From Base to Binder: The Asphalt Paving Crew's Ultimate Checklist

Asphalt Construction Procedural Checklist

Hold a meeting with the Asphalt contractor to review the plan, schedule, and safety procedures.

They need to submit the specified Mix design for approval by the civil engineer and the construction manager.

Required Submittals by the Asphalt Trade for approval by the civil engineer, & construction manager.

Job Mix Formula (JMF)

The final "recipe" proposed for production includes the precise percentages of each component (aggregate, asphalt binder, additives).

Submittals

 Certifications and test reports for all raw materials:

1)  Asphalt Binder: Certificate of Analysis (COA) confirming the Performance Grade

2)  Aggregates: Sieve analysis (gradation), specific gravity, absorption, and quality tests (e.g., Los Angeles Abrasion, Flat & Elongated particles, Fine Aggregate Angularity) for each aggregate source.

3) Volumetric Properties Report: Results of the laboratory mix testing (e.g., using Superpave gyratory compactor) showing:-

                 - Optimum Asphalt Content (Pb​)

                 - Air Voids (VTM)

                 - Voids in Mineral Aggregate (VMA)

                 - Voids Filled with Asphalt (VFA)

5) Tensile Strength Ratio (TSR): The test result is used to ensure the mix has    

    sufficient resistance to moisture damage (stripping).

 6) Quality Control Plan (QCP):

    A document detailing the contractor's internal procedures for managing

    quality, including:

         - Testing frequency and locations (plant, field).

  7) Mix Sampling & Testing Plan:

          - Sampling Location & Method:

 How and where samples will be taken (e.g., behind the pugmill, on a truck bed) using random sampling methods.

- Testing Schedule (Frequency): A table showing the minimum frequency for each test:

- Mix Gradation, Asphalt Content (AC): e.g., once per 500 tons of production.

- Volumetric Properties (VMA, VTM): e.g., once per day's production.

- Moisture Content: e.g., a minimum of one per day.

               - Personnel qualifications (certified technicians).

- Corrective action plans for non-conforming materials.

8) Asphalt Plant Information 

Details on the plant that will produce the mix, often including a letter of certification that the plant is calibrated and approved by the governing transportation authority.

9) Laydown Plan / Construction Procedures

A detailed plan for how the mix will be placed, which may include:

- Equipment list (paver model, number, and type of rollers).

- Proposed rolling pattern (to achieve specified density).

- Temperature control procedures (mixing and compaction temperatures).

10. Provide tack Coat/Prime Coat Material Data:

 Manufacturer's product data sheets ("cut sheets") and Material Safety Data Sheets (MSDS) for the asphalt emulsion (e.g., SS-1h, CRS-2) used between layers or on the base.  

Construction Procedures

1. Install or adjust all catch basins, inlets, storm pipes, and ensure proper tie-ins to curb and gutter lines.

2.   Verify subgrade as to: Grading & Stabilization

3.    Compaction- has the soil test been taken?  4. Lay the specified crushed aggregate (gravel) base layer(s) to the required depth (e.g., 4" - 12").

5. Grade the base layer for the final drainage slope and compact it to the required density and smoothness. Ensure all utility structures are at the correct height.

6. Install any separation fabric or geogrid, if specified, between the subgrade and base layers.

7. Tack Coat Application Apply a light coat of emulsified asphalt (tack coat) between all layers (base, binder, surface) to ensure they bond. Allow to break (turn black) before paving.

8. Asphalt Placement (Binder Course)

Place the asphalt binder course (structural layer) using a paver, ensuring consistent thickness and temperature.

9. Binder Course Compaction

Compact the binder course immediately using vibratory rollers to achieve the specified density.

10. Check the temperature of the mix. Typical Asphalt temperature during placement is 270-325 degrees.

11. Do not place the asphalt pavement less than 2 inches thick when the surface temperature taken in the shade and away from artificial heat is below 50 degrees and falling. Asphalt may be placed when the temperature is 40 degrees and rising.

12. Asphalt Placement (Surface Course)

Place the final asphalt surface course (wearing layer) using a paver, maintaining the proper temperature and laydown rate.

13. Surface Compaction & Joints

Compact the surface course to the final required density and smoothness. Ensure all joints (longitudinal and transverse) are properly sealed and compacted.

14. Visually inspect the finished asphalt mat for segregation, puddles (depressions), or poor joint work. Check for surface smoothness.

15. Perform density tests as required by the specification. Proper roadway compaction is probably the most important factor in determining the longevity of the roadway. Every effort must be made to obtain the target roadway density during the compaction process.

16. Achieve the required density in as little coverage as necessary while preserving smoothness.

17. Perform coring of the newly placed asphalt to ensure the required thickness is achieved.

As your construction manager, we will ensure that our quality control measures are adhered to on your project.

We will ensure that our Geotechnical firm is on-site performing the necessary tests for a successful, well-built asphalt paving parking lot. 

Shettig Construction Management provides Professional Construction Management services from the inception of your project through completion.