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BestPracticesForFullDepthRepair,TackCoat,andLongitudinalJoint
ConstructionGregHarder,P.E.RegionalEngineerAsphaltInstitute
NJAsphaltPavingConference
March14,2017
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SurfacePreparation
The performance of a hot mix asphalt pavement is strongly related to the condition of the surface on which it is constructed.
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SurfacePreparation
• Subgrade• Granular Base Course (Aggregate Base)• Existing Asphalt Pavement• Existing PC Concrete Pavement
The most common surfaces overlaid with HMA or WMA include:
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Subgrade&BaseSupport
•Goodsupportcriticaltoobtainproperdensity•Spongyorunstablesupport
•Provideslittleresistancetotherollers•Mixturenotconfined,energydissipated
•Mixturemovesandcracksratherthancompacts
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SubgradePreparation
– The subgrade is the pavement foundation– Must support the pavement and
anticipated traffic• Soil type considered in thickness
design– Must be properly graded to provide
drainage• Transverse and longitudinal grade• Smoothness and cross slope
– Must be uniformly compacted to required density
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ProofRolling
•Tire pressure at least 90% of maximum
•At least 6600 lb. per tire•Roll full width using two complete passes
•If test rolling reveals soft, yielding, or unstable areas, remove
•Replace with approved material
•Test roll corrected area
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Prime Coat
• To seal in the subgrade at the proper moisture content
• To fill the surface voids and protect from the weather
• To stabilize the surface fines • To promote bonding to the subsequent
pavement layer
Why do we use Prime Coat?
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Prime Coat
•Often use MC-30 or MC-70•Can use emulsion on non-cohesive soils or in areas where cutbacks banned, but are often not effective
•Remove loose material from roadway before application
•0.2 to 0.5 gal/yd2
•Blot excess prime with sand•Broom off excess sand
Allow prime coat to cure 24 - 72 hours
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Aggregate Base Preparation
• Mix to proper moisture content• Best Practice - place using a
laydown machine• Place in 4” - 8” compacted lifts• Stagger longitudinal and transverse
joints at least 1’ in each succeeding layer
• Compact base to percentage of Proctor specified
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Preparing to Overlay Existing HMA
Preparing an existing asphalt surface may be as simple as sweeping (multiple passes may be necessary) the existing surface and applying tack coat
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PreparingtoOverlayExistingHMA
Or it may involve one or more of the following:
• Patching• Cleaning and filling cracks• Placing a leveling course• Milling the surface
Failed areas MUST be cleaned, repaired and brought into good structural condition before overlaying.
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Patching
• Make sure to get at least 1 foot into the sound pavement when you mark the patch for removal
• Use good straight lines that are cut with vertical faces
• Remove all loose material• Tack base and all vertical
surfaces• Patches must be strong
enough to become a part of the permanent structure or they will be back!
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Patching
Irregularpatch- gettingpropercompactionisgoingtobedifficultonthisone.
Nicestraightlines,nodistressvisibleoutsidethepatchedarea
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• Rarely gets due consideration• It is often time consuming and labor intensive• Asphalt layers cover up the potential problems• THE PROBLEMS WE DO NOT TAKE CARE OF
TODAY WILL NOT GO AWAY• Often the problems get worse• They are more costly to fix the second time
Surface Preparation
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• Topromotethebondbetweenpavementlayers.
• Preventslippage/shovingfailures• Fullbondisvitalforstructuralperformanceofthepavement.
• Whenbonded,alllayersworkingtogether.• Criticalthattackmaterialsareapplieduniformly atappropriateapplicationrate
• Applytackcoatonallsurfacesincludingverticalsurfaces.
PurposeofTackCoats
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WhydoweuseTackCoats?
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Fartoofrequentpractices
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ConsequencesofPoorBonding
• Poorpavementperformance• Slippagecracks• Shoving• Earlyfatiguecracking
• Bottomup• Topdown
• Costlypavementrepairs• Repairofisolatedarearelativelyinexpensive• Removalandreplacementofaportionortheentirepavementstructureisveryexpensive
• Shorterthanexpectedpavementlifecanbedevastatingforagencybudgets
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Dayslater!CourtesyofRoadScience
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• Layerindependence• Reducedfatiguelife• Increasedrutting• Slippage• Shoving
• Compactiondifficulty
ConsequencesofPoorBonding
Directionoftraffic?
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½” Deflection,60# Load
¼” Deflection, 160# Load
Fully BondedUnbonded
BondingDemonstration
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• 5 unbondedlayersdeflected4xmorethan5 bondedwiththesameloading.
• 2 bondedlayershadlessdeflectionthan5 unbondedwiththesameloading.
• 5 bondedlayerswithover2½xtheload deflectedhalfasmuchas5unbonded.
BondingDemonstrationHighlights
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Unbonded
0 50 100 150 200-50-100-150-200
0 50 100 150 200-50-100-150-200
BondedHORIZONTALMICROSTRAIN
compression
compression
tension
tension
HORIZONTALMICROSTRAIN
ConsequencesofDebonding
CourtesyofNCAT
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• MayandKing:• 10%bondloss=50%lessfatiguelife
• RoffeandChaignon• Nobond=60%lossoflife
• BrownandBrunton• NoBond=75%lossoflife• 30%bondloss=70%lossoflife
LossofFatigueLifeResearch
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• ConditionofExistingPavement• TackCoatApplicationRate• ResidualBinderContent• ProperDistributorOperation• EmulsionBreakandSetTimes
KeyFactorsforTackCoatSuccess
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Emulsionsareasphaltdropletssuspendedinwater• Breaking• ContactwithsurfacechangespH;reducingcharge
• Setting• Evaporationleadstocoalescence• Originalasphaltcharacteristicsreturn
EmulsionBreaking&Setting
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TackCoatApplication
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• Surfacesneedtobecleananddry.• Uniformapplication.• Allsurfacesaretacked.• Tackshouldnotbetrackedofftheroad.
BestPractices
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• Matchapplicationtoconditions.
• Materials• Residualrate
• Verifyapplicationrate.• Resisttackingtoofaraheadofpaver.
BestPractices
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• Consultwithdistributortruckmanufacturertomatchthematerialtothenozzle.
• ONESIZEDOESNOTFITALL
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NozzleSelection
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EffectofNozzleOrientation
Propernozzleangleof15-30%assuresproperoverlapbetweennozzleswithoutinterferenceoftackstreams.
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SprayBar/Nozzles
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Tack Coat
Full width of mat to minimize movement of unsupported edge
PhotoCourtesyofJimScherocman
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• Checktrucksetup.• Spraybarheight(~12”)• Appropriatenozzles• Nozzleorientation (15-30°)
• Checkapplicationrategaugeintruck
• Checkapplicationtemperature
• Collectsamples.
• Knowthedesiredapplicationandresidualrates.
• Visuallyinspectapplication• Verifyapplication.
• Volume• Mass• ASTMD2995
KeyItemsforInspectors
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• “WhencanIpaveontheemulsion?”• Hasemulsionbroken?• Doesitneedtobeset?
• AsphaltInstituterecommendspavingbeginaftertheemulsionhasbroken.
• “HowcanIpreventtackpull-up/tracking?”• Makesuretackcoatisbroken• Useemulsionswithhardbaseasphalt(CSS-1h)• Useaproprietaryreduced-trackingemulsion• Useaspraypaver
CommonTackCoatQuestions
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• Whatistheoptimalapplicationrate?• Surfacetype• Surfacecondition
• AsphaltInstituterecommendedranges
CommonTackCoatQuestions
SurfaceType ResidualApplicationRate (gsy)
NewAsphalt 0.020– 0.045
ExistingAsphalt 0.040- 0.070
Milled Surface 0.040 – 0.080
PortlandCementConcrete 0.030– 0.050
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• WhentoRe-Tack?• Tracking• ContaminationRe-Tackwhenindoubt.
• IsDilutionokay?• Followstatespecs• Verifydilutionamount• Cannotbeusedto“stretch”tackasresidualvalueiskey.
Limitdilutiontosupplier.
CommonTackCoatQuestions
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SuccessfulTackCoat
TheUltimateGoal:Uniformtackcoatcoverage
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LongitudinalJointsareaMajorIssueforMostAgencies.
Alaska 38
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I-84 in CT
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ALASKA
Some States have morechallenges than others!
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Toooftenlongitudinaljointsaretheweaklink inanotherwisedurable long-lastingasphaltpavement.
- Majorconcernforindustryaswellasagencies
- Offersgreatestopportunity toimproveoveralllife.
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Joint IssuesIn PA
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LONGITUDINAL JOINT DENSITY SUMMARY
YEAR DENSITY LOTS
AVG. JOINT DENSITY
AVG. MAT DENSITY
2007 18 87.8% 93.9%
2008 43 88.9% 94.1%
2009 29 89.2% 94.1%
2010 NO DATA, TRANSITION TO PWL SPEC.
2011 137 91.1% 94.1%
2012 162 91.6% 94.0%
2013 167 91.4% 93.9%
2014 316 92.3% 94.1%44
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CT DOT Average In-Place Lot Density on Cores for Entire Year
Roadway (Non-Bridge)
Year Mat(Rqd. Min. of 92%)
Joint(Rqd. Min. of 91%)
Prior to 2010: Acceptance from gauges
2011 92.6% 91.6%2012 93.0% 91.4%
Std. Dev. 2.07(on 2082 measurements)
2.40(on 1863 measurements)
2013 93.1% 91.8%45
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TheBestLongitudinalJoint:EchelonPaving
RolledHot
NewJersey
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EchelonPavingLongitudinalJoint
Jointpassesbetweenthequarters47
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But,theneedtomaintaintrafficlimitstheopportunitiestopaveinechelon
Consequently,mostlongitudinaljointsarebuiltwithacoldjoint. 48
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Key:ProperOverlap Key:SufficientMaterialforRoll-Down
LowDensityArea
UnsupportedEdgeWillHaveLowerDensity
Cold side Hot side
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ExpertsEvenlyDividedonPreferredJointType
NotchedWedge
Butt
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Offsetjointsbetweenlayersbyatleast6-inches;surfacejointshouldbenearcenterline(notinwheelpath)
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PlantoAvoidPlacingJointWhereStripingWillGo
DELDOT52
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IfNot,CanEventuallyResultInThis
DELDOT53
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TackCoat
Fullwidthofmattominimizemovementof
unsupportededge
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FirstPassMustBeStraight!Unanimousthatastring-lineshouldbeusedto
assurefirstpassisstraight
String-lineSkipPaintReference
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GreatResults
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Toughtogetproperoverlap(1”)withnextpass
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VibratoryScreedShouldAlwaysBeOn
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UniformHeadofMaterial
MaintainedAcrossWidthofAuger
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ExtendAugerstoWithin12-18inchesofEndGate
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TocontrolmaterialflowatouteredgesofscreedanddeliverhomogenousHMAatjoint
ExtendTunnelstheSameDistance
Tunnels61
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ExamplesofAugerOverload…
LikelytoSegregate
Tunnel
Tunnel?
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AugerandTunnellikelynot extendedwithin12to18-inchesoftheendgate.
TheResult- SEGREGATIONatjoint 63
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RollersNeedtoBeKeptClosetothePaver
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BestWaytoRollaJoint
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Roller
6”
4”- 6”
4”- 6”
Option1Hangover4-6”
Roller
Roller
Option21st Pass4”-6”inside
2nd Passhangover4”-6”
RollingUnsupportedEdge?Experts50-50onWheretoPut1st Pass
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PainttheSideofJoint(ButtorWedge)
Emulsion(Good),PGAsphalt
(Better),
OrJointAdhesive
(JA)(Best)
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WhenClosingJoint,SetPaverAutomationtoNeverStarvetheJointofMaterial
• Targetfinalheightdifferenceof+0.1”onhot-sideversuscoldside• NHspecrequires1/8”higher
• JointMatcher(versusSki)isbestoptiontoensureplacingexactamountofmaterialneeded
• Ifhot-sideisstarved,rollerdrumwill“bridge”ontocoldmatandnofurtherdensificationoccursatjoint
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AutomaticGradeControl
Joint Match
CourtesyofCaterpillar
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DestinedforFailure Hotsideofjointstarved
ofmaterialateachendofload.Bridgingoccurs.
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Proper Overlap:• 1.0 + 0.5 inches• Exception:
Milled or sawed joint should be 0.5 inches
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Don’t Rake Overlap Across the Joint! –Starves the Joint
Photo byJames Scherocman, P.E
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LutetheLongitudinalJoint
Thislutepersonisdoingagreatjob
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1st passallonhotmatwithrolleredgeoffjointapprox 6-12inches
2nd passoverlapsoncoldmat3-6inches
RollingtheSupportedEdgeOurRecommendationtoMinimizeBridging:
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• Manyexpertsbelievekneadingactionhelpsinprovidingatightersurfacethatismoredenseandlesspermeablecomparedtodrumrollers.
•Researchsupportsthis
• Butmustkeeptheseawayfromtheunsupportededgetoavoidexcessivelateralmovementofmat• Useduringintermediaterollingofthesupportededge.
•Notfinishrolling.
PneumaticRubberTiredRollers
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•Mill&PaveOneLaneataTime• CutBackJoint• JointHeaters• SurfaceSealersOverJoint
AlternativeTechniques/ProductsNotMentionedToday
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Commonlyaskedquestions
• Doesthefirstpasshavetobestraight?• Absolutelyinordertomatchup
• Whenmatchingup,whatistheproperoverlapontothecoldsideofthejoint?
• 1”+/- 0.5”(0.5”formilledorsawedjoints)
• Istackcoatrequired?• Yes– onallsurfacesincludingverticalfaces– PGbinderorjointadhesivesmayalsoused
• Whichautomationshouldusedwhenmatchingup?• Jointmatcherwillinsuretherightamountofmaterialtonotstarvethejoint–accountforrolldown andfinish0.1”higher(skiisforsmoothness)
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OURGOAL:JointLife=MatLife
� 14yearoldsurface� I-65inIN:SR252toUS31 79
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Questions?