Materials Procedure 96-02 M

NEW YORK STATE DEPARTMENT OF TRANSPORTATIONMATERIALS BUREAU ALBANY, NY 12232-0861

MATERIALS PROCEDURE

Materials Procedure No.: NY 96-02

Issue Date: May 1, 2003Subject Code: 7.42-2

SUBJECT: QUALITY CONTROL AND QUALITY ASSURANCE PROCEDURES FOR HOT MIXASPHALT (HMA) PRODUCTION

APPROVED: /s/ Robert L. SackSupersedes: MP 96-02 M; MP 94-04 MDated: June 1, 2000

Robert L. Sack, Director, Technical Services Division

PAGEI. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

II. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A. Quality Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1. Control Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32. Quality Control Technician . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

B. Quality Assurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31. Quality Assurance Technician . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42. Independent Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

C. Production Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41. Plant Lot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42. Plant Sublot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43. Certified Lot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44. Mixture Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55. Night Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56. Highway Permit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57. Rounding Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58. Random Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59. Quality Control Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

a. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7b. Resample of HMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7c. Retest of HMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7d. Untested Sublot Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

10. Quality Assurance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811. Retesting Out-Of-Tolerance Split Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1012. Retaining Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

D. Mixture Quality Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101. Aggregate Gradation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102. Air Voids - Volumetric Design Mixes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103. Determination of PG Binder Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104. Mixture Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115. Moisture Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

a. Aggregate Moisture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11b. Mix Moisture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6. PG Binder Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117. Friction Aggregate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118. Recycle Mixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

E. Air Void and Gradation Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

NYSDOTMP: 96-02Date: May 1, 2003

F. Sampling and Testing Disputes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12G. Plant Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1. Automation and Recordation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122. Production of HMA in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123. Determination of HMA Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124. Failure of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

a. Printer Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13b. Gyratory Compactor Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

H. Plant Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

III. QUALITY ADJUSTMENT FACTORS (QAF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14A. Volumetric Mixes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14B Non-Volumetric Mixes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15C. Certified Lots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16D. Unavailable Resample Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

QAF Example No. 1, Form BR 324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17QAF Example No. 2, Form BR 343a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18QAF Example No. 3, Form BR 307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

IV. DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20A. QC/QA Process Control Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20B. Delivery Ticket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20C. Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

V. TABLESTable 1, Allowable Specimen Tolerance Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Table 2, Allowable Split Sample Testing Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Table 3, QC/QA Sampling and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Table 4, Delivery Ticket Mix Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Table 5, Air Voids In Plant Mixture (Volumetric Designs) . . . . . . . . . . . . . . . . . . . . . . . . . 22Table 6, Percent Passing (Non-Volumetric Designs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Appendix A, Random Numbers for Sampling HMA Mixtures at The Plant . . . . . . . . . . . . 25Appendix B, File Copy of Forms for QC/QA Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31


of 45MP96-02 (May-03).wpd

I. SCOPE

This procedure describes routine Quality Control and Quality Assurance activities performed during the productionof Hot Mix Asphalt (HMA) as outlined in NYSDOT Standard Specification Section 401, Plant Production.

II. GENERAL

A. Quality Control.

Quality Control (QC) is defined as all activities required to produce Hot Mix Asphalt (HMA) that meets allspecification requirements. The Producer will incorporate a Quality Control system for all plant production ofHMA and assume responsibilities for all QC activities at the production facilities. All QC activities are theresponsibility of the Quality Control Technician (QCT). The State has the right to monitor any QC sampling andtesting and test any production material or retained samples for specification conformance.

1. Control Plan. The Producer will provide a Control Plan to the Regional Materials Engineer (RME) thatoutlines all phases of HMA production. The Control Plan will serve as an official agreement with the RME andit will outline all QC activities performed to ensure the HMA production is in compliance with the specificationrequirements. The Control Plan will list all personnel associated with HMA production, including the names andtheir functions necessary to implement the QC program. The Control Plan will also include the Control PlanAdministrator, a designated assistant, QC personnel, and phone numbers. The Control Plan Guidelines areavailable from the RME. The control plan will be submitted to the RME for initial approval at least 15 workingdays prior to HMA production for the State. After the control plan has been assigned initial approval, theProducer will submit a statement outlining the control plan status to the RME each subsequent year at least15 working days prior to any HMA production. Also, the Producer will submit amendments to the control planor personnel changes for approval annually prior to production and as changes occur during the constructionseason. The Producer will assume the responsibility of administering the approved Control Plan. The Statereserves the right to stop production in the event the Control Plan, or any part thereof, is not being followed.

A separate Control Plan is required for each production facility site. However when more than one plant islocated at a production facility site, only one Control Plan is required.

2. Quality Control Technician. The QCT must possess a current New York Construction MaterialsAssociation Certification or its equivalent, as determined by the Director, Materials Bureau. The productionfacility must have a sufficient number of QCTs to perform QC sampling and testing, but at least one certifiedQCT at each production facility site. Non-certified technicians may be utilized to supplement a certified QCT.HMA production will not be accepted unless a certified QCT is present during production. However, a certifiedQCT is not required to be present for HMA production of 150 Mg or less, if approved by the RME. Techniciansassociated with private testing organizations must meet the requirements specified above.

The State reserves the right to stop plant production in the event unacceptable technician performance is noted.The RME or representative will immediately inform the plan administrator of the reasons for stopping productionoperations. The State may require the Producer to replace unacceptable technicians before HMA production isallowed to continue.

B. Quality Assurance.

Quality Assurance (QA) is defined as all activities performed by the State to assure that HMA production meetsthe specification requirements. QA must be performed on a random basis at frequencies necessary to assure thatHMA production is in conformance with these requirements. The frequency of QA testing is listed in Table 3,Quality Control/Quality Assurance Sampling and Testing. The frequency refers to split sample testing. QA



frequencies and/or activities can be modified as necessary by the Regional Materials Engineer (RME). The RMEwill review the Control Plan to assure the plan includes all the necessary information as required by the ControlPlan Guidelines.

1. Quality Assurance Technician. The Quality Assurance Technician (QAT) must possess a current NewYork Construction Materials Association Certification or its equivalent. All State QA activities are theresponsibility of the QAT. However, non-certified technicians may be utilized to supplement certified QATs.The QAT, under the direction of the RME, is responsible for routinely monitoring and verifying HMA qualitycontrol sampling and testing procedures. Also, the QAT is responsible for routinely monitoring the productionprocess and determining if the Control Plan is being followed as submitted.

The QAT is responsible for calculating the final Quality Adjustment Factor (QAF) for each mix design produced.Table 5, Air Voids in Plant Mixture, is used to calculate the QAF for volumetric design mixes while Table 6,Percent Passing, is used to calculate the QAF for non-volumetric design mixes. The final QAF is used to calculatethe quality payment adjustment for each day’s production at the project site.

2. Independent Sampling. Table 3, Quality Control/Quality Assurance Sampling and Testing, showsfrequencies the QAT is supposed to perform as a quality assurance test on the HMA mixture. The assurance testsare generally performed on the split samples where a portion of the sample is tested by the QCT and the otherportion by the QAT. However, the QAT will test at least one independent sample per production week. The QATwill request the QCT take this sample. The QCT will take two independent samples, one for the QAT and theother for the QCT. In order to compare the test results, these sample must be taken at the same location and time.The results between the QC sample and the QA sample must be within the allowable tolerances in Table 2,Allowable Split Sample Testing Tolerances, of this procedure.

C. Production Controls.

1. Plant Lot. A plant lot is defined as the quantity, in metric tons (Mg), of HMA produced per plant for eachmix design in one day, whether daytime or nighttime production. If a plant is producing continuously for acalendar day or more, the plant lot will be defined when the plant’s employee shift change occurs. The Producermust notify the RME when continuous production is anticipated at least one day prior to any production of thistype. When different mix designs are produced on the same day, then each mix design represents a separate plantlot. For each mix design produced, the QCT will assign plant lots numbered consecutively throughout theproduction season starting with the number one at the beginning of each calendar year’s production and increasethe lot number by one for each day’s production.

2. Plant Sublot. A Plant lot is subdivided into sublots. A sublot is defined as a portion of a plant lot not toexceed 1250 Mg. When production exceeds 1250 Mg and the excess is not greater than 150 Mg, the excess willbe incorporated into the previous sublot. The sublots are assigned a consecutive letter (A-E) on a daily basis.

3. Certified Lot. HMA production can be certified without the required QC testing for plant lot quantities of150 Mg or less. All certified production must meet the requirements outlined in this specification. The QCT willcheck and initial the batch tickets to ensure compliance with all batching requirements prior to certifying theproduction, i.e., produced in automatic mode, no double out-of-tolerance, etc. Friction aggregate samples mustbe obtained as outlined in MM 28 for all certified production placed in pavement surface courses requiringfriction aggregate. BR 307, Quality Control HMA Certification must be transmitted to the Project Engineer ona daily basis for the quantity of certified production. Certified plant lots have a QAF of 1.00.



4. Mixture Storage. When volumetric mixtures are stored prior to delivery, the stored quantity will beincorporated into the plant lot associated with the date of delivery. If there is no production to incorporate into,consider the stored quantity a new plant lot. When non-volumetric mixtures are stored prior to delivery, the storedquantity will be incorporated into the plant lot associated with the date of production. The lot number and dailyQAF determined during production will be associated with the stored quantity.

5. Night Production. A plant lot during night production is similar to the one defined above under “PlantLot” in this subsection.

6. Highway Permit Production. HMA production supplied to highway permit projects will meet allrequirements outlined in Section 401 of the Standard Specification. However, quality payment adjustments arenot applicable. All HMA production placed is subject to rejection as outlined in §401-2 Materials, of the StandardSpecifications.

7. Rounding Test Results. For reporting the results, use the following rules for rounding off for allcalculations:

a. When the digit to be dropped (1 digit beyond the significant digit) is less than 5, the preceding digit willnot change.

b. When the digit to be dropped (1 digit beyond the significant digit) is 5 or greater, the preceding digit willbe increased by 1.

8. Random Sampling. Random Sampling is a technique used for determining where the HMA sample willbe obtained within a sublot. For each mix design produced, the plant lots are numbered consecutively throughoutthe production season starting with the number "1" at the beginning of each calendar year’s production andincrease the lot number by one for each day’s production. Sublots are assigned a consecutive letter (A-E) andbeginning with "A" for each production day. The QCT will determine plant lots and sublots as describedpreviously for each day per mix design and generate these sample points based on the anticipated dailyproduction. Random sample points must be determined prior to the start of production. To generate a randomsample point, a random number is selected for each plant lot and sublot designation of numbers and lettersrespectively using tables in Appendix A of this procedure.

The selected random number is multiplied by the sublot quantity. The resultant quantity will be the sample pointwhere the random sample is taken within the sublot. Once a row number is used for a plant lot, it will not be usedagain for that production season.

When a random sample point falls outside the testable portion of a lot, the QCT will select another random samplepoint using the alternate random numbers. The alternate random numbers will be used starting with Column 1and following consecutive order until a sample point within the testable portion of the lot is determined. The lotnumber and sublot letter will be documented on the BR 331, Production Summary Sheet, and the BR 303, QualityControl Daily Diary.

The QCT will take randomly selected samples at a location such that samples will represent the mixture qualitybeing produced. The QCT will take a large enough sample of the mixture so that split testing can be performed.The QCT will test one portion of the split sample and the QAT may test the other portion. Only the results ofsamples taken at the sampling points will be used to determine QAFs, unless the production was either re-sampledor retested as described in this procedure and in the specification. The random sampling point is allowed to berecalculated to accommodate changes in the anticipated production.



Examples of Random Sample Point Calculations

The following example illustrates how to determine the sample points for a Plant Lot #2 where the estimatedproduction is 2950 Mg.

a. Determine the number of sublots to be tested.

2950 ÷ 1250 = 3 sublots

b. Determine the tonnage for each sublot.

Sublot A = 1250 MgSublot B = 1250 MgSublot C = 450 Mg

c. Determine the sample point for each sublot.

Sublot A: Sample Point = Random Number x 1250Random Number for Lot # 2, Sublot A is 0.049 (use 0.888 from Alt. 1 column)Sample Point = 0.888 x 1250 Sample Point = 1110

A sample point for sublot A is at 1110 Mg

Sublot B: Sample Point = Random Number x 1250Random Number for Lot # 2, Sublot B is 0.932Sample Point = 0.932 x 1250 Sample Point = 1165

A sample point for sublot B is at 1165 Mg

Sublot C: Sample Point = Random Number x 450Random Number for Lot # 2, Sublot C is 0.167Sample Point = 0.167 x 450Sample Point = 75

A sample point for sublot C is at 75 Mg

d. Determine the sample points for the plant lot production.

Sublot A: Sample Point = 1110 MgSublot B: Sample Point = 1250 + 1165 = 2415 MgSublot C: Sample Point = 2500 + 75 = 2575 Mg

*Note: If a Random number corresponding to the first and the last sublot designation results in asample point within the non-testable quantity, i.e., the first or the last 150 Mg portion of thelot, use Random numbers corresponding to Alternate Columns 1 thru 5 such that theresultant sample point is within the testable portion of the lot.

9. Quality Control Testing. Quality Control testing must be performed by a Quality Control Technician(QCT). QC testing frequencies and the test methods are outlined in Table 3, Quality Control/Quality AssuranceSampling and Testing. Quality Control testing is not required on the first or last 150 Mg portion of a lot. Thistesting exclusion, however, does not apply for lots greater than 150 but less than 300 Mg, retest samples, or anysample obtained when production is terminated before the anticipated production for that plant lot. When a plant



lot is greater than 150 but less than 300 Mg, a sample will be taken from the portion greater than 150 Mg. Ifdesired, the QCT may elect to test any production less than 150 Mg. However, this option must be documentedin the Control Plans that this option of testing quantities less than 150 Mg is selected and such testing will beperformed for all mixes throughout the production season. Occasionally, the QCT may take a sample fromquantities of 150 Mg or less when the anticipated production may go beyond 150 Mg, as long as it is documentedin the BR 303, QC Diary. The diary should include the time, the sample point, and the reason for taking thesample.

QCT will perform tests on the produced material using the appropriate test procedures outlined in Table 3. Whentesting volumetric mixtures, the QCT will check if the bulk specific gravities of the gyratory specimens ormaximum theoretical specific gravities of the loose mix samples are within the acceptable tolerance range givenin Table 1, Allowable Specimen Tolerance Range. This check must be done before air void analysis is performed.Note that all the gyratory specimens made by the QCT will be used for testing. If the results of either the bulkspecific gravities or the maximum theoretical specific gravities are not within the specified range, the specimensare considered invalid and the results will not be used in the calculation of the plant lot final QAF. In that case,the QCT must immediately re-sample and document in BR 303, Quality Control Plant Diary, the time the samplewas taken and the reason for re-sampling.

Table 1Allowable Specimen Tolerance Range

MixTypes

All Mix Types except for37.5 mm Maximum Sp.Gr. 37.5 mm

Number ofSpecimens

BulkSp.Gr.

Maximum Sp.Gr.

Maximum Sp.Gr.

2 .020 .011 .019

3 .023 ----- -----

4 .025 ----- -----

a. Process Control. The QCT may test any portion of a plant lot for process control. Based on the testresults of process control testing, the QCT may make adjustments to the production to assure the mix designaggregate targets and the volumetrics, i.e., air voids, VMA, VFB, are within the specification limits. Theresults obtained from samples during process control will not be used for calculating QAF.

b. Resample of HMA. The QCT will resample HMA mixture immediately when:

i. The HMA sample does not represent the production, i.e., a gyratory specimen is damaged, orii. The bulk specific gravities of the compacted specimens or maximum theoretical specific gravity test

results exceed the tolerances specified in Table 1, Allowable Specimen Tolerance Range. Thisdetermination is done prior to calculating air voids.

The material for resample is not required to be obtained randomly and can be from any remaining portion ofa sublot. The QCT will enter the test results in the appropriate BR forms.

c. Retest of HMA. The QCT may obtain another HMA sample within the same sublot for a retest afterthe official randomly selected sample has been tested and air voids calculated. If a lot has 2 or more sublots,the retest sample must be taken prior to the beginning of the next sublot. The sample point for retesting ofHMA within the sublot will be at the Producer's discretion. The Producer may perform process control duringthe adjustments to the mixture before a retest sample is taken. However, prior to performing any tests,



including those during process control, the Producer shall declare the intent of the test, i.e., test for processcontrol or a retest. When a retest is performed, the absolute difference values for both the retest sample andthe required sublot sample will be averaged to determine the sublot's test value as outlined in Section III,Quality Adjustment Factors. The QCT will enter the test results in the appropriate BR forms.

d. Untested Sublot Material. When production stops before a sublot sample is obtained, the untestedsublot quantity must be incorporated into the previous sublot of the same day. If there is no previous sublotto incorporate it into, the untested sublot quantity is considered a plant lot and the QAF for that amount willbe 1.00. The untested sublot quantities will not be incorporated into any subsequent or previous day’s plantlot production. When production stops after a sublot sample is obtained and the quantity is less than1250 Mg, it is still considered a sublot.

10. Quality Assurance Testing. Quality Assurance testing must be performed by the QAT to verify the QCtesting procedures and determine if the production process is in conformance with the requirements outlined inthe specification. QA testing must be performed on the split sample portion of a QC sample or on an independentsample as defined under II.B.2, Independent Sampling, of this procedure. Table 1, Allowable SpecimenTolerances Range, applies to QAT’s testing. QA testing frequencies and the test methods are outlined in Table 3,Quality Control/Quality Assurance Sampling and Testing. These QA frequencies are allowed to be modified asdeemed necessary by the RME.

The QAT will verify the QCT’s test procedures by testing samples and comparing the results. After completionof the test, the QAT will fill out the appropriate BR form and also verify that the QCT’s portion of the BR formis complete.

The QAT will compare the test results to those achieved by the QCT for the criteria being tested. The QCT’s andthe QAT’s results must be within the allowable split testing tolerances as outlined in Table 2, Allowable SplitSample Testing Tolerances. When the test results exceed the allowable tolerance, a retest must be performed.

Table 2Allowable Split Sample Testing Tolerances

Test PropertyTolerance

Within Lab* Lab to Lab

Gradation $ 425µm Sieve ± 5.0 % ± 7.0 %

Gradation < 425µm Sieve ± 2.0 % ± 3.0 %

Bulk Specific Gravity ± 0.020 ± 0.028

Maximum Specific Gravity ± 0.011 ± 0.019

*The tolerance for 37.5 mm is ± 0.019.



Table 3Quality Control/Quality Assurance Sampling and Testing

Plant Test Property

SampleLocation

TestMethod

Quality ControlFrequency

QualityAssuranceFrequency 8

Aggregate Gradation MM 5.0 AASHTO T27 Note 1 1 per Plant Lot per

Mix Type 7

Aggregate Moisture 6 MM 5.0 MM 5.0 1 every other sublot

minimum 2 per day Monitor and Verify

Air Voids 3 MM 5.0 AASHTO T166 & T209MM 5.16M 1 per sublot 1 per Plant Lot per

Mix Type 7

Mix Moisture 2, 4, 8 MM 5.0 MM 5.0 1 minimum per day Monitor and Verify

Mix Temperature Plant andHaul Vehicle N/A Routinely

minimum 4 per day Monitor and Verify

Asphalt BinderContent 9 MM 5.0

MM 5.0 or Test MethodNY 400-13C for Ignition

Oven

Routinelyminimum 4 per day

per mixMonitor and Verify

RAP Binder Content MM 5.0 MM 5.0

NY400-13C 2 per week Monitor and Verify

RAPGradation MM 5.0 AASHTO T 27 2 per week Monitor and Verify

RAPMoisture MM 5.0 MM 5.0 1 per day Monitor and Verify

Asphalt BinderSampling 5, 8 MM 8.1 MM 8.1 1 per day As Necessary

FrictionAggregate MM 28 MM 28 As Outlined in

MM 28As Outlined in

MM 28

Notes to Table 3:1. Volumetric design mixes - one test every other sublot, minimum one per day.

Non -Volumetric design mixes - one test every sublot.2. Required for drum mix plants, but optional for batch plants or as requested by the RME.3. Required for volumetric design mixes.4. Required for batch and drum mix plants when producing recycled mixes.5. The State is responsible for sample submission.6. Required for drum mix plants only.7. The frequency refers to split sample testing. In addition one (1) independent sample as defined under

Section II. B. 2 “Independent Sampling” must be tested per production week.8. May be modified by the RME.9. The frequency indicated is the combination of both the Ignition Oven and the MM 5 method.



11. Retesting Out-Of-Tolerance Test Samples. When the QCT’s and the QAT’s sample test results arenot within the allowable tolerance specified in Table 2, Allowable Split Sample Testing Tolerance, a retest mustbe performed on the same day and the sample must be from the material being produced or delivered. The samplemust be split and tested by both the QCT and the QAT for the property which exceeded the allowable tolerance.If, for any reason, the production has been terminated, a retest must be performed during initial production of thenext plant lot. In that case, the QCT’s test results are used to calculate the daily QAF and the QCT/QAT splitsample test results will be used as a retest verification.

If the retest results exceed the allowable tolerance, the QAT will notify the RME. Under the guidance of theRME, the QAT will terminate the production. The QAT will use QCT’s results up to this point to calculate thedaily QAF. Further production will not be allowed until the cause for the excessive deviation in the verificationis resolved to the satisfaction of the RME.

12. Retaining Samples. During production, the QCT will retain a split sample from a QC hot bin or compositeaggregate sample. At least one aggregate split sample must be obtained per day for each mix type produced. TheQCT will reduce to testing size, identify and retain the aggregate split sample at the production site for a minimumof ten (10) business days. The QCT must identify the retained aggregate split samples by specifying the facilitynumber, production date, plant lot, sublot, and mix description. The hot bin aggregate samples must be packagedseparately by bin and retained together. For the composite samples, dry the aggregate samples before packaging.

In addition, the QCT will retain all compacted hot mix specimens and the corresponding maximum specificgravity samples at the production site for a minimum of ten (10) business days. All retained specimens must beair dried and identified by the facility number, production date, plant lot, sublot, and mix type. All retainedaggregate samples, compacted specimens and the maximum specific gravity samples may be discarded at the endof the specified time period, unless directed by the RME.

D. Mixture Quality Analysis.

1. Aggregate Gradation. An aggregate gradation analysis will be performed at a frequency outlined inTable 3 of this procedure meeting the requirements of §401-3.04 B.1. Aggregate Gradation. An aggregategradation for any mix type is considered in control when all QC sieve test values remain within the Job MixFormula (JMF) tolerance.

2. Air Void Analysis - Volumetric Design Mixes. The air void content will be determined using theprocedures outlined in Materials Method (MM) 5.16, Superpave Hot Mix Asphalt Mixture Design and MixtureVerification Procedures. A minimum of one air void analysis must be performed for each plant sublot ofvolumetric design mix produced. All HMA samples used for determining the air voids must be obtained fromthe delivery vehicle and must be compacted to Ndesign. When holding bins are used for storage, the air voidanalysis must be determined after the storage time.

In conjunction with the air void analysis, the Voids in Mineral Aggregate (VMA), and Voids Filled with Binder,(VFB) must be calculated.

Table 2, Allowable Specimen Tolerance Range, will be used to determine if the specimens are acceptable forcalculating Air Voids.

3. Determination of PG Binder Content. The QCT will determine the PG binder content using theprocedures outlined in Materials Method (MM) 5 or Test Method NY 400-13C for Ignition Oven. The PG bindercontent calculations must be performed at a minimum combined frequency of four as indicated in Table 3 toverify specification compliance. For example, if one sample is tested using the ignition oven, then the remaining



three will be performed in accordance to MM 5. The QAT will check at least once per day as a QA procedurefor specification compliance.

4. Mixture Temperature. The QCT will monitor and transmit the mix temperatures to the project paving sitea minimum of four times a day. The QCT will take temperatures of the mix in the delivery trucks and indicateit on the delivery ticket. The mix temperatures must be routinely monitored to verify specification conformance.The mix temperature should not exceed the temperatures specified in the Standard Specification, which is between120/C and 165/C, unless higher temperatures are recommended by the PG binder supplier. The mix temperaturesfor Permeable Base mixtures should be between 110/C and 150/C as specified in the Standard Specification. TheQAT will witness at least one of the QCT’s temperature measurements per day as a QA procedure forspecification compliance.

5. Moisture Content. The QCT will perform aggregate and mix moisture using procedures outlined in MM 5and at a frequency detailed in Table 3.

a. Aggregate. The aggregate moisture must be routinely monitored at a drum mix plant. The QCT isrequired to perform a minimum of two tests per day equally spaced throughout the production day. At leastone of the tests must be performed on a composite sample. Moisture testing on individual aggregate bins isallowed and will be accepted as a test. As a QA procedure, the QAT will perform moisture tests by eithertesting moisture of individual aggregate bins or testing a composite sample. The RME may increase theQAT’s testing frequency if conditions warrant, i.e., based on QC results, change in weather conditions, heavyrains the previous night, etc. The QAT will check if the results input into the automation system are accurate.

b. Mix Moisture. The QCT is required to perform a minimum of one moisture content on the HMA andRAP per day for drum mix plants. The frequency may be increased by the RME. In addition, the RME mayrequest moisture testing of HMA at a batch plant. The QAT will perform moisture tests as a QA procedure.The moisture content in the HMA mixture must be 0.5% or less.

6. PG Binder Sampling. The QCT will obtain PG binder samples using the procedures outlined in MaterialsMethod (MM) 8.1, Quality Assurance Procedures for Paving Asphalt Cement. A minimum of one sample isrequired for each production day, but may be increased at the discretion of the RME. The samples must beidentified and stored at the facility site. The State will supply sample containers and forms, and will beresponsible for submission of the samples to the Main Office for testing at a frequency outlined in MM 8.1. TheQAT should witness, if possible, the sampling procedures on a random basis to assure the PG Binder is sampledfrom the appropriate tank.

7. Friction Aggregate. The QCT will perform all QC friction aggregate sampling and testing usingprocedures outlined in Materials Method (MM) 28, Friction Aggregate Control and Test Procedures, for allsurface courses to assure the aggregate will meet the requirements of §401-2.02, Aggregates. Friction testing willbe performed at the production facility site at frequencies outlined in MM 28 or as noted on the JMF. Thefollowing action/suspension guidelines are required to be followed by the QCT:

a. If the friction test results are greater than the JMF requirements, continue process control.b. If the friction test results are greater than the specification requirements, but less than the JMF

requirements, aggregate adjustments must be made and the friction property retested.c. If the friction test results are less than the specification requirements, production must be stopped, the

RME notified, the problem corrected, and the friction property retested. The retest friction property mustbe in specification conformance before production can be resumed.

The QAT will sample aggregate and submit for friction testing as outlined in MM 28. As a QA procedure, theQAT will also monitor the above action/suspension guidelines which are required to be followed by the QCT.



8. Recycle Mixes. All sampling and testing of recycle design mixtures will be performed using this procedureand as outlined in §401-3.04 B.8, Recycled Mixes.

E. Air Void and Gradation Reporting.

Test results of QC/QA samples should be reported as follows:

1. All bulk and maximum theoretical specific gravities will be reported to the nearest 0.001.2. All Air Void test results will be reported to the nearest 0.01 of a percent.3. All aggregate gradation test values reported to the nearest 0.1 of a percent.

F. Sampling and Testing Disputes.

When a sampling and/or testing dispute occurs, the State, as directed by the RME will perform referee samplingand testing. Referee samples must be obtained randomly and independently of the QC samples and tested at theRegional or Central Office Laboratory. A minimum of one independent sample per plant lot must be obtainedand tested for non-volumetric mixes. A minimum of one sample per sublot must be obtained and tested forvolumetric mixes. If production has been terminated, the Producer's retained samples will be tested.

The RME may utilize the Independent Assurance Sampling and Testing (IAST) staff, the Regional Laboratory,or the Central Office Laboratory to evaluate and/or perform referee sampling and testing. All NYSDOTlaboratories are qualified to validate the quality of the material and determine the final acceptance of any disputedmaterial. However, other laboratories meeting the approval of the Director, Materials Bureau may be utilized.The State’s independent referee sample test results are final and will be used to determine the QAF of anydisputed quantity and the acceptance of the in-place production material.

G. Plant Requirements.

1. Automation and Recordation. The QAT will routinely monitor the plant automation and recordationsystem and verify that all design ingredients are programmed correctly and produced within productiontolerances. Also, the QAT will review the automation production records for specification conformance. Theserecords are required to be stored at the production facility site by the Producer and be available for review.

2. Production of HMA in Automatic Mode. When the automatic proportioning system interruptsproduction due to ingredients outside the allowable production tolerances, the Producer must correct the problemimmediately. All production is required to be in the automatic mode. Material produced in the non-automaticmode is not to be shipped. If non-automatic mode material is produced, the Producer is required to notify theRME immediately.

Material produced in the automatic mode that exceeds twice the production tolerance is also not to be shipped.Material produced in the automatic mode that is between the single and double tolerance may be shipped.However, the RME will review the production documentation to determine if the material is acceptable.

The Producer is allowed to discard any out-of-tolerance material during production provided the system remainsin the automatic mode and all actions are documented in the QC Plant Diary.

3. Determination of HMA Quantity. The Producer is required to determine on a daily basis the quantity ofeach plant lot produced and delivered to the project. The quantity must be measured by the number of actualmetric tons (nearest 0.01 of a metric ton) of each mix type produced at the plant facility. The quantity must bedetermined from the automated proportioning system or the delivery vehicle weigh system. The quantity can beobtained directly from the automated system printout, calculated based on the automated measured amount or



obtained directly from the vehicle weigh system recordation. Also, all quantities delivered to the project mustbe accompanied with a delivery ticket meeting the requirements outlined in specification §401-4, Method ofMeasurement.

4. Failure of Equipment.

a. Printer Breakdown. When the automated proportioning system or delivery weigh system printer isnot properly working, the Producer must notify the QAT at the plant site. However, when a QAT is notpresent, the Producer must notify the RME immediately. Production is allowed during the breakdown periodprovided the tons produced are properly documented as outlined by the RME. The breakdown period shallnot exceed 48 hours.

b. Gyratory Compactor Breakdown. When the gyratory compactor breaks down, the Producer willnotify the RME immediately. The RME may allow production to continue for an limited time period not toexceed 48 hours. Mix type, placement location, test results, and/or any problems occurring with the mixtureat the plant or project will be primary considerations for determining if, and how long, production will beallowed to continue. When permitted during the breakdown period, the following shall apply:

1. HMA samples (enough for at least 2 specimens) will be taken at the normal specified required frequency,retained until the gyratory compactor is repaired, then tested for informational purposes.

2. Aggregate gradations will be performed and recorded for each sublot produced during the breakdownperiod.

3. The final QAF shall be 1.00 for all mix accepted by the Project Engineer during the breakdown period.

H. Plant Monitoring.

Plant monitoring is an essential QC/QA activity which must be performed in order to determine the status of theproduction process. Plant monitoring must be performed to assure that all productions, including all individualingredients are in conformance with the specification. The following outlines the production control proceduresand actions the Producer is allowed to perform during production to ensure process control:

1. Make process control adjustments providing the mix design target values are strived for.

2. Target value adjustments are allowed providing the target value remains within the specification generallimits and the adjustments are properly documented in the plant QC Plant Diary. In addition, all volumetricmix properties must remain within the specification production limits when these adjustments are made toany volumetric mix design target value.

3. Only the aggregate gradation production tolerance is allowed to exceed the general limits.

4. Take corrective action when any test value consistently falls outside the allowable production tolerance. TheRME must be notified prior to production of any subsequent adjusted sublot.

The Producer may terminate production at any time. However, the Project Engineer and the RME must benotified immediately by the Producer. When production is terminated, the quantity produced up to that point isconsidered a plant lot and the final QAF is determined using all the required QC test values and any additionaltest values obtained from the terminated plant lot. HMA in storage from any terminated plant lot having a QAFless than 0.90, or any testing not in conformance with the specification requirements is considered unacceptable.



When production of any mix type consistently yields a final QAF less than 1.00 or when the VMA and/or VFBare outside the plant production tolerances, the RME may rescind the mix design’s “Production Status.” Whenthe final QAF of any mix type is less than 0.90 for two consecutive production days, corrective actions must betaken. If by the end of the third production day, corrective actions did not yield a final QAF of 0.90 or greater,production of that mix will be terminated. When production is terminated under these conditions, the Producermust demonstrate by trial production that production yields a final QAF of 0.90 or greater. The Producer mustimmediately notify the RME when production yields a final QAF less than 0.90.

III. QUALITY ADJUSTMENT FACTORS (QAF)

The QAT is responsible for calculating and transmitting the final QAF to the project. The QAT will calculate theQAF using a BR 324, Computation of Final Quality Adjustment Factors, by entering the sample test results. Onlythe QCT’s results will be used to calculate the plant QAF unless the production is under dispute as described in thisprocedure and the Standard Specification. Also, the QAT will use a BR 343a, Daily Hot Mix Asphalt AuthorizedShipments, to transmit the final QAF and the daily production quantity to the project.

The Producer is responsible for transmitting a BR 307, Quality Control Hot Mix Asphalt Certification, to the projectno later than the end of the next work day for all certified quantities. Certified quantities have a final QAF of 1.00.

A. Volumetric Mixes.

QAFs for Volumetric mixtures are based on plant air voids. The final QAF for each plant lot is calculated usingTable 5, Air Voids in Plant Mixture (Volumetric Designs). When HMA holding bins are used for Volumetricmixtures, the final QAF for the stored mixture is determined on the day the material is delivered to the project.The QAT will follow the steps below as a guide to determine the QAF for Volumetric mixes:

1. The criteria used is Air Voids.

2. Obtain the verified QCT’s test values from each tested sublot.

3. Check to see if the air void test values are calculated to the nearest 0.001 of a percent and reported to thenearest 0.01 of a percent. If not, then request the QCT to recalculate to the required digits. Determine theabsolute difference between each air void test value and 4.00%.

4. Average the calculated absolute difference values and round the average number to the nearest 0.01%.

5. Go to Table 5, Air Voids in Plant Mixture (Volumetric Designs) to determine the range in which the averageabsolute value falls between. Follow across the appropriate row to determine the QAF.

6. Report the QAF as final on the BR 343a. In addition, enter the quantity of mixture produced represented bythe final QAF. Transmit the BR 343a to the project.

Examples of QAF calculations for Volumetric Mixes

A 12.5 mm HMA mix having a plant lot quantity of 2950 Mg (see the example BR 324 on page 17).

1. The number of sublots tested are

2950 Mg ÷ 1250 Mg = 3 sublots



2. Take each sublot's air void test value from the BR 328, Air Void analysis, and enter them on the BR 324.Calculate the absolute difference between the test values and 4.0%.

4.52 - 4.00 = 0.52, 3.70 - 4.00 = -0.30 (0.30), 4.17 - 4.00 = 0.17

3. Average the calculated absolute difference value for each test and round to the nearest 0.01 of a percent.

Average absolute difference value = 0.33

4. Use Table 5 to determine the final QAF.

The final QAF = 1.04

5. Enter the final QAF and the HMA quantity it represents on the BR 343a and then transmit the form to theproject. See example BR 343a on page 18.

B. Non-Volumetric Mixes.

QAFs for Non-Volumetric mixtures are based on plant mixture aggregate gradations. The final QAF for eachplant lot is calculated using Table 6, Percent Passing (Non-Volumetric Designs). The QAF is calculated for allJMF sieves having design target values less than 90 percent passing. The final QAF for Non-Volumetric designmixtures is the lowest QAF obtained from Table 6, unless each individual QAF is 1.00 or greater. If eachindividual QAF is equal to or greater than 1.00, the highest calculated QAF is used.

The QAT will calculate the final QAF of a plant lot using the following steps:

1. The criteria used is Percent Passing from JMF targets for each sieve used for mixture production.

2. Obtain the verified QC test values from each tested sublot.

3. Check and see if the aggregate gradation test values are calculated to the nearest 0.01 of a percent andreported to the nearest 0.1 of a percent.

4. On the BR 324, enter the Percent Passing value for each corresponding sieve and calculate the absolutedifference between each sieve’s percent passing test value and its JMF target value. If there is more than onesublot, average the absolute difference values for each sieve.

5. Use Table 6, Percent Passing (Non-Volumetric Designs) to determine the QAF for each of the sieve’s averageabsolute difference value.

6. Use the following criteria to determine the final daily QAF for the non-volumetric mixes:

a. if a QAF of any individual sieve on the BR 324 is less than 1.00, then the final daily QAF will be thelowest individual sieve QAF obtained, otherwise

b. if QAF of any individual sieve is equal to or greater than 1.00, then the final daily QAF will be thehighest individual sieve QAF obtained.

7. The final QAF and the HMA quantity will be transmitted to the project on form BR 343a.



Examples of QAF Calculations for Non-Volumetric Mixes

Type 1 Permeable Base Course having a plant lot quantity of 2950 Mg (see the example BR 324 on page 17).

1. The number of sublots tested are

2950 Mg ÷ 1250 = 3 sublots

2. The calculated data is shown on the BR 324 on page 17 of this procedure. Use Table 6 to determine the dailyfinal QAF.

The final QAF = 0.94

The QAF for the 75µm sieve is determined to be less than 1.00 and it was the lowest of all the individual sieve’sQAF.

3. Report the final QAF on the BR 343a. In addition, enter the quantity of mixture produced represented by thefinal QAF. Transmit the BR 343a to the project. See example BR 343a on page 18.

C. Certified Lots.

The Producer can certify any HMA production lot 150 Mg or less without testing the mixture. By certifying thelot, the Producer assures the mixture is in compliance with the specification requirements, including frictionrequirements for surface courses. The Producer will take aggregate samples for friction testing in accordance withMM 28. The final QAF for a certified lot is 1.00.

Example of a Certified Quantity

A 12.5 mm Superpave mix having a plant lot quantity of 135 Mg was certified and shipped to the project (seeexample BR 307 on page 19).

1. The Producer fills out and transmits a BR 307 to the project no later than the end of the next work day.

2. Final QAF = 1.00.

D. Unavailable Resample Material. When the QC test values exceed the allowable tolerance and the plantproduction has been terminated such that a re-sample cannot be obtained, then the plant lot final QAF is 1.00when a plant lot consists of one sublot. When a plant lot consists of multiple sublots, an absolute difference valueof 0.92 will be used for the sublot for which a sample was unobtainable. This value will be averaged with allother sublot’s absolute difference value(s) to calculate the plant lot final QAF.



BR 324M (5/99) EXAMPLE BR 324

NEW YORK STATE DEPARTMENT OF TRANSPORTATION - MATERIALS BUREAUCOMPUTATION OF FINAL QUALITY ADJUSTMENT FACTORS

Plant Name Location Production Date Regional Hot Mix Asphalt Corp. Anywhere, NY April 10, 2002

Facility No. Region : Batch QAF Calculated By 10000 12 G Drum Joe Bushey, Jr.

NON - VOLUMETRIC MIXES - AGGREGATE GRADATIONLot No.

Percent Passing Mix Description Proj. QAF 0.94

2 ATPB Type 1 Final QAF 0.94

SieveSize

JMFTarget

Actual Sublot Test Values Absolute Diff. From JMF Target Avg. of Diff.

Sieve QAFA B C D A B C D

50.0 mm 100 100.0 100.0 100.0 ----- 0.0 0.0 0.0 ----- 0.0 Note 1

37.5 mm 100 100.0 100.0 100.0 ----- 0.0 0.0 0.0 ----- 0.0 Note 1

25.0 mm 95 97.0 98.5 95.0 ----- 2.0 3.5 0.0 2 ----- 1.8 Note 1

12.5 mm 74 78.3 70.9 74.0 ----- 4.3 3.1 0.0 2 ----- 2.5 1.02

6.3 mm 51 50.3 51.0 51.0 ----- 0.7 0.0 2 0.0 2 ----- 0.2 1.05

3.2 mm 39 40.5 37.2 39.0 ----- 1.5 1.8 0.0 2 ----- 1.1 1.04

850 µm 25 31.5 21.0 24.0 ----- 6.5 4.0 1.0 ----- 3.8 1.01

425 µm 19 19.5 20.1 19.5 ----- 0.5 1.1 0.5 ----- 0.7 1.05

180 µm 11 13.4 8.0 10.8 ----- 2.4 3.0 0.2 ----- 1.9 1.02

75 µm 4 6.6 6.8 6.5 ----- 2.6 2.8 2.5 ----- 2.6 0.94Notes: 1. Design target value for sieve is greater than 90 percent passing.

2. 0.0 value is used when averaging.

VOLUMETRIC MIXES - AIR VOIDS

Mix Description LotNo.

Actual Sublot Test Values Absolute Diff. From 4.0% Avg. ofDiff.

FinalQAF

Proj.QAFA B C D A B C D

12.5 mm 1 4.52 3.70 4.17 ----- 0.52 0.30 0.17 ----- 0.33 1.04 1.04

Notes: 1. When a retest is performed on a sublot, the absolute difference values are averaged and used for that sublot.2. The project QAF may be different from the final QAF due to specification requirements.

Sheet 1 of 1



BR 343a (5/99) EXAMPLE BR 343a - VOLUMETRIC & NON-VOLUMETRIC QUANTITY

NEW YORK STATE DEPARTMENT OF TRANSPORTATION-MATERIALS BUREAUDAILY HOT MIX ASPHALT AUTHORIZED SHIPMENTS

Sheet 1 of 1

REPORT NO. DATE REGION FACILITY NO. JOB STAMP

1 April 10, 2002 12 10000PLANT SURGE BIN USED

Regional Hot Mix Asphalt Corp. 9 YES : NO

LOCATION

Anywhere, NY

PROJECTD292000

PROJECTD290000

MIX DESCRIPTION QUANTITY LOT NO. QAF MIX DESCRIPTION QUANTITY LOT NO. QAF

ATPB Type 1 2950 Mg 2 0.94 12.5 mm (12F24YC) 2950 Mg 2 1.04

PROJECT PROJECT


REMARKS:

AUTHORIZED BY: (QAT Signature)Joe Bushey Jr.

PROJECT REVIEWER: (Signature)



BR 307 (5/99) EXAMPLE BR 307 - CERTIFIED QUANTITY

NEW YORK STATE DEPARTMENT OF TRANSPORTATIONMATERIALS BUREAU

QUALITY CONTROL HOT MIX ASPHALT CERTIFICATION

SHIPPED FROM: JOB STAMP

PLANT Regional Hot Mix Asphalt Corp

LOCATION Anywhere, NY

FACILITY NO. 10000

REGION 12 SHIPPING DATE May 29, 2002

SHIPPED TO: MIX DESCRIPTION QUANTITY LOT

PROJECT NO. D290000 12.5 mm (12F24YC) 135 Mg 12LOCATION Anywhere, NY

This certified quantity represents a non-tested plant lot of 150 Mg or less and the final QAF for this quantity is 1.00.

I certify that the hot mix asphalt delivered to this project is in conformance with all contract requirements.

By Joe Bushey Sr. Title Plan Administrator Date 05/29/2002



IV. DOCUMENTATION

A. QC/QA Process Control Documentation.

The QCT will maintain all process control test data at each plant facility. This test data must be kept in a ringedtype book and stored in the facility laboratory. All test data are required to be legible and updated within a24-hour period following each plant lot production. As a minimum, this book must contain the Control Plan,JMFs, design criteria, test data summaries, and daily production quantities. All forms, except control charts aresupplied by the State.

The QCT will perform the following:

1. Document all test data on a BR 331, Production Summary Sheet. A separate production summary sheet isrequired for each mix design produced.

2. Document all process control actions on a BR 303, Quality Control Daily Diary, and plot air void test valueson control charts. The control charts will be posted in the laboratory or in a separate book. These controlcharts must be updated within a 24-hour period. Separate control charts are required for each volumetric mixdesign produced.

The QAT will perform the following:

1. Review the summary sheets, verify the results were documented correctly, and initial the forms whereapplicable.

2. Review plant production documentation, including the automation printouts for completeness, accuracy, andspecification conformance.

3. Review the control charts and document any applicable information regarding the control process in the QCPlant Diary.

4. Review the QC Plant Diary and verify the daily process control information is documented by the QCT ona daily basis as required by the Control Plan.

B. Delivery Ticket.

Each delivery vehicle supplying HMA production to the project site must be accompanied with a delivery ticketmeeting the requirements outlined in §401-4, Method of Measurement. Also, all delivery tickets must be codedas outlined in Table 4, Delivery Ticket Mix Coding. The mix codes may be printed by the automatedproportioning system or the delivery vehicle weigh system. All delivery ticket information including the mixcodes must be legible. The QAT will spot check the delivery tickets for specification conformance.



Table 4Delivery Ticket Mix Coding

MixType Code Code 1

DesignESAL Code

ConsensusProperties 2 Code

PG Binder Type Code 3

9.5 mm 09 F1 <0.3 million 1 <100 mm Y PG 58-34 A

12.5 mm 12 F2 <3.0 million 2 >100 mm N PG 64-22 B

19.0 mm 19 F3 <10 million 3 PG 64-28 C

25.0 mm 25 F9 <30 million 4 PG 70-22 D

37.5 mm 37 ----- >30 million 5 PG 76-22 E

OTHER G

Notes:1. Friction Aggregate Classification Codes.2. If at least 75% of a layer is deeper than 100 mm below the pavement surface, the >100 mm aggregate consensus properties

applies for that layer.3. “F” in the PG Binder Type Codes was excluded to avoid conflict with the Friction designation.

Mix Coding Examples:

12.5 mm surface course(12), F2 friction conditions, <30 million ESALS(4),<100 mm from a pavement surface(Y), PG 64-28(C).

< System Coding = 12F24YC

12.5 mm surface course(12), F3 friction conditions, <3 million ESALS(2), <100 mm from a pavement surface(Y),PG 64-28(C).

< System Coding = 12F32YC

25.0 mm binder(25), F9 friction conditions, <0.3 million ESALS(1), >100 mm from a pavement surface(N),PG 58-34(A).

< System Coding = 25F91NA



C. Forms.

The Producer will use the following NYSDOT forms during production and shipping of HMA to State projects:A file copy of these forms is attached and is available through the Regional Materials Engineer.

Form Name Form No.

Hot Bin Analysis - Superpave BR 154Drum Mix Plant Production - Superpave BR 157Drum Mix Plant Production - Non-Superpave BR 159Hot Bin Analysis - Non-Superpave BR 161Quality Control Daily Diary BR 303Quality Control HMA Certification BR 307Determination of % NC in Marshall Mixes BR 310Computation of Final QAF BR 324Computation of Volumetric Mix Properties BR 328Determination of % NC in Superpave Mixes BR 330Production Summary Sheet BR 331Daily HMA Authorized Shipments BR 343a

Table 5Air Voids In Plant Mixture (Volumetric Designs)

Average AbsoluteValue of

(Test Value - 4.0)

QualityAdjustment

Factor (QAF)0.00 - 0.17 1.050.18 - 0.33 1.040.34 - 0.50 1.030.51 - 0.67 1.020.68 - 0.83 1.010.84 - 1.00 1.001.01 - 1.10 0.991.11 - 1.20 0.981.21 - 1.30 0.971.31 - 1.40 0.961.41 - 1.50 0.951.51 - 1.60 0.941.61 - 1.70 0.931.71 - 1.80 0.921.81 - 1.90 0.911.91 - 2.00 0.90 over 2.00 0.851

Note 1: Refer to Section II. H, Plant Monitoring.



Table 6Percent Passing (Non-Volumetric Designs)

Average Absolute Value of(Test Value - JMF Target Value) Quality

AdjustmentFactor

Sieve Size425 µm and

Larger

Sieve Size180 µm

Sieve Size 75 µm

0.0 - 0.8 0.0 - 0.5 0.0 - 0.3 1.050.9 - 1.5 0.6 - 1.0 0.4 - 0.5 1.041.6 - 2.3 1.1 - 1.5 0.6 - 0.8 1.032.4 - 3.0 1.6 - 2.0 0.9 - 1.0 1.023.1 - 4.5 2.1 - 3.0 1.1 - 1.5 1.014.6 - 6.0 3.1 - 4.0 1.6 - 2.0 1.006.1 - 6.3 4.1 - 4.2 2.1 0.996.4 - 6.6 4.3 - 4.4 2.2 0.986.7 - 6.9 4.5 - 4.6 2.3 0.977.0 - 7.2 4.7 - 4.8 2.4 0.967.3 - 7.5 4.9 - 5.0 2.5 0.957.6 - 7.8 5.1 - 5.2 2.6 0.947.9 - 8.1 5.3 - 5.4 2.7 0.938.2 - 8.4 5.5 - 5.6 2.8 0.928.5 - 8.7 5.7 - 5.8 2.9 0.918.8 - 9.0 5.9 - 6.0 3.0 0.90over 9.0 over 6.0 over 3.0 0.851

Note 1: Refer to Section II. H, Plant Monitoring.



NOTES



Appendix A

Random Numbers for SamplingHot Mix Asphalt (HMA) Mixtures at

The Plant



RANDOM NUMBERSSUBLOT DESIGNATION ALTERNATE RANDOM NUMBERS

A B C D E 1 2 3 4 5

LOT DESIGNATION

1 0.067 0.241 0.025 0.359 0.779 0.851 0.808 0.925 0.657 0.1882 0.049 0.932 0.167 0.997 0.539 0.888 0.433 0.676 0.145 0.0833 0.209 0.960 0.465 0.487 0.535 0.441 0.503 0.376 0.626 0.1224 0.289 0.951 0.510 0.393 0.593 0.231 0.068 0.242 0.026 0.3635 0.784 0.941 0.503 0.376 0.622 0.290 0.951 0.510 0.392 0.5946 0.310 0.913 0.681 0.171 0.199 0.006 0.366 0.775 0.860 0.7797 0.850 0.806 0.922 0.653 0.102 0.326 0.760 0.890 0.637 0.1318 0.119 0.299 0.908 0.690 0.002 0.377 0.624 0.293 0.956 0.4739 0.553 0.400 0.609 0.279 0.854 0.830 0.721 0.065 0.252 0.87410 0.793 0.944 0.495 0.549 0.409 0.690 0.003 0.376 0.625 0.12311 0.291 0.952 0.512 0.380 0.615 0.274 0.857 0.820 0.745 0.05112 0.396 0.585 0.215 0.975 0.557 0.424 0.657 0.187 0.167 0.20513 0.968 0.480 0.581 0.223 0.066 0.253 0.879 0.615 0.273 0.84014 0.738 0.035 0.441 0.503 0.376 0.623 0.289 0.952 0.509 0.39115 0.592 0.228 0.077 0.259 0.890 0.637 0.144 0.098 0.316 0.75416 0.878 0.629 0.115 0.273 0.840 0.725 0.057 0.424 0.658 0.18917 0.999 0.543 0.444 0.493 0.547 0.448 0.517 0.344 0.811 0.91518 0.703 0.967 0.478 0.578 0.261 0.892 0.594 0.310 0.914 0.70119 0.007 0.369 0.796 0.946 0.513 0.383 0.639 0.135 0.143 0.09620 0.314 0.750 0.042 0.457 0.472 0.564 0.249 0.040 0.453 0.51121 0.393 0.595 0.312 0.918 0.706 0.973 0.553 0.400 0.609 0.32322 0.767 0.844 0.810 0.914 0.701 0.007 0.370 0.801 0.909 0.69223 0.991 0.526 0.362 0.782 0.937 0.667 0.208 0.958 0.458 0.46124 0.483 0.571 0.266 0.886 0.644 0.097 0.316 0.754 0.878 0.62625 0.125 0.123 0.291 0.955 0.471 0.565 0.252 0.875 0.792 0.95726 0.459 0.463 0.484 0.574 0.256 0.869 0.799 0.906 0.605 0.33227 0.722 0.065 0.251 0.876 0.622 0.289 0.933 0.676 0.146 0.08628 0.214 0.985 0.529 0.352 0.826 0.757 0.871 0.800 0.909 0.68929 0.999 0.543 0.443 0.494 0.549 0.406 0.606 0.319 0.745 0.04830 0.406 0.686 0.166 0.205 0.968 0.481 0.567 0.240 0.024 0.35731 0.820 0.764 0.882 0.621 0.300 0.911 0.677 0.146 0.087 0.23132 0.067 0.240 0.024 0.357 0.819 0.743 0.044 0.442 0.489 0.52333 0.339 0.738 0.021 0.336 0.714 0.988 0.521 0.335 0.715 0.97534 0.557 0.424 0.657 0.185 0.164 0.202 0.009 0.391 0.636 0.14435 0.096 0.313 0.748 0.038 0.431 0.672 0.199 0.018 0.345 0.81336 0.747 0.036 0.430 0.652 0.113 0.285 0.942 0.491 0.524 0.35737 0.821 0.763 0.883 0.639 0.135 0.140 0.136 0.142 0.094 0.31138 0.916 0.702 0.009 0.388 0.630 0.117 0.277 0.864 0.772 0.83739 0.732 0.071 0.264 0.884 0.638 0.133 0.139 0.135 0.142 0.09340 0.231 0.068 0.241 0.024 0.356 0.817 0.739 0.020 0.333 0.708




A B C D E 1 2 3 4 5

LOT DESIGNATION

41 0.961 0.464 0.489 0.522 0.338 0.734 0.075 0.256 0.868 0.79742 0.904 0.601 0.309 0.913 0.681 0.169 0.196 0.012 0.380 0.61543 0.274 0.857 0.819 0.744 0.046 0.449 0.519 0.348 0.803 0.90144 0.612 0.282 0.937 0.667 0.207 0.960 0.462 0.481 0.568 0.24145 0.027 0.363 0.786 0.927 0.646 0.086 0.214 0.989 0.522 0.33846 0.737 0.033 0.439 0.500 0.542 0.457 0.472 0.566 0.253 0.87847 0.626 0.126 0.122 0.289 0.932 0.673 0.156 0.185 0.163 0.18348 0.175 0.160 0.177 0.147 0.087 0.231 0.067 0.239 0.020 0.33349 0.708 0.958 0.458 0.458 0.458 0.461 0.464 0.488 0.521 0.33550 0.712 0.981 0.568 0.241 0.027 0.363 0.785 0.928 0.651 0.11151 0.281 0.856 0.819 0.745 0.049 0.408 0.690 0.002 0.377 0.62752 0.127 0.126 0.122 0.290 0.950 0.505 0.367 0.776 0.861 0.78153 0.855 0.831 0.720 0.062 0.418 0.693 0.992 0.528 0.350 0.80754 0.924 0.659 0.190 0.001 0.373 0.789 0.952 0.510 0.392 0.59355 0.231 0.069 0.245 0.048 0.406 0.605 0.332 0.721 0.063 0.24856 0.038 0.434 0.662 0.179 0.152 0.112 0.283 0.936 0.665 0.20357 0.011 0.392 0.594 0.230 0.082 0.209 0.960 0.464 0.486 0.53158 0.355 0.831 0.720 0.063 0.247 0.039 0.432 0.673 0.156 0.18559 0.163 0.181 0.171 0.196 0.015 0.385 0.641 0.091 0.223 0.05260 0.396 0.585 0.212 0.984 0.573 0.267 0.843 0.730 0.081 0.22061 0.061 0.415 0.701 0.008 0.388 0.632 0.119 0.296 0.947 0.51662 0.341 0.724 0.055 0.420 0.695 0.995 0.551 0.410 0.692 0.99163 0.526 0.362 0.782 0.935 0.664 0.202 0.009 0.388 0.633 0.13964 0.135 0.142 0.093 0.229 0.079 0.218 0.979 0.579 0.216 0.97465 0.552 0.398 0.589 0.237 0.032 0.435 0.663 0.184 0.175 0.16066 0.191 0.003 0.376 0.625 0.292 0.954 0.466 0.474 0.554 0.40267 0.600 0.304 0.903 0.599 0.305 0.920 0.697 0.014 0.384 0.63968 0.134 0.138 0.133 0.139 0.134 0.138 0.132 0.120 0.298 0.90369 0.598 0.301 0.895 0.583 0.211 0.964 0.487 0.532 0.435 0.66370 0.184 0.162 0.182 0.174 0.158 0.187 0.168 0.206 0.969 0.55971 0.411 0.677 0.146 0.086 0.214 0.987 0.535 0.441 0.504 0.37872 0.629 0.129 0.128 0.129 0.115 0.275 0.859 0.824 0.768 0.84573 0.810 0.915 0.700 0.008 0.389 0.635 0.140 0.137 0.131 0.12074 0.298 0.903 0.601 0.307 0.923 0.654 0.101 0.308 0.925 0.65775 0.185 0.164 0.201 0.010 0.390 0.637 0.131 0.116 0.274 0.85776 0.819 0.743 0.047 0.448 0.520 0.334 0.713 0.987 0.534 0.43977 0.500 0.542 0.457 0.459 0.463 0.487 0.532 0.435 0.664 0.18278 0.173 0.155 0.106 0.318 0.741 0.027 0.362 0.782 0.935 0.66379 0.181 0.172 0.155 0.104 0.330 0.721 0.064 0.249 0.040 0.45180 0.507 0.368 0.797 0.948 0.517 0.343 0.730 0.082 0.223 0.988




A B C D E 1 2 3 4 5

LOT DESIGNATION

81 0.025 0.186 0.453 0.201 0.804 0.637 0.076 0.495 0.270 0.77582 0.153 0.569 0.481 0.764 0.293 0.943 0.589 0.107 0.370 0.25583 0.453 0.348 0.317 0.735 0.978 0.419 0.435 0.400 0.690 0.67984 0.163 0.019 0.966 0.877 0.627 0.093 0.149 0.669 0.529 0.60485 0.158 0.560 0.755 0.117 0.023 0.847 0.963 0.748 0.575 0.82186 0.109 0.710 0.745 0.089 0.616 0.202 0.721 0.049 0.061 0.63187 0.937 0.057 0.438 0.456 0.486 0.902 0.080 0.395 0.221 0.93588 0.636 0.975 0.841 0.109 0.655 0.353 0.079 0.707 0.112 0.16989 0.256 0.241 0.708 0.029 0.581 0.739 0.877 0.371 0.595 0.92490 0.626 0.882 0.509 0.382 0.376 0.366 0.227 0.834 0.063 0.78791 0.128 0.566 0.453 0.164 0.075 0.559 0.993 0.751 0.209 0.74092 0.569 0.609 0.614 0.458 0.018 0.167 0.781 0.735 0.904 0.16393 0.989 0.402 0.984 0.108 0.150 0.486 0.489 0.535 1.000 0.25794 0.940 0.818 0.006 0.377 0.806 0.170 0.341 0.197 0.611 0.45895 0.571 0.921 0.908 0.906 0.292 0.438 0.722 0.517 0.199 0.14396 0.572 0.031 0.894 0.033 0.325 0.644 0.866 0.865 0.516 0.69597 0.780 0.964 0.005 0.276 0.152 0.009 0.221 0.164 0.212 0.74198 0.033 0.004 0.221 0.558 0.892 0.097 0.048 0.620 0.689 0.12899 0.565 0.921 0.101 0.480 0.433 0.336 0.563 0.489 0.489 0.939100 0.003 0.101 0.040 0.693 0.936 0.644 0.691 0.954 0.306 0.624101 0.800 0.600 0.943 0.204 0.758 0.980 0.245 0.928 0.404 0.048102 0.642 0.673 0.888 0.161 0.368 0.383 0.082 0.340 0.031 0.031103 0.155 0.110 0.077 0.431 0.547 0.799 0.563 0.214 0.126 0.676104 0.972 0.428 0.161 0.047 0.960 0.775 0.368 0.613 0.385 0.560105 0.971 0.730 0.720 0.315 0.891 0.822 0.483 0.250 0.498 0.601106 0.249 0.809 0.491 0.169 0.717 0.012 0.928 0.340 0.123 0.152107 0.138 0.787 0.635 0.057 0.429 0.124 0.519 0.989 0.907 0.649108 0.338 0.371 0.118 0.454 0.256 0.397 0.754 0.200 0.611 0.862109 0.966 0.528 0.008 0.781 0.222 0.705 0.607 0.302 0.164 0.570110 0.090 0.148 0.265 0.316 0.175 0.718 0.820 0.355 0.198 0.225111 0.062 0.998 0.321 0.405 0.626 0.359 0.979 0.860 0.378 0.907112 0.712 0.039 0.518 0.025 0.434 0.621 0.459 0.825 0.594 0.640113 0.206 0.914 0.228 0.523 0.172 0.553 0.038 0.005 0.826 0.878114 0.148 0.174 0.195 0.087 0.726 0.986 0.741 0.868 0.241 0.735115 0.224 0.540 0.431 0.272 0.436 0.300 0.238 0.625 0.836 0.246116 0.452 0.292 0.723 0.618 0.853 0.304 0.843 0.348 0.693 0.752117 0.863 0.562 0.553 0.213 0.915 0.036 0.949 0.031 0.655 0.197118 0.159 0.120 0.014 0.717 0.104 0.049 0.428 0.115 0.986 0.916119 0.669 0.960 0.014 0.203 0.905 0.493 0.343 0.830 0.328 0.213120 0.667 0.740 0.840 0.843 0.623 0.056 0.016 0.378 0.018 0.809




A B C D E 1 2 3 4 5

LOT DESIGNATION

121 0.859 0.891 0.904 0.273 0.372 0.576 0.261 0.802 0.573 0.949122 0.606 0.971 0.208 0.190 0.793 0.893 0.363 0.080 0.918 0.752123 0.196 0.555 0.864 0.498 0.830 0.237 0.092 0.772 0.652 0.105124 0.217 0.741 0.731 0.060 0.603 0.237 0.836 0.274 0.427 0.170125 0.865 0.076 0.954 0.875 0.214 0.347 0.647 0.490 0.251 0.305126 0.724 0.462 0.009 0.240 0.029 0.251 0.782 0.497 0.270 0.977127 0.350 0.372 0.531 0.201 0.758 0.577 0.032 0.499 0.353 0.969128 0.712 0.406 0.002 0.376 0.403 0.956 0.912 0.145 0.531 0.944129 0.304 0.036 0.124 0.941 0.865 0.268 0.527 0.017 0.112 0.188130 0.498 0.078 0.404 0.351 0.794 0.608 0.669 0.850 0.028 0.077131 0.429 0.207 0.309 0.110 0.986 0.310 0.459 0.807 0.729 0.601132 0.510 0.593 0.016 0.653 0.381 0.073 0.605 0.852 0.689 0.990133 0.348 0.445 0.585 0.143 0.494 0.013 0.075 0.055 0.328 0.268134 0.661 0.051 0.125 0.758 0.824 0.199 0.758 0.375 0.925 0.285135 0.480 0.608 0.247 0.773 0.560 0.984 0.420 0.243 0.827 0.548136 0.721 0.912 0.879 0.499 0.647 0.196 0.023 0.003 0.009 0.918137 0.918 0.724 0.261 0.903 0.025 0.003 0.211 0.025 0.819 0.969138 0.698 0.368 0.658 0.445 0.604 0.008 0.533 0.054 0.447 0.585139 0.300 0.871 0.140 0.485 0.278 0.895 0.712 0.103 0.443 0.108140 0.205 0.722 0.453 0.274 0.060 0.686 0.027 0.957 0.353 0.088141 0.686 0.045 0.822 0.392 0.129 0.410 0.608 0.100 0.260 0.462142 0.843 0.761 0.238 0.148 0.366 0.768 0.229 0.624 0.827 0.713143 0.435 0.043 0.537 0.293 0.686 0.091 0.882 0.435 0.125 0.327144 0.571 0.132 0.346 0.087 0.231 0.651 0.224 0.825 0.328 0.608145 0.075 0.330 0.691 0.532 0.229 0.156 0.688 0.201 0.070 0.669146 0.081 0.716 0.847 0.349 0.097 0.966 0.831 0.567 0.049 0.153147 0.182 0.921 0.734 0.996 0.082 0.368 0.227 0.036 0.169 0.002148 0.178 0.003 0.918 0.797 0.517 0.952 0.976 0.465 0.294 0.338149 0.255 0.251 0.039 0.995 0.495 0.912 0.623 0.001 0.422 0.261150 0.147 0.467 0.221 0.283 0.529 0.834 0.072 0.119 0.849 0.138151 0.589 0.052 0.777 0.138 0.512 0.272 0.794 0.452 0.623 0.680152 0.135 0.943 0.278 0.015 0.029 0.196 0.390 0.487 0.361 0.887153 0.149 0.229 0.789 0.204 0.850 0.101 0.333 0.920 0.238 0.661154 0.524 0.998 0.844 0.935 0.148 0.357 0.437 0.263 0.710 0.653155 0.451 0.733 0.463 0.019 0.773 0.101 0.379 0.981 0.282 0.657156 0.303 0.311 0.285 0.098 0.626 0.744 0.327 0.250 0.388 0.615157 0.429 0.436 0.612 0.330 0.966 0.895 0.492 0.132 0.190 0.041158 0.446 0.044 0.950 0.040 0.188 0.270 0.161 0.735 0.867 0.434159 0.316 0.010 0.341 0.683 0.412 0.902 0.530 0.669 0.694 0.982160 0.289 0.218 0.549 0.157 0.918 0.706 0.396 0.864 0.984 0.631




A B C D E 1 2 3 4 5

LOT DESIGNATION

161 0.517 0.796 0.930 0.294 0.264 0.215 0.521 0.558 0.699 0.322162 0.900 0.089 0.524 0.081 0.633 0.057 0.227 0.018 0.305 0.963163 0.482 0.681 0.705 0.928 0.725 0.472 0.542 0.312 0.156 0.450164 0.455 0.522 0.429 0.051 0.263 0.940 0.956 0.187 0.509 0.795165 0.584 0.978 0.915 0.770 0.917 0.733 0.592 0.869 0.938 0.176166 0.617 0.367 0.301 0.293 0.218 0.953 0.370 0.347 0.757 0.476167 0.994 0.293 0.604 0.301 0.761 0.357 0.465 0.459 0.715 0.608168 0.908 0.833 0.035 0.389 0.771 0.055 0.117 0.830 0.071 0.715169 0.552 0.405 0.489 0.178 0.847 0.872 0.627 0.488 0.829 0.025170 0.084 0.863 0.763 0.660 0.427 0.941 0.075 0.706 0.708 0.956171 0.649 0.142 0.833 0.099 0.315 0.854 0.093 0.406 0.168 0.754172 0.509 0.510 0.226 0.531 0.302 0.412 0.737 0.152 0.532 0.751173 0.094 0.250 0.323 0.690 0.724 0.802 0.297 0.586 0.042 0.042174 0.534 0.311 0.147 0.917 0.495 0.756 0.576 0.830 0.393 0.139175 0.995 0.275 0.941 0.369 0.934 0.010 0.974 0.199 0.060 0.934176 0.867 0.663 0.611 0.587 0.464 0.120 0.427 0.262 0.499 0.014177 0.631 0.433 0.841 0.229 0.972 0.446 0.026 0.086 0.001 0.147178 0.952 0.196 0.436 0.547 0.405 0.883 0.858 0.203 0.795 0.508179 0.328 0.489 0.223 0.907 0.916 0.623 0.405 0.635 0.690 0.945180 0.341 0.151 0.550 0.414 0.618 0.037 0.546 0.019 0.333 0.361181 0.335 0.627 0.212 0.466 0.762 0.476 0.983 0.659 0.877 0.013182 0.072 0.752 0.365 0.787 0.892 0.556 0.653 0.060 0.649 0.298183 0.695 0.331 0.727 0.261 0.306 0.238 0.432 0.262 0.105 0.334184 0.041 0.583 0.152 0.624 0.872 0.774 0.202 0.033 0.142 0.402185 0.127 0.254 0.360 0.823 0.016 0.314 0.092 0.727 0.591 0.061186 0.379 0.963 0.417 0.619 0.441 0.759 0.448 0.384 0.440 0.493187 0.894 0.097 0.250 0.727 0.903 0.154 0.853 0.377 0.100 0.397188 0.826 0.319 0.276 0.574 0.087 0.689 0.256 0.664 0.786 0.497189 0.681 0.485 0.957 0.472 0.405 0.131 0.025 0.462 0.816 0.464190 0.106 0.563 0.829 0.778 0.285 0.227 0.477 0.910 0.402 0.828191 0.470 0.836 0.338 0.352 0.253 0.415 0.215 0.026 0.223 0.183192 0.304 0.467 0.533 0.375 0.870 0.893 0.317 0.019 0.874 0.756193 0.417 0.242 0.423 0.335 0.352 0.849 0.202 0.786 0.974 0.144194 0.239 0.038 0.582 0.748 0.410 0.443 0.723 0.123 0.519 0.787195 0.721 0.343 0.289 0.933 0.653 0.821 0.813 0.005 0.771 0.486196 0.837 0.889 0.280 0.887 0.583 0.244 0.745 0.960 0.766 0.036197 0.507 0.198 0.932 0.084 0.028 0.141 0.797 0.370 0.237 0.771198 0.511 0.621 0.413 0.765 0.550 0.644 0.921 0.257 0.526 0.604199 0.694 0.165 0.148 0.018 0.149 0.917 0.696 0.863 0.791 0.856200 0.533 0.192 0.628 0.717 0.333 0.352 0.647 0.096 0.571 0.949



Appendix B

File Copy ofForms for QC/QA Program



BR 154 - Hot Bin Analysis - Superpave

This form is filled out by the QCT and the QAT as required by the testing frequencies. Aggregate gradations from eachhot bin being used to produce the mix are determined, and mathematically combined to determine the compositegradation. The combined aggregate gradation is checked against the JMF for specification compliance.

BR 157 - Drum Mix Plant Production Tests - Superpave

This form is completed by the QCT and the QAT as required by the testing frequencies. Composite aggregategradation results, moisture contents (as required by the mix), and PG binder contents (as required by the mix) arerecorded and checked for specification compliance.

BR 159M - Drum Mix Plant Production Tests

This form is completed by the QCT and the QAT for non-volumetric mixes, as required by the testing frequencies.Composite aggregate gradation results, moisture contents (as required by the mix), and PG binder contents (as requiredby the mix) are recorded and checked for specification compliance

BR 161M - Hot Bin Analysis

This form is filled out by the QCT and the QAT for non-volumetric mixes, as required by the testing frequencies.Aggregate gradations from each hot bin are determined, and mathematically combined to determine the compositegradation. The combined aggregate gradation is checked against the JMF for specification compliance.

BR 303 - Quality Control Daily Diary

This form is filled out daily by the QCT and is used to determine when sampling takes place. The sublot tonnage onthis form is an estimate for the day which is used with a random number to determine the sample point. This formincludes a diary type summary by both the QCT and QAT which should include items such as changes in mixes,problems encountered, weather conditions, and any actions taken to control the HMA production process.

BR 307 - Quality Control Hot Mix Asphalt Certification

This form is used to certify production of 150 tons or less. When the material needs to be certified, the QCT mustcompletely fill out and sign the form. This includes picking a lot number. Although testing is not required, the lotnumber will still be required on the BR 331. The QAF for these certified materials is always 1.00. The form istransmitted to the Project Field office each day certified material is produced.

BR 310M - Determination of Percent Non-Carbonate Particles in Marshall HMA Top Course Mixtures

*** This form will not be used for NYSDOT projects. It is provided for the use of towns, counties and othermunicipalities that specify Marshall designed mixes.

The QCT uses this form to record the test results of the aggregate friction testing for all Marshall surface course mixesas required by the specification and Materials Method 28.



BR 324M - Computation of Final Quality Adjustment Factors

This form is filled in by the QAT and is used to determine the QAF using Table 5 or Table 6 of this document(Table 401-8 or Table 401-9 of the Standard Specification Book).

BR 328M - Computation of Volumetric Mix Properties

This form is completed by the QCT and the QAT as required by the testing frequencies. The maximum theoreticalspecific gravity and the bulk specific gravity test results are recorded and checked for specification compliance.

BR 330M - Determination of Percent Non-Carbonate Particles in Superpave HMA Top Course Mixtures

The QCT uses this form to record the test results of the aggregate friction testing for all Superpave surface course mixesas required by the specification and Materials Method 28.

BR 331M - Production Summary Sheet

The production summary sheet is a summary of the test results and other calculations for daily production per mixdesign. The QCT fills out this form and is initialed by both the QCT and the QAT. The lot quantities on BR 331 arethe exact tonnages produced. These quantities will not be the same as those shown on the BR 303 since the quantitieson the BR 303 are only estimates. The QAT determines the QAF using the absolute difference from 4.00% and usingTable 401-8 Air Voids in Plant Mixture for volumetric designs or Table 401-94 for non-volumetric designs. Theexception is for certified materials of 150 tons or less, where the QAF is 1.00. All lots including certified materialsare entered on this form.

BR 343a - Daily Hot Mix Asphalt Authorized Shipments

This form is filled out by the QAT and includes quantity and QAF. This form needs to be submitted to the ProjectField office and to the Regional Materials Engineer as soon as completed.


BR 154 (10/99) NEW YORK STATE DEPARTMENT OF TRANSPORTATION - MATERIALS BUREAU HOT BIN ANALYSIS - SUPERPAVE

PRODUCER LOCATION FACILITY NO. SAMPLE TIME MIX DESCRIPTION FORMULA LOT SUBLOT SAMPLE DATE

Sieve SizeNo. 2 BIN No. 1 BIN No. 1A BIN No. 1B BIN FINE BIN MINERAL FILLER

Weight%

Ret.%

Pass. Weight%

Ret.%

Pass. Weight%

Ret.%

Pass. Weight%

Ret.%

Pass. Weight%

Ret.%

Pass. Weight%

Ret.%

Pass.

50.0 mm

37.5 mm

25.0 mm

19.0 mm

12.5 mm

9.5 mm

4.75 mm

2.36 mm

1.18 mm

600 µm

300 µm

150 µm

75 µm

PAN

TOTAL

BIN WeightBatched

PercentBatched

COMBINED GRADATION (% Passing)

50.0 mm 37.5 mm 25.0 mm 19.0 mm 12.5 mm 9.5 mm 4.75 mm 2.36 mm 1.18 mm 600 µm 300 µm 150 µm 75 µm

2

1

1A

1B

FINES

Min. Fill

RAP

TOTAL 100.0%

JMF TARGET VALUE

QAT RESULTS

QCT: (signature) QAT: (signature) Date:

BR 157 (10/99)


NEW YORK STATE DEPARTMENT OF TRANSPORTATION - MATERIALS BUREAUDRUM MIX PLANT PRODUCTION TESTS - SUPERPAVE

Plant Name Location Facility No.

Mix Description Formula No. Lot No. Sublot % RAP

MOISTURE CONTENT BINDER CONTENT

Calculation Composite Mixture RAP QA Calculation Mixture RAP QA

Wet Wt. (A) Sample Wt. (A)

Dry Wt. (B) Aggregate Wt. (B)

Diff. Wt.(A - B) Filter Gain Wt. (C)

Binder Wt. A - [B + C]

SAMPLE TIME

Composite Moisture RAP Moisture % Binder

Mixture % Binder RAP % Binder % Binder Target

Mixture Moisture

SieveSize

QC Gradation%

Agg.

%Min.Fill.

Total%

Pass.

QA Gradation%

Agg.

%Min.Fill.

Total%

Pass.JMF

Target JMF RangeWeight % Ret. % Pass. Weight % Ret. % Pass.

50.0 mm37.5 mm25.0 mm19.0 mm12.5 mm9.5 mm4.75 mm2.36 mm1.18 mm600 µm300 µm150 µm75 µmPanTotal

QCT: (signature) Date: QAT: (signature) Date:

BR 159 M (11/99)


NEW YORK STATE DEPARTMENT OF TRANSPORTATION - MATERIALS BUREAUDRUM MIX PLANT PRODUCTION TESTS


Mix Description Formula No. Lot No. Sublot % RAP

MOISTURE CONTENT BINDER CONTENTCalculation Composite Mixture RAP QA Calculation Mixture RAP QA

Wet Wt. (A) Sample Wt. (A)

Dry Wt. (B) Aggregate Wt. (B)

Diff. Wt. (A - B) Filter Gain Wt. (C)

Binder Wt. A - [B + C]

SAMPLE TIME

Composite Moisture RAP Moisture % Binder

Mixture % Binder RAP % Binder % Binder Target

Mixture Moisture

SieveSize

QC Gradation%

Agg.

%Min.Fill.

Total%

Pass.

QA Gradation%

Agg.

%Min.Fill.

Total%

Pass. JMF

Target JMF RangeWeight % Ret. % Pass. Weight % Ret. % Pass.

50.0 mm

37.5 mm

25.0 mm

19.0 mm

12.5 mm

6.3 mm

3.2 mm

850 µm

425 µm

180 µm

75 µm

Pan

Total

QCT: (signature) Date: QAT: (signature) Date:

BR 161 M (10/99)


NEW YORK STATE DEPARTMENT OF TRANSPORTATION - MATERIALS BUREAU HOT BIN ANALYSIS

PRODUCER LOCATION FACILITY NO. SAMPLE TIME

MIX DESCRIPTION FORMULA LOT SUBLOT SAMPLE DATE

Sieve Size

No. 2 BIN No. 1 BIN No. 1A BIN No. 1B BIN FINE BIN MINERAL FILLER

Weight%

Ret.%

Pass. Weight%

Ret.%

Pass. Weight%

Ret.%

Pass. Weight%

Ret.%

Pass. Weight%

Ret.%

Pass. Weight%

Ret.%

Pass.

50.0 mm

37.5 mm

25.0 mm

19.0 mm

12.5 mm

6.3 mm

3.2 mm

850 µm

425 µm

180 µm

75 µm

PAN

TOTAL

BINWeightBatched

PercentBatched

COMBINED GRADATION (% Passing)

50.0 mm 37.5 mm 25.0 mm 19.0 mm 12.5 mm 6.3 mm 3.2 mm 850 µm 425 µm 180 µm 75 µm

2

1

1A

1B

FINES

Min. Fill

RAP

TOTAL 100.0%

JMF TARGET VALUE

QAT RESULTS

QCT: (signature) QAT: (signature) Date:

BR 303 (10/99)


NEW YORK STATE DEPARTMENT OF TRANSPORTATION - MATERIALS BUREAU

QUALITY CONTROL DAILY DIARYPlant Location Facility No.

Weather Low Temp. Plant Type G Batch G Drum

Storage Bin Used G Yes G No

Date High Temp.

JMFNumber

MixDescription

LotNo.

SubLot

Rand.No.a

SublotAmount

(Mg)b

SamplePoint

[a x b]c

Previous SublotTotal 1

d

AccumSamplePoint 2[c + d]

SubLot

QAF

MixTemp.Time

MixTemp.

Notes: 1. When there is more than 1 sublot, the Previous Sublot Total [d] is the sum of the Sublot Amount [b] less the current sublot.2. “Accum Sample Point” is the sample point in metric tons (Mg) for that sublot from the beginning of the plant lot production.

ASPHALT BINDER SAMPLE Sample Time

am Primary Source Lot No. PG Grade Sample ID BR 170 Serial No.

Sample Time pm

Primary Source Lot No. PG Grade Sample ID BR 170 Serial No.

QCT Inspection Summary

QAT Inspection Summary

QCT (signature) Date QAT (signature) Date

BR 307 (5/99)



QUALITY CONTROL HOT MIX ASPHALT CERTIFICATION


PLANT

LOCATION

FACILITY NO.

REGION SHIPPING DATE

SHIPPED TO: MIX DESCRIPTION QUANTITY LOT NO.PROJECT NO.

LOCATION



By Title Date

---------------------------------------------------------------------------------------------------------------------------------------------------------

BR 307 (5/99)NEW YORK STATE DEPARTMENT OF TRANSPORTATION

MATERIALS BUREAUQUALITY CONTROL HOT MIX ASPHALT CERTIFICATION


PLANT

LOCATION

FACILITY NO.

REGION SHIPPING DATE

SHIPPED TO: MIX DESCRIPTION QUANTITY LOT NO.PROJECT NO.

LOCATION



By Title Date

BR 310 M (7/99)


NEW YORK STATEDEPARTMENT OF TRANSPORTATIONMATERIALS BUREAUDetermination of Percent Non-Carbonate Particles in Marshall HMA Top Course Mixtures

PRODUCER G.P. NO.

PRODUCER LOCATION FACILITY NO.

REGION SOURCE NO. SOURCE NO.

OTHER

MIX CODE/TYPE JMF/MIX NO. PLANT LOT NO. SUBLOT DATE SAMPLED

HOT BIN G COMPOSITE G BR 3a SERIAL NO. TESTED BY TIME SAMPLED

SieveSizes

No. 1 Stone or Type 6 Composite No. 1A Stone or Type 7 Composite

WO WX WXS(1) %RX WNC %NCX WO WX WXS

(1) %RX WNC %NCX

a b c b/a(100) d d/c(100) e f g f/e(100) h h/g(100)

6.3 mm

3.2 mm

WO = Mass of sample prior to gradation analysis. WNC = Mass of non-carbonate particles.WX = Mass of material retained on sieve x. %NCX = Percent of WXS that is non-carbonate particles.%RX = Percent of WO retained on sieve x. %B(2) = Batch Percentage for the appropriate stone size.WXS = Mass of split sample before non-carbonate analysis.(1) Note: Use all percentages in the decimal form when performing calculations.

Mixture Type or BinPercentBatched

Type 6 Mixture Type 7 MixtureTotal

PercentNon-Carbonate

+6.3 mm +3.2 mm +3.2 mm

%B(2) (%R6.3)(%NC6.3)(%B) x 100 (%R3.2)(%NC3.2)(%B) x 100 (%R3.2)(%NC3.2)(%B) x 100

Type 6 or No. 1

Type 7 or No. 1A

Total

1)When WX is of an appropriate size for testing (the sample does not need to be reduced further), enter the value of WX under both WX and WXS.2)Enter Percent Batched as a percentage of TOTAL aggregate. For stockpiles %B = 100%. For drum plants %B = 100 - % mineral filler.

BR 324 M (5/99)


NEW YORK STATE DEPARTMENT OF TRANSPORTATION

MATERIALS BUREAUCOMPUTATION OF FINAL QUALITY ADJUSTMENT FACTORS

Plant Name Location Production Date

Facility No. Region G Batch QAF Calculated ByG Drum

NON - VOLUMETRIC MIXES - AGGREGATE GRADATIONLot No.

Percent Passing Mix Description Proj. QAF

Final QAF

SieveSize

JMFTarget

Actual Sublot Test Values Absolute Diff. From JMF Target Avg. of Diff.

Sieve QAFA B C D A B C D

50.0 mm

37.5 mm

25.0 mm

12.5 mm

6.3 mm

3.2 mm

850 µm

425 µm

180 µm

75 µm

VOLUMETRIC MIXES - AIR VOIDS

Mix Description LotNo.

Actual Sublot Test Values Absolute Diff. From 4.0% Avg.of Diff.

FinalQAF

ProjQAFA B C D A B C D

Notes: 1. When a retest is performed on a sublot, the absolute difference values are averaged and used for that sublot.2. The project QAF may be different from the final QAF due to specification requirements.

Sheet of



COMPUTATION OF VOLUMETRIC MIX PROPERTIESFormula No. Mix Description Lot No. Sublot

Plant Location Facility No.

Combined Bulk SG(Gsb) Consensus Properties

Aggregate Bulk SGGi

% Agg.Pi

CAAng.

FAAng.

Flat &Elong

SandEquiv

No.3 Stone

No.2 Stone

No.1 Stone

No.1 StoneNon-Carb.

No.1A Stone

No.1A StoneNon-Carb.

Manuf. Sand

Natural Sand

Min. Filler

Volumetric Property Descriptions

Gmm = Maximum Sp Gr of HMA mixtureA = Weight of dry sample in air (g)D = Weight of flask filled with airless water at 25/C (g)E = Weight of flask filled with water & sample at 25/C (g)Gmm = A ÷ [A +D - E]VMA= 100 - [( Gmb x Ps ) ÷ Gsb ]VFB = 100 [( VMA - Pa ) ÷ VMA ]Gmb = Bulk Sp. Gr. for the total HMA mixtureGsb = Bulk Sp. Gr. for the total aggregate,

[ Ps ] ÷ [ P1/G1 + P2/G2 +....Pn/Gn ]Ps = Aggregate, percent by total weight of HMA mixturePa = Percent voids in total HMA mixturePi = Percent of individual agg. component in HMA mixtureGi = Sp. Gr. of individual agg. component in HMA mixture

BR 328 (1/02)

@NDesign = gyrations @NInitial = gyrations

Weight - gramsVolume

MaximumSp. Gr.

Gmm

SampleHeight

mm

BulkSp. Gr.

Gmb

% Gmm% AirVoids

SampleHeight

mm

BulkSp. Gr.

Gmb

% Gmm VMA VFB

SampleID

CompactionTemperature

° c

In air In water SSD

a b c d e f g h i j k l m n

c - b a ÷ d 100 (g÷e) 100 - h (f÷j) x g 100 (k÷e)

QC avg.

QA avg.

QC Sample QA Sample

1A 1B 1A 1B

A

D

E

Gmm

Avg Gmm

QCT: Date:

QAT: Date:

BR 330 M (7/99)


NEW YORK STATEDEPARTMENT OF TRANSPORTATIONMATERIALS BUREAUDetermination of Percent Non-Carbonate Particles in Superpave HMA Top Course Mixtures

PRODUCER G.P. NO.

PRODUCER LOCATION FACILITY NO.

REGION SOURCE NO. SOURCE NO.

OTHER

MIX CODE/TYPE JMF/MIX NO. PLANT LOT NO. SUBLOT DATE SAMPLED

HOT BIN G COMPOSITE G BR 3a SERIAL NO. TESTED BY TIME SAMPLED

SieveSizes

No. 1 Stone or 12.5 mm Composite No. 1A Stone or 9.5 mm Composite

WO WX WXS(1) %RX WNC %NCX WO WX WXS

(1) %RX WNC %NCX

a b c b/a(100) d d/c(100) e f g f/e(100) h h/g(100)

9.5 mm

4.75 mm(2)

3.2 mm

WO = Mass of sample prior to gradation analysis. WNC = Mass of non-carbonate particles.WX = Mass of material retained on sieve x. %NCX = Percent of WXS that is non-carbonate particles.%RX = Percent of WO retained on sieve x. %B (3) = Batch Percentage for the appropriate stone size.WXS = Mass of split sample before non-carbonate analysis.(1) Note: Use all percentages in the decimal form when performing calculations.

Mixture Type or BinPercentBatched

12.5 mm Mixture 9.5 mm Mixture TotalPercent

Non-Carbonate+9.5 mm +3.2 mm +4.75 mm +3.2 mm

%B(3) (%R9.5)(%NC9.5)(%B)x100 (%R3.2)(%NC3.2)(%B)x100 (%R4.75)(%NC4.75)(%B)x10 (%R3.2)(%NC3.2)(%B)x100

12.5 mm or No. 1Stone

9.5 mm or No. 1AStone

Total

1)When WX is of an appropriate size for testing (the sample does not need to be reduced further), enter the value of WX under both WX and WXS.2)When calculating the friction aggregate content for a 12.5 mm mixture the 4.75 mm sieve is not used.3)Enter Percent Batched as a percentage of TOTAL aggregate. For stockpiles %B = 100%. For drum plants %B = 100 - % mineral filler.



PRODUCTION SUMMARY SHEET

Year


Mix Description JMF No. Plant Type: G Batch G Drum

BR 331 M (10/99)

Date LotNo.

SubLot

SubLot

QAF

LotQAF

Total LotTons

Agg.Grad.P/F

%Non

Carb.

BulkSp.Gr.

Gmb

MaxSp.Gr.

Gmm

%Air

Voids

Agg.BulkGsb

%VMA

%VFB

(1)Wet

75 µm

Target%

BinderQCT QAT

Note 1. OptionalSheet of

BR 343a (5/99)


NEW YORK STATE DEPARTMENT OF TRANSPORTATION MATERIALS BUREAU

DAILY HOT MIX ASPHALT AUTHORIZED SHIPMENTS

Sheet of

REPORT NO. DATE REGION FACILITY NO. JOB STAMP

PLANT SURGE BIN USED 9 YES 9 NO

LOCATION

PROJECT PROJECT


PROJECT PROJECT


REMARKS:

AUTHORIZED BY: (QAT Signature) PROJECT REVIEWER: (Signature)

Materials Procedure 96-02 M

Documents

Transcript of Materials Procedure 96-02 M