DesignBuild Materials Testing and Acceptance Requirements for Asphalt Concrete

1
Design-Build Materials Testing and Acceptance
Requirements for Asphalt Concrete

• October 7, 2008
• William R. Bailey III, PE
• Assistant State Materials Engineer

2
Design-Build Materials Testing and Acceptance
Requirements for Asphalt Concrete

• Objectives
• Review Quality Assurance for Asphalt on
  Design-Build Projects
• Answer Frequently Asked Questions and point out
  unknowns
• Highlight major differences from traditional QA
  Asphalt Program
• Quality Assurance Manager for Design-Builder
• QA/QC plan
• Minimum QC and QA Testing for Design-Build
• Plant
• Field
• Minimum Field Inspection Requirements for
  Design-Build

3
Design-Build QA/QC Guide

• Minimum
• Quality Control Quality Assurance
• Requirements
• for
• Design-Build
• Public-Private Transportation Act
• Projects
• August 2007
• Website http//www.virginiadot.org/business/resou
  rces/ApprovedQA_QC_Guide4DB.pdf

4
Frequently Asked Questions on Design-Build

• Does Quality Control and Quality Assurance
  testing for Design-Build projects differ from
  tradition VDOT projects?
• Who will be responsible for the testing?
• What are the Plant and Lab testing requirements?
• What are the Field testing requirements?
• How will Design-Build affect Field testing and
  Inspection?
• What role will VDOT play?
• Will Design-Build require more certifications/test
  ing?

5
Quality Management Definitions

• QC Asphalt Contractors quality control testing
  performed at the plant or in the field to control
  the level of quality of the asphalt.
• QA A process performed independently of the
  asphalt contractor for the purpose of determining
  the conformance of the work by examining the QC
  data and/or providing objective evidence
  (independent sampling and testing), to verify the
  contractors quality control sampling and
  testing. (Design-Build Firms Quality Assurance
  Manager or QAM)

6
Quality Management Definitions

• VDOT Participation - Definitions for IA and IV
• IA Inspection performed by VDOT (or agent) to
  Independently evaluate all sampling and testing
  procedures used in acceptance decision/program to
  assure results are representative of asphalt.
  This may include split samples, calibration
  checks and/or observations.
• IV Inspection performed by VDOT (or agent) that
  serves as an oversight role for the Design-Build
  QA/QC Team. Owner Independent Verification is
  performed to satisfy VDOT and FHWA requirements
  for documenting that proper QA/QC is being
  performed on the Project and to provide adequate
  assurance that the public is receiving the
  desired quality during construction.

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Who Does What Traditional VDOT Projects

• Contractor Provides
• Plant Testing (Mix) QC testing
• Field Testing (Density) QC testing on a project
  basis
• Field Testing (Depth) none
• VDOT Provides
• Plant Testing (Mix) QA and IA testing on a
  system approach
• Field Testing (Density) QA and IA on a project
  basis
• Field Testing (Depth) QA on a project basis
• VDOT Road Bridge Specifications, Manual of
  Instructions and Virginia Test Methods
• Define acceptance
• Outline procedures
• Referee test methods

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Who Does What Design-Build Projects
9
Design-Build QA/QC Staff

• Quality Assurance Manager (QAM)
• Virginia PE
• 10 years experience in inspection or Materials
  Testing
• QA Testing Technicians Inspection Technicians
• VDOT Certified
• 3 years experience
• Report to QAM
• QC Technician
• VDOT Certified
• Report to Contractors production forces

10
Design-Build QA/QC Plan

• Requirements
• Organizational Structure
• Name, Duties and Responsibilities
• Minimum Inspection Requirements (Table 105-5)
• Minimum QC and QA Test Frequencies (Table 105-4)
• Procedure to meet Department Requirements for
  corrective action when QC or QA criteria are not
  met.
• Acceptance Criteria for testing and inspection
• Documentation on random sampling
• Referee test procedure
• Construction Inspection checklists

11
Design-Build Asphalt Plant Testing Lab
Requirements

• QC Testing Lab
• VDOT Inspected
• Technicians hold VDOT Certifications
• Mix Design Lab/QC Manager
• Plant School Lab Technicians
• QA Testing Lab
• VDOT Materials Lab
• AASHTO Accreditation Program
• Technicians hold VDOT Certifications in Mix
  Design Plant School

12
Design-Build Asphalt Plant QA/QC

• Asphalt Plant Testing Program
• unchanged
• VDOT will retain responsibility for testing and
  monitoring
• (Table 105-1 D-B Guide)

13
Design-Build Construction QA/QC

• Asphalt Field Testing Program
• under control of
• Design-Build QA/QC Plan
• and Minimum Design-Build Requirements
• (Table 105-4 D-B Guide)

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QA Field Program Comparisons
15
Normal Density Testing VDOT Verification with
Cores
16
Normal Density Testing VDOT Verification with
Cores
NR Nuclear Reading
17
Design-Build Density Testing VDOT Verification
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Design-Build Density Testing VDOT Verification
NR Nuclear Reading
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Design-Build QA/QC Plan

• QA/QC Plan should define
• Control over the plugs from control strip (VDOT
  MOI)
• Checks to insure random sampling and testing by
  QC QA
• Checks on test equipment and procedures (VDOT IA)
  
• Criteria for QA staff on Acceptance
• Written instructions on what are passing QA/QC
  results (VDOT MOI)
• Referee procedure
• Written procedure when QC results fail
• Written procedure when QA results fail

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Design-Build QA/QC Plan

• Potential Referee Procedure
• What will happen when a QC test fails to meet
  specification?
• VDOT Specification Section 315.05 on QC tests
  used as acceptance two failing Nuclear test on
  successive sub lots a new roller pattern and
  control strip.
• This will have to be detailed in QA/QC Plan
• What will happen when QA Core Fails to meet
  Specification?
• VDOT Manual of Instructions Chapter V
• Take two more cores average all three test
  results and compare to specification?
• Corrective action?
• This will have to be detailed in QA/QC Plan

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SMA Density Depth
22
SMA Density Depth
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Design-Build Construction Inspection QA/QC

• Asphalt Field Inspection Program
• under control of
• Design-Build QA/QC Plan
• and Minimum D-B Inspection Requirements
• (Table 105-5 D-B Guide)

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Design-Build Minimum Field Inspection, Sampling
and Testing (Table 105-5)
25
Design-Build Materials Testing and Acceptance
Requirements for Asphalt Concrete

• In Summary
• Quality Assurance for Asphalt on Design-Build
  projects is very similar to tradition VDOT
  projects
• Major difference is that the Design-Build Quality
  Assurance Manager will assume VDOT traditional
  role
• VDOT retains oversight
• Asphalt Plant and Lab testing requirements are
  identical
• Asphalt Field QC testing and inspection are the
  same
• Asphalt Field QA testing is slightly different
• Design-Build Projects will not require more
  certifications or testing for contractors by VDOT
• Design-Build projects are increasing

26
Design-Build Materials Testing and Acceptance
Requirements for Asphalt Concrete

• October 7, 2008
• William R. Bailey III
• Assistant State Materials Engineer