Incorporating Nondestructive Testing in Quality Assurance of Highway Pavement Construction: Manual (2023)

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2023 N A T I O N A L C O O P E R A T I V E H I G H W A Y R E S E A R C H P R O G R A M NCHRP RESEARCH REPORT 1082 Incorporating Nondestructive Testing in Quality Assurance of Highway Pavement Construction MANUAL Harold L. Von Quintus Shree Rao Praveen Gopisetti ARA Inc. Champaign, IL Chetana Rao Rao Research and Consulting, LLC Vienna, VA Subscriber Categories Construction • Materials • Pavements Research sponsored by the American Association of State Highway and Transportation Ofcials in cooperation with the Federal Highway Administration

NATIONAL COOPERATIVE HIGHWAY RESEARCH PROGRAM Systematic, well-designed, and implementable research is the most effective way to solve many problems facing state departments of transportation (DOTs) administrators and engineers. Often, highway problems are of local or regional interest and can best be studied by state DOTs individually or in cooperation with their state universities and others. However, the accelerating growth of highway transporta- tion results in increasingly complex problems of wide interest to high- way authorities. These problems are best studied through a coordinated program of cooperative research. Recognizing this need, the leadership of the American Association of State Highway and Transportation Officials (AASHTO) in 1962 ini- tiated an objective national highway research program using modern scientific techniques—the National Cooperative Highway Research Program (NCHRP). NCHRP is supported on a continuing basis by funds from participating member states of AASHTO and receives the full cooperation and support of the Federal Highway Administration (FHWA), United States Department of Transportation, under Agree- ment No. 693JJ31950003. The Transportation Research Board (TRB) of the National Academies of Sciences, Engineering, and Medicine was requested by AASHTO to administer the research program because of TRB’s recognized objectivity and understanding of modern research practices. TRB is uniquely suited for this purpose for many reasons: TRB maintains an extensive com- mittee structure from which authorities on any highway transportation subject may be drawn; TRB possesses avenues of communications and cooperation with federal, state, and local governmental agencies, univer- sities, and industry; TRB’s relationship to the National Academies is an insurance of objectivity; and TRB maintains a full-time staff of special- ists in highway transportation matters to bring the findings of research directly to those in a position to use them. The program is developed on the basis of research needs iden- tified by chief administrators and other staff of the highway and transportation departments, by committees of AASHTO, and by the FHWA. Topics of the highest merit are selected by the AASHTO Special Committee on Research and Innovation (R&I), and each year R&I’s recommendations are proposed to the AASHTO Board of Direc- tors and the National Academies. Research projects to address these topics are defined by NCHRP, and qualified research agencies are selected from submitted proposals. Administration and surveillance of research contracts are the responsibilities of the National Academies and TRB. The needs for highway research are many, and NCHRP can make significant contributions to solving highway transportation problems of mutual concern to many responsible groups. The program, however, is intended to complement, rather than to substitute for or duplicate, other highway research programs. Published research reports of the NATIONAL COOPERATIVE HIGHWAY RESEARCH PROGRAM are available from Transportation Research Board Business Office 500 Fifth Street, NW Washington, DC 20001 and can be ordered through the Internet by going to https://www.mytrb.org/MyTRB/Store/default.aspx Printed in the United States of America NCHRP RESEARCH REPORT 1082 Project 10-108 ISSN 2572-3766 (Print) ISSN 2572-3774 (Online) ISBN 978-0-309-70926-2 Library of Congress Control Number 2023950417 © 2023 by the National Academy of Sciences. National Academies of Sciences, Engineering, and Medicine and the graphical logo are trade- marks of the National Academy of Sciences. All rights reserved. COPYRIGHT INFORMATION 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, APTA, FAA, FHWA, FTA, GHSA, or NHTSA 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. NOTICE The research report was reviewed by the technical panel and accepted for publication according to procedures established and overseen by the Transportation Research Board and approved by the National Academies of Sciences, Engineering, and Medicine. The opinions and conclusions expressed or implied in this report are those of the researchers who performed the research and are not necessarily those of the Transportation Research Board; the National Academies of Sciences, Engineering, and Medicine; the FHWA; or the program sponsors. The Transportation Research Board does not develop, issue, or publish standards or spec- ifications. The Transportation Research Board manages applied research projects which provide the scientific foundation that may be used by Transportation Research Board sponsors, industry associations, or other organizations as the basis for revised practices, procedures, or specifications. The Transportation Research Board; the National Academies of Sciences, Engineering, and Medicine; and the sponsors of the National Cooperative Highway Research Program do not endorse products or manufacturers. Trade or manufacturers’ names or logos appear herein solely because they are considered essential to the object of the report.

e National Academy of Sciences was established in 1863 by an Act of Congress, signed by President Lincoln, as a private, non- governmental institution to advise the nation on issues related to science and technology. Members are elected by their peers for outstanding contributions to research. Dr. Marcia McNutt is president. e National Academy of Engineering was established in 1964 under the charter of the National Academy of Sciences to bring the practices of engineering to advising the nation. Members are elected by their peers for extraordinary contributions to engineering. Dr. John L. Anderson is president. e National Academy of Medicine (formerly the Institute of Medicine) was established in 1970 under the charter of the National Academy of Sciences to advise the nation on medical and health issues. Members are elected by their peers for distinguished contributions to medicine and health. Dr. Victor J. Dzau is president. e three Academies work together as the National Academies of Sciences, Engineering, and Medicine to provide independent, objective analysis and advice to the nation and conduct other activities to solve complex problems and inform public policy decisions. e National Academies also encourage education and research, recognize outstanding contributions to knowledge, and increase public understanding in matters of science, engineering, and medicine. Learn more about the National Academies of Sciences, Engineering, and Medicine at www.nationalacademies.org. e Transportation Research Board is one of seven major program divisions of the National Academies of Sciences, Engineering, and Medicine. e mission of the Transportation Research Board is to mobilize expertise, experience, and knowledge to anticipate and solve complex transportation-related challenges. e Board’s varied activities annually engage about 8,500 engineers, scientists, and other transportation researchers and practitioners from the public and private sectors and academia, all of whom contribute their expertise in the public interest. e program is supported by state transportation departments, federal agencies including the component administrations of the U.S. Department of Transportation, and other organizations and individuals interested in the development of transportation. Learn more about the Transportation Research Board at www.TRB.org.

C O O P E R A T I V E R E S E A R C H P R O G R A M S CRP STAFF FOR NCHRP RESEARCH REPORT 1082 Waseem Dekelbab, Deputy Director, Cooperative Research Programs, and Manager, National Cooperative Highway Research Program Inam Jawed, Senior Program Officer Mireya Kuskie, Senior Program Assistant Natalie Barnes, Director of Publications Heather DiAngelis, Associate Director of Publications NCHRP PROJECT 10-108 PANEL Field of Materials and Construction—Area of Specs, Procedures, and Practices Richard L. Bradbury, Maine Department of Transportation, Scarborough, ME (Chair) Chelsea E. Bennett, Minnesota Department of Transportation, St. Paul, MN Tara L. Cavalline, University of North Carolina, Charlotte, Charlotte, NC Ervin L. Dukatz, Jr., Flyereld Consulting, LLC, La Crosse, WI Enad Mahmoud, Texas Department of Transportation, Austin, TX Tommy E. Nantung, Indiana Department of Transportation, West Lafayette, IN Robert Otto Rasmussen, The Transtec Group, Inc., Austin, TX Timothy E. Stallard, Michigan Department of Transportation, Lansing, MI Zhihui Sun, University of Louisville, Louisville, KY Matthew Corrigan, FHWA Liaison Casey Soneira, AASHTO Liaison

NCHRP Research Report 1082 is a manual designed to assist state departments of trans- portation (DOTs) in selecting and incorporating applicable nondestructive testing (NDT) methods into their quality assurance (QA) programs for highway pavement construction. NDT techniques considered applicable to the QA process are explained in adequate detail. State DOTs and others interested in using the NDT methods in their pavement construction QA process should find this guide helpful. State DOTs, as part of their routine practice, use various QA procedures in their acceptance process for highway pavement construction. However, conspicuously absent from this QA process is the use of NDT methods, despite their many potential benefits to the process. For example, as part of the QA process, these methods could enable DOTs to (1) quickly assess product uniformity during construction; (2) identify potential defects during con- struction to allow for timely corrective actions; (3) perform more frequent inspection and testing without coring and other destructive testing; and (4) minimize testing and inspection costs while improving construction quality. The most likely reasons behind this reluctance or the lack of interest by the DOTs in the use of NDT methods appear to be the relative complexity of some of the NDT technologies, inadequate training of the QA technicians and inspectors in their use, a lack of instruction on how to incorporate these technologies into the overall QA program, and the traditional reluctance of the users to adopt a new technology. Under NCHRP Project 10-108, Applied Research Associates, Inc., was tasked to develop an easy-to-follow manual to help state DOTs select and incorporate appropriate NDT methods into their QA programs for highway pavement construction. A literature review and a scan of current and emerging NDT technologies and practices provided an overview of NDT QA procedures for potential highway pavement construction applications. A number of candidate techniques were identified for possible QA applications. This manual presents those technologies in necessary detail, including their potential benefits, operating principles, detection and measurement capabilities, and limitations and shortcomings. The intent of this manual is not to recommend certain specific NDT techniques to the users; it is to illustrate the features and capabilities of NDT techniques and their applicability in the QA process at various stages of pavement construction. It is for the users to decide what techniques they would like to use. The manual is accompanied by a conduct of research report, which details the activi- ties performed in the development of the manual. The report is available on the National Academies Press website (nap.nationalacademies.org) by searching for NCHRP Web-Only Document 375: Incorporating Nondestructive Testing in Quality Assurance of Highway Pave- ment Construction: Conduct of Research Report. F O R E W O R D By Inam Jawed Staff Officer Transportation Research Board

1 Chapter 1 Introduction 2 Chapter 2 NDT: Definition and Benefits 3 Chapter 3 Scope of Manual: Significance and Use 5 Chapter 4 Elements in a QA Program 5 4.1 Quality Control 6 4.2 Acceptance 7 4.3 Qualified and Accredited Laboratories 7 4.4 Qualified and Certified Testing and Sampling Personnel 7 4.5 Independent Assurance Program 8 4.6 Dispute Resolution 8 4.7 Verification Sampling and Testing 9 4.8 Validation Process or Check 10 4.9 Inspection 10 4.10 NDT Response Data Management 11 Chapter 5 NDT Technologies for QA 11 5.1 NDT Response and the Quality Characteristic 15 5.2 NDT Use in PC Plans 25 5.3 NDT Use in Acceptance Plans 40 Chapter 6 Independent Assurance 42 Chapter 7 Dispute Resolution 43 7.1 Types of Samples/Tests for Dispute Resolution 47 7.2 Resolving Differences or Discrepancies Between QC and Acceptance NDT Datasets 49 7.3 Project Start-Up 50 Chapter 8 NDT Response Data Management: Acquisition, Processing, and Storage 52 Chapter 9 Implementing NDT Technologies Within a QA Program 53 9.1 Create a Training Program: Understanding the Outcome— NDT Response Variable and Its Use in QA Programs 53 9.2 Establish Certification Program for NDT Technologies 54 9.3 Building Confidence Within Industry 55 9.4 Precision and Bias Statements C O N T E N T S

57 Chapter 10 Selecting NDT Technologies for QA 57 10.1 Evaluation Factors Included in Selection Process 59 10.2 Evaluating NDT Technologies for Use in QA 60 Chapter 11 Emerging NDT Technologies 60 11.1 GPR, Layer Thickness; ASTM D4748 60 11.2 Ultrasonic Surface Waves, Portable Seismic Pavement Analyzer, Layer Stiffness; ASTM C215 62 11.3 IC, Unbound Layer Stiffness; AASHTO PP 81-18 63 11.4 Duomorph Asphalt Rheology Tester (DART), Asphalt Binder Stiffness 64 Abbreviations and Terms 66 References Note: Photographs, figures, and tables in this report may have been converted from color to grayscale for printing. The electronic version of the report (posted on the web at nap.nationalacademies.org) retains the color versions.