calibration of slurry seal micro surfacing equipment conference...• in slurry surfacing, all mix...
TRANSCRIPT
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Calibration of Slurry Seal Micro Surfacing Equipment
Doug Hogue, PE Vice President VSS Macropaver
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Presentation Overview
• What is Calibration? • Why do we do it?
• How is it done?
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What is Calibration?
…”the act of checking or adjusting (by comparison with a standard) the accuracy of a measuring instrument”…
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The Calibration Theory • In Slurry Surfacing, all mix designs and formulations are
based on the combined weight of dry aggregate and the weight of any mineral filler. To set the machines to a
given mix design and to produce a consistent material, accurate information on the machine, feed rates or
aggregate, emulsified asphalt, water, and additives is necessary. The mix design is based on dry aggregate
and dry mineral filler. Corrections for moisture for aggregate could be necessary.
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Why Calibrate?
• Proper Materials • Equipment • Proper Proportions
Good Info In = Good product out
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Materials Used
Water
Aggregate
Polymer Modified Emulsion
Mineral Filler
Liquid Additive
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Sample Mix Design
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Sample Mix Design
Aggregate 100.0%
Cement 1.0%
Water Added 10.0%
Emulsion 14.0% +/- 1.0%
Aluminum Sulfate As Needed
*Shown as a % of Aggregate
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Typical Slurry Machine in operation 1. Aggregate Hopper
2. Filler Bin
3. Aggregate Gate
4. Emulsion Pump
5. Gearbox
6. Conveyor
7. Water
8. Emulsion
9. Pugmill
10. Slurry
11. Spreader Box
1. 2.
3.
6. 7. 8.
9.
10. 11.
5. 4.
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Emulsion Calibration • What type of pump are you
using?
Fixed Displacement Pump Variable Positive Displacement Pump
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Emulsion continued
• Fill the machine with Emulsion.
• Determine the gross weight
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Emulsion continued • Hook up pump outlet to a second
container.
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Emulsion continued • Run desired counts on the head pulley/
emulsion counter.
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Emulsion continued • Determine weight of emulsion that has
been pumped from machine.
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• Weight pumped # of Counts = Weight per Count
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• Record results and run 3 tests to ensure accuracy of results
X 3
*within 2% Average of 3 runs
Record Results
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How It’s Done. Aggregate Calibration
• Determine moisture content of aggregate – Normally is determined by a laboratory
*ASTM C566-97
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How It’s Done. Aggregate Calibration
• Select 3 gate settings that will be used to perform the calibration
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Aggregate continued
• Load the aggregate into the hopper
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Aggregate continued • Weigh the machine
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Aggregate continued • Make sure the counter is at Zero • Run out your desired counts
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Aggregate continued • Re-weigh the machine
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Aggregate continued • Do this 3 times at 3 different gate settings
• Record Information
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= Weight per count • Weight of aggregate # of Counts
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How It’s Done. Dry Additive/Mineral Filler
Calibration • Two types of methods to supply dry additive.
Mechanically connected: – Usually directly connected to Aggregate Belt – Would use a gate to adjust the amount of material
delivered.
Hydraulically connected: – Would use a hydraulic flow control to adjust the
amount of material being delivered.
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Dry Additive continued
• Load Fines into machine
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Dry Additive continued • Weigh small box, can or bucket • Use small box, can or bucket to catch dry
mineral that falls from the feeder
Fines
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• Run counts for about 20 lbs. of material (9.1kg)
Dry Additive continued
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• Weigh the container with material
• Subtract the weight of the container
Dry Additive continued
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• Weight pumped • # of Revolutions = Weight per count • Weight of fines
# of Counts
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Calibration Charts
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Example of Loading Emulsion
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Weighing Emulsion in Machine
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Pumping Emulsion
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Loading Aggregate
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Weighing Machine
G:\Data\Powerpoint Presentations
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Run out desired counts
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• Moisture Factor = decimal equivalent of your moisture % + 1.00 – For Example:
• Agg. with moisture content of 2%
Moisture Factor = .02 + 1.00 = 1.02 • Dry Aggregate Weight per Count =
average Agg. weight per count divided by moisture factor.
70.00 1.02 = 68.63
How to Calculate Dry Agg. Weight/Count
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Pounds Per Count
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Pounds Per Count = 96 pounds
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Fines being loaded into machine
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Run desired counts on machine
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• Before determining flow rates, determine weight of aggregate per minute.
• Gearbox that drives the conveyor has a 15:1 ratio, so at
emulsion pump speed of about 450 RPM the conveyor will be turning at 30 RPM.
Gate Opening: 5.52” giving us 96 lbs/count
96lbs/count x 30 RPM = 2880 lbs/minute
How To Determine Flow Rate of liquids
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Example: Additive specific gravity = 11.15 lbs/gallon
Water specific gravity = 8.4 lbs/gallon
% (from mix design) x weight/minute = weight/minute Flow Rate weight/minute
Specific gravity = gpm
* Can be measured liters or kilograms
How To Determine Flow Rate continued
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Water Example § Gearbox that drives the conveyor has a 15:1 ratio, so at emulsion
pump speed of 450 RPM the conveyor will be turning at 30 RPM. § At a gate setting of 5.52”, the aggregate output is:
96 lbs/count x 1 count/rev x 30 RPM = 2880 lbs/minute *Other machines count/rev will vary
§ With water requirement of 10%, the flow rate required is:
.10 x 2880 = 288 lbs/minute
§ Assuming the water specific gravity is 8.34 lbs/gallon, then the flow rate is: 288 lbs/minute 8.4 lbs/gallon = 34.28 GPM
*Calculated using a Centrifugal pump with flow meter
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Liquid Additive Example § Gearbox that drives the conveyor has a 15:1 ratio, so at emulsion
pump speed of 450 RPM the conveyor will be turning at 30 RPM. § At a gate setting of 5.52”, the aggregate output is:
96 lbs/count x 1 count/rev x 30 RPM = 2880 lbs/minute *Other machines count/rev will vary
§ With an additive requirement of 1%, the flow rate required is:
.01 x 2880 = 28.8 lbs/minute
§ Assuming the additive specific gravity is 11.15 lbs/gallon, then the flow rate is: 28.8 lbs/minute 11.15 lbs/gallon = 2.58 GPM
*Calculated using a Centrifugal pump with flow meter
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Positive Displacement Additive Pumps
• Determine the lbs/count (net weight) of your additive by weighing what you pumped from your machine and then subtracting the weight of your container (Empty Weight).
Full Weight – Empty Weight = Net Weight • Next, take your net weight and divide it by the number of counts from your meter to get your lbs/count of additive.
Net Weight = lbs/count # of counts
*Consult owners manual for specific directions on how to calculate Flow and set your positive displacement pump.
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Advanced Calibrations Factors
• Bulking Effect: Moisture makes the aggregate expand like a
sponge changing the density.
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Advanced Calibrations Factors
• Calibration by percent residual asphalt:
The amount of asphalt that is in your emulsion.
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Advanced Calibrations Factors
• Variable Displacement Pumps vs. Fixed Displacement Pumps.
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Calibration is done! Now what?
• Are your materials staged?
• Is your personnel ready?
• Are you ready to make money?
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Test Strip
• Perform test strip • Use calibration
factors to perform spread / application rate checks
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Importance of a Test Strip
The intention of the test strip is to assure adequate workmanship, aesthetics and cure time of the mixture is achievable when applied with the personnel, equipment and materials intended for use during execution of the project. The test strip should be performed in similar conditions as those expected during actual application.
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Test Strip Evaluation
• Proportion optimization • Application rate verification • Uniformity of surface texture • Equipment in good condition • Adequate workforce • Cure time • Workmanship
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Spread Rate
• Performance of the slurry system is directly related to the proper application rate of the materials
• ISSA recommends that a minimum of four spread rate checks be performed daily.
• Used to ensure that the specified application rate is being met
• Utilize the factors determined during the calibration process
• Application rates are based upon dry aggregate pounds per square (ft. or yd.)based
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Calculating Spread Rate
• SR = spread rate or application rate
• Typical units are pounds per square yard or kilograms per square meter
• Agg. lbs per count - from calibration calculations on slide 48
• Agg. Counts – read off the slurry machine
• BW = Box Width – measured
• LOP = Length of Pass - measured
Agg. lbs/count x Agg. Counts BW x LOP
SR =
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Breakdown of Spread Rate (SR) equation:
• Agg. lbs/count is determined by your calibration data (shown on slide 48)
• Agg. counts are from the machine • Box Width • Length of pass
Spread Rate continued
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Spread Rate Example Agg. lbs/count x Agg. Counts
BW x LOP SR =
• SR = spread rate/application rate
• Agg. lbs per count = ????
• Agg. Counts = 100
• BW = Box Width = 12 Feet (4 yards)
• LOP = Length of Pass = 504 Feet (168 yards)
SR = ?? lbs/count x 100 4 yd x 168 yd
= ????
Spread Rate = ????
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Spread Rate Example Agg. lbs/count x Agg. Counts
BW x LOP SR =
• SR = spread rate/application rate
• Agg. lbs per count = 96 pound per count
• Agg. Counts = 100
• BW = Box Width = 12 Feet (4 yards)
• LOP = Length of Pass = 504 Feet (168 yards)
SR = 96 lbs/count x 100 4 yd x 168 yd
= 14.28
Spread Rate = 14.28 lbs/yd 2
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Calibration Experts!
• What is Calibration?
• Why do we do it?
• How is it done?
? ?
?
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ISSA Online Training
www.bit.ly/ISSA-OLT
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www.bit.ly/ISSA-OLT
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Thank You!
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