Warm Mix Asphalt Technologies

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John DAngelo, Michael Rafalowski, and Matthew
Corrigan
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Overview

• Background
• Where we have been
• Where we are now
• Current Resources
• Where we are going
• Short term
• Long term

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Background

• Why is Quality Assurance Important?
• Approximately 50 of construction costs are
  spent on the PURCHASE of materials.

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Quality Assurance Costs are Small However, they
Critically Impact the Overall Quality of the
Whole Project
Quality Assurance Costs
Project Costs
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Background

• Acceptance procedures
• Once material is in place it stays in place
• Only industry paying for marginally acceptable
  material

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Where We Have Been

• Method type specs
• 1950-1960s AASHO Test Road
• Recognition of Material variability
• 1960s Blatnik Investigations
• Federal regulation on sampling and testing
• Final record samples
• Process record samples
• Acceptance testing

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Where We Have Been

• 1970s Experimentation with QA specifications
• 1980s Implementation of QA specifications
• 1990s Use of contractor test results for
  acceptance

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Where We Are Now

• Quality Assurance Specifications
• Percent Within Limits Specifications
• Design Build
• Short Term Warranty/Guarantee

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Where We Are Now

• POLICY (23CFR 637.205(a)) Each SHA shall
  develop a quality assurance program The
  program must meet the criteria in 637.207 and be
  approved by the FHWA.

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Quality Assurance Program

• Acceptance Program
• States Verification Testing
• Inspection
• May use Contractor test results
• Dispute resolution
• Qualified Technicians
• Accredited / Qualified Labs
• Independent Assurance Program
• Materials Certification

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Where We Are Now

• Not enough State Verification Testing
• Not enough State personnel
• Reluctance to spend money on construction
  engineering not even for consultants
• Ineffective validation procedures
• Increasing volume of projects/workload

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Resources
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Resources

• Questions and Answers on the Quality Assurance
  Regulation (23 CFR 637)
• Revisions completed
• Will be posted on Web

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Resources
TECHNICAL ADVISORY T 6120.3Use of Contractor
Test Results in the Acceptance Decision,
Recommended Quality Measures, and Identification
of Contractor/Department Risks
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Resources

• FHWA-RD-02-095 Optimal Procedures for Quality
  Assurance Specifications
• FHWA-HRT-04-046 Evaluation of Procedures for
  Quality Assurance Specifications
• (Burati, Weed, Hughes, Hill)

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Resources

• NHI Course 134042 Materials Control and
  Acceptance - Quality Assurance
• FHWA Basic PWL Workshop
• SPECRISK software (mid 2007)
• NHI Course 134059 Quality Assurance
  Specification Development and Validation Course
  (end 2008)
• 2003-2005 Summary Report
• www.fhwa.dot.gov/pavement/materials/stewardreview2
  006.cfm

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Highway Materials Engineering Course - 131023
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National Review On Materials Quality Assurance

• Result of FHWA Risk Assessment Survey
• Sponsored by Office of Professional and Corporate
  Development and Office of Infrastructure
• Scope FHWA Division office review, approval and
  monitoring activities
• Locations Utah, Texas, Pennsylvania, Alabama,
  District of Columbia, Wyoming, and Illinois

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Where We Are Going Short Term

• Reduce Risks
• Lots not restricted to a single day
• More State Verification Testing as compared to
  Contractor Testing
• Statistically Proper Validation Procedures
• PWL Basics
• SPECRISK and PWL-Pay Programs
• Specification Development Course

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Evolution
QA Specs
Performance Specs
Design Build Warrant Maintain
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Where We Are Going Long Term

• Domestic Scan of other industries
• Move toward Quality Management Systems by all
  contractors and suppliers
• Beyond ISO 9000 sector specific requirement
• Aerospace AS9100
• Automotive ISO/TS16949
• Quality Based Selection and Procurement
• Design Build Warrant Maintain

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Design Build Warrant Maintain - The Final QA?

• Long Term Warranty
• Performance based contract
• Guarantees product integrity
• Contractor responsible for repair of defects or
  replacement
• Warranty Period
• Pre specified for repair defects

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and beyond!

• Cannot continue on same path of regulate and
  enforce
• Cannot continue to police contractors trying to
  catch them in the act
• System needed to match contractors priorities
  in-line with agencys
• Quality and long term performance