1. AMERICA RIDES ON US HMA ECONOMICS 101 Minimizing Project Costs without Sacrificing Quality Purdue Road School March 09, 2011 M. Dudley Bonte PE Regional Q C Director

2. AMERICA RIDES ON US Tips for Stretching Your Paving Dollars

3. AMERICA RIDES ON US Use Current Technologies and Systems ABCs of HMA Mix –INDOT Standard Specifications & Recurring Special Provisions –401 QC/QA HMA –402 HMA Appropriate mixes Recycled Materials APAI Local Specification guideline

4. AMERICA RIDES ON US No need to reinvent the wheel

5. AMERICA RIDES ON US ABC’s of HMA Section 400-Asphalt Pavements 401-QC/QA HMA Pavement 402-HMA Pavement 410-QC/QA HMA Surface-SMA Pavement

6. AMERICA RIDES ON US Mixture Types- QC/QA HMA Pavement Item Description –QC/QA HMA, ___, ___, ___, ___mm ESAL Category (Traffic) Binder Grade (PG high temp.) Course (layer) Aggregate Size (NMAS) QC/QA HMA, 2,64,intermediate,19.0 mm ESAL Category 2 PG64-22 Intermediate Course 19.0 mm NMAS Sec 401

7. AMERICA RIDES ON US Possible JMF Combinations Which to choose? ESAL Categories -5 PG Grades (Incl. RAP) -6 Courses -3 (base, intermediate, surface) Sizes(mm) –25.0, 19.0, 12.5, 9.5, 4.75, OG 25.0, OG 19.0

8. AMERICA RIDES ON US Mixture Types- QC/QA HMA Pavement Item Description –QC/QA HMA, ___, ___, ___, ___mm ESAL Category (Traffic) Binder Grade (PG high temp.) Course (layer) Aggregate Size (NMAS) Sec 401

9. AMERICA RIDES ON US ESAL Category (Traffic) Equivalent Single Axle Loads (Design Life of Pavement) CategoryESALs1<0.3M 2 0.3 -<3 M 3 3 -<10 M 4 10 -<30 M 5 ≥30 M 18,000 lb. Axles

10. AMERICA RIDES ON US One = 6000

11. AMERICA RIDES ON USCategory No. of Gyrations (N design ) 150 275 3100 4100 5125 Mix Design

12. AMERICA RIDES ON US Rule #1: Specify mix for the appropriate traffic volume

13. AMERICA RIDES ON US Mixture Types- QC/QA HMA Pavement Item Description –QC/QA HMA, ___, ___, ___, ___mm ESAL Category (Traffic) Binder Grade (PG high temp.) Course (layer) Aggregate Size (NMAS) Sec 401

14. AMERICA RIDES ON US PG Grades (based on climate) PG 64-22 PerformanceGrade Avg. 7 Day Max Pavement Temperature 64°C = 147°F Low Pavement Temperature -22°C = -8°F

15. AMERICA RIDES ON US Permanent Deformation ( rutting ) High temperature stiffness –Un-aged binder –Short-term aged Heavy Trucks n PG 58 n PG 64 n PG 70 n PG 76 stiffer

16. AMERICA RIDES ON US Low Temperature Cracking Low temperature stiffness –PAV-aged binder –Simulates end of pavement life PG - 22 PG -28 PG -34 better

17. AMERICA RIDES ON US Binder Description Item Label PG Grade PG Grade 0- 25% RAP PG Grade PG Grade >25% RAP 6464-2258-28 7070-2264-28 7676-2270-28

18. AMERICA RIDES ON US 2. Specify the Appropriate PG Grade Higher grades cost more (than PG64-22) Higher grades may not give better performance for low volume applications Estimated cost difference for a one grade bump from PG64-22 to PG70-22 ≈ $2 per ton of mix @ 5% binder

19. AMERICA RIDES ON US Greatest cost savings is through Recycling

20. AMERICA RIDES ON US Recycled Asphalt Pavement (RAP) The US has more than 2.5 million miles of paved roads 94% are surfaced with asphalt Approx 100 million tons of asphalt pavements are reclaimed annually 75 million tons used as RAP and returned to asphalt pavements 20 million tons used in other ways for road building HMA is the most recycled material 20

21. AMERICA RIDES ON US Recycling in HMA Pavements (Linear landfills?) Fly ash Foundry sand Glass Tires (GTR) –Dry or wet process –Carbon black Blast & Steel Furnace Slag (BFS, SFS) Recycled Asphalt Pavement (RAP) Recycled Asphalt Shingles (RAS) 21

22. AMERICA RIDES ON US What is RAP and RAS? RAP (Recycled Asphalt Pavement) –Existing pavements removed and reused –Milling -- Upper pavement layers removed and replaced with new pavement –Full-Depth Removal -- Pavement completely removed and reprocessed RAS (Recycled Asphalt Shingles) –Manufacturer’s Waste - tabs, rejects –Post Consumer Shingles -Tear offs 22

23. AMERICA RIDES ON US RAP from Milling Removes old/distressed pavement Improves smoothness Eliminates costly shoulder work Maintains drainage features, curbs, clearance Valuable rehab option Generally requires no additional processing before reuse (QC tested) 23

24. AMERICA RIDES ON US RAP-Composite Sources 24 Usually chunks and slabs from full depth pavement removal Plant cleanout Reject material or excess returned from jobs Excavation

25. AMERICA RIDES ON US 25 Composite RAP must be reprocessed (i.e. crushed, screened, stockpiled and QC tested)

26. AMERICA RIDES ON US Processing RAS- Manufacture’s Waste Shredding to - 1/2” Stockpiling Tip fees 26

27. AMERICA RIDES ON US Processing RAS- Post Consumer Tear Offs Permitted RAS recycler Tip fees Tested for asbestos Limited stockpiles Sorted to remove wood, etc. Magnet to remove nails Shredding to -1/2” 27

28. AMERICA RIDES ON US RAP Studies-2009 Two studies lead to change in allowable RAP/RAS –North Central Superpave Center Studied RAP blends from Indiana & Michigan –INDOT Research Studied RAP stockpiles from throughout Indiana

29. AMERICA RIDES ON US Conclusions & Outcome Up to 25% can be used without using a softer virgin grade (i.e. PG4-22) Up to 40% RAP can be used with a one grade decrease (e.g. use PG58-28 when PG 64-22 is specified) Change method of computing RAP/RAS in HMA mixtures(Binder replacement)

30. AMERICA RIDES ON US Binder Replacement Binder Replacement %= (A x B)+(C x D) x 100 E Where: A =% Binder content in RAP B = % RAP in mixture C =% Binder in RAS D = % RAS in mixture E = % Binder in total mix RASRAP

31. AMERICA RIDES ON US Maximum Binder Replacement ( Can be RAP or RAS* or a blend of RAP/RAS) Mix Type (402) Base and Intermediate Surface A40% B C 15% D40%15% *RAS material cannot contribute more than 25% by weight of the total binder content

32. AMERICA RIDES ON US Cost/Benefits of RAP/RAS Milling or Pavement Salvage Costs –Mill, haul & stockpile: ≈$6.50/ ton –Excavate, haul & stockpile: ≈ $7.00/ton –Reprocessing: ≈ $5.00/ton Processing Shingles –Manufactured Waste: ≈ $9.00 –Tear offs ≈ $40.00 Virgin Material Costs –Coarse Aggregate ≈ $12.00/t –Fine Aggregate ≈ $8.00 –PG Binder ≈ $450.00 (PG64-22) 32

33. AMERICA RIDES ON US Cost Savings using RAP for a typical 19.0mm Intermediate % RAPPer ton Savings $ (materials only) Notes 00 15$3.40 25$5.50Does not include premium PG58-28 40$6.80Includes premium PG58-28 33 25% RAP in an intermediate 19.0mm HMA will save approximately 11% per ton Assuming a 3” lay; for every 1 million resurface dollar this will equate to approximately 2.2 lane miles of additional paving.

34. AMERICA RIDES ON US Cost Savings using RAS for a typical 19.0mm Intermediate % RASPer ton Savings $ (materials only) Notes 00 3$2.40Manuf. waste 5$4.05Manuf. waste 3$2.25Tear offs 5$2.25Tear offs 34 Manufactured waste shingles contain 16-20% asphalt binder Tear off shingles contain 20-25% asphalt binder

35. AMERICA RIDES ON US 3. Allow RAP/RAS

36. AMERICA RIDES ON US A Simpler Way for Local Gov’t 402 HMA Description HMA (course) Type ____

37. AMERICA RIDES ON US Sec. 402 Mixtures Mixture Type A Type B Type C Type D ESAL ESAL200,000 2 Million 9 Million 11 Million ≈ AADT 4000 4000- 15,000 15,000- 30,000 >30,000 Surface 12.5, 9.5, 4.75 mm Interm. 9.5, 12.5, 19.0, 25.0 mm Base 19.0, 25.0 mm

38. AMERICA RIDES ON US Sec. 402 Mixtures Binder Type A Type B Type C Type D ESAL ESAL200,000 2 Million 9 Million 11 Million ≈ AADT <4000 4000- 15,000 15,000- 30,000 >30,000 Surface PG 64-22 PG 70-22 Interm. PG 64-22 PG70-22 Base

39. AMERICA RIDES ON US Specification Comparison Requirement401402 Certified HMA Plant√√ Certified CAPP Aggregates√√ Certified Binder Supplier√√ Certified HMA Technicians√√ Plant Quality Control Plan –QCP (ITM 583)√√ Job Quality Control Plan (ITM 803)√√ Mix design by approved design lab√√ Approved mix design (JMF)√√ Certified HMA Field Supervisor (ITM 803)√√

40. AMERICA RIDES ON US Specification Comparison Acceptance procedures401402 Per cent within limits (PWL)√ Plate sampling & testing by Agency (INDOT lab) √ Density testing by cores (INDOT lab)√ Incentive /disincentive pay based on volumetric properties and cores √ Contractor quality control tests (per QCP)√ Type “D” certification√ Density control by “methods specification” i.e. roller patterns √

41. AMERICA RIDES ON US 4.Refer and Use INDOT Section 402 for HMA Mixtures

42. AMERICA RIDES ON US Local Government Specifications Recommends Section 402 with Modifications

43. AMERICA RIDES ON US 2011 HOT MIX ASPHALT (HMA) PAVEMENT GUIDE SPECIFICATIONS FOR 2011 HOT MIX ASPHALT (HMA) PAVEMENT GUIDE SPECIFICATIONS Mixture TypeType A *Type B*Type C*Type D * Design ESAL200,0002,000,0009,000,00011,000,000 AADT<40004000- 15,00015,000-30,000>30,000 Surface4.75, 9.5, 12.5 mm 4.759.5, 12.5 mm4.75, 9.5, 12.5 mm Surface - PG Binder64-22 70-2276-22 Intermediate9.5, 12.5,19.0,25.0 mm Intermediate - PG Binder 64-22 76-22 Base19.0, 25.0 mm Base - PG Binder64-22 * A higher category mix may be used for a lower category application if the contractor so elects. The substitution will be at no additional cost to the agency.

44. AMERICA RIDES ON US HMA mixtures utilizing RAP or RAS or a blend of RAP and RAS Maximum Binder Replacement, % Mixture Category Base and IntermediateSurface Dense Graded 25. 0 mm 19.0 mm12.5 mm 9.5 mm 12.5 mm 9.5 mm 4.75 mm A40.0* B C 25.0 D40.0*25.0 *RAS materials shall not contribute more than 25% by weight (mass) of the total binder content for any HMA mixture. Recycled Materials (RAP/RAS % based on Binder Replacement %)

45. AMERICA RIDES ON US Surface Aggregate Type: For Type C Mixtures, surface aggregates shall meet the requirements for less than 3,000,000 ESAL as per Section 904.03(d). Coarse Aggregate TypeTraffic ESALs < 3,000,000 Air-Cooled Blast Furnace SlagYes Steel Furnace SlagYes SandstoneYes Crushed DolomiteYes Polish Resistant AggregatesYes Crushed StoneYes GravelYes

46. AMERICA RIDES ON US For Type D mixtures, surface aggregates shall meet the requirements for less than 10,000,000 ESAL as per section 904.03(d).R Coarse Aggregate TypeTraffic ESALs < 10,000,000 Air-Cooled Blast Furnace SlagYes Steel Furnace SlagYes SandstoneYes Crushed DolomiteYes Polish Resistant AggregatesYes Crushed StoneNo GravelNo

47. AMERICA RIDES ON US Keep on rolling Thank You www.asphaltindiana.org mdbonte@rieth-riley.com Dudley Bonte (317) 634-5561