ASPHALT LABORATORY MANUAL

ALMISNAD Document. No : GAM-610-ALM-01 Page: 1 of 13

TITLE : ASPHALT LABORATORY MANUAL,

REV.00

S
i
0 17-02-2019 For Laboratory Use Dep. g Head
Desig: QA/QC n(QHSE)
Manager :
Rev. Date Description Prepared Approved
 ASPHALT LABORATORY MANUAL
ALMISNAD

Table of Contents

Section Title Page

1.0 Quality Management Manual for Asphalt Plants
1.1 General 3
1.2 Galfar Al Misnad’s Quality Plan 3
1.3 Organization, Responsibilities, and authorities 4
1.4 Personnel Qualifications 6
1.5 Organogram 7
1.6 Qualifications and Trainings 8
2.0 Job Mix Formula
2.1 General Description of Materials 8
2.2 Job Mix Formula Approval 10
3.0 Sampling and Testing
3.1 General Description 11
3.2 Quality Assurance / Quality Control Procedures 11
3.3.1 Attached QA/QC Procedures 13

Revision no. Date Document No. Page no

0 17-02-2019 GAM-610-ALM-01 2 of 13
 ASPHALT LABORATORY MANUAL
ALMISNAD

SECTION 1

QUALITY MANAGEMENT SYSTEM FOR ASPHALT PLANTS

1.1 General

This Asphalt Laboratory Manual is intended to serve as guidelines for the asphalt laboratory
operations within the Asphalt Plant owned and operated by Galfar Al Misnad Engineering and
Contracting WLL, located at Mesaieed in the State of Qatar.

This manual is based on the requirements of Section 6 Part 7 of the Qatar Construction
Specification 2014 (QCS 2014) that specifies the requirements and operational guidelines for
Asphalt Plants in the State of Qatar, the Business Management Manual currently utilized by the
company as overall QMS operational tool that complies to the requirements of ISO 9001:2015,
BS 14001:2015 and BS 45001:2018 and the Factory Production Control Quality Plan, FPC-610-
R0.

The basic concept of this process is for the company to perform adequate testing and inspection
to ensure a quality asphalt paving material and that those inspections and tests are carried-out
adequately and accurately. This system requires Galfar Al Misnad to have technicians that are
competent in production, sampling and testing of asphalt paving material. The idea if for the
company to perform the necessary tests and inspection to ensure the likelihood that all mixes
meets the specifications. This approach gives the company much more control over its total
operations from production to the delivery stage.

Galfar Al Misnad under this manual is responsible for the Quality Assurance and Quality Control
through its Business Management Manual. It is responsible in providing competent personnel to
perform its production, quality assurance and quality control. The requirements and details of
qualifications and certifications for these personnel to perform the QA/QC Work is given in this
manual and is in accordance with the Business Management Procedure for Human Resource,
BMP05.

The requirements of the company’s Quality Control Sampling and testing are contained in this
manual. The frequency of these activities may vary with the process and the materials or may
depend on the project requirements and specifications. When test results vary from the design
and / or specifications, changes to the process shall be made. The frequency of the appropriate
QC activities may be increased until the proper conditions has been restored. The minimum
frequency requirements for QA sampling and testing is detailed in this manual.

Galfar Al Misnad may utilize innovative equipment or technique not addressed by the
specifications or these provisions to produce or monitor the production of the mix, subject to the
approval of ASGHAL or other regulatory authorities in the State of Qatar.

1.2 Galfar Al Misnad’s Quality Plan

This Asphalt laboratory Manual was prepared to support the Factory Production Control Quality
Plan established by Galfar Al Misnad through its QHSE Department for its Asphalt Plant in
Mesaieed Area. Such Factory Production Control Quality Plan was prepared in order to provide
operational guidance and ensure that activities on the plant is undertaken in accordance to the
established procedures.

Revision no. Date Document No. Page no

0 17-02-2019 GAM-610-ALM-01 3 of 13
 ASPHALT LABORATORY MANUAL
ALMISNAD

1.3 Organization, Responsibilities and Authorities

The organizational structure indicating various functional and administrative relationships

together with lines of communications for effective asphalt plant management and execution of
plant and laboratory activities as indicated in this Asphalt Laboratory Manual.

The responsibilities, reporting and communication hierarchy provided herein are specific to the
asphalt plant and was conceptualized with the intent of following the requirements of the Business
Management Manual.

1.3.1 Executive Director

a. Lay the policies, guidelines and strategies of the company.

b. Manage the entire company’s operation.
c. Designate personnel to run the day to day business affairs of the company.
d. Design and implement business strategies.
e. Meet and attend meeting with clients.

Report to the Board of Directors.

1.3.2 Sr. General Manager

a. Comply with the policies, guidelines and strategies laid down by the Executive Director.
b. Provide the resources required for the plant and ensure through the Plant Production
Manager, the effective management of the plant in terms of production and quality.
c. Liaise with the clients and initiate the marketing works.
d. Ensure that the Quality & HSE Systems of the Company are effectively implemented in
the plant.

Report to the Executive Director. He is the Business Unit Head of the Infrastructure
Division.

1.3.3 Head - Quality & HSE / Management Representative

a. Approve this Asphalt Quality Manual and/or its revisions.

b. Approve and issue the Business Management System Manual, the BMM Procedures
and authorize and issue specific procedures / Plans & Work Instructions for the plant
operation and quality assurance processes.
c. Ensure through the QA/QC Engineer that the processes at all stages are carried out as
per this manual, engineering codes and standards, and specifications.
d. Nominate auditors to conduct internal audits.
e. Provide assistance during external Quality Audits.
f. Verify corrective & preventive action and initiate actions to close out the CARs as
appropriate.
g. Identify training requirements for Quality and HSE.
h. Initiate and Schedule Quality Training Plan in compliance with the established company
objectives.

Report to the Executive Director

Revision no. Date Document No. Page no
0 17-02-2019 GAM-610-ALM-01 4 of 13
 ASPHALT LABORATORY MANUAL
ALMISNAD

1.3.4 Plant Production Manager

a. In-charge of overall operation and administration of the Plant.

b. Liaise with the Head - Quality & HSE for the updating of this Asphalt Production Quality
Manual.
c. Authorize the use of the Asphalt Production Quality Manual.
d. Ensure that the Company Quality Management System is effectively implemented in
the plant.
e. Attend meetings with the client when required.
f. Coordinate with the involved functions for obtaining the necessary resources for the
plant and deploy as required.
g. Submit the monthly report as required.
h. Identify training needs and coordinate with appropriate function for fulfilling the training
requirements.
i. Identify the plant objectives and monitor compliance.

Report to the Sr. General Manager.

1.3.5 Laboratory Manager

a. Overall in-charge of the plant’s laboratory facilities.

b. Familiarize with the applicable engineering codes and sample and test requirements.
c. Familiarize with different sampling and testing procedures.
d. Evaluation of Laboratory Technicians and personnel.
e. Monitoring of laboratory apparatus including calibration and repair.
f. Initiate Job Mix Design in accordance with the requirements.
g. Initiate trial mix in accordance with the job mix design.
h. Preparation and scheduling of random testing and sampling of raw materials.
i. Coordinate with the 3rd Party Laboratories for other testing requirements that can’t be
performed in the plant’s laboratory.
j. Scheduling of plant calibration in coordination with the plant production manager.
k. Request of necessary office equipment and supplies needed in the operation.
l. Program resources and ensure proper deployment.
m. Coordinate with the Sr. QA/QC Engineer.
n. Approval of Test Results.

Report to the Plant Production Manager.

1.3.6 Sr. QA/QC Engineer

a. Preparation and updating of the Asphalt Production Quality Manual.

b. Ensure that the Business Management Procedure is implemented in all levels of the
Asphalt Plant Management.
c. Coordinate with the QHSE Head for issues concerning Quality at the Asphalt Plant.
d. Coordinate with the Plant Production Manager and the Laboratory Manager regarding
quality issues on the Asphalt Plant.
e. Initiate inspection of the laboratory instruments and the plant facilities and ensure that
calibration is up to date.
f. Request resources when applicable.
g. Preparation of the Quality Plan.

Revision no. Date Document No. Page no

0 17-02-2019 GAM-610-ALM-01 5 of 13
 ASPHALT LABORATORY MANUAL
ALMISNAD

h. Preparation of the Inspection and Test Plan in coordination with the Laboratory
Manager.
i. Ensure that random sampling and testing is conducted on raw materials.
j. Documentation and recording in accordance with BMP26.
k. Conduct routine inspection of the plant and the raw materials.
l. Assist in the internal audit works.

Report to the Plant Production Manager administratively and the QHSE Head functionally.

1.3.7 Material Engineer

a. Assist the Laboratory Manager in his work.

b. Coordinate with the Sr. QA/QC Engineer.
c. Conduct inspection of the delivered raw material.
d. Supervise the raw material sampling and testing works.
e. Ensure that the need for calibration is satisfied.
f. Familiarize with the applicable engineering code and testing requirements / processes.
g. Evaluate suppliers and provide recommendation to the Laboratory Manager.
h. Review and approval recommendation of the Test Results.

Report to the Laboratory Manager.

1.3.8 Laboratory Technicians

a. Familiarize with the sampling and test procedures.

b. Familiarize with the instrument and apparatus operations and control.
c. Initiate sampling and testing work under the supervision of the Materials Engineer.
d. Conduct audit of laboratory consumables and report to the materials engineer.
e. Ensure that laboratory apparatus were properly calibrated.
f. Ensure that the laboratory apparatus are in good condition and properly maintained.
g. Preparation of the test reports for approval of the materials engineer.

Report to the Materials Engineer.

1.3.9 HSE Advisers

a. Preparation of the HSE Plan for the Asphalt Plant.

b. Ensure compliance with the HSE Plan in all levels of the plant management and
operation.
c. Ensure safety of all the personnel by adhering to the safety regulations.
d. Prepare and submit HSE Report.
e. Coordination with Medical Facilities.
f. Provide Risk Assessment of the plant.
g. Ensure compliance to Environmental Regulations.

Report to the Plant Production Manager administratively and the QHSE Head functionally.

1.4 Personnel Qualifications

Revision no. Date Document No. Page no

0 17-02-2019 GAM-610-ALM-01 6 of 13
 ASPHALT LABORATORY MANUAL
ALMISNAD

Technical personnel including Engineers and Technicians associated or directly involved in the
laboratory works must be competent in their trade and has achieved years of experience as well
as the necessary education leading to the competency required as either technician or engineer.

Qualification of personnel shall be based on the regulatory requirements of the State of Qatar and
its implementing agency.

Hiring and deployment of personnel for the plant shall be carried-out in accordance with the
procedures stated in Business Management Procedure, BMP05 – Human Resources.

Evaluation of the personnel’s individual performance shall be taken periodically to gauge his skills
of and technical know-how. Results shall be the basis of any skill’s enhancement training that he
takes. Training facilities may either through internal or external means wherein training centers if
external shall be duly sanctioned by the State of Qatar through its implementing agencies.

1.5 Organogram

The organizational chart for the plant shall be made and prominently displayed at each office. It
shall be updated whenever there are changes in the personnel due to one reason or another.

1.5.1 Plant Organizational Chart

Revision no. Date Document No. Page no

0 17-02-2019 GAM-610-ALM-01 7 of 13
 ASPHALT LABORATORY MANUAL
ALMISNAD

1.6 Qualification and Training

Selection and deployment of professional and skilled personnel to the asphalt plant shall be
governed by BMP05, Human Resource and as prescribed in the Factory Production Control
Quality Plan, FPC-610-R0, Clause 15. Personnel shall be deployed based on their professional
and skill qualifications that are appropriate to the requirements of the asphalt plant as well as the
legal and statutory requirements.

When at the time of internal audit or during the evaluation period, gaps within the qualification
requirement and that of the deployed personnel are found, appropriate trainings shall be given to
those personnel to close the gap found. Evaluation shall be in accordance to Evaluation of
Competency of Asphalt Laboratory Personnel and Training, QA-GEN-G10. The Plant Manager
shall recommend those who are needing trading to the Administration Manager of Galfar Al
Misnad.

Trainings may also be given in cases where new technologies are introduced to the laboratory or
when new apparatus has been purchased. Training may be conducted by a third-party training
center, the vendors or by internal means.

SECTION 2

The Job Mix Formula

2.1 General Description

The Asphalt Institute MS-2 “Mix Design Methods for Asphalt Concrete and other Hot-Mix Types”
shall be used in designing the bituminous mixtures using Marshall design method.

All asphalt mixes shall be proportioned and graded such that they meet the requirements of a job
mix formula compliant to the requirement of QCS 2014, Section 6 Part 5 and approved by the
Ministry of Environment, Laboratories and Standardization Affairs. The job mix formula will be
based on the mix design performed by Galfar Al Misnad and validated by the Materials and Test
Laboratory to where this manual is intended to. The Laboratory Manager is responsible for the
mix design formula and the corresponding validation / laboratory works to validate its compliance
with the requirements.

The source and grades of material, blend proportions of each of the various aggregates used,
specific gravity information, and other applicable data and notes shall be given on the formula.

The Job Mix Formula gradation target values will be established within the design criteria specified
for the particular type of asphalt mixture to be produced. The Job Mix Formula’s asphalt binder
content will be established as shown on table B below, unless otherwise approved.

The mixing temperature during production at the asphalt plant will be established in the job mix
formula. The mixing temperature is based on the grade of the asphalt binder required for a specific
mix type. The mixing temperature will be different depending on which grade of asphalt binder is
used.

The following table of requirements are derived from Section 6, Part 5 QCS 2014.

A. Combined Aggregate Gradation for Asphalt Concrete Marshall Design Mixes

Revision no. Date Document No. Page no

0 17-02-2019 GAM-610-ALM-01 8 of 13
 ASPHALT LABORATORY MANUAL
ALMISNAD

ASTM Sieve Sizes Percentage Passing (By Weight)

Base Course Base Course Wearing Course

(Class A) (Class B)
37.5 mm 100 - -
25.0 mm 80 - 100 100 100
19.0 mm 62 - 92 80 - 100 86 - 100
12.5 mm - 63 - 85 69 - 87
9.5 mm 45 - 75 57 - 77 58 - 78
4.75 mm 30 - 55 40 - 60 40 - 60
2.36 mm 20 - 40 25 - 45 25 - 45
0.850 mm 15 - 30 15 - 30 15 - 30
0.425 mm 10 - 22 10 - 22 10 - 22
0.180 mm 6 - 15 6 - 15 6 - 15
0.075 mm 2-8 2-8 2-8

B. Design Criteria for Marshall Design Mixes

Parameter Base Course Base Course Wearing Course

(Class A) (Class B)
Aggregate Properties Tables 5.1 and 5.2, Section 6, Part 5, QCS 2014
Aggregate Grading Tables 5.7 Section 6, Part 5, QCS 2014
Number of
Compaction blows at 75 75 75
each end of
specimen
Binder Content (% of
Total mix) inclusive of 3.2 – 4.4 3.4 – 4.4 3.4 – 4.4
tolerances
Stability Minimum
(kN) 9.5 min. 9.5 min. 11.5 min

Flow (mm) 2 to 4 2 to 4 2 to 4
Marshall Quotient
(Stability/Flow) 4.75 min 4.75 min 4.75 min
(kN/mm)
Voids in Mix (Air
Voids) (%) 4 to 8 4.5 to 8 5 to 8

Voids in Mineral
Aggregate VMA (%) Table C

Voids Filled with

Asphalt VFA (%) 50 to 70 50 to 75 50 to 75

Voids in Marshall
Specimen at 400 3.2 mm 3.4 mm 4.0 mm
Blows per face at

Revision no. Date Document No. Page no

0 17-02-2019 GAM-610-ALM-01 9 of 13
 ASPHALT LABORATORY MANUAL
ALMISNAD

optimum binder
content (%)
Retained Stability (%) 75 min. 75 min. 75 min.
(Filler / Binder) Ratio 0.8 to 1.5 0.8 to 1.5 0.75 to 1.35

C. Minimum Percent Voids in Mineral Aggregate (VMA)

Minimum VMA, Percent

Nominal Maximum Particle Size (mm) Design Air Voids, Percent
3.0 4.0 5.0
1.18 21.5 22.5 23.5
2.36 19.0 20.0 21.0
4.75 16.0 17.0 18.0
9.5 14.0 15.0 16.0
12.5 13.0 14.0 15.0
19.0 12.0 13.0 14.0
25.0 11.0 12.0 13.0
37.5 10.0 11.0 12.0
50 9.5 10.5 11.5
63 9.0 10.0 11.0

D. Job Mix Tolerance for Field Mixtures

Job Mix tolerance

Description Base Course Base Course Wearing
(Class A) (Class B) Courses
Aggregate retained on 4.75 mm +/- 5% +/- 4% +/- 4%
sieve or larger
Aggregate Passing 4.75 mm sieve +/- 4% +/- 3% +/- 3%
and retained on 850 µm sieve
Aggregate passing 850 µm sieve +/- 3% +/- 2% +/- 2%
and retained on 75 µm sieve
Aggregate passing 75 µm sieve +/- 1.5% +/- 1.0% +/- 1.0%
Binder Content +/- 0.3% +/- 0.2% +/- 0.2%

2.2 Job Mix Formula Approval

Based on test results of the Field Mixtures, the specific Job Mix Formula is submitted to the
Ministry of Environment, Laboratories & Standardization Affairs for the issuance of the
“Conformity Certificate for the Technical Requirements in the Field of Construction and Building
Products Manufacturer / Supplier”.

The Job mix formula is subject to the approval of the Ministry of Environment, Laboratories &
Standardization Affairs through the issuance of the Conformity Certificate for the Technical
Requirements in the Field of Construction and Building Products Manufacturer / Supplier.

Revision no. Date Document No. Page no

0 17-02-2019 GAM-610-ALM-01 10 of 13
 ASPHALT LABORATORY MANUAL
ALMISNAD

SECTION 3

Sampling and Testing

3.1 General Description

Sampling and testing in accordance with the relevant standard as stated in Section 6 Part 5 of
QCS 2014 shall be carried-out at Galfar Al Misnad Asphalt Plant’s Laboratory for the purpose of
knowing the physical properties of the ingredients and use the data obtained in the Job Mix design
and for the verification of the Job Mix characteristics of the trial mixes. Such result will then be
compared to the requirements of QCS 2014 to verify compliance.

Sampling and Testing to be carried-out by the Asphalt Plant Laboratory is limited to those that are
mentioned in this laboratory manual. Field sampling and testing of asphalt mix during production
shall be carried-out by a third-party laboratory engaged by the company for such purposes.

3.1 Laboratory Apparatus

The Laboratory apparatus and tools used in the laboratory shall be properly maintained and kept
in good condition. Calibration of the apparatus shall be carried-out in accordance with the
requirements as stated in the Business Management Procedure for Monitoring and Measuring
Equipment, BMP19.

The laboratory manager is the focal point in monitoring and safekeeping of the calibration records
which is made through the format BMP19-F/01 Rev.0.

3.2 Quality Assurance / Control Procedures

The quality assurance / procedures are documents that serves as guidelines and are essential in
Laboratory operations.

The following are the QC Procedures applicable to the operation of the Asphalt Plant Laboratory.

Item Document No. Document Title Revision Issue Date

No. No.
1 QC-GEN-R09 Sieve Analysis of Soil and Aggregate 2 30.01.2016
2 QC-GEN-R10 Determination of Soundness of 2 10.01.2016
Aggregates
3 QC-GEN-R11 Test for Specific Gravity and Water 2 20.01.2016
Absorption of Aggregates
4 QC-GEN-R12 Determination of Liquid Limit and 2 05.01.2016
Plastic Limit of Soil
5 QC-GEN-R18 Determination of Aggregate Abrasion 1 10.04.2009
6 QC-GEN-R20 Analysis of Bituminous Mixtures 4 08.01.2018
Using Marshall Apparatus
7 QC-GEN-R21 Quantitative Extraction of Bitumen 2 10.01.2018
from Bituminous Paving Mixtures
8 QC-GEN-R23 Test for Aggregate Crushing Value 0 10.04.2009

Revision no. Date Document No. Page no

0 17-02-2019 GAM-610-ALM-01 11 of 13
 ASPHALT LABORATORY MANUAL
ALMISNAD

9 QC-GEN-R27 Test for Sand Equivalent Value of 0 10.04.2019

Aggregates and Soil
10 QC-GEN-R28 Test for Determination of flat ang 0 20.06.2016
elongated particles in course
aggregates
11 QA-GEN-G04 Inspection and Process Control of 0 15.01.2019
Bitumen Mixing Plant
12 QA-GEN-R02 Sampling of Bituminous Material 0 25.02.2007
13 QA-GEN-G09 Material Storage and Handling 0 01.04.2014
14 QA-GEN-G010 Evaluation of Competency of Asphalt 0 10.08.2016
Laboratory Personnel and Training

Any applicable sampling or testing requirements that are not covered by the QA/QC Procedures
mentioned above shall be carried-out in accordance with the applicable standards mentioned in
Section 6, Part 5 of QCS 2014.

Calibration of laboratory apparatus and the asphalt plant shall be carried-out by a duly certified
third-party laboratory in accordance with the applicable standards.

Revision no. Date Document No. Page no

0 17-02-2019 GAM-610-ALM-01 12 of 13
 ASPHALT LABORATORY MANUAL
ALMISNAD

ANNEXURE – A

QA and QC PROCEDURES

Revision no. Date Document No. Page no

0 17-02-2019 GAM-610-ALM-01 13 of 13