Supporting Materials for NCHRP Report 626 (2009)

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ACKNOWLEDGMENT This work was sponsored by the American Association of State Highway and Transportation Officials (AASHTO), in cooperation with the Federal Highway Administration, and was conducted in the National Cooperative Highway Research Program (NCHRP), which is administered by the Transportation Research Board (TRB) of the National Academies. COPYRIGHT PERMISSION Authors herein are responsible for the authenticity of their materials and for obtaining written permissions from publishers or persons who own the copyright to any previously published or copyrighted material used herein. Cooperative Research Programs (CRP) grants permission to reproduce material in this publication for classroom and not-for-profit purposes. Permission is given with the understanding that none of the material will be used to imply TRB, AASHTO, FAA, FHWA, FMCSA, FTA, Transit Development Corporation, or AOC endorsement of a particular product, method, or practice. It is expected that those reproducing the material in this document for educational and not-for-profit uses will give appropriate acknowledgment of the source of any reprinted or reproduced material. For other uses of the material, request permission from CRP. DISCLAIMER The opinion and conclusions expressed or implied in the report are those of the research agency. They are not necessarily those of the TRB, the National Research Council, AASHTO, or the U.S. Government. This report has not been edited by TRB.

Project No. 10-65 COPY NO. NONDESTRUCTIVE TESTING TECHNOLOGY FOR QUALITY CONTROL AND ACCEPTANCE OF FLEXIBLE PAVEMENT CONSTRUCTION VOLUME 2—RESEARCH REPORT Prepared for: National Cooperative Highway Research Program Transportation Research Board National Research Council Of National Academies Prepared By: Harold L. Von Quintus, P.E., ARA (Principal Investigator) Chetana Rao, PhD., ARA (Project Manager) Robert E. Minchin, Jr., Ph.D., P.E., UFL, Gainesville Kenneth R. Maser, PhD., P.E., Infrasense, Inc. Soheil Nazarian, PhD., P.E., UT, El Paso Brian Prowell, P.E., NCAT Champaign, IL June 2008

TABLE OF CONTENTS Page No. Abbreviations and Nomenclature.............................................................................................. iv Terms and Symbols .................................................................................................................viii Acknowledgments .................................................................................................................... x Abstract ..................................................................................................................xii EXECUTIVE SUMMARY ......................................................................................................... 1 1 INTRODUCTION ............................................................................................................. 1 1.1 Objectives .............................................................................................................. 1 1.2 Integration of Structural Design, Mixture Design, and QA................................... 2 1.3 Products.................................................................................................................. 2 2 NDT DEVICES INCLUDED IN THE FIELD EVALUATION....................................... 4 3 PROJECTS AND MATERIALS INCLUDED IN FIELD EVALUATION..................... 9 4 FIELD EVALUATION OF NDT DEVICES.................................................................... 9 4.1 Identifying Anomalies and Physical Differences .................................................. 9 4.2 Estimating Laboratory Measured Moduli.............................................................. 9 4.3 Accuracy and Precision of Different NDT Devices ............................................ 15 4.4 Summary of Evaluations...................................................................................... 15 5 CONCLUSIONS.............................................................................................................. 23 5.1 Unbound Layers and Materials............................................................................ 23 5.2 HMA Mixtures..................................................................................................... 25 6 RECOMMENDATIONS................................................................................................. 27 PART I—INTRODUCTION .................................................................................................... 29 CHAPTER 1 - INTRODUCTION............................................................................................... 31 1.1 Background.......................................................................................................... 31 1.2 Definition of Highway Quality Assurance Terms ............................................... 32 1.3 Research Problem Statement ............................................................................... 33 1.4 Research Objectives............................................................................................. 33 1.5 Project Organization ............................................................................................ 34 1.6 Scope of Project Document and Research Report ............................................... 35 PART II—SUMMARY OF FINDINGS .................................................................................. 37 CHAPTER 2 – MATERIAL PROPERTIES FOR CONTROL AND ACCEPTANCE.............. 39 2.1 Quality Characteristics Used in Previous and Current QA Programs ................. 39 2.2 Control and Acceptance Procedures .................................................................... 39 2.3 Sampling Plans for Measuring Quality Characteristics ....................................... 40 2.4 Integration of Design and Acceptance Procedures .............................................. 41 2.5 Issues with Existing QA Tests for Measuring Quality Characteristics................ 41 2.6 Summary of Material Properties Used for QA .................................................... 43 - i -

CHAPTER 3 – REVIEW OF NONDESTRUCTIVE TESTING TECHNOLOGIES................. 47 3.1 Nondestructive Testing and Evaluation – Definitions and Terminology ............ 47 3.2 Overview of Nondestructive Evaluation Technologies ....................................... 48 3.3 NDE Technologies for Evaluating Flexible Pavements ...................................... 48 3.4 Impact Devices and Technology for Unbound Materials and Layers ................. 52 3.4.1 Dynamic Cone Penetrometer ................................................................... 52 3.4.2 Clegg Impact Soil Tester ......................................................................... 56 3.5 Deflection Measuring Devices and Technology.................................................. 57 3.5.1 Falling Weight Deflectometer.................................................................. 58 3.5.2 Light Weight Deflectometer or Portable FWDs ...................................... 60 3.5.3 Application to Flexible Pavement Testing............................................... 60 3.6 Ground Penetrating Radar Devices and Technology........................................... 62 3.6.1 Operation Principles................................................................................. 62 3.6.2 Equipment and Software.......................................................................... 64 3.6.3 Application to Flexible Pavement Testing............................................... 65 3.6.4 Application to HMA Density and Air Void Content Determination....... 66 3.7 Infrared Thermography Technology.................................................................... 67 3.7.1 Operation Principles................................................................................. 69 3.7.2 Equipment and Software.......................................................................... 70 3.7.3 Application to Flexible Pavement Testing............................................... 71 3.8 Ultrasonic/Seismic Devices and Technology ...................................................... 73 3.8.1 Spectral Analysis of Surface Waves Test Method—SASW.................... 78 3.8.2 Impact-Echo Test Method........................................................................ 80 3.8.3 Impulse Response Test Method............................................................... 82 3.8.4 Ultrasonic Surface Wave Test Method—USW ....................................... 83 3.8.5 Ultrasonic Body Wave Test Method—UBW .......................................... 85 3.8.6 Scanning Test Systems ............................................................................ 86 3.8.7 Acoustic Emission Test Method .............................................................. 88 3.8.8 Laser-Induced Ultrasonic Test Method ................................................... 89 3.9 Steady-State Vibratory Devices and Technology................................................ 90 3.9.1 Principle of Operation.............................................................................. 91 3.9.2 Application to Flexible Pavement Testing............................................... 91 3.10 Magnetic Imaging or Tomography Technology.................................................. 91 3.10.1 Principle of Operation.............................................................................. 92 3.10.2 Measuring Procedure ............................................................................... 92 3.11 Non-Nuclear Density Estimating Devices & Technology................................... 93 3.11.1 Roller-Mounted Density/Stiffness Systems............................................. 94 3.11.2 Non-Roller-Mounted, Non-Nuclear Electric Devices ........................... 102 3.12 Surface Condition Measuring Systems and Devices ......................................... 109 3.12.1 Surface Texture...................................................................................... 109 3.12.2 Noise and Skid ....................................................................................... 111 3.12.3 Ride Quality ........................................................................................... 112 3.13 Summary of NDT Technologies and HMA Pavement Evaluation.................... 113 ii

CHAPTER 4 – NDT TECHNOLOGIES FOR APPLICATION TO QUALITY ASSURANCE ................................................................................................................ 115 4.1 Evaluation Factors and Topics........................................................................... 115 4.2 Data Sources for Evaluation .............................................................................. 117 4.3 Deflection Based Methods—FWD and LWD ................................................... 118 4.4 Impact Method—DCP ....................................................................................... 123 4.5 Ground Penetrating Radar Methods—GPR....................................................... 127 4.6 Infrared Tomography Methods and Technology ............................................... 135 4.7 Ultrasonic/Seismic Methods—PSPA and DSPA............................................... 138 4.8 Steady-State Vibratory Response Method—GeoGauge.................................... 141 4.9 Non-Nuclear, Electrical Sensing Methods—PQI, PaveTracker, EDG, and Purdue TDR ....................................................................................................... 142 4.10 Non-Nuclear-Roller-Mounted Density/Stiffness Methods—IC Rollers ........... 143 4.11 Surface Condition Characteristics...................................................................... 143 4.11.1 Smoothness ............................................................................................ 143 4.11.2 Noise ...................................................................................................... 144 4.11.3 Surface Texture...................................................................................... 144 4.11.4 Skid Resistance ...................................................................................... 144 4.12 Summary of Evaluation ..................................................................................... 144 CHAPTER 5 – FIELD EVALUATION OF NDT DEVICES................................................... 153 5.1 Projects and Materials Included in Field Evaluation ......................................... 153 5.2 Field Testing Plan .............................................................................................. 153 5.3 NDT Test Results of Unbound Materials and Soils........................................... 153 5.3.1 Impact Penetration Test—DCP.............................................................. 156 5.3.2 Deflection Testing—FWD and LWD.................................................... 161 5.3.3 Ultrasonic Test—DSPA......................................................................... 169 5.3.4 Steady-State Vibratory Test—GeoGauge.............................................. 169 5.3.5 Comparison of Test Results from the DSPA and GeoGauge ................ 171 5.3.6 Ground Penetrating Radar Testing, Air Horn Antenna ......................... 177 5.3.7 Non-Roller-Mounted Density Testing, Non-Nuclear—EDG................ 181 5.3.8 Roller-Mounted Density and Stiffness Devices..................................... 186 5.4 NDT Test Results of HMA Mixtures ................................................................ 191 5.4.1 Seismic Test—PSPA ............................................................................. 192 5.4.2 Deflection Testing—FWD..................................................................... 199 5.4.3 Ground Penetrating Radar Testing, Air Horn Antenna ......................... 201 5.4.4 Non-Roller-Mounted Density Testing, Non-Nuclear—PQI and PaveTracker ........................................................................................... 207 5.4.5 Roller-Mounted-Density and Stiffness Measuring Devices .................. 217 5.5 Laboratory Measured Modulus.......................................................................... 219 5.5.1 Unbound Aggregate Materials/Embankments and Subgrade Soils—Resilient Modulus Values .......................................................... 219 5.5.2 HMA Mixtures—Dynamic Modulus Values......................................... 222 5.5.3 Comparison of Laboratory Measured Modulus to NDT Measured Values .................................................................................................... 223 5.6 Summary of Field Projects................................................................................. 224 iii

PART III – DATA INTERPRETATION AND APPLICATION........................................ 235 CHAPTER 6 – APPLICABILITY OF NDT TECHNOLOGIES ON CONSTRUCTION PROJECTS ................................................................................................................ 237 6.1 Ultrasonic—PSPA and DSPA .......................................................................... 237 6.2 Steady-State Vibratory—GeoGauge.................................................................. 240 6.3 Deflection Based Methods................................................................................. 242 6.3.1 Falling Weight Deflectometer................................................................ 242 6.3.2 Lightweight Deflectometer .................................................................... 243 6.4 Dynamic Cone Penetrometer ............................................................................. 246 6.5 Ground Penetrating Radar.................................................................................. 247 6.6 Electric Current/Electronic ................................................................................ 248 6.6.1 Electrical Density Gauge ....................................................................... 248 6.6.2 Pavement Quality Indicator—PQI......................................................... 249 6.6.3 PaveTracker ........................................................................................... 250 6.7 Intelligent Compactors/Rollers with Mounted Response Measuring Device.... 251 6.7.1 Asphalt Manager and Vari-Control System........................................... 251 6.7.2 Ammann Compaction Expert ................................................................ 251 6.7.3 Summary ................................................................................................ 252 6.8 Summary of Process Impact .............................................................................. 252 CHAPTER 7 – MATERIALS TESTING FOR CONSTRUCTION QUALITY DETERMINATION ................................................................................................................ 255 7.1 Identification of Material Anomalies and Differences ...................................... 255 7.1.1 Unbound Layers..................................................................................... 255 7.1.2 HMA Layers .......................................................................................... 258 7.2 Estimating Target Modulus Values ................................................................... 260 7.2.1 Unbound Layers..................................................................................... 260 7.2.2 HMA Layers .......................................................................................... 267 7.3 Accuracy and Precision...................................................................................... 269 7.3.1 NDT Devices for Unbound Layers ........................................................ 269 7.3.2 NDT Devices for HMA Mixtures .......................................................... 276 7.3.3 Summary ................................................................................................ 278 7.4 Comparison of Results—Between NDT Technologies ..................................... 279 7.4.1 NDT Modulus Comparisons .................................................................. 279 7.4.2 NDT Volumetric Property Comparisons ............................................... 282 7.4.3 Volumetric—Modulus Comparisons ..................................................... 284 7.5 Supplemental Comparisons ............................................................................... 290 7.5.1 Modulus and Density-Growth Relationships for Monitoring the Rolling Operation............................................................................................... 290 7.5.2 Multiple Operators and NDT Gauges .................................................... 298 7.5.3 Agency and Contractor Use of NDT Devices........................................ 301 7.6 Summary of Evaluations.................................................................................... 301 7.6.1 NDT Devices for Unbound Layers and Materials ................................. 301 7.6.2 NDT Devices for HMA Mixtures and Layers ....................................... 303 7.6.3 Limitations and Boundary Conditions ................................................... 305 iv

v CHAPTER 8 – CONSTRUCTION QUALITY DETERMINATION....................................... 309 8.1 Quality Control and Acceptance Application .................................................... 309 8.2 Control Limits for Statistical Control Charts..................................................... 310 8.2.1 Target Modulus or Value ....................................................................... 311 8.2.2 Combined or Pooled Standard Deviation .............................................. 312 8.3 Parameters for Determining PWL ..................................................................... 312 8.3.1 Determining Quality Indices.................................................................. 312 8.3.2 Determining Specification Limits.......................................................... 313 PART IV – CONCLUSIONS AND RECOMMENDATIONS ............................................ 315 CHAPTER 9 – CONCLUSIONS AND RECOMMENDATIONS........................................... 317 9.1 Conclusions........................................................................................................ 317 9.1.1 Unbound Materials................................................................................. 317 9.1.2 HMA Mixtures....................................................................................... 319 9.2 Recommendations.............................................................................................. 321 9.3 Impediments to Implementation of Recommended Technologies .................... 321 REFERENCES ................................................................................................................ 323

ABBREVIATIONS AND NOMENCLATURE AAD Average Absolute Deviation AASHTO American Association of State Highway and Transportation Officials ADCP Automated Dynamic Cone Penetrometer ASNT American Society of Nondestructive Testing ASTM American Society for Testing and Materials BCI Base Curvature Index CBR California Bearing Ratio CCC Continuous Compaction Control CMV Compaction Meter Value CT Circular Track Texture DBP Deflection Basin Parameter DCP Dynamic Cone Penetrometer DMI Distance Measuring Instrument DOT Department of Transportation EDG Electrical Density Gauge EPIC Electronic Pavement Infrastructure, Inc. EMAT Electromagnetic-Acoustic Transducer FAA Federal Aviation Administration FCC Federal Communication Commission FFT Fast Fourier Transform FHWA Federal Highway Administration FWD Falling Weight Deflectometer GDP German Dynamic Plate GPR Ground Penetrating Radar HMA Hot Mix Asphalt HWD Heavy Weight Deflectometer IC Intelligent Compaction IE Impact Echo IR Infrared IV Impact Value JMF Job Mix Formula KTC Kentucky Transportation Center LCL Lower Control Limit LSL Lower Specification Limit LTPP Long Term Pavement Performance LWD Light Weight Deflectometer M-D Moisture-Density M-E Mechanistic-Empirical MEPDG Mechanistic-Empirical Pavement Design Guide MMA Machine Milled Accelerometer MnROAD Minnesota Road Research MTV Material Transfer Vehicle NCAT National Center for Asphalt Technology NDE Nondestructive Evaluation - vi -

NDT Nondestructive Testing ODMS Onboard Density Measuring System OGFC Open-Graded Friction Course OMV Oscillo-Meter-Value PATB Permeable Asphalt Treated Base PCA Pavement Composition Analysis PCC Portland Cement Concrete PFWD Portable Falling Weight Deflectometer PG Performance Grade PQI Pavement Quality Indicator PR Penetration Rate PRS Performance Related Specification PSPA Portable Seismic Pavement Analyzer PTA Pavement Thickness Analysis PVA Pavement Void Analysis PWL Percent Within Limits QA Quality Assurance QC Quality Control QC/QA Quality Control/Quality Acceptance RAP Recycled Asphalt Pavement RCP Relative Compaction Profile RDD Rolling Dynamic Deflectometer ROSAN Road Surface Analyzer RTRRM Response-Type Road Roughness Measuring Device RWD Rolling Wheel Deflectometer SASW Spectral-Analysis-of-Surface-Waves SHRP Strategic Highway Research Program SMA Stone Matrix Asphalt SPA Seismic Pavement Analyzer SPL Standard Plate Load SPS Special Pavement Studies SSG Soil Stiffness Gauge (now referred to as the GeoGauge) SSR Subgrade Stress Ratio TDR Time Domain Reflectometry TF Transfer Function TFT TRL Foundation Tester TTI Texas Transportation Index UBW Ultrasonic Body Wave UCL Upper Control Limit USL Upper Specification Limit USW Ultrasonic Surface Wave VMA Voids in Mineral Aggregate VTM Voids in Total Mix vii

TERMS AND SYMBOLS a = Acceleration AGPR = Amplitude of the reflection from the top of the layer AGPR = Regression coefficient from calibration of GPR data using cores Apl = Amplitude of the reflection from a metal plate bGPR = Regression coefficient from calibration of GPR data using cores CBR = California Bearing Ratio C = Damping coefficient Clay = Percent clay in the soil D = Depth of the reflector E = Young’s or elastic modulus E = Emissivity of an object EVIB = Dynamic stiffness under vibratory loading f = frequency fr = Resonance frequency G = Shear modulus IV = Impact Value k1,2,3 = Regression constants from resilient modulus tests K = Spring stiffness Lr = Wave length LL = Liquid limit M = Constrained or Bulk modulus MR = Resilient Modulus N = Phase spectrum pa = Atmospheric pressure, psi P3/8 = Percent passing the 3/8 inch sieve P#4 = Percent passing the number 4 sieve P#40 = Percent passing the number 40 sieve P#200 = Percent passing the number 200 sieve PI = Plasticity index PR = Penetration rate (from DCP) Q = Radiation emitted from an object Silt = Percent silt in a soil t = Travel time of a wave between the source aand receiver tGPR = Time delay between the reflections from the top and bottom of the layer from GPR readings TIR = Absolute temperature of an object To[IR] = Absolute temperature of the surroundings TF = Transfer function V = Velocity of object from vibrations VGPR = Velocity from GPR reflection VP = Compression wave velocity VR = Rayleigh (surface) wave velocity viii

VS = Shear wave velocity ws = Water content of the soil wopt = Optimum water content of the soil; AASHTO T 180 X = Receiver spacing X(f) = FFT transform of the hammer input Y(f) = FFT transform of the receiver output ∆ = Displacement εa[GPR] = Dielectric constant of the layer εs[GPR] = Dielectric constant of surface layer θ = Bulk stress Ф = Phase angle or shift ρ = Mass density σ1,2,3 = Principal stress σIR = Stefan-Boltzman constant τoct = Octahedral shear stress λ = Lame’s constant γ = Density of layer γMax = Maximum dry density of a material, AASHTO T 180 γs = Dry density of a material ν = Poisson’s ratio ix