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BITUMEN DESIGN MIX

METHOD STATEMENT FOR BITUMEN DESIGN MIX

Rev. No.

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BITUMEN DESIGN MIX

1.

OBJECTIVE The objective of this method statement is to define bitumen design mix inspection process at all Projects of the company.

2.

SCOPE This method statement shall be used for the Bitumen Design Mix activity under the scope of project specifications.

3.

REFERENCES The following documents are considered as reference documents: Applicable codes and standards Project specifications Project Quality Plan Quality Inspection Plan

4.

ABBREVIATIONS/DEFINATIONS SM QIP I/C QA&QC SOP PSI HSE BA FRM MS Site Manager Quality Inspection Plan Incharge Quality Assurance and Quality Control Standard Operating Procedure Project Specific Items Health, Safety & Environment Business Area Form Method statement

5.

RESPONSIBILITIES Area Incharge will ensure that the bitumen design mix activities are conducted according to this method statement, latest project drawings & specifications. QA&QC inspector will assure that all the relevant work is carried out in conformance with project specification, PQP and QIP. In case of any nonconformance, it will be controlled by corrective action request (CAR).

6.

PROCEDURE 6.1 Instructions to Supplier The Supplier shall develop a Quality inspection plan for the purpose of design and control of the bituminous mixtures in accordance with specifications and shall get it approved by the QA&QC.

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6.2

Production The bituminous mixture shall be composed of mineral aggregates and bituminous material. The Contractor shall develop a Job Mix Formula (JMF) to comply with the specified composition limits and mix design criteria and submit to the Laboratory for approval prior to the start of production. During production of the mixture, QA&QC method statement shall be used adequately to furnish assurance to the QA&QC engineer that the mixture delivered to the paving site is in reasonable conformance with the project specification. Control of the mixture shall be based upon the composition of samples taken and analyzed by the Supplier in accordance with the approved Quality inspection plan.

6.3

Composition Prior to producing bituminous mixtures, the Supplier shall submit a proposed Job Mix Formula (JMF) for each combination of aggregates in writing to the Laboratory. The optimum percentage of bituminous material selected for each JMF shall be based on the results of the specified tests evaluated, insofar as practicable, as recommended. A mix design with at least four points is required, including a minimum of two points above and two points below the optimum. For each Job Mix Formula (JMF) submitted, the Contractor shall include certified test data to demonstrate that mixtures conforming to the proposed JMF will have properties as specified.

6.4

Job Mix Formula (JMF) Field adjustment. The Contractor determines from the results of his quality control tests that adjustments are necessary to the mix design to achieve the specified properties in place, he may adjust the JMF gradation within limits without a redesign of the mixtures as hereinafter provided.

6.5

Monitoring Testing and reviewing periodically the Contractor's Quality Inspection plan for compliance with project specifications. The QA&QC inspector at any time can stop the production based on their review. This notification to the Supplier to stop production shall be made in writing.

6.6

Asphalt Mix Design Two separate mix design procedures will be used to estimate the "design" asphalt content. These approaches are: 6.6.1 Marshall Mix Design

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6.6.1.1 Selection of Design Asphalt Content In order to determine the optimum asphalt content, three levels of asphalt content (4, 5 and 6%) will be used for each mix. At each asphalt content, three replicates will be prepared and the average of the three is then used `to develop the typical Marshall Test result plots. The final "Marshall Design" asphalt contents and appropriate volumetric/stability results (at the design asphalt content) are shown [here]: 6.6.1.2 Marshall Design Summary The table indicates that the design binder content, for each of the two virgin mixtures, is increased by 0.5% binder when 2.0% Elvaloy polymer is added. The Marshall Stability results also show that a slight improvement in stability occurs as the Elvaloy percentage is increased. Another Marshall parameter of interest is the Stability/Flow ratio (sometimes referred to as the Marshall Quotient). This parameter is thought to be an empirical indicator of the mix stiffness. As noted in the table, the Marshall Quotient appears to slightly decrease with increased percentage of the Elvaloy polymer. The slight decrease of the ratio values with the modified asphalts is the result of the increase in the flow values for these mixtures. 6.6.2 SUPERPAVE Gyrator Level I Mix Design This approach requires specimen compaction with a gyratory compactor in accordance with SHRP Standard Method of Test M-002.The compactor provides a consolidation pressure of 0.60 MPa with an angle of gyration of 1.25 degrees and speed of gyration of 30 rpm. The gyratory device continuously monitors the increase in specimen density (expressed as a percent of its theoretical maximum specific gravity). For all mixes, specimens were compacted in a 100-mm diameter mold for up to 200 gyrations. Similar to the Marshall test, three levels of asphalt content, each with two replicate samples were used for each mixture evaluated. The "design" asphalt content was based on number of gyration criteria specified by the SUPERPAVE Level I procedure. A design gyration number of 96 were used, along with a 4% air void criterion to select the design asphalt content. This gyration number corresponds to an average design air temperature between 37-38 degrees C and traffic level of less then 10 million ESAL, in order to be as comparable as possible to the Marshall 75 blow compactive effort. Based upon the procedure previously presented, the "design" asphalt contents were found to be:

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6.6.2.1 Selection of Final Design Asphalt Contents The following table is a summary of the "design" asphalt contents determined for each of the six mixtures evaluated, by both the Marshall and SUPERPAVE Level I approaches. Also shown in this table, are the final recommended design asphalt contents, for each mix, that were subsequently used to prepare all remaining specimens to be evaluated for the: dynamic (complex) modulus; static creep testing and repeated load permanent deformation tests. 6.6.2.2 Summary of Design Asphalt Contents

It is quite obvious from the results shown that little, if any, correlation is noted between "design" asphalt contents found by the Marshall and Gyratory Level I results. For the Sample No. 1 mixtures, the two Elvaloy modified mixtures yielded lower gyratory based design asphalt contents compared to the Marshall design. However, the opposite trend was found for the polymer-modified mixtures used in Sample No. 2. Because the SUPERPAVE Level I approach to mix design is a recent technical innovation, there is a paucity of historic data in the literature to either agree or disagree with the differences in asphalt content found from each "mix design procedure."

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As a result, the principal author developed the final recommended values for the design based upon an evaluation of well established volumetric mix principles relating to air voids; voids in the mineral aggregate and voids filled with bitumen. As can be observed, these "final" values are generally "compromises" between the Marshall and Gyratory approaches. With each study mix, asphalt Content increments of 0.2% were used for each level of Elvaloy percentage compared to the virgin (0% Elvaloy) mixture. 6.7 Calculations 6.7.1 Laboratory Mixed Specimen The actual asphalt binder content of a laboratory mixed specimen is determined as follows: Wb = (Pb W s)/(100-Pb) Where Wb = Weight (mass) of asphalt binder in specimen, grams. Pb = Actual percent of asphalt binder in specimen. Ws = Weight (mass) of aggregate in specimen, gram. 6.7.2 Quality Control program. The contractor is bound to follow a Quality Inspection Plan to assure the asphalt concrete mix delivered to the paving site meets the specification requirements. The Quality Inspection Plan is to be updated and submitted, in case of any change or revision The Quality Inspection Plan shall, as a minimum: Specify the assignment of quality control and HSE responsibilities. Include provisions to meet the project specifications Establish detailed procedures for Inspection, testing and corrective actions. Include copies of all worksheets and test reports Maintaining, record keeping, calibration, testing of equipment and maintenance as per procedures.

6.8

Testing Facilities

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The Contractors quality control personnel to perform tests in accordance with the requirements of the specifications shall provide suitable space and testing equipment at the plant site for use 6.9 Inspection Guide lines The Quality Inspection Plan shall include the performance of regularly scheduled inspection procedures to assure that: Mixing plant at all times shall conform to the specification requirements. Only approved materials are used and that their specified characteristics are not altered by improper storage or handling. The materials are prepared, proportioned, and mixed so as to produce a mixture conforming to specification requirements. The mixture is reasonably uniform in composition and temperature. Each load is delivered to the paving site essentially as produced with a minimum heat loss and without becoming contaminated. Except for the testing and reporting specifically required herein, the nature and the extent of the inspection and the Contractor shall determine procedures performed in these areas.

6.10

Required Quality Control Tests. The Contractor shall perform quality control tests to control the asphalt concrete mix within the specifications. These quality control tests shall measure the bitumen content, gradation, air voids, and Maximum Specific Gravity (MSG) in accordance with the Contractor's approved Quality Control Program. Each quality control test shall be performed a minimum of one time each half of a production day or night.

6.11

Joints For surface courses, all transverse construction joints shall be formed or cut to a vertical face and coated in accordance to relevant project specifications.

7.

TOOLS AND EQUIPMENT Tools and Equipment will be applied as per applicable standard requirements of project specifications and as per scope of work.

8.

HSE INSTRUCTIONS Bitumen Design Mix process shall be performed in accordance with relevant project HSE instructions & HSE policy of DESCON at all temporary and permanent site.

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Material or equipment should be maintained in an orderly manner and labeled in accordance with statutory requirements and use in safe manner. Any liquid fuel spills and accidental waste disposal should be avoided and properly cleaned up. All materials safety data sheet (MSDS) will be available at job site. Material safety data sheets will be explained to workers & requirements of the sheet will be complied with.

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