalt additive.

F Indicates the mix contains a water-based warm mix asphalt additive or is produced as warm mix asphalt using water-based binder foaming.

S Indicates the mix contains a surfactant-based warm mix asphalt additive.

A Indicates the mix contains a bitumen adhesion agent.

M1000 Indicates the mix contains M1000 Multigrade bitumen binder complying with AS 2008.

1 # is to be replaced by the relevant nominal aggregate size

Table A2 - Manufacturer abbreviations

Manufacturer Abbreviation

Allens Asphalt AL

Boral Resources (Qld) B

Brisbane City Council BCC

Downer EDI Works D

Fulton Hogan Industries FH

Hastings NQ H

Pioneer North Queensland PNQ

Rock’n’Road Bitumen R

Sunstate Asphalt SA

Trico Asphalt RPQ

Tropic Asphalts T



Appendix B - Mix design certificate example