Lab-to-pavement methodology integrates field services with lab testing to achieve Superior Asphalt Performance

Combining asphalt design expertise in the lab with an array of asphalt field services can make a decided difference in achieving pavements that can stand the test of time. Field services like core samples, friction testing, pavement condition analysis, density testing, and job site quality assurance help bridge the gap between theoretical design and practical application. They also allow pavers to make adjustments during pavement installation that can significantly improve performance and longevity.

Case in point:  Man O’ War Drive

In the summer of 2020, the Lexington Fayette Urban County Government (LFUCG) called on BATT to help with the replacement of a concrete-paved intersection at the heavily traveled entrance on Man O’ War Drive into the Lexington Bluegrass Airport.

Before making the switch to asphalt pavement, engineers with the LFUCG wanted reassurance that an asphalt installment could be designed to equal the strength of concrete. Working with ATS Construction, the BATT Team designed three lifts of hot mix asphalt for the project, each reinforced with an aramid fiber product to provide additional tensile strength:

1)    A four-inch baselift containing ¾” NMAS and 30% recycled asphalt pavement (RAP) with PG 58-28 and a single dose of aramid fiber.

2)    A four-inch mid-layer containing ¾” NMAS and 20% RAP and a stiffer PG 76-22 with a single dose of aramid fiber.

3)    A two-inch surface layer containing 3/8” NMAS, 20% RAP, PG 76-22 with a single dose of aramid fiber.

After designing the hot mixes, BATT provided job site quality assurance and density verification to ensure the asphalt achieved the necessary compaction. Almost five years later, the roadway shows no distresses and is holding up well under traffic loads.

When and why to integrate asphalt lab and field services

Adding third party field services like density testing, core sampling, friction testing, and on-site quality assurance and inspections may seem like an extra expense, but these measures can ultimately save money and improve overall project performance.

Additionally, paving contractors often do not have the manpower to conduct the level of quality control and on-site testing that a project requires. Other times, an independent and objective opinion is needed, especially for investigations into failed pavements. And some projects may benefit from highly specialized services, such as BATT’s digital pavement condition analysis.

When considering on-site testing from an asphalt lab, it’s important to match the type of field service to the paving challenge. For example, density testing can ensure proper compaction, which is critical to the pavement’s ability to withstand constant stress. Projects in regions with extreme weather — whether intense heat, heavy rains, or freeze-thaw cycles — can benefit from on-site quality assurance testing to confirm that each batch of the mix design will perform well under environmental challenges.

For innovative or experimental asphalt mixtures, core samples can provide immediate feedback to fine-tune the application process. And in cases where road safety and longevity are paramount, such as in urban centers or in critical infrastructure projects, friction testing can determine if aggregates in the asphalt mix will provide a safe, skid-proof roadway.

A holistic approach to achieve asphalt pavement longevity

            BATT’s lab-to-pavement concept seamlessly integrates lab-based mix design, on-site quality assurance and testing, and annual pavement condition inspections to ensure that every phase of asphalt — from initial design to long-term performance monitoring — is optimized to deliver pavements that not only meet rigorous standards but also perform reliably over time.

Our comprehensive process integrates planning, design, and on-site execution, ensuring that each layer of pavement is optimized for durability and efficiency. With BATT’s dedicated team by your side, you can trust that your asphalt pavements are engineered to stand up to today’s challenges as well as tomorrow’s demands. For information about BATT Field Services, visit us online.