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W09 contractors update fdr - mc keon

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  • 1. A Contractors Updateon Full DepthReclamationFDRPresented to APWA Annual ConferenceBarry McKeonTechnical ManagerHubbard Construction CompanyApril 2013

2. Presentation Outline Introductions / Brief Overview of The Hubbard Group Common Types of Asphalt Recycling FDR (Full Depth Recycling) The Process The Advantages CIR (Cold In-Place Recycling) Equipment Overview Project Applications Contractors Quality Control Economic & Environmental Benefits Conclusions 3. Common Types of Roadway Recycling in theUS Hot Recycling (HR) Hot Mix Asphalt (HMA) Hot-In-Place Recycling (HIR) Full Depth Reclamation (FDR) Cold-In-Place Recycling (CIR) Cold-In-Plant Recycling (CIP)The Hubbard Group are Members of theAsphalt Recycling & Reclaiming Association 4. Full Depth ReclamationFDR 5. FDR- 612 blend of asphalt andbase materialsFull Depth Reclamation (FDR) 6. Cold Full-Depth Reclamation (FDR) Full-Depth Reclamation is aneconomical, recycling technique inwhich the full flexible (asphalt)pavement section and a portion ofthe underlying base materials areuniformly pulverized, blended andthen stabilized with a bondingagent Typically Utilizes 1.5% - 3.5%emulsion or foamed asphaltmaterial as a bonding agent. Cement can also be used toenhance bitumen, modify soils toCBR/LBR or produce Soil Cement(Rigid Base). 7. The FDR Process 8. Advantages Uses 100% of existing materials Extremely GREENprocess. Eliminates Cracks and Resists Future FatigueCracking. Much quicker than traditional base reconstructionmethods. Load bearing strength of existing base section canbe increased. 9. More Advantages Very effective on projects requiring widening. longitudinal re-profiling and grade correction can beaccomplished. Cross slope corrections can be realized. Base courses constructed using the FDR processcan result in more moisture tolerant base courses. 10. Moisture SusceptibilityFlorida Limerock FDR with 3% emulsion 11. Cold-In-PlaceRecycling(CIR) 12. CIR Equipment 13. CIR: 4-6, 100% Asphalt, on well supported base.Creates new asphalt base layer.FDR: 6 12 blend of asphalt and base material.Creates new base structure layer.CIR vs. FDR Whats TheDifference? 14. Recycled Materials at AugerRecycled material at Auger before screed, well mixed and well graded material 15. CIR Finished SurfaceRecycled Material Surface Finish / Mix 16. FDR Equipment OverviewPulverizing, Injection &Stabilization: Wirtgen 2500 S Cold Recycler &Stabilizer. 2 Pumps with 2 Spray Bars 1 foremulsion (or water) & 1 for foam. Capable of Cold FDR withEmulsion or Foam injection. Drum width = 8 Cutting Depth: Up to 20 depth. 17. TEREX Reclaimer 18. Cutting & InjectionNo Cross Mixing 19. Transferring & Monitoring Materials 20. Steering Considerations 21. Recycling Train 22. 2009/10 FDR FieldApplicationCounty Road 609Martin County, Florida 23. Existing Roadway Conditions 24. Initial Pulverization & Widening 25. Widening Trench 26. Shaping & Compacting 27. Elevation Changes Required byPlans18 28. Injection of Emulsion 29. Existing Material with 2% EmulsionInjected 30. Final Grading & Compaction 31. Primed FDR with Temporary Stripes 32. 2.5 Superpave HMA OverlayOther overlay options for rural applications:- Double Chip Seal- Cape Seal- Micro-surfacing 33. Average recycling speed for theproject 27.5 ft/min.This average speed at a depthof 6 ins and a width of 12.5ftequates to an hourly recyclingtonnage of 610 tons per hours.Application & Production Average Depth: 7 Emulsion Content = 2% Daily average production: Pulverization -8,000 SY / Day * Emulsion Injection 5,000 SY /Day All materials were meteredelectronically by the machine.* 2 WR 2500s in Tandem 34. FDR Project Overview CR 609 in MartinCounty Total Contract Price:$2,117,145.96 Length: 9.2 Miles (18.4 LaneMiles) Completion Time: 60 Days 35. Bumby Avenue Full DepthReclamation ProjectCity of Orlando, Florida 36. Bumby Ave. Project Description Heavily traveled urban roadway on the east side of Downtown Orlando Approximately 4,800 long x 60 wide (5 Lanes) = 32,000 Square Yards 18,000 square yards existing soil cement base 14,000 square yards existing lime rock base Curb and gutter & utilities throughout project Work to be performed in 9 phases due to Citys concerns: Impact on businesses Experience with previous contractors Contract time = 180 Calendar Days All work performed during normal business (daylight) hours 37. ProjectLocation 38. Description of Work: Pulverize 11 of existing base and pavement Remove 3 of material from site Inject remaining 8 with emulsion Grade new materials to 2% cross slope matching curb & utilities Prime and sand new base Allow 48-hour cure Overlay with 3 SuperPave Hot Mix Asphalt 2 12.5 TL-C structure course 1 9.5 TL-C surface course New pavement markings 39. Completion of FDR & HMA WorkBumby Avenue, City of Orlando Contract time allowed 180 CalendarDays All structural asphalt completed 83Calendar Days / 51 Working Days 40. Plymouth Ave.20,146 Square YardsHigh Traffic VolumeAsphalt from 8 to 2Base Materials Lime Rockand Snail Shell2 Mix DesignsSoil CementVolusia County 2012 41. Carlton AvenueDouglas AvenueForest AvenueHowry AvenueVolusia County5,756 Sys Total Residential AreaLow Traffic Volume 42. Stevens Avenue3,200 Sys Residential AreaLow Traffic Volume Asphalt Thickness: 1.5 to 2.5Cement Spread Rate: 15lb/SYBase Material: Clayey Sand 43. RMI Cement SpreaderVolusia County Projects2012 44. MinnesotaAvenueVolusia County6 Foot WideningExcess Lime Rock Materialfrom PlymouthBlended into Existing BaseAsphalt Thickness: 1.5 to 2.5Cement Spread Rate: 15lb/SYBase Material: Clayey Sand 45. Uniform across new 22widthMinnesota Ave 46. Before and AfterMinnesotaAvenue 47. Downtown Tampa 48. Cores and Mixer Sample 49. Good base under very thin asphalt did not require any additive.Desoto Memorial HospitalBefore 50. Resurfaced with Double Chip and Cape Seal 51. Pre-Mixing and Re-Grading 52. Cement Spread 53. Mixing and Compacting 54. Checking Gradation of Pre-MixedMaterials 55. LBR Samples 56. Roadway Surfaces Favorable For In-PlaceRecycling Block Cracking Caused by insufficient asphalt thickness,weak structural base, heavy traffic & agingroadway Minor Rutting Caused by insufficient thickness of asphalt,poor asphalt mix design formulation,improper compaction methods or heavytraffic Major Rutting Caused by very heavy traffic conditions,deficient structural capacity, deficientcompaction or deficient drainage conditionsBlock Cracking Minor RutsMajor Ruts Raveling 57. Materials and Mix DesignMarshall Stability Tensile Strength 58. Specifications & References for Mix Design ProceduresThe Wirtgen Cold Recycling Manual Published in many languages &utilized all over the world.Other Primary References: ARRA Basic Asphalt RecyclingManual Asphalt Institute Asphalt Cold MixManuals (MS 14 and MS 19) PCA Soil Cement LaboratoryHandbook 59. Mix Design Methods for FDR 60. Laboratory Mix Design Methodology:Steps Required for Mix Design Development: Cut cores or exploration windows to obtain representative materials Pulverized materials for gradation characterization Binder selection (emulsion or foam usually required by contractspecifications) Determine optimun water content Determine optimun asphalt binder determination Determine optimun cement/lime binder content (if needed)71 61. Sampling 62. Obtaining Materials for DesignRequirements Perform enough cores todetermine if variables exists Depending on size of area &known base types, cut or millwindows to obtainrepresentative samples neededto prepare mix design(s) 63. Documentation of Existing RoadwayConditionsExisting Asphalt RangedFrom 2.5 to 6 deep.Avg Depth = 4.5 64. Mix Design Considerations Mix Design Methods Modified Marshall Stability (Asphalt Inst. or ARRA) Tensile Strength (Wirtgen) Compressive Strength(Soil Cement) (PCA) CBR/LBR (AASHTO/FDOT)(Cement Modified) 65. Laboratory Mix Design MethodologyBinder Options In-Place Recycling Processes: Asphalt binders Asphalt emulsion (CSS-1, CSS-1H, SS-1 et CMS-2) Foamed asphalt (usual grade without silicone ) Hydraulics agents Cement Hydrated lime Composites binders Asphalt emulsion + Cement Asphalt emulsion + Hydrated lime Foamed asphalt + Cement Foamed asphalt + Hydrated lime 66. Pre-Bid Information Client Provided Core Information Client Provided Mix Design Criteria Client Provided Additive Pay Items Client Provided Contractor Quality Control Requirements 67. Quality Control BestPractices for Full DepthReclamationBarry McKeon, Technical DirectorRMI/Hubbard Construction Company 68. Contractor Project Specific QCPlan Description of process i.e.FDR Project Assessment and Site Investigation Sampling and Mix Design Mixing Equipment and Mixing Operations Spreading Finishing and Compacting Priming and Curing Quality Control 69. Speedy Moisture Content Early verification ofmoisture content Monitor throughout theoperation and adjust asneededMoisture content by nuclear gauge can not be used when RAP is present 70. Quality Control During Field Operations?Why is Moisture Content Important?2 ReasonsCoating and Compaction 71. Pre Mixing for Widening or Cross Slopeadjustments 72. Sampling Full Depth of Mixture Check for Depth Uniformity GradationMaximumSize (95% pass2) 73. Check Cross Slopes 74. Compaction 75. Nuclear Density TestsEstablish ControlStripWet Density96% Min 76. Prime and Cure Always applyBituminous Prime Protects base fromweather Holds better under traffic Provides bond to newsurfacing (HMA, Chip,Micro) 77. Environmental Advantages of In-Place RecyclingMethods Removal of trucks hauling materials to and from the project greatly reducescongestion associated with traditional road rehabilitation projects. Shorter construction duration & reduced equipment requirements enhanceproject efficiencies & reduce fuel and energy consumption at the project site. Elimi

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