Tom Skinner

Best Practices
Quality Asphalt Placement
Short Course In Asphalt Paving
& Construction
Tom Skinner, Dean of the BK/IR Road
Institute

Best Paving Practices
Goal of This Presentation
Achieving
- Highest Quality
- Maximum Production
- Lowest Cost Per Ton

“Laying a Quality Mat”
Construct a Non-Segregated,
Homogeneous Mat, Free of
Surface Blemishes, &
Consistent in Density That Can
be Compacted Into a Finished
HMA Product That Will Live up
to Design Expectations.

Your Company Goals
• Improve Quality
• Grow Their Business
• Increase Their Return on Investment
You Say, “I’m DOT and Those Are Not My Goals!” I Just
Want Them to Go by the Book! Live by the “Spec Book”
Then We’ll Have Quality! Quality Isn’t in the Book it is in
Partnering Together With a Common Goal, “Quality.”
Understanding How to Get the Most for the Dollars Spent,
“Lowest Life Cycle Cost”, Stretching Those Tax Dollars
as Far as They Can Go!

Reachable Goals
Maintaining the Highest Quality
& Reasonable Profit
In These Unstable Times

“Without a Goal”
“Discipline is Nothing
More Than
Punishment!”

Get Your Pen & Note
Pad!
Retain These Important
- Cost Reducing
- Quality Enhancing Operational
Procedures

Highways
Define Quality Hot Mix
Asphalt Products
Parking Lots
Streets & Alleys

Quality Pavements
Proper Mix Design
Smooth
Accurate Profile
Skid Resistant
Non-Segregated
Blemish Free
Specified Density
Sound Joints
No Water Permeation
All Over Sound Base
“Lowest Life Cycle Cost!”

Defining Quality

All Over A Sound Base
Quality
Commercial
Proper Mix Design
Accurate Profile
Non-Segregated
Blemish Free
Specified Density
Sound Joints
No Water Permeation

Starts at the Top
Quality
- Mix Design
- Production
- Transportation
Compacting for Density Placement for Quality

Quality in HMA Pavements
“Is Everyone’s Responsibility!”
Let’s Make The Best Use Of The
Next Hour or So Learning-
“How To Build Quality Highways!”

Where Do We Look?
• Loading The Hauling Units
• Transportation to the Paving Site
• Presentation of HMA to the Paver
Hopper
• Moving HMA Through the Paver
Without Segregation (Rock or
Thermal)
• Screeding for Quality

From Start to Finish

Controlling Quality
• Loading the Hauling Units
• Transportation to the Paving Site
• Presenting HMA to the Paver Hopper
• Moving HMA Through the Paver With
Minimum Segregation
• Screeding for Quality
Quality Should = Production and
Lowest Cost Per Ton

“Let’s Get Down to Where the
Rubber Meets the Road!”
Quality in Placing Hot Mix
Asphalt.

Controlling Quality
• Loading the Hauling Unit

Truck Driver’s
Responsibilities
We Want to Deal With
Items 4 through 9

Loading the Hauling Unit
• To Minimize Segregation
- End of Load
- Beginning of Load
“Use Multiple Dump Loading
Procedures”

Define Sensitive Mixes
Broadcast a Shovel Full of
HMA Across a Flat Surface
If the larger Aggregate
Separates and Leaves the Mass
of Finer Materials (By at Least 2
-3 Feet)HMA is Sensitive &
Prone to Segregation.

Finer Materials
Sensitive Mix
Large Aggregate
2 to 3 Ft.

Proper Truck Loading
Sensitive Mixes
Require
Very Close
Attention
Minimize
Segregation
in Loading

Front
Single Dump
Rear
Single Dump Loading
Front & Rear
Segregation
Material Breaks
and Runs

Minimize Segregation in Corners
First Dump
Minimizing Segregation
Outside Edges
Third Dump
Second Dump
Multi Dump Loading
Procedures

Simple Segregation Solution
Wood Board
When Loading Trucks
Paint Line (Third Dump)
Paint Line (Second Dump)
Paint Line (First Dump)
•Board to be of Sufficient Length to Fasten Along Side
the Truck on the Silo Structure.
•Position the Board so the Rear View Mirrors of the
Truck Align at Each Position for Dumping.
(Different Trucks Use Different Colors.)

Controlling Quality
• Transportation to the Paving Site

Transportation

Tarp the Load
Limit
Heat
Loss!

Heat Loss At Truck

Breaking the Load
Raise the Bed
Until the Load
Shifts to the
Rear

Controlling Quality
• Presenting HMA to the Paver Hopper

Presentation of HMA to the
Paver Hopper or Hopper
Insert
• Present HMA Without Changing the
Non-Segregated, Homogeneous
Blend of HMA Within a Specified
Temperature Range to the Paver
Hopper, Hopper Insert or Material
Transfer Machine.

Presenting HMA to Paver Hopper
Direct Discharge Pick Up Machine
Material Transfer

Direct Discharge
Hauling Unit Discharges Material Directly
Into the Paver Hopper
• Areas of Concern
– Don’t Run the Hopper Empty Between Loads
– Don’t Hold the Truck in the Hopper Too Long
– Don’t Allow to HMA Dribble When Raising Bed
– Don’t Bump the Paver
– Don’t Hold the Truck Brakes Too Tightly
– Don’t Disturb the Paver Steering.
– Don’t Clean and Leave Piles of HMA on Grade

Dump Person
“Role in Watching These Don’ts”
Areas to be
Monitored

Don’t Run the Hopper
Empty!

Don’t Hold the Truck in the
Hopper Too Long!

Don’t Allow HMA to Dribble
When Raising the Bed!
Segregation

Don’t Bump the Paver!

Don’t Hold the Brakes Too
Tightly!

Don’t Disturb the Paver
Steering

Don’t Clean & Leave Piles of
HMA on the Grade!

Windrow Paving
Promotes Non-Stop Paving With a
Surge Capacity on the Grade, Uses
Bottom Dump Trailers, Eliminates
Truck to Paver Contact and Can
Reduce Potential Load to Load
Problems.

Windrow Paving
Surge Capacity

Windrow Paving
Mission Statement
“Receive HMA at the Paving Site
Place it in a Windrow Sized to Match
Capacity of Paving Width & Depth.
Try to Pave Non-Stop With the
Correct Amount of HMA in the Hopper
at All Times Without Inducing Rock or
Thermal Segregation.”

Windrow Paving
Dump Person’s Responsibilities:
• Sizing the Windrow
• Alignment of Windrow
• Pick the Windrow Up Cleanly
• Monitor the Hopper Level
Make Sure Pick Up Machine Doesn’t Vibrate
the Paver or Affect the Smooth Forward
Paving Speed.

“Windrow Paving Operation”
Sizing the Windrow
Most Critical of All Operational Procedures
• Calculate HMA Volume Required (Length x Width
x Depth) Match the Volume Required With the
Volume Size of Windrow.
• If End of Load Segregated or Cooler HMA
Appears Try Over Lapping the Ending and
Beginning of the Windrow.
• Make the Windrow Just Slightly Less Than
Volume Required, Keep a Load Near to Add to the
Windrow if and When Necessary.

Start Up Procedures
“Windrow Paving Operation”
Get Enough HMA
Out on the Grade to
Fill the Hopper and
Get Off the Joint

“Too Little or Too Much!”
Is This Enough?
Solution
What’s Wrong?

“Windrow Paving Operation”
Don’t Run the Hopper Empty
Rocks + Rocks = Segregation

Alignment of the Windrow
• Align the Windrow so it Matches the
Pick Up Machine Right in the Center.
• Watch the Wings That They Don’t
Pick Up Any Foreign Materials.
Safety
Must
Prevail
Don’t Get
Near the
Elevating
Chains!

Aligning the Windrow
Center the Windrow
With the Pick Up
Machine

Pick Up the Windrow Cleanly
• Adjust the Height of the Scraper to
Pick Up the Windrow Cleanly.
• Watch That the Scraper Doesn’t
Catch on Some Raised Obstruction.
Safety
Must
Prevail
Don’t Get
Near the
Elevating
Chains!

Pick Up the Windrow
Cleanly
Watch the Amount Left on the Grade

Setting the Pick Up Height
Raise or Lower
For Clean Pick Up

Watch For Segregation!
Rock and Thermal:
• At the Windrow (The HMA “Breaks &
Runs” Down the Outsides of Windrow and
Accumulates along the Edges).
• In the Corners of the Pick Up Head as the
HMA is Being Elevated Up Into the
Hopper.
• In the Hopper Where HMA is Allowed to
“Break & Run” Forming Segregation in
the Corners and Pockets. (Add Plates to
Minimize Segregation)

Watch For Segregation!
Rock and Thermal:
• At the Windrow (The HMA “Breaks &
Runs” Down the Outsides of Windrow and
Accumulates along the Edges).
• In the Corners of the Pick Up Head as the
HMA is Being Elevated Up Into the
Hopper.
• In the Hopper Where HMA is Allowed to
“Break & Run” Forming Segregation in
the Corners and Pockets. (Add Plates to
Minimize Segregation)

Watch For Segregation
Here!!!!

Material Transfer Units
- Promotes Non-Stop Paving
- Gives Ability to Accurately Control
Material Flow Through the Paver
- Can Reblend HMA

MC-330 Material Transfer

Roadtec Shuttle Buggy

Hopper Insert Level 60% or
Above

Don’t Dump Material on
Don’t Dump HMA
on the Grade
Grade!

Material Transfer Units
Desensitizes the Paving Operation.
But Will Never Remove
The Need
for Quality
Workmanship!

Paving Speed
• Determining Your Paving Speed
- HMA Delivery to the Job Site
- Consumption (Width & Depth)
- Paver Capacity
- Compaction Ability
“Operators Look in Three Directions
and Set Paving Speed Accordingly”

Paving Speed
“Operators Look in Three Directions
and Set Their Paving Speed
Accordingly”
- Look Out at What is Coming
- Down at Consumption & Capacity
- Back at Compaction Ability

Controlling Quality
• Moving HMA Through the Paver With
Minimum Segregation

Moving HMA Through the
Paver
“Minimizing Segregation”
Rock & Thermal

Moving HMA Through the
Paver
• Move Homogeneous Blend of HMA
Through the Paver Without Inducing
Rock or Thermal Segregation
• Do it in a Manner That Does Not
Restrict Quality or Productivity

Eight Paver Areas
“Where Segregation Can Be Generated”

Eight Areas Where Segregation May Occur
Sink Holes in
Hopper
Spillage
3
4
Outer Edges of
Augers
Center Guard
2
8
1
Hopper
Corners
7
5
6
Center
Drive Box
End of Conveyors
Auger Bearing
Pedestal

1 Hopper Corners
Solution
Plates can be Fitted to
Eliminate Sharp
Hopper Corners

Clean Corners
During the Truck Exchange!

4
Identifying Segregation Potentials
“From the Front of the Paver”

Spilled Onto Grade
During Truck
Exchange
Out of Truck
& Onto the Grade

Identifying Segregation
Potentials
“From The Rear Of The Paver!”
5

Centerline
Segregation
Not a Texture
Differential
Rock
Segregation

5
If Kick Back Flights are Worn or Missing,
Material Flow Under Drive Box Will be
Effected, & Segregation can Occur
Correct Positioning of Kick Back Flights

Identifying Segregation
Potentials
“From The Rear Of The Paver!”
6

Centerline Streak
Quarter Point Streak
Segregation
is
Normally
an Auger
Feed
Problem

Auger Bearing Pedestal
6
Worn or Broken
Timing of Flights

Identifying Segregation
Potentials
“From The Rear Of The Paver!”
8

Segregation on the Outside Edge
Poor Longitudinal Joints

Controls the
Volume of HMA Here
Sense Off the Live Head
of Material

Large Aggregate
“Breaks & Runs”
to Outside
Edge of
Mat.

Segregation Here
12 to 18”
“Break & Run This Area”

Control of the Head of
Material
“With Minimal Segregation
Rock or Thermal”

Head of Material
• Most Important Operational
Procedure on the Asphalt Paver
• 95 to 98% of all Paving Deficiencies
Come From Not Properly Controlling
the Head of Material
• Once Established Hold the
Volumetric Size of the Head of
Material +/- One Inch.

Controlling the Head of Material
+/- 1”
Head Of Material

HMA Volume Established
Need Tunnel
& Auger Extensions
Set Material Sensors
Observe &
Fine Tune
Proper
Volume
Required

Watch That Head of Material

Controlling Quality
“Reading The Mat”
• Blemish Free Mat
• Determining the Difference Between
Segregation & Texture Deficiencies

Segregation Vs Texture
Streaking
• Segregation Has Larger Aggregate
Particles Showing Up in the Mat
Surface. (Segregation is Normally an
Auger Feeding Problem)
• Texture Streaking is Bright & Dull
Streaks Running Longitudinally.
(Normally is a Screed Adjustment
Problem)

Lines or Steps in the Mat
Steps or Lines
Requires a Screed
Adjustment

Surface Segregation
Normally Auger Feed Problem
Larger
Aggregate
on the
Surface

Screeding For Quality
Joints Smoothness
Slope

Screeding For Quality
“Smoothness!”

Screeding For Smoothness
• Proper Use of Automatic Controls
• Strive for Non-Stop Paving
• Consistent Material Flow (Plant to Screed)
• Maintain Proper Head of Material
• Don’t Run the Hoppers Empty Between
Loads
• Proper Folding of the Hoppers
• Utilize Rapid Start/Stop Procedures
• Orchestrate Good Truck Exchanges

Quality
• Quality Workmanship Allows You to
Increase Paving Speed (Within
Limits)
• Increased Speed Equals Higher
Production (But Not at the Cost of
Quality)
• Increased Production Should Lower
the Cost Per Ton

Mission Statement
Satisfy Our Customer’s
Demands and Expectations With
Asphalt Products That Meet or Exceeds the
“Life Cycle Cost” (Value) and Appearance
of any Competitive Product.
Goal:
- Highest Quality
- Maximum Production
- Lowest Cost Per Ton

Plan of Action
Apply the Expertise Learned at This
Seminar to Improve
The Quality of Our Asphalt Paving Operation
by (2) on a Scale of (1 to 10).
Watch Closely these Areas for Improvement:

Where Do We Look?
• Loading The Hauling Units
• Transportation to the Paving Site
• Presentation of HMA to the Paver Hopper
• Moving HMA Through the Paver Without
Segregation (Rock or Thermal)
• Screeding for Quality
• Reading the Mat
• Longitudinal & Transverse Joints
• Productivity
• Safety

Plan of Action
“Loading the Hauling Units”
Most Important Items to Monitor
• Education of Truck Drivers
• Load to Minimize Segregation
• Multidump Loading of Sensitive Mixes
• Use Wooden Guide for Truck Drivers
• Clean Out Hauling Units Properly
• Tarp the Loads to Prevent Heat Loss

Plan of Action
“Transportation, Plant To Paver”
Most Important Items to Monitor
• Safety
• Expeditious Delivery & Return
• “Break the Load”
• Remove Heat Retention Device
• Don’t Dump Excess on the Grade
• Cleaning & Release Agent Usage

Plan of Action
“Presentation to the Paver Hopper,
MTV, Hopper Insert or Windrow”
Most Important Items to Monitor
• Don’t Bump the Paver
• Stop Short of the Paver 12-18 Inches
• Release the Tailgate When Paver Contact
is Made
• Respond the Paver Operator Directions
• Hold Brakes Slightly to Prevent Spillage
• Raise Bed to Full Extension ASAP
• Exit Immediately When Empty

Plan of Action
“Move HMA Through the Paver”
(Segregation Minimization)
Most Important Items to Monitor at Hopper
• Don’t Run the Hopper Empty Between
Loads
• Watch Segregation (Rock & Thermal) in
Outside Rear Corners of the Hopper
• Flow Gate Adjustments
• Overflow Guards in Good Repair (Out of
Hopper Segregation)
• Proper Folding of Hopper

Plan of Action
“Move HMA Through the Paver”
(Segregation Minimization)
Most Important Items to Monitor at Auger
• Reverse Auger & Kick Backs at Center of
the Auger Drive Box Arrangement
• Timing of Auger Extensions at the
Bearing Pedestal
• Proper Use of Auger Tunnel Extensions
• Controlling the Volume of the “Head of
Material” +/- One Inch

Plan of Action
“Move HMA Through the Paver”
(Segregation Minimization)
Most Important Items to Monitor at Auger
• Reverse Auger & Kick Backs at Center of
the Auger Drive Box Arrangement
• Timing of Auger Extensions at the
Bearing Pedestal
• Proper Use of Auger Tunnel Extensions
• Controlling the Volume of the “Head of
Material” +/- One Inch

Plan of Action
“Screeding for Smoothness”
Most Important Items to Monitor
• Setting the Proper Paving Speed
• Strive for Non-Stop Paving
• Practice Rapid Start/Stop Procedures
• Maintain “Head of Material” Tolerance
• Screed to Side Arm Looseness (Depth
Cranks)
• Edger Plates Sticking
• Correct Auto Grade & Slope Application

Plan of Action
Transverse & Longitudinal Joints
Most Important Items to Monitor
Longitudinal
• Segregation Minimized at the Joints
• Steer a Straight Line
• Proper Depth for Compaction
• Correct Overlap
• Compaction Procedures
Transverse
• Joint Preparation
• Nulling Out Procedures
• Filling the Augers Properly

Plan of Action
“Productivity”
Most Important Items to Monitor
• Plan Your Jobs to Minimize Loss of
Labor
• Have All Components of Machines
on the Job Site
• Troubleshooting & Maintenance
• Continuos Paving Operation

Plan of Action
“Safety”
Most Important Items to Monitor
• Number One
• Think Safety
• Live Safety
Use Your Fumes Extraction
System

There You Have It!
Highest Quality
Maximum Production Rate
Lowest Cost Per Ton

Those Who Learn
and Apply Will Drive
Quality
to the Limit!
Treat a person as he is, and
he will always be what he is! Treat a person
as you think they can be and they will excel
All expectations.

Biblical Truth
To Him That Knoweth to do
good and doeth it not, “To him
it is sin!”