IN ASPHALT PAVEMENT CONSTRUCTION GILBERT O. CAGA-ANAN OIC- Section Chief Materials Testing Section QUALITY ASSURANCE AND HYDROLOGY DIVISION
Prepared and Edited by:
MARK JOEMAR L. CALMA TABLE OF CONTENTS Introduction Asphalt Mix Production Control Asphalt Pavement Construction
Sampling, Testing and Acceptance
Foundation and Drainage Control
Conclusion “QUALITY MEANS DOING IT RIGHT WHEN NO ONE IS LOOKING” INTRODUCTION Quality Control refers to the processes and procedures that are involved to ensure that all materials and completed projects meet high standards and criteria that are put in place during the planning stages of the process. QUALITY CONTROL
The sum total of activities It is always the Contractor’s Focuses on the process of performed by the seller to responsibility. batching, placing, and make sure that a product finishing the pavement to be meets contract specification sure that the pavement will requirements.” (AASHTO 1996) meet or exceed QA test criteria DPWH’S QC POLICIES & GUIDELINES DPWH Standard Specifications for Highways, Bridges, and Airports (Volume II) Sampling and Testing of Construction of Materials (D.O. No. 13, s. 1987) Testing of construction materials be conducted prior to their incorporation into the works (D.O. No. 213, s. 2004) Accreditation of Private Testing Laboratories (D.O. 22, s. 2018) DPWH’S QC POLICIES & GUIDELINES Accreditation of Contractors’/Consultants’ Materials Engineers (D.O. 98, s. 2016) Accreditation of Contractors’/Consultants’ Project Engineers (D.O. 10, s. 2019) Accreditation of Asphalt and Portland Cement Concrete Batching Plants (D.O. 253, s. 2003) QUALITY ASPHALT PAVEMENT Good Design Good Quality of Materials Good Construction Control or Workmanship Good Foundation Good Drainage ASPHALT MIX PRODUCTION CONTROL Asphalt Mixture Plant is an assembly of mechanical and electronic equipment where aggregates, recycled materials, or other additives are blended, heated, dried, and mixed with a binder to produce an asphalt mixture meeting specified requirements. TYPICAL BATCH PLANT TYPICAL DRUM PLANT PARTS AND MECHANISMS STOCK PILE Aggregate stockpiles (fine and coarse aggregates) shall be properly spaced and stored according to sizes
Aggregates shall be clean and free from laitance
COLD BINS Cold bins shall be properly spaced and stored according to size to prevent contamination and mixing of different aggregate sizes
Also, it is used to proportion the material to the plant
COLD CONVEYORS Cold conveyor belt and roller shall be clean and operational with no damage
It is equipped with two devices to determine the
amount of aggregate being delivered to the plant DRYER The dryer consists of a revolving cylinder, a large burner, and a fan
The drying chamber shall be equipped with a
temperature gauge to ensure that the drying temperature is monitored from time to time DUST COLLECTOR A primary dust collector can either be a wet scrubber system or a baghouse secondary collector can be used
The emissions shall be regularly tested
BITUMEN TANKS The bitumen tank shall be air-tight and properly maintained
Also, it shall be equipped with a temperature gauge
to ensure the bitumen is flowing HOT ELEVATOR The hot elevator carries the aggregate from the dryer to a screening unit
It shall be equipped with scrapers to prevent
carryover (belt drippings) VIBRATING SCREEN The vibrating screen shall be equipped with motors that shake a set of screens, sorted the heated aggregates by size, and deposit them into a new set of aggregate bins
Screens shall be capable, clean and not worn-out
WEIGHING AND MIXING SYSTEM Hot Bins - Temperature control is best when production is steady , Material is not allowed to stay in the hot bins too long Weigh Box and Asphalt Weigh Bucket - Scales shall be clean and calibrated, Weigh box gates should not leak when closed Pugmill - Mix time should be the minimum, Clearance between paddle tips and pugmill is gen. 3/8” to 5/8” LOADING OF HMA The mix is then discharged into trucks either directly or after storage in a “surge silo”
Shall have minimum clearance between the hopper
of batching and truck
Trucks shall be drained and equipped with tarpaulins
or covers CONTROL ROOM The plant shall have a fully air conditioned control room, well-maintained, wellequipped and conducive Weigh Batcher Control – manual, semi-automatic or automatic; with an operating panel and readable digital indicators
The aggregates and asphalt feed been and scales
shall be calibrated QC LABORATORY Minimum testing equipment are - Marshall Stability Apparatus with flow test, Centrifuge Extraction Machine, Thermostatically controlled oven, Set of sieves, Thermometer, Balances, Set of molds, Caliper, Hot plate, and As required in Item 8.1.3 of DO 253 s. 2003 OTHERS TO BE CONSIDERED: The asphalt batching plant is accredited by DPWHBRS (DO 253, s. 2002) Legally identifiable (Business License, DTI or SEC Registration, Quality Manual) All records are complete and up-to-date Shall have product design and process control OTHERS TO BE CONSIDERED: The plant shall have a program of calibration of all measuring and testing equipment/apparatus (Section 8.5 of DO 253, s. 2002) Proper maintenance and repair program for all equipment/ machineries (Section 8.3 of DO 253, s. 2002) OTHERS TO BE CONSIDERED: Availability of trucks, asphalt paver, pneumatic roller, tandem roller, and/or payloader QUALITY CONTROL IN ASPHALT MIXING PLANTS • Periodic checking of weighing scale and volume controls • Constant checking of the gradation of aggregates and proportion of asphalt to aggregate: QUALITY CONTROL IN ASPHALT MIXING PLANTS • Constant checking of the gradation of aggregates and proportion of asphalt to aggregate: QUALITY CONTROL IN ASPHALT MIXING PLANTS • Constant checking of stability and compressive strength of the asphalt mix as often as possible:
• During measurement, aggregate should be handled in a manner as to obtain the
desired grading and all materials should be weighed to the tolerances required. QUALITY CONTROL TESTS FOR ASPHALT MIX ASPHALT PAVEMENT CONSTRUCTION REQUIREMENTS • Weather Limitations Bituminous plant mix shall not be placed on any wet surface or when weather conditions would prevent the proper handling or finishing of the bituminous mixtures. CONDITIONING OF EXISTING SURFACE THANK YOU DPWH - QAHD / RO-IX
