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Presentation on Warm Mix Asphalt delivered by Tony Limas of Granite Construction at the California Asphalt Pavement Association Spring Conference April 25, 2013 in Ontario, CA.

Presentation on Warm Mix Asphalt delivered by Tony Limas of Granite Construction at the California Asphalt Pavement Association Spring Conference April 25, 2013 in Ontario, CA.

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  • 1. WARM MIX ASPHALTWARM MIX ASPHALTA Contractors ExperienceA Contractors ExperienceCalAPA Spring ConferenceApril 25, 2013Ontario, CATony LimasGranite Construction Company
  • 2. 2Todays Discussion WMA Experience - By the Numbers Granite WMA Projects Challenges WMA Optimization TakeawaysCalAPA 2013
  • 3. 3By the Numbers Over 60 HMA plants capable of producingWMA Approximately 30 asphalt plants retrofittedwith WMA mechanical foaming units• Astec Double Barrel Green• Gencor Green Machine Ultrafoam GX• Maxam AQUA Black• Stansteel Eco-Blend Some plants using other WMA technologiesCalAPA 2013
  • 4. 4Accumulative WMA Tonnage to DateCalAPA 2013
  • 5. 5WMA Technologies ExperienceWMA Technologies Used to Date: Gencor Ultrafoam (Water Injection Foam) Astec Double Barrel Green (Water Injection Foam) Evotherm ET/DAT/M1 (Chemical) Maxam (Water Injection Foam) RediSet WMX (Chemical) Sasobit (Wax) Advera (TR Foam) Stansteel (Water Injection Foam) Cecabase RT (Chemical)CalAPA 2013
  • 6. 6Typical Granite WMA ProjectsCalAPA 2013
  • 7. State/Local/Private Caltrans- I-5 Northern CA (+400,000 tons) 15% RAP WSDOT- SR-12 Add Lanes (80,000 tons) 20% RAP WSDOT – SR 410 Emergency Repair (13,000 tons) 20% RAP WSDOT - US 12 FT. to Walla Walla (81,034 tons) 18% RAP Alaska - Anchorage International Airport (6,500 tons) Alaska - City of Anchorage (1,200 tons) Washington - City of Ocean City (40,000 tons) 30% RAP Pacific Gas & Electric (200 tons) 15% RAP Conoco Philips – Kuparak AK (46,000 tons) Cameron Airpark – Cameron Park, CA (9,200 tons) 20% RAP Geyser Industries, Geyserville, CA (3,000 tons) 15% RAP Granite Construction, Tucson AZ (225 tons) 15% RAP Granite Construction, Salt Lake City, UT (200 tons) 40% RAPCalAPA 2013
  • 8. 8Granite’s 1st WMA Test SectionPlant Access Road – Indio, CA (2008)AstecDouble Barrel Green ½” Dense WMA/15% RAPCalAPA 2013
  • 9. 9Rubberized Crack FillerNo Crack Sealant SwellingCalAPA 2013
  • 10. 10August 2010 (2 year review)Inbound WMA Outbound WMANo RuttingCalAPA 2013
  • 11. 11August 2010 (2 year review)Typical Surface TextureTypical Reflective CrackingHMAWMAHMA WMACalAPA 2013Reflective Crack
  • 12. 12City of Indio, CA½ Dense GradedPlant Prod Temp: 270 F. (Astec Double Barrel)Job Mix Temp/Breakdown Rolling: 230 F.Intermediate Rolling 175 F.Final Rolling: 160 F.Average Density: 93% RICECalAPA 2013
  • 13. 13City of Indio, CACalAPA 2013
  • 14. 14Warm Mix Hot MixCity of Indio, CACalAPA 2013
  • 15. 15City of Indio Test SectionsWarm Mix92.9% RICEHot Mix92.6% RICECalAPA 2013
  • 16. 16WSDOT SR-3 ½” Dense Graded PG 64-22 Plant Prod Temp: 330 F(Gencor Ultrafoam) Job Mix Temp: 300 F Job Ambient Temp: 60 F Density: 92 - 95% RICECalAPA 2013
  • 17. 17Conoco Philips AirfieldCalAPA 2013
  • 18. 18Kuparak, Alaska¾” Dense Graded Mix– Northern-most runway in USACalAPA 2013
  • 19. 19Kuparak, Alaska WMA/Anti-Strip Additive: Evotherm M-1 3G (0.50% BTW of binder) Lift thickness: Three 2” lifts in structural sectionCalAPA 2013
  • 20. 20Kuparak, Alaska Tender mix – 93.5% LTMD compaction for first 5,000 TN Reduced compaction temperature - slowed production Reduced WMA dosage to 0.30 - Tenderness eliminated – Productionincreased 95.5% LTMD compaction for last 41,000 TN Compaction achieved at 180 - 190˚ F Pay Factor: 1.044 over 46,000 TNCalAPA 2013
  • 21. 21WMA Dosage (Kuparak, AK)%RAP.1 .2 .3 .4 .5% Evotherm M1 G3*Coverage0 .1 .2 .3 .4 .5% Evotherm M170 % Min*Mathy ConstructionAlaska TM T-414CalAPA 2013
  • 22. 22Cameron Airpark, Cameron Park , CA½” Dense GradedPlant Prod Temp: 270 F. (Gencor Ultrafoam)Job Mix Temp: 245 F.Completed Compaction 160 F.92-96% RICECalAPA 2013
  • 23. 23Cameron Airpark, Cameron Park, CATypical WMA Over FabricCalAPA 2013
  • 24. 24Warm Mix over FabricCameron AirparkCalAPA 2013Good Bond
  • 25. 25Caltrans SR-101 Scotia, CA¾” RWMA Type GWMA: 5.0% Evotherm DATPlant Prod Temp: 250 F.Job Mix Temp: 230 F.Ambient Temp: 55 F.Density: 92-94 RICENotched Wedge JointCalAPA 2013
  • 26. 26Caltrans SR-101 Scotia, CAMaterial Transfer Device (MTD)CalAPA 2013
  • 27. 27WSDOT – Nile Road Project 1/2” Dense Graded PG 64-28 PM WMA Technology: (Gencor Ultrafoam) Plant Prod Temp: 270 – 275 Haul: 60 min, (tarps/insulated beds) Project Mix Temp: 260 – 270 Job Ambient Temp: Brisk? Density: 92-93% RICECalAPA 2013
  • 28. 28WSDOT - Nile Road ProjectChecking Mat TempCalAPA 2013
  • 29. 29WSDOT - Nile Road ProjectCalAPA 2013
  • 30. 30WSDOT Nile Road Project“ We had to work at getting everything started in the cold weather. Therewere very few problems, but it was a challenge to get things de-iced andgoing in the morning”“ We were very successful using warm mix. The long hauls and the coolingmix would have caused a problem with HMA. By using the warm mix wewere able to learn a lot about how well the mix compacts at lowertemperatures.“The job was able to pull the 3rdroller.”“From this experience we are more confident about long hauls, and coolweather paving when using WMA”CalAPA 2013
  • 31. 31Caltrans SR-70 Oroville, CA3 Month Detour on SR 703 Month Detour on SR 70AADT 18,500, Trucks 15% on 5% GradeAADT 18,500, Trucks 15% on 5% GradeCalAPA 2013
  • 32. 32Caltrans SR-70 Oroville, CA ½” DGAC w/ PG 64 -16 Plant Prod Temp: 240 F. Haul Time: 10 minutes Job Mix Temp: 230 F. (Evotherm DAT) Density: 92-94% RICEBreakdown Roller Temp 183 – 225 F.92% RICE achieved at 160 F.CalAPA 2013
  • 33. 33Caltrans SR-70 Oroville, CAWheel PathWheel PathNo RuttingCalAPA 2013
  • 34. 34Chism St.Taylor St.McCarran Blvd.Bravo Ave.LocalWMAReconstructionProjectsLocalWMAReconstructionProjectsCalAPA 2013
  • 35. 35Bravo Ave. Reconstruction 2010CalAPA 2013
  • 36. 36Reno - Taylor St Reconstruction In-Place Recycle Existing HMA + Base (partial depthHMA cold milling first) Gencor UltraFoam WMA w/ 15% RAP Surface CourseCalAPA 2013WMA
  • 37. 37Anchorage International¾” Dense Graded PG 64-34WMA: Evotherm DATPlant Prod Temp: 235 F.Job Mix Temp: 230 F.Avg. Density: 95% RICEEchelon PavingCalAPA 2013
  • 38. 38Anchorage International¾” Dense Graded PG 64-34 PMWMA: Evotherm DATPlant Prod Temp: 285 F.Job Temp: 260 F.Avg. Density: 95% RICECalAPA 2013
  • 39. Anchorage InternationalPulling Field SamplesCalAPA 2013
  • 40. 40Anchorage InternationalWearing Course ¾” Dense Graded PG 64-34 PMCalAPA 2013
  • 41. 41Interstate 5 (CA)Total Tons WMA >450,000Mainline Overlay.10 - 1/2" RHMA -Type O WMA.12 - 3/4" RHMA Type G WMA.13 - 3/4" RHMA Type G WMA.20 - 3/4" dense graded WMAGeosynthetic Pavement Interlayer (GPI).20 - 3/4" dense graded WMACalAPA 2013Median Widening.25 - 3/4" RHMA Type G WMA.25 - 3/4" dense graded WMA.25 - 3/4" dense graded WMA
  • 42. 42Interstate 5 (CA)¾” Dense Graded PG 64-105.0% Evotherm DAT 2GPlant Prod Temp: 310 F.Job Mix Temp: 300 F.93 – 94% RICE at 150 -170 F.CalAPA 2013
  • 43. 43Interstate 5 (CA)1/2” RWMA-G5.0% Evotherm DAT 2GSpec Plant Prod Temp: 285 minPlant Temp: 310 F. (Evotherm DAT)Job Temp: 300 F.93 - 94% RICE at 130 - 150 F.CalAPA 2013
  • 44. 44Interstate 5 (CA)½” RHMA-O5.0% Evotherm DAT 2GPlant Temp: 310 F. (cold/wind nights)Job Mix Temp: 300 F.CalAPA 2013
  • 45. 45Challenges½” Dense Graded Mix/20% RAP (Washington) (Washington) WMA Additive: Gencor Ultrafoam WMA Dosage: 2.0% by weight of binder Anti Strip: Evotherm M1 3G (added at refinery) Anti Strip Dosage 0.5% by weight of binder (WSDOT) Lift thickness: 0.15’Production temperature: 265 – 285 F. 4 rollers on pavement (3 steel 1 rubber tire) Finish rolling: 120 -130 F. Struggled to achieve consistent compaction entire project Pay Factor: 0.90 (3 Lots)Takeaway: Overdose of WMA technology/AdditiveCalAPA 2013
  • 46. 46ChallengesWMA Pilot Project (District 11) ¾” RHMA-G Advera PQ Corporation 0.25% by wt. of RWMA Rediset Aksonobel 0.75% by wt. of binder Sasobit Sasol Wax 1.5% by wt. of binder Evotherm MeadWestvaco (DAT) 5.0% by wt. of binder 0.20 foot lift on cold planed surfaceElevated paving temperatures (day paving) Ambient: 101 F. ± Substrate surface: 142 F. ±Struggled to meet compactionCalAPA 2013
  • 47. 47ChallengesI-8 WMA Pilot Project (con’t) RWMA produced in desert temperatures at elevated WMAproduction temperatures (275 F min) Mix temperatures did not drop fast enough to get below the“tender zone” during daytime paving operations?Takeaway: - No value added using WMA additivesCalAPA 2013
  • 48. 48WMA Optimization What is WMA Optimization?“The efficient and sustainable use of a WMAtechnology resulting in the least cost”CalAPA 2013
  • 49. 49WMA Optimization Managing the Mix Cessation Temperature (2 edge sword) Factors to consider Environmental/Project Conditions Choice of WMA Technology WMA Additive Dosage Plant Production Temp (minimize – maximize)CalAPA 2013
  • 50. 22.533.544.5MixStiffnessMix Stiffness vs. Temperature - Optimization GoodWMABreakdownTenderZoneIntermediat/FinishWater Injection Foam (Cameron Airpark)Prduction Temp: 270 F.CalAPA 2013
  • 51. 22.533.544.5MixStiffnessMix Stiffness vs. Temperature - Optimization PoorWMABreakdownTenderZoneIntermediate/FinishChemical 5%Prod Temp 270 F.CalAPA 2013
  • 52. 22.533.544.5MixStiffnessMix Stiffness vs. Temperature - Optimization GoodWMABreakdownTenderZoneIntermediate/FinishChemical 3%Prod Temp 270 F.CalAPA 2013
  • 53. 22.533.544.5MixStiffnessMixStiffness vs. Temperature- OptimizationGoodWMABreakdownTenderZoneIntermediate/FinishChemical 3%Prod Temp 240 F.CalAPA 2013
  • 54. 54Todays Takeaways Warm Mix Asphalt: Can reduce plant energy consumption at the plant Allows for longer hauls Extends mix life in cooler temperatures Extends mix life in thinner lifts May reduce the equipment needs (roller)CalAPA 2013
  • 55. 55Todays Takeaways Warm Mix Asphalt Dosage can influence: The intensity and duration of the tender zone The final compaction temperature (two-edge sword)CalAPA 2013
  • 56. Thank YouQuestions?CalAPA 2013