QCT Level 2 Study Aid & Reference Materials

GDOT Hot Mix Asphalt Quality Control Technician – Level 2Services Manager within 14 days of the incident. The written complaint must specify theexamination date, the examiner, and the nature of the complaint or protest.Complaints and protests should be reviewed and a recommendation made to theChairman of the Appeal Board. All complaints and protests will be promptly answered inwriting.5. Qualification5.1 GDOT will maintain a registry of technicians who have successfully completed therequirements of QCT Level 2 certification. The registry will include:(a) Name, qualification identification number, and address;(b) Courses, and dates completed;(c) Course content:Test methods included;Lecture or laboratory;Written examination5.2 GDOT shall provide the qualified technician with documentation of the certification inthe form of a registration card and certificate. The document will include an expirationdate.The registered certified technician should maintain a current address on file. Send changeof address notice to: Bituminous Technical Services Manager, Georgia Department ofTransportation, 15 Kennedy Drive, Forest Park, GA 30297.5.3 Recertification Requirements - The QCT Level 2 certification is valid for 3 years.Recertification for QCT Level 2 will be required 3 years after initial certification. The requalification process may include refresher courses and/or re-testing. Written testingrequirements for recertification will be waived if a QCT Level 2 attends at least 18 hoursof training per 3 years, prior to certification expiration.Please see Table 1 below for information concerning training hours for recertification.Table 1 – Training Hour Requirements for RecertificationCredit Hours Required for QCT Level 2 Required ClassesRecertification18 hours required over the 3 Option 1: Two QCT Level 2 Training Work Shops (12 Hours)year periodand 3 annual IA Evaluations (2 hours each for a total of 6hours).Option 2: One QCT Level 2 Training Work Shop (6 hours)plus 6 hours of other eligible supplemental training, and 3annual IA Evaluations (2 hours each for a total of 6 hours).Option 3: One QCT Level 2 Work Shop (6 Hours) plus 12hours of other eligible supplemental training.Note: Regardless of other eligible training hours, IA evaluations are required yearly foractive Acceptance Sample Testing certified QCT Level 2 technicians in accordance withSOP 30.November 20196

GDOT Hot Mix Asphalt Quality Control Technician – Level 2Additional supplemental training that has been approved for use as the additionalmiscellaneous bituminous material related training is detailed in Table 2.Table 2 – Approved Supplemental TrainingTraining Eligible for Additional Hours CreditOfferedBituminous Construction Work ShopOMAT Approved Industry Sponsored TrainingGeorgia Quality Initiative (GQI) ConferenceAsphalt Quality Paving ConferenceQCT Level 1 trainingGDOT Current IT or Computer Acceptance Sample DataSystemSoutheastern Asphalt User/Producer Group (SEAUPG)AnnuallyAs AvailableAs AvailableAs AvailableAs AvailableAs AvailableCreditHours64-66666Annually6As detailed in Table 2, the Office of Materials and Testing may consider other bituminousmaterials or construction related training. Technicians should send copies of trainingworkshop agenda(s) and proof of attendance (e.g. certificates) to submit for considerationto either the Bituminous Technical Services Manager or the Assistant BituminousTechnical Services Manager.If the QCT has not fulfilled the continual training hours requirements within theestablished time period, he or she must retake the certification written test to continueperforming QCT Level 2 duties.6. Conflict Resolution (QCT Level 2)6.1 Incorrect Procedures - QCTs will be made aware of incorrect sampling and testingmethods or failure to comply with QCT responsibilities at the time the incorrect procedureis identified. The QCT Level 2 Manager will be made aware of these discrepancies at thesame time. The QCT will be instructed on how to correct discrepancies. (See Diagram 1for description of process)6.2 Discussion Meeting - If the QCT continues to fail in performing the duties as required,a meeting will be held at the District Lab in the District where the discrepancies occurredor the Central Lab. The QCT, the QCT Manager and Bituminous Technical Servicespersonnel will be present to discuss the discrepancies to address the problem and/orcommunicate the correct procedure. The meeting will be formally documented andpossible future disciplinary action will be noted in the follow-up letter.6.3 Progressive Actions - If further problems are encountered:(a) The QCT will be required to re-take the performance and/or written certificationexam (at their existing Level) for failing to demonstrate the abilities of a Level 1 orLevel 2 QCT.(b) Certification may be suspended for a period of time.November 20197

GDOT Hot Mix Asphalt Quality Control Technician – Level 26.4 Intentional Falsification of Records - Falsification of records or acceptance test resultswill result in permanent revocation of QCT Certification. A certified letter will be sent tothe QCT, the QCT Manager, and the Corporate Head of the company that employs theQCT providing notification of permanent revocation and the appeal process.6.5 Appeal Process - The QCT will have the right to appeal any adverse action whichresults in suspension or permanent revocation of certification by responding to an AppealBoard within 10 calendar days after receiving notice of the proposed adverse action.Failure to appeal within 10 calendar days will result in the proposed adverse actionbecoming effective on the date specified in the notice. Failure to appeal within the timespecified will result in a waiver of all future appeal rights regarding the adverse actiontaken. The QCT may appeal in writing or in person to the Chairman of the Appeal Boardat: Director of Construction, Georgia Department of Transportation, One Georgia Center,600 West Peachtree Street, Atlanta, GA 30308. The Director of Construction may bereached by phone at 404-631-1970 between the hours of 8 a.m. and 4 p.m. (Mondaythrough Friday) in order to schedule an appointment. The QCT may continue workingduring the appeal process. An Appeal Board meeting will be scheduled as needed by theChairman of the Appeal Board within 10 days of receiving the appeal notice. There willbe five members on the Appeal Board, called by the Chairman:GDOT Division Director of Construction - (Chairman of the Appeal Board)GDOT Construction Liaison (not from affected District)Consultant (nominated by the Consultant community)Contractor (other than the QCT’s company- nominated by the Contracting Industry)FHWA Resource Center Material Engineer or designeeThe Appeal Board will hear the appeal and make a decision within 5 days of hearing theappeal. Decisions of the Appeal Board shall be final and shall be made in writing to theQCT.November 20198

GDOT Hot Mix Asphalt Quality Control Technician – Level 2Diagram 1 – Conflict Resolution Diagram1Communicate problem to QCTand QCT Level 2 Managerverbally.Communicatediscrepanciesin QCTSampling andTestingprocedures.1AFalsification of Revocationofrecords or testCertificationresults.2Discussion Meeting with QCTand QCT Level 2 Manager heldat Branch Lab.Follow-up letter sent to QCTAnd QCT Manager.Continueddiscrepanciesin QCTSampling andTestingprocedures.Result:Written warning3QCT will receive notice ofsuspension of certificationand/or be required to retakecertification exam.Continueddiscrepancies in QCTSampling and Testingprocedures.Result:Certificationsuspension, retakeexam4QCT may appealadverse action toAppeal Board.November 2019Right toAppeal9

GDOT Hot Mix Asphalt Quality Control Technician – Level 2ExercisesNovember 2019

SOP 2 – Appendix DMethod of calculating Credited Asphalt Cement content for asphaltic concrete mixturesincorporating reclaimed asphalt pavement (RAP) or recycled asphalt shingles (RAS)Example: 12.5 mm SMA Mix with 6.1 % original optimum AC (OOAC) with 15 % RAP with 5.75 % ACin RAPUsing standard mix design procedure, RAP binder contribution constitutes5.75 x 0.15 0.86 % AC for 100 % binder creditUsing factor to calculate Credited AC (CAC)0.86 x 0.75 0.65 % CACUsing factor to calculate Non-Credited AC (NCAC)0.86 - 0.65Add 0.21 % 6.1 % 0.21 % NCAC 6.31 % COACThe COAC is 6.31 % On JMF COAC 6.30This will be noted on the bottom of the design and submitted for job mix formulas

SOP 2 – Appendix DMethod of calculating Credited Asphalt Cement content for asphaltic concrete mixturesincorporating reclaimed asphalt pavement (RAP) or recycled asphalt shingles (RAS)Example: 12.5 mm SMA Mix with 6.1 % original optimum AC (OOAC) with 15 % RAP with 5.75 % ACin RAPUsing standard mix design procedure, RAP constitutes5.75 x 0.15 0.86 % AC for 100 % binder creditUsing factor to calculate Credited AC (CAC)0.86 x 0.60 0.52 % CACUsing factor to calculate Non-Credited AC (NCAC)0.86 - 0.52 0.34% NCACAdd 0.34 % 6.1 % 6.44 % COACThe COAC is 6.44 % On JMF COAC 6.40This will be noted on the bottom of the design and submitted for job mix formulas

Short CutExample: 12.5 mm SMA Mix with 6.1 % original optimum AC (OOAC) with15 % RAP and RAP AC is 5.75 %Using short cut method5.75 x 0.15 x 0.40 0.34 % Non-credited Binder ACAdd 0.34 % 6.1 % 6.44 % COACThe COAC is 6.44 % On JMF COAC 6.40This will be noted on the bottom of the design and submitted for job mixformulas

What are the minimum and maximum sample weights for12.5 mm SMA mix?

Where do you find the PG binder grade requirements forvarious mix types?

Blending Problem 1- 12.5 mm SMAPlant Type Drum15 % RAPPlant Speed 300 TPHMix Type 12.5 mm SMARAP AC 5.75 %COAC 6.40 %12.5 mm SMAPercent Lime 1.0 %15 % RAP

Blending Problem – 1 – 12.5 mm SMAWhat are the Bin Pulls for Each Material?Sieve Size37 mm25 mm19 mm12.5 mm9.5 mm4.75 mm2.36 mm300 um75 .10.521W1010010010010010092846.24.40RAP Fly Ash Lime Comb. Grad. JMF100 100 100100.0100100 100 100100.0100100 100 100100.0100100 100 10092.99398 100 10070.17083 100 10028.12875 100 10023.7244799 10018.2189.5 84.3 10010.51115 9.1 0.9100

Blending Problem 2 - 12.5 mm SPPlant TypeDrumDrumMix Type 12.5 mm SP25 % RAPOptimum AC 5.35 %Percent Lime .9%SIZESOURCE1 1/2"1"3/4"1/2"3/8"#4#8#16#30#50#100#200PullRAP AC 4.75 %Plant Speed 250 643332618115.5

12.5 mm Superpave Mix with 5.35 % original optimum AC (OOAC) with 25 % andAC in 4.75 % RAP (25% RAP with RAP AC of 4.75%)Using short cut method

Blending Problem – 2 – 12.5 mm SPWhat are the Bin Pulls for Each Material?Sieve Size37 mm25 mm19 mm12.5 mm9.5 mm4.75 mm2.36 mm75 721225Lime Comb. 10043.71005.40.9100JMF100100100988659435.5

Aggregate BinAggregate Bin Pull %Initial WeightFinal Dry Weight007089W10RAP500484500472500463500459

Calculate the extraction below:Type of Mix: 12.5 mm SuperpaveTotal Weight2257.4Dry WeightDifference WeightPercent ACJob Mix Formula AC5.5Temperature:Final Weight ofSilicaBeginning WeighSilicaDifference Dry SampleWeightTotal Dry Weight305258.8125.02014.0

You are producing the12.5 mm Superpave mix through a drum plant using 007, 089, 810,W10 and RAPCalculate the extraction below:Type of MixTotal WeigthTotal Dry WeightDifference in Wt.Percent ACJMF AC %12.5 mm SP1665.601665.65.50Mix TemperatureFinal Wt. SilicaBeginning Wt. SilicaDifference in Wt. Dry WeightTotal Dry Weight300199.51251502.80 Total Dry Weight of SampleSIEVES19 mm12.5 mm9.5 mm2.36 mm75 umWEIGHT022.18215.8986.51502.41% RET.#DIV/0!#DIV/0!#DIV/0!#DIV/0!#DIV/0!% PASSING#DIV/0!#DIV/0!#DIV/0!#DIV/0!#DIV/0!Does this Sample Meet Mixture Control Tolerances in Section 828?JMF1009886435.5

A second QA sample was obtained on the 12.5 mm Superpave mix and the following sample informationwas obtainedCalculate the extraction below:Type of MixTotal WeigthTotal Dry WeightDifference in Wt.Percent ACJMF AC %12.5 mm SP1660.301660.35.50Mix TemperatureFinal Wt. SilicaBeginning Wt. SilicaDifference in Wt. Dry WeightTotal Dry Weight300192.71251500.50 Total Dry Weight of SampleSIEVES19 mm12.5 mm9.5 mm2.36 mm75 umWEIGHT021.8213.6981.51501.1% RET.#DIV/0!#DIV/0!#DIV/0!#DIV/0!#DIV/0!% 86435.5

For the 12.5 mm Superpave mix in the Previous ProblemDoes this sample meet GDOT specified requirements?What must the contractor do at this pointWhat about the mix in the silo?

Blending Problem 3 – 9.5 mm SP Type 2Mix Type :9.5 mmPlant TypeDrumPlant SpeedSIZESOURCE300 TPH71 .01821.511Type 79564124103.110010010010010099876752352011Percent of RAP 30%AC in RAP 4.89 %Percent of AC 5.50%Lime %0.9%COAC RAPLimeCOMB.JMF 0010010098-10090-10055-7542-476.0 5.0-7.0

9.5 mm Superpave Mix with 5.50 % original optimum AC (OOAC) with 30 % and AC in 4.89 % RAPUsing short cut method

What if Anti-strip additive was also required at a rate of 0.5 percent ofneat AC. How many pounds per minute of additive will be required?

Blending Problem - 3 - 9.5 mm SP Type IIWhat are the Bin Pulls for each Material?Sieve Size7 89 W1037 mm100 100 10025 mm100 100 10019 mm100 100 10012.5 mm71 100 1009.5 mm18 99 1004.75 mm2 39 992.36 mm 1.5 67975 um013.10 37 b. 01009870476

Aggregate Bin Pull CalculationsIn Pounds per MinuteTotal Aggregate TPH0Aggregate Type (size)0Total Plant Production TPH (A)0Aggregate Bin Pull % (B)0Each Agg. % TPH (C A x (B/100)0.00Convert Tons to Pounds (D C x 2000)0Calculate PPM (E D/60)0.0Total Calculated Aggregate TPHTotal Calculated Aggregate .10.0000.00300.0000.00 Agg. TPH0 Agg PPMLime00.90.0000.0

Using the information below, calculate the maximum and effective specific gravitiesFlask NumberPercent of ACSample Wt in AirFlask Wt in AirNet WtSample Wt in WaterFlask Wt in WaterNet Wt in WaterDifferenceMaximum SPGSPG of ACEffective SPGMaximum SPG (Air Weight)Effective 1.0331.0331.033(Air Weight)(Air Weight-Water Weight)(% Aggregate)(100/Maximum SPG) - (% AC / AC SPG)

Combined Specific Gravity of Aggregate2.779Percent of Asphalt Cement5.20 %Percent of Hydrated Lime0.90 %Lot Tonnage1250 tonsDetermine T1% Aggregate x 2.75T1 Tx %Y% AC combined bulk Specific Gravity100T1Pay weight, tonnage (Mg)T Actual weight% AC Percent asphalt cement by weight of total mixture% Aggregate Percent aggregate by weight of total mixture minus the hydrated limeCombined Bulk Sp. Gr. Calculated combined bulk specific gravity of various mineral aggregates used in themixture% Y Percent hydrated lime by weight of mineral aggregate

Original Job Mix Formula ApprovalAfter the Contract has been awarded, Job mix Formulas must be submitted atleast two weeks prior to the beginning of mixing operations in accordance withSection 400.1.03.C.No asphaltic concrete work will be started until the Bituminous TechnicalServices Engineer has approved a Job Mix Formula for the mixture to be used.No mixture will be accepted until the Job Mix Formula is approved.Revised Job Mix Formula ApprovalThe Contractor may request a revision to the original Job Mix Formula during theadjustment period in accordance with Section 400.3.06.B if improvement indensity is required. The Bituminous Construction Technical Services Engineermay make revisions to the Job Mix Formula to address any mixture qualitycontrol issues.Job Mix Formula revisions must be submitted in writing meeting therequirements of Section IIJob Mix Formulas will not be revised after the beginning of a lot of asphalticconcrete. If a revision is required during production, the lot will be closed andnew one established prior to any revisions being used on the 159.

Request for Approval of Asphaltic Concrete Job Mix FormulaOnly a approvedMix Design can be used?Company Name:Who is responsiblefor submitting JMF?Project No.:County:Contr. ID No.:PI No.:Bituminous TSE:Date:Area Engineer:District:Plant Location:Plant No.:Person Responsible for Quality Control:Type of MixOriginal Mix Design IDAgg. SizePercentageSource No.Source/LocationSiteManager Mix ID #Material CodeType of MixWho is responsible forapproving the JMF?Original Mix Design IDSiteManager Mix ID #Material CodeWhat determines theJMF mix temperature?Type of MixOriginal Mix Design IDSiteManager Mix ID #Material CodeGrade of AC:Maximum Three (3)Sources per AC GradeType of Anti-strip AdditiveFiberJMF Temp FJMF Temp FJMF Temp FJMF Temp FJMF Temp FJMF Temp FPG:PG:PG:PG:PG:PG:HydratedLimeLiquid A.S.MineralCelluloseMIXTURE DATAMix TypeWhat is the temperaturetolerance from thetemperature specified onthe JMF?Mix TypeMix Type1-1/2" / 37.5 mm1" / 25 mm3/4" / 19mm1/2" / 12.5 mm3/8" / 9.5 mmNo. 4 /4.75 mmNo.8 /2.36 umNo.50 /300 umNo. 200 /0.75 umPercent A.C.Theo. Spec. Gravity (Gmm)Calibration FactorApprovedBY:DisapprovedRemarks / Locations:COPIES TO:Date:What is the frequency forchecking mixturetemperature at the asphaltplant

Sieve789 W10 M10 RAP Lime Comb. Grad37 mm100.0 100.0 100.0 100.0 100.0 100.0100.025 mm100.0 100.0 100.0 100.0 100.0 100.0100.019 mm100.0 100.0 100.0 100.0 100.0 100.0100.012.5 mm 86.9 100.0 100.0 100.0 99.0 100.099.89.5 mm43.9 99.0 100.0 100.0 93.0 100.097.94.75 mm4.0 44.0 99.0 98.0 65.0 100.073.32.36 mm1.6 5.0 69.0 80.0 50.0 100.045.975 um0.5 1.0 4.4 11.0 10.0 100.06.3AC0.0 31.0 32.1 11.0 25.0 0.9100.0Is this a Type I or Type II 9.5 mm SP mix?JMF100.0100.0100.098.073.046.06.05.80

Sieve789 W10 M10 RAP Lime Comb. Grad37 mm100.0 100.0 100.0 100.0 100.0 100.0100.025 mm100.0 100.0 100.0 100.0 100.0 100.0100.019 mm100.0 100.0 100.0 100.0 100.0 100.0100.012.5 mm 86.9 100.0 100.0 100.0 99.0 100.099.89.5 mm43.9 99.0 100.0 100.0 93.0 100.098.04.75 mm4.0 44.0 99.0 98.0 65.0 100.078.72.36 mm1.6 5.0 69.0 80.0 50.0 100.053.475 um0.5 1.0 4.4 11.0 10.0 100.07.3AC6.150.0 21.0 32.1 21.0 25.0 0.9100.0What Changes would you make?JMF100.0100.0100.098.073.046.06.05.80

Sieve789 W10 M10 RAP Lime Comb. Grad37 mm100.0 100.0 100.0 100.0 100.0 100.0100.025 mm100.0 100.0 100.0 100.0 100.0 100.0100.019 mm100.0 100.0 100.0 100.0 100.0 100.0100.012.5 mm 86.9 100.0 100.0 100.0 99.0 100.099.89.5 mm43.9 99.0 100.0 100.0 93.0 100.097.84.75 mm4.0 44.0 99.0 98.0 65.0 100.064.62.36 mm1.6 5.0 69.0 80.0 50.0 100.035.075 um0.5 1.0 4.4 11.0 10.0 100.05.4AC5.600.0 47.0 22.1 5.0 25.0 0.9100.0What Changes would you make?JMF100.0100.0100.098.073.046.06.05.80

Sieve789 W10 M10 RAP Lime Comb. Grad37 mm100.0 100.0 100.0 100.0 100.0 100.0100.025 mm100.0 100.0 100.0 100.0 100.0 100.0100.019 mm100.0 100.0 100.0 100.0

1.2 The term QCT Level 2 identifies a Quality Control Technician (QCT) at Level 2. 1.3 An individual must be QCT Level 1 certified before obtaining the QCT Level 2 certification. 1.4 Superpave Mix Design Technician is not currently covered by this guideline but is considered to address the function of mix design and is available through the .