Quality Assurance Essentials Emulsion Emulsion Tas ask k For orce ce Mee Meeting ting By: Colin A. Franco, P.E. Associate Chief Engineer RIDOT Den Denver er - May May 21 21-22 22, , 20 2017 17
Quality Assurance - Definition AASHT HTO O R10 0 & TR & TRB Cir ircula lar r E-C173 73 Qualit ity y Assura rance nce – Al All t l thos ose planned and systematic act ctio ions s nece cess ssar ary to provide confidence that a product or facility will perform satisfactorily in service …
Applicability of 23 CFR 637 • Applies to projects on the NHS • State administered and locally administered • Including Design-Build - 23CFR637.207(b) “All provisions of 637.207(a) are applicable to Design-Build projects and other alternative contracting methods.” • Non-NHS projects • Many States apply same QA procedures as NHS
Core Elements of a Quality Assurance Program Agency Acceptance Personnel Dispute Qualification Resolution QA Program Lab Independent Qualification Assurance Contractor QC
Core Elements of a QA Program Quality Assurance Agency Quality Acceptance Control Independent Assurance Dispute Resolution Laboratories Personnel
Agency Acceptance • All acceptance activities must be carried out by the Agency or their “ Designated Agent ” • Agency independently performs: Acceptance (Verification) Testing
Acceptance Program • Acceptance program. All factors that comprise the Agency determination of the quality of the product as specified in the contract requirements. These factors include: • verification sampling, • testing, • inspection
Acceptance Function • Acceptance is not focused on directing the methods used to achieve conformance • The primary objectives of agency acceptance are: • Measure the Quality of all materials produced and placed by the contractor • Determine the corresponding payment the contractor should receive
Acceptance Function • Quality measurement is achieved through three general acceptance activities: • Monitoring the adequacy of contractor QC activity • Performing acceptance inspection to identify visually deficient work • Performing Acceptance sampling and testing for key quality characteristics • Agency is obtaining information to confirm that all products meet the specified quality level
Independent Assurance - IA Independent Assurance - “Activities that are an unbiased and independent evaluation of all the sampling and testing procedures used in the Quality Assurance Program”
Scope of IA Activities Independent Assurance activities: • Provide an assessment of personnel proficiency and equipment for both agency and contractor
Independent Assurance – IA (cont.) • Performed by Agency or Designated Agent personnel who are not directly responsible for project Acceptance sampling and testing • Provides periodic independent evaluation of QC and Acceptance personnel and their equipment • Not used to make a determination of work quality or acceptability
Contractor Quality Control Quality Control - QC - “The system used by a Contractor party to monitor, assess and adjust their production or placement processes to ensure that the final product will meet the specified level of quality.” Definition
Contractor Responsibility for Quality Control • QC is the responsibility of the Contractor • The party producing or placing the product is in the best position to exercise Quality Control
Scope of Quality Control Activities • Contractor’s QC system should address: • Materials production processes • Materials transportation and handling • Field placement procedures • Calibration and maintenance of equipment • Activities (sampling, testing and inspection) to maintain each process in control • Means to make timely adjustments and corrections
Contractor QC Operating Documents • Quality Control Plan - A project specific document prepared by the contractor which identifies QC personnel and procedures that will be used to maintain production and placement processes in control and meet the agency specification requirements.
Requirements for Laboratory Accreditation • Central Laboratories • Consultant Labs used for Independent Assurance (IA) • Consultant Labs used for Dispute Resolution
Qualified Laboratories “Laboratories that are capable as defined by appropriate programs established by each Agency.”
Laboratory Qualification • Laboratory Qualification Program • All other Labs performing sampling and testing that is utilized in the Agency’s acceptance decision
Qualified Personnel Qualified Personnel - “Personnel who are capable as defined by appropriate programs established or recognized by each Agency .” Definition
Certified Personnel Definition Personnel who are recognized by a formal certifying body as qualified to perform specific procedures.
Requirement for Personnel Qualification / Certification A complete personnel qualification/certification program should include, at minimum: • Proficiency demonstration • Formal training • A written exam • On-the-job training • A process for disqualification or • Specified re- decertification qualification intervals
Materials Testing Dispute Resolution • Dispute Resolution - The procedure used to resolve discrepancies between the Agency’s Acceptance and Contractor’s QC testing results that could impact payment. • Dispute Resolution system required when QC results used in Acceptance decision.
Responsibility for Dispute Resolution • Can be performed within the DOT • Use of accredited third party laboratory can be used.
1. EMULSION APPLICATIONS 2. ASPHALT EMULSION GRADES PERFORMANCE TESTS 4. DESIGN/ 6. 3. 5. PRECONSTRUCTION IN-SERVICE PERFORMANCE REQUIREMENTS FUNCTION MANUFACTURING OF LIQUID BITUMEN EMULSION CONSTRUCTION ENGINEERING AND DURABILITY FATTINESS RESISTANCE-EARLY APPLICATION MIX DESIGN DRAIN OUT/ SPRAYABILITY ADHESION TO SUBSTRATE ADHESION TO AGGREGATE ADHESION TO SUBSTRATE A. B. FIELD COATING TEST LONG TERM RAVELLING WETTING OF STONES THERMAL CRACKING C. FATIGUE CRACKING MATERIAL ENGINEERING MATERIAL MANUFACTURING COMPACTABILITY AGGREGATE LOSS BREAKING RATE GENERAL WORKABILITY RESISTANCE RESISTANCE SWEEP TEST PLACEMENT AND DESIGN (STABILITY/CONSISTENCY) STABILITY RAVELING OXIDATION RUTTING SHOVING SKID UV FT OIL DISTILLATE ID OF CATIONIC RESIDUE AND EVAPORATION EVAPORATION DEMULSIBILITY EXAMINATION ABILITY AND WEIGHT PER RESIDUE BY LOW- RESIDUE BY CHARGE OF RESIDUE BY SETTLEMENT MISCIBILITY WITH WATER RESISTANCE TEMPERATURE VISCOSITY (SAYBOLT SIEVE TEST STABILITY OF RESIDUE SLOW SET EMULSIONS PARTICLE CATIONIC COATING STORAGE DISTILLATION CONTENT CEMENT COATING FREEZING GALLON WATER WATER VACCUUM FUROL) MIXING TACK COAT FOG SEAL SCRUB SAND SEAL SLURRY SEAL MICROSURFACING CRS-2, CMS-2, RS-2, HFMS-2 W 13075-1, NF T66- PATTI Adhesion ASTM D244, P, ASTM D244, P, ASTM D244, P, ASTM D244, P, ASTM D244, P, ASTM D244, EN SKID TESTER - ASTM D244, P ASTM D244, P ASTM D244, P ASTM D244, P ASTM D244, P ASTM D244, P ASTM D244, P ASTM D244, P ASTM D244, P ASTM D244, P ASTM D244, P ASTM D244, P ASTM D244, P ASTM D244, P ASTM D244, P Test, PE, A, IA ASTM D244, D 6930, EN ASTM D244 PE, A, IA PE, A, IA LATEX D 7000 PE, A PE, A PE, A 12847 D7276 019 PE SAMPLE CHIP SEAL A A A A A A A A A A A A A A A A FOAM ASPHALT NOVA VIRGIN MIXES RECYCLED CIR Quality Assurance Testing SECTION DESCRIPTION P - Process Control performed by the contractor/vendor over all production operations. This will entail the constant monitoring of equipment, materials, and production activity to insure that the materials 1. List of various applications for bitumen emulsions meet all applicable requirements and are produced within specifications A - Acceptance testing performed by the agency, or its designated agent, to evaluate acceptability of 2. List of the all grades of bitumen emulsions that can be used for the final product. Also called verification sampling and testing when specifically used to validate the each application contractor's data 3. Describes the various tests associated with the IA - Independent assurance are activities that are an unbiased and independent manufacturing of bitumen emulsions evaluation of all the sampling and testing (or inspection) used in the QA program PE - Product evaluation is based on compatibility with established standards and A. Lists test performed when designing the emulsion specifications, tested properties, performance history and suitablity to specific liquid to be manufactured applications performed by the puchasing agency or independent laboratory. B. Process control tests conducted during the manufacturing of the emulsion liquid C. Material conformance testing 4. Tests and processess to establish the design and construction criteria utilizing specific materials and resources 5. Tests performed during the construction of the emulsified application process 6. Tests associated with post construction/in- service performance
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