WARM MIX ASPHALT WARM MIX ASPHALT A Contractors Experience A Contractors Experience

CalAPA Spring ConferenceApril 25, 2013

Ontario, CA

Tony LimasGranite Construction Company

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Today's Discussion

WMA Experience - By the Numbers

Granite WMA Projects

Challenges

WMA Optimization

Takeaways

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By the Numbers Over 60 HMA plants capable of producing

WMA Approximately 30 asphalt plants retrofitted

with WMA mechanical foaming units • Astec Double Barrel Green• Gencor Green Machine Ultrafoam GX• Maxam AQUA Black• Stansteel Eco-Blend

Some plants using other WMA technologies

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Accumulative WMA Tonnage to Date

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WMA Technologies Experience

WMA 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)

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Typical Granite WMA Projects

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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% RAP

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Granite’s 1st WMA Test SectionPlant Access Road – Indio, CA (2008)

Astec Double Barrel Green ½” Dense WMA/15% RAP

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Rubberized Crack Filler

No Crack Sealant Swelling

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August 2010 (2 year review)

Inbound WMA Outbound WMA

No Rutting

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August 2010 (2 year review)

Typical Surface Texture Typical Reflective Cracking

HMA

WMA

HMA WMA

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Reflective Crack

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City of Indio, CA

½ Dense GradedPlant 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% RICE

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City of Indio, CA

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Warm Mix Hot Mix

City of Indio, CA

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City of Indio Test Sections

Warm Mix

92.9% RICE

Hot Mix

92.6% RICE

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WSDOT 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% RICE

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Conoco Philips Airfield

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Kuparak, Alaska¾” Dense Graded Mix

– Northern-most runway in USA

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Kuparak, Alaska WMA/Anti-Strip Additive: Evotherm M-1 3G (0.50% BTW of binder) Lift thickness: Three 2” lifts in structural section

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Kuparak, 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 – Production

increased 95.5% LTMD compaction for last 41,000 TN Compaction achieved at 180 - 190˚ F Pay Factor: 1.044 over 46,000 TN

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WMA Dosage (Kuparak, AK)%

R

AP

.1 .2 .3 .4 .5% Evotherm M1 G3*

Co

vera

ge

0 .1 .2 .3 .4 .5% Evotherm M1

70 % Min

*Mathy Construction

Alaska TM T-414

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Cameron Airpark, Cameron Park , CA

½” Dense GradedPlant Prod Temp: 270 F. (Gencor Ultrafoam) Job Mix Temp: 245 F.Completed Compaction 160 F.92-96% RICE

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Cameron Airpark, Cameron Park, CA

Typical WMA Over Fabric

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Warm Mix over Fabric

Cameron Airpark

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Good Bond

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Caltrans SR-101 Scotia, CA¾” RWMA Type GWMA: 5.0% Evotherm DAT Plant Prod Temp: 250 F. Job Mix Temp: 230 F.Ambient Temp: 55 F.Density: 92-94 RICE

Notched Wedge Joint

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Caltrans SR-101 Scotia, CA

Material Transfer Device (MTD)

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WSDOT – 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% RICE

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WSDOT - Nile Road Project

Checking Mat Temp

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WSDOT - Nile Road Project

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WSDOT Nile Road Project

“ We had to work at getting everything started in the cold weather. There were very few problems, but it was a challenge to get things de-iced and going in the morning”

“ We were very successful using warm mix. The long hauls and the cooling

mix would have caused a problem with HMA. By using the warm mix we were able to learn a lot about how well the mix compacts at lower temperatures.

“The job was able to pull the 3rd roller.”

“From this experience we are more confident about long hauls, and cool weather paving when using WMA”

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Caltrans SR-70 Oroville, CA

3 Month Detour on SR 703 Month Detour on SR 70AADT 18,500, Trucks 15% on 5% GradeAADT 18,500, Trucks 15% on 5% Grade

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Caltrans 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.

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Caltrans SR-70 Oroville, CA

Wheel PathWheel Path

No Rutting

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Chism St.Taylor St.

McCarran Blvd.

Bravo Ave.Lo

cal W

MA

Reco

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cal W

MA

Reco

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Bravo Ave. Reconstruction 2010

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Reno - Taylor St Reconstruction In-Place Recycle Existing HMA + Base (partial depth

HMA cold milling first)

Gencor UltraFoam WMA w/ 15% RAP Surface Course

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WMA

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Anchorage International

¾” Dense Graded PG 64-34WMA: Evotherm DAT Plant Prod Temp: 235 F. Job Mix Temp: 230 F.Avg. Density: 95% RICE

Echelon Paving

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Anchorage International

¾” Dense Graded PG 64-34 PMWMA: Evotherm DAT Plant Prod Temp: 285 F. Job Temp: 260 F.Avg. Density: 95% RICE

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Anchorage International

Pulling Field Samples

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Anchorage International

Wearing Course ¾” Dense Graded PG 64-34 PM

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Interstate 5 (CA)Total Tons WMA >450,000

Mainline 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 WMA

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Median Widening .25' - 3/4" RHMA Type G WMA.25' - 3/4" dense graded WMA.25' - 3/4" dense graded WMA

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Interstate 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.

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Interstate 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.

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Interstate 5 (CA)

½” RHMA-O5.0% Evotherm DAT 2GPlant Temp: 310 F. (cold/wind nights) Job Mix Temp: 300 F.

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Challenges

½” 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/Additive

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Challenges WMA 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 surfaceElevated paving temperatures (day paving)

Ambient: 101 F. ± Substrate surface: 142 F. ±

Struggled to meet compaction

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Challenges

I-8 WMA Pilot Project (con’t)

RWMA produced in desert temperatures at elevated WMA production 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 additives

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WMA Optimization

What is WMA Optimization?

“The efficient and sustainable use of a WMA technology resulting in the least cost”

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WMA 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)

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2.5

3

3.5

4

4.5

Mix

Stif

fnes

s

Mix Stiffness vs. Temperature - Optimization Good

WMA

Breakdown

Tender Zone

Intermediat/Finish

Water Injection Foam (Cameron Airpark) Prduction Temp: 270 F.

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2.5

3

3.5

4

4.5

Mix

Sti

ffn

es

s

Mix Stiffness vs. Temperature - Optimization Poor

WMA

Breakdown

TenderZone

Intermediate/Finish

Chemical 5%Prod Temp 270 F.

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2.5

3

3.5

4

4.5

Mix

Sti

ffn

es

sMix Stiffness vs. Temperature - Optimization Good

WMA

Breakdown

TenderZoneIntermediate/Finish

Chemical 3%Prod Temp 270 F.

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2.5

3

3.5

4

4.5

Mix

Stif

fnes

s

Mix Stiffness vs. Temperature - Optimization Good

WMA

Breakdown

Tender Zone

Intermediate/Finish

Chemical 3%Prod Temp 240 F.

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Todays 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)

• WMA allows for paving in cooler temperatures

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Todays Takeaways

Warm Mix Asphalt Dosage can influence:

The intensity and duration of the tender zone

The final compaction temperature (two-edge sword)

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Thank You

Questions?

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