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Al TER ATIVE FLEXIBLE OVERLAYS

FINAL REPORT IOWA HIGHWAY RESEARCH BOARD

PROJECT HR-229

March 1983

Highway Division

Iowa Department of Transportation

Final RP.port Iowa IHohway Research Boar<'!

Proiect HR-7.7.9

ALTEPNA.TIVE FLEXIBLE OVERLAYS

bv Tom Sny<ler, P.E.

Osceola Countv Engineer and

Mark Callahan Office of Materials

Iowa Department of Transpnrtatinn Ames, Iowa

515-:>19-1382

March 1988

DI SC!,AIMER

The opinions, findings, and conclusions expressed in this report are those of the authors and not necAssarily those of Osceola Countv or the Iowa DepartmP-nt of Transportation

Table of Contents

Acknowledgement • . .. . .. " ............................................... . Abstract ....• .. .. .. .. . . .. .. .. .. .. . " .......................................... . Introduction.

Objective ....•......

Project Description.

Plan Preparation.

Test Sections ....

Mix Designs .. ...................................................................... Construction. .. ............................................................... .

Preparation Road Mixing. Plant Mixing

for Road Mixing ...

and Paver Laying.

Page

1

2

3

4

4

4

6

9

10

10 12 16

Construction Costs... . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . 1 7

Construction

Plant Mix Road Mix

Discussion ..

Testing.

Testing. Testing ..

Plant Mixed Sections. Road Mixed Sections .•

Performance •.....•.......

Plant Mixed Sections. Road Mixed Sections ..

Conclusions ....

Plant Mixed Sections. Road Mixed Sections ..

18

18 19

19

19 20

21

21 24

26

26 26

Table of Contents (Cont'd)

Paqe Appendix

A. Contract Quantities and Special Provisions .. 28 B. Aggregate Test Reports ...................... 33 C. Test Section Layout .•...............•......• 37 D. Mix Design Repo~ts .......................... 40 E. Asphalt Penetrations and Viscosities .....•.. 53 F. Density Test Results ................•....... 55 G. Maintenance Work and Seal Coat Construction. 57 H. Rut Depth Measurements ...............•••.... 60 I. Crack Survey Results .•..............••...... 62 J. Road Rater Results.......................... 66

PAGE 1

ACKNOWLEDGEMENT

Research project HR-229 was sponsored by the Iowa Hiqhway Research

Board and the Iowa Department of Transportation. Fundinq for this

project was from the Secondary Road Research Fund in the amount of

$130,000.

The authors wish to extend appreciation to the Osceola County Board

of Supervisors and the Iowa DOT for their support in developing and

conducting this project. We also wish to thank the Rohlin Con­

struction Company for their cooperation durinq the pro:iect. The

Osceola County inspection personnel also deserve recognition for

the extra effort put forth on the proiect.

PAGE 2

ABSTRACT

The objective of this proiect was to determine if any of several

cutback and emulsified asphalt plant mixed and road mixed overlavs

had the ability to resist thermal cracking at low temperatures

without inducing shoving and/or rutting at high temperatures. A

2.6 mile section of Osceola County road A-34 and a 7.0 mile section

of A-46 were divided into 14 test sections of various lengths. Af­

ter six years, results show an MC-3000 asphalt cutback cold mix can

reduce the amount of reflective cracking when compared to an AC-5

hot mix. This can be done without inducing high temperature re­

lated problems.

Cold road mixing can be effective in reducing cracking on low vol­

ume roads. However, more experience is required if the full bene­

fits of road mixing are to be realized.

PAGE 3

INTRODUCTION

Many of the first paved roads in Iowa, particularly in the north­

west part of the state, were constructed bv usinq a cutback asphalt

mixed with crushed pit run gravel. With low traffic volumes, this

type of flexible bituminous pavement has performed well, showing

little sign of transverse cracking or deterioration of the asphalt

binder. Manv of these roads carried traffic over 20 years before

needing resurfacing.

With time, the county road departments began constructing paved

roads using hot mix that normally contained 85 to 100 penetration

asphalts. The mixes were produced at a central plant and laid with

an asphalt paver. The result was a smooth, hard, uniform asphalt

concrete roadway. Transverse crackina of these pavements has be­

come a costly maintenance problem. One reason for the cracking is

the brittle pavement behavior at low temperatures. As degradation

occurs at the crack, a depression forms. The result is a reduction

in riding quality and a loss of pavement life.

In an attempt to avoid the cracking problem, highway engineers are

looking for ways of improving the low temperature characteristics

of asphalt pavements with little sacrifice in the moderate to high

temperature characteristics. One potential alternative may be to

return to a cutback or emulsified asphalt for county roads that

carry light traffic. Research project HR-229 was conducted to <le­

termine if several flexible bituminous base sections had the abil-

PAGE 4

ity to resist thermal cracking at low temperatures and resist

rutting and shoving at high temperatures.

OBJECTIVE

The objective of the project was to evaluate several bituminous

concrete base overlays to determine jf any had the potential to re­

duce future construction and maintenance costs.

PROJECT DESCRIPTION

Two roadways in Osceola Countv were selected for placement of the

experimental overlays. The sections included a 2.6 mile section of

county road A-34 and 7.0 mile section of county road A-46

(Figure 1). The existing roadbeds of A-34 and the east four miles

of A-46 consisted of a 3" cold laid bituminous concrete base over a

6" gravel base. The west three miles of A-46 were constructed as

Iowa Highway Research project llR-18 in 195/ and consisted of vari­

ous bases with a cold laid bituminous concrete wearing surface.

Average daily traffic is 138 to 195 vehicles on A-34 and 135 to ?.19

vehicles on A-46.

PLAN PREPARATION

The original concept for the project included four bituminous con­

crete overlay test sections and a control section of Type B asphalt

cement concrete overlay to be constructed on two separate roadways.

It was later decided to add test sections utilizing cold mix recy­

cling on A-46. Four 1/2 mile test sections were added to the

project. The additional sections were to be constructed by

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PAGE 6

removing 1 1/2" of the existing 3" bituminous pavement, adding new

aggregate and bituminous binder, and relayinq the mix.

The construction plans and special provisions for A-46 were devel­

oped to allow for alternate construction. The first alternative

was seven miles of bituminous overlay and thfl second alternative

was five miles of bituminous overlay and two miles of cold mix

pavement recycling. Contractor bids for the A-46 pro1Act were to

be submitted on the first construction alternative onlv. It was

intended that, if determined feasible, alternative ?. would be con­

structed. Pavment for all work in the recvcled portion of alterna­

tive 2 was to be made on the basis of the contract quantities of

alternative 1 for items i.n that area, with no measurement for pay­

ment. Special provisions and contract quantities for both A-34 and

A-46 are in Appendix A.

TEST SECTIONS

The various bituminous concrete bases were mixed usinq the follow­

ing six bituminous binders from Bituminous Materials of Algona,

Iowa:

1. AC-5 grade asphalt cement. Penetration of the asphalt was to

be a minimum of 140. The AC-5 asphalt was the control section

for comparison.

2. MC-3000 grade cutback asphalt. Residue from the distillation

test of this matflrial was to be a mini.mum of 140 penetration.

PAGE 7

3. MC-800 grade cutback asphalt. The MC-800 was added to the

project after trial mixes with some of the intended aggregates

indicated adequate performance could be achieved with the

softer asphalt.

4. SC-800 grade liquid asphalt. ASTM D 2026 was the only require­

ment specified for this material.

5. HFMS-2 High float anionic emulsified asphalt with a minimum of

5% oil distillate. Again a minimum penetration of 140 was

specified for the residue from the distillation test.

6. CSS-1 cationic emulsified asphalt with a minimum of 5% oil

distillate.

Gravel aggregate for the bituminous concrete sections, the

bituminous recycled sections, and the Type B asphalt concrete con­

trol sections was produced by Maudlin Construction Companv. Fif­

teen percent pea gravel (AATl-532) from Floyd River Sand and Gravel

was added to the 3/4" qravel (AATl-591) for the Type B ace control

section on A-46. All other sections were constructed using onlv

Maudlin gravel. See Appendix B for aggregate test reports.

On A-46, ten test sections were constructed 22 feet wide using the

bituminous binders. Six of the ten sections were mixed at a cen­

tral plant with 3/4" gravel aggregate and laid with a paver to a 2"

nominal thickness. The other four sections consisted of 67% milled

PAGE 8

bituminous pavement from the road and 33% virgin aggregate. This

blend was mixed on the road with four of the bituminous binders and

placed 2 1/4" thick with a motor patrol. The test sections are

listed in Table I,

TABLE I A-46 TEST SECTIONS

Asphalt Section Length Section No. Binder Adde<l % Mix Tv12e (Ft.)

1 AC-5 6.6 Plant Mix 5940

2 MC-3000 5.7 Plant Mix 1365 5.3 8550

3 HFMS-2 6.4 Plant Mix 2440

4 HFMS-2 4.7 Road Mix 2601

5 CSS-1 4.9 Road Mix 2549

6 CSS-1 6.5 Plnnt Mix 2880

7 MC-3000 5.5 Plant Mix 2620

8 MC-800 2.9 Road Mix 2594

9 SC-800 2.8 Road Mix 2556

10 SC-800 5.1 Plant Mix 1600 4.6 1085

On A-34, four test sections were constructed 23 feet wide. The

sections were mixed at a central plant with 1/2" gravel aggregate

and laid with the full width paver. Original plans specified a

nominal 3/4" overlay, but due to construction problems, the thick-

ness had to be increased to over one inch. The test sections are

listed in Table II.

PAGE 9

TABLE II A-34 TEST SECTIONS

Section I,ength Section No. Binder Asphalt % Thickness (In.) (Ft.)

11 HFMS-2 6.4 1 1 I/. 1520

*12 AC-5 6.4 1 1/4 2740

13 MC-3000 5.2 1 1/8 4570

14 SC-800 5.4 l 1/8 4876

*Constructed in 198/. due to failure of or~ginal section.

Plan layouts for the test sections are shown in Appendix C.

MIX DESIGNS

Fourteen mix designs were prepared for the research project. Pre-

paring trial mixes for Ma.rshall testing required some deviation

from standard asphalt concrete mix preparation. The MC-3000 and

SC-800 mixes with the 3/4" and 1/2" gravels were mixed at 180°F. A

curing time of 16 hours at a temperature of 140°F was allowed be-

fore molding the Marshall specimens. Marshall testing was done at

77°F.

The 3/4" and 1/2" gravels for mixes with HFMS-::> and CSS-1 were wet-

ted to 5.5 percent moisture prior to mixing. Mixing, curing and

molding temperature for the emulsion mixes was 130°F. The cure

time before molding specimens was 16 hours and the Marshall testing

was done at 77°F.

Mixes for the blend of milled pavement and new aggregate were

mixed, cured and compacted at room temperature. The MC-800 and

PAGE 10

SC-800 were heated to 160°F prior to mixing, while the HFMS-2 and

CSS-1 emulsions were applied at room temperature to the aggregate

blend. The mixes were allowed to cure for 20 hours before being

compacted and were tested at 77°F. The mix design reports are in

Appendix D.

CONSTRUCTION

Rohlin Construction Company of Estherville, Iowa, began con­

struction on September 14, 1981.

Preparation for Road Mixing

The contractor began construction by milling the two miles of pave­

ment on A-46. A 12 foot wide CMI Rotol'.lill was used to remove

1 1/2" of the existing 3" bituminous pavement (Figure 2). The

milling was completed in two days. Milling for the sections was

done without water to avoid adding excess moisture to the material.

After completion of the milling, virgin gravel was hauled to the

road to be mixed at the rate of 1:? with the milled bituminous ma­

terial. Both a Seaman Pulverizer and a Bros Pulverizer were used

to blend the materials and to further break up the millings. De­

spite many passes by the pulverizer, very little reduction in maxi­

mum particle size was obtained. The asphalt content of the

combined materials was 3 percent prior to the addition of new as­

phalt cement.

PAGE 11

,'

Figure 2. Mi11ing on county road A-46

PAGE 12

The combined aggregate and recycled material for the MC-800 and

SC-800 sections was spread across the roadway and allowed to dry.

The additional drying time was necessary to lower the moisture con­

tent below 2% before applying asphalt. To tack the base, the ag­

gregate was windrowed at one side of the road. The opposite side

was broomed clean and tacked with MC-70. The material was then

bladed onto the tacked surf ace allowing the other side to be

cleaned and tacked.

Road Mixing

In the special provisions, the preferred equipment for mixing and

relaying the milled material was a traveling pug and a laydown ma­

chine. A traveling pug was not available, so an asphalt distribu­

tor and a Seaman or Bros Pulverizer were accepted for asphalt

application and mixing. The contractor decided to use a motor pa­

trol to spread the mix rather than an asphalt paver.

Mixing of the milled material and the SC-800 began September 18.

The air temperature ranged from 68°F to 74°F. After cleaning and

tacking the base, the milled material was spread across the roadwav

the width of the distributor bar (Figure 3). The SC-800 asphalt

was heated to 170°F prior to application. Unfortunately, the dis­

tributor wasn't capable of delivering the specified 2.8 percent as­

phalt in one pass. Following the initial pass of the distributor,

a patrol bladed the mix into a windrow for the pulverizer mixing.

The first pass of the pulverizer left the asphalt "balled-up" with

the fine portion of the aggregate. The material was again spread

PAGE 13

across the road and the rernaininq SC-800 was applied in two addi­

tional passes. Blading the mix back and forth and subsequent

passes with the pulverizer did break up most of the asphalt balls

(Figure 4). As expected, 100 percent coating of the material was

not achieved in the cold mix process.

After 96 hours of aeration (Figure 5), the mix was spread across

the road to the 1/2" per foot cross slope. Initial compaction was

by two rubber tired rollers followed by a large steel vibrating

roller (Figure 6). Four days later the surface was rerolled with

the rubber tired rollers.

The second section mixed was the MC-800 section. In an attempt to

avoid the balling problem experienced on the SC-800 section, the

material was split into three windrows and asphalt was added. The

MC-800 asphalt was heated to 225°F prior to application. The dis­

tributor was then able to apply the 2.9 percent asphalt specified

in one pass per windrow. The smaller windrows could also be han­

dled much easier by the patrol and the pulverizer. Despite the

change, some balling of the asphalt still occurred. The completed

mix was spread and compacted the same as the previous section. Air

temperature remained moderate, around 70°F, during mixing and plac­

ing of the MC-800.

The HFMS-2 and CSS-1 emulsions were l)lixed in a similar manner.

Percentages of emulsion required in the mixes were 4.7 for the

HFMS-2 and 4.9 for the CSS-1. This required six passes of the

PAGE 14

Figure 3. First apolication of SC-800 to road mix

Figure 4. Mixing windrow with a pulverizer

PAGE 15

Figure 5. SC-800 road mix left to aerate after mixing.

Figure 6. Compaction of road mix section

PAGE 16

distributor on each section. The emulsions caused only minor ball-

ing in the mix. Air temperatures during mixing and placing were

between 52°P and 65°P. The emulsions were heated to 140°P for ap-

plication, but quickly cooled because of the air temperature and a

strong wind. After several days the compacted surface exhibited a

dark brown color and produced dust as traffic passed.

Plant Mixing and Paver Laying

The mixes composed of 3 I 4" and 1I2" gravel were mixed in a con tin--

uous drum mix plant set up one mile south of Ashton. Asphalt tern-

peratures and mix temperatures for the various mixes are shown in

Table III.

TABLE III Temperatures (op)

Binder Asphalt Temp. op Mix Temp. op

AC-5 250° to 305° 280° to 350°

SC-800 210° 195° to 200°

MC-3000 230° to 250° 190° to /. 3 5 °

HPMS-2 150° 180° to 210°

*CSS-1 150° to 175° 140° to 210°

*Mix temperature was raised above 190°P because poor coating and poor laying qualities of the mix resulted at lower temperatures.

The plant mix sections were laid with a Blaw Knox full width paver.

To simplify storage of the asphalt binders, the paver was first

used on A-34 to lay 1/2" mix with a particular binder and then

moved to A-46 to place the 3/4" mix using the same asphalt binder.

PAGE 17

Problems began on the SC-800 section of A-34. A 1/2" mix could not

be placed 3/4" thick as the plans had specified. The contractor

increased the mat thickness to between 1 1/8" and 1 1/2" so that it

could be laid without tearing. The problem was the same for each

mix on A-34.

Another problem occurred while mixing and placing the CSS-1 mate­

rial. At a mix temperature of 140°F to 150°F, poor coating 0f the

aggregate was observed. It was difficult to lay the mix at that

temperature due to dragging and tearing of the mat even at the in­

creased thickness. At a 190°F mix temperature the problems were

reduced. No significant problems arose during the resurfacing of

A-46.

Compaction included a vibratorv steel roller, followed by a ruhber­

tired roller and final rolling with a static steel roller. Gener­

ally, the rollers were held back from the paver to allow the mats

to cool to between 120°F and 140°F in order to gain stability.

CONSTRUCTION COSTS

The construction costs for all plant mix sections were similar to

the construction costs for the Type B ace overlav. Using bid

prices for the different asphalt binders, and actual quantities

used, the cost of binder per ton of mix ranged from $13.53 for the

HFMS-2 emulsion to $16.15 for the MC-3000. Binder cost per ton of

mix for AC-5 asphalt was $15.31. The cost per ton of mix was

$13.74 for CSS-1 emulsion and $14.42 for SC-800. Bid prices for

PAGE 18

mixing, placing and compacting the hases were the same for each of

the plant mixed sect.ions. Due to the bid procedure for the road

mixed sections, no bid price cost could be developed.

CONSTRUCTION TESTING

The construction of fourteen different test sections required sub­

stantial testing. Samples of each mix were taken from the roadway

prior to rolling. Density samples for each section were obtained

from the compacted mats.

Plant Mix Testing

From the mix sample.s obtained, the asphalt binders were extracted

and tested for penetration and viscosity (Appendix E). As was ex­

pected, the SC-800 was too fluid to test for penetration. The

other extreme was the CSS-1 emulsion extracted from the 3/4" and

1/2" mixes as penetrations of 78 and 83 indicated a relativelv hard

asphalt binder (similar to an AC-10). Penetrations ranging from

108 to 148 for the other three extracted asphalts were generally

consistent with project expectations for the plant mixes.

The lab densities, field densities and field voids were determined

for each section and are given in Appendix F. No minimum density

requirements were specified for the bituminous concrete test

sections. Four inch diameter cores were cut from the AC-5 Type B

control section and weighed to verify that field densities met the

required 94% of Marshall density. The bituminous concrete sections

PAGE 19

were too soft for cutting cores so a nuclear density gauge was used

to obtain field densities.

Road Mix Testing

Bituminous binders extracted from the road mixed sections con­

structed with 67% reclaimed bituminous pavement had relatively low

penetrations except for the SC-800 (Appendix E) . This was expected

due to the presence of 3% old asphalt cement with a penetration of

40 in the mix. The very soft SC-800 had a dramatic effect on the

old asphalt binder and produced a penetration of 140 for the ex­

tracted asphalt combination.

The field densities for the road mix sections were obtained by use

of the nuclear density gauge. Lab densities, however, were based

on modified proctor densitv rather than Marshall density. ~ab den­

sities, field densities and field voids are given in Appendix F.

DISCUSSION

The purpose of the project was to construct flexible bituminous

concrete base overlays which have the potential to reduce future

maintenance and construction costs. The recycled portions of the

project were added as a possible alternative to overlay con­

struction for a deteriorated road.

Plant Mixed Sections

The construction of the plant mixed sections was generally success­

ful using standard asphalt construction equipment and procedures.

PAGF. 20

One disappointment was the stripping of aggregate on the CSS-1

sections. During trial mixing no special consideration was given

to the compatibility of the aggregate and the binder. In the fu­

ture, more attention should be paid to .the electrical charge of

both aggregate and emulsion in order to minimize the potential of

stripping or premature failure.

Another problem which was not expected was the necessity to in­

crease the thickness of the 1/2" mix to avoid tearing the mat.

Common practice for paver laid hot mix is to use a maximum aggre­

gate size which is no larger than 50 percent of the mat thickness.

The relatively low mix temperatures may have contributed to the

problem.

Road Mixed Sections

The construction of the road mixed sections was somewhat disap­

pointing. Equipment used on the job was not the optimum. The ini­

tial problem was how to eliminate oversized pieces of milled

pavement. Passes by the pulverizers had only marginal success at

reducing the amount of 1" plus chunks. As a result of several

passes by the pulverizer, additional fine material was produced.

The other problem encountered was inadequate mixing. Addition of

asphalt binder through an asphalt distributor caused the binder to

flow on top of the aggregate and cool before the pulverizer could

mix the materials.

PAGF. 21

The mixing equipment used on this project could not adequately mix

the recycled pavement and the small amount of binder. An improved

procedure would have been to first screen .. off the .oversized pieces

of milled pavement (or run the millings through a traveling

crusher) . A more effective means of mixing the materials would be

to use a traveling pug mill or a pulverizer equipped to applv the

required percentage of binder.directlv into the mixing chamber.

Despite the difficulties during construction, the MC-800 and SC-800

produced a surprisingly good surface. The two emulsion sections,

however, appeared very lean on asphalt. Both emulsion sections re­

mained a dark brown color after construction and produced dust as

traffic passed.

PERFORMANCE

The late completion date of the paving forced the county to post­

pone the application of the seal coat surfacing planned for the

project. A winter seal was applied only to the surface of the road

mix sections before winter.

Performance of Plant Mixed Sections

It was apparent, shortly after construction, that the plant mixed

CSS-1 emulsion sections were not performing well. Besides having

low penetrations, the sections experienced aggregate loss from the

surface. The emulsion may not have been compatible with the gravel

aggregate. Eventually the 1/2" mix of CSS-1 on A-34 had to be

bladed off with a motor patrol. The CSS-1 sections on A-46 experi-

PAGE 22

enced the same problem, but to a much lesser extent. The other

plant mixed sections performed satisfactorily with little notice­

able difference in appearance.

In early summer of 1982, county road A-46 was used as a haul road

for 15 ton aggregate trucks transporting material to a four-mile

pee paving project. The heavy trucks caused some areas of the

CSS-1 emulsion section to lose surface aggregate. The surface of

the 1/2 mile CSS-1 section was corrected by resurfacing with an as­

phalt sand mix in July 1982.

Also in July 1982, 1 1/4" of Type B mix of AC-5 and 1/2" gravel was

placed on A-34 where the CSS-1 section had earlier been removed.

The resurfacing of A-46 and A-34 was completed with a seal coat

surface over the test sections. One-half mile of the AC-5 section

and 1200 feet of the SC-800 plant mix section on A-46 were left

with no seal coat to observe the effects of traffic and weather on

the base material. However, these sections were covered when A-46

was seal coated a second time. The east 4 miles were seal coated

in 1985 and the west 3 miles in 1986. Specific locations of con­

struction and maintenance, excluding this seal coat, are shown in

Appendix G.

At the end of the five year research period, several statements can

be made concerning the condition of the pavement. First, rut depth

measurements made at the end of the research period show that no

significant rutting has taken place throughout the length of any

PAGE 23

one section. Ten sets of four readings were made in the wheel

paths of each section (Appendix H) . The largest average rut depth

was 0.12 inch in the MC-3000 section on A-34. In 9eneral, rutting

of the experimental sections on A-34 was slightly greater than

those of similar sections on A-46. It should be noted, however,

that A-34 had a rutting problem prior to construction and had known

subbase problems.

Also, the degree of base degradation at crack locations appears to

be minimal since no depressions were noticed upon visual in-

spection.

Section No.

1 2 3 4 5 6 7 B 9

10

11 12 13 14

TABLE IV CRACKING AND RUTTING VAI,UES

Average Rut Depth (Inches)

0.10 0.10 0.09 0.11 0.06 0.08 0.07 0.22 0.16 0.07

0.11 0. 09 0.12 0.10

Linear Feet of Transverse Cracks

Per Station (12-21-87)

22.6 9.4

95.1

86.9 22.9 29.3 93.0

1.5 4.0 4.1 9.5

Although the paved sections have performed similarly in terms of

rutting and crack degradation, it was obvious at the end of the

PAGF: 24

six-year test period the MC-3000 and HFMS-2 sections had outper-

formed the SC-800 and CSS-1 sections. This conclusion is based on

crack surveys taken throughout the research period. Results of the

surveys are given in terms of linear feet of transverse cracks per

station of pavement (see Appendix I). The better performance of

these sections is also directly related to their higher structural

ratings as determined with the Road Rater (Appendix J).

Also from available information, the percentage of original cracks

i i which reflected to the surface could be calculated for several

sections. From these calculations it became clear the MC-3000

! I ' sections had the best performance record of all the paver 1aid

sections.

Performance of Road Mixed Sections

The two emulsion road mixed sections, having a sand seal only, per-

formed better than expected through the winter of 1981-82. Al-

though sampl,es from the roadway contained nearly 7% asphalt, the

sections appeared very lean on asphalt. It was evident the

emulsions did little to activate the old asphalt.

The following summer (1982) both road mixed emulsion sections re-

quired maintenance. A 1300 foot ac surface patch was placed on the

HFMS-2 section and the entire one-half mile CSS-1 section was re-

surfaced with asphalt concrete. The two sections were then seal

coated as originally planned. As mentioned previously, these

sections were again resurfaced when A-46 was seal coated in 1985.

PAGE 25

The incompatibility of the emulsion and aggregate was the expected

cause for the failure of the CSS-1 section.

The road mixed SC-800 and MC-800 sections have performed satisfac­

torily during the research period. The initial construction of

these sections was completed bv applying a seal coat in July 198?.

A 1000 foot segment in both the SC-800 and MC-800 sections was dou­

ble seal coated in an attempt to correct surface distortions. The

double seal coat technique provided a good surface, indicating a

double seal coat treatment might be justified on future projects.

Overall, the road mixed sections were superior to the paver laid

sections of A-46 in terms of cracking. The HFMS-2 section was es­

pecially impressive, averaging only 1 transverse crack every 4

stations. The MC-800 and SC-800 sections averaged nearly 1 crack

per station. (Appendix I). Undoubtedly these results were greatly

influenced by the additional surface work the road mixes required

beyond the seal coats applied in 1982 and 1985-86, especially those

of the HFMS-2 section.

Rutting became a more severe problem in the SC-800 and MC-800

sections, with rut measurements averaging 0.16 inch and 0.22 inch,

respectively, being taken at the end of the research period. The

emulsion sections had little rutting, due to the major resurfacing

of these sections (Appendix H) .

i i

PAGE 26

CONCLUSIONS

From the construction and performance of the paver laid and road

mixed sections, several conclusions can be drawn.

Plant Mixed Sections

The success of the MC-3000 mixes in reducing the amount of reflec­

tive cracking (especially section 2) shows the paver laying process

using a cutback asphalt can result in a pavement equal to hot mixed

asphalt in terms of preventing reflective cracking. The lower mix

temperature of the cutback mixes apparently resulted in less ther­

mal contraction after placement and during cold weather. The lower

mixing temperature and surface seal seemed to keep the asphalt from

oxidizing. Also, test results show high temperature effects, such

as rutting and shoving, are not a concern under moderate traffic

conditions.

The use of cutback asphalts, especially the MC-3000, can be used

successfully on low volume roads to reduce the amount of mainte­

nance resulting from cracking of a normal asphalt concrete mix.

Road Mixed Sections

The road mixed sections generally had fewer cracks per station than

the plant mixed sections.

Lab and field densities of the road mixed sections were low because

of mixing at ambient temperatures. This resulted in a pavement

more susceptible to rutting, as evidenced by the higher rutting

PAGE 27

values of the road mixed MC-800 and SC-800 sections. The unrutted

condition of the other road mixed sections was due to the

replacement/repair of these sections.

The generally poor results of the road mixed sections were the re­

sult of inexperience in both mix design and construction. The con­

tractor was allowed to start too late into the construction season

using equipment not suited for road mixing. Future construction

involving road mixing must address these problems if more success­

ful results are to be realized.

PAGE 28

Appendix A

Contract Quantities and Special Provisions

PAGE 29 · Contract Quantities County Road A-34

ITEM I QUANTITY! UNIT I UNIT PRICE I AMOUNT

Base, Cleaning & Preparation of 6.817 Miles 100.00 681.70

2 Primer of Tack-Coat Bitumen 5.872 Gals. .95 5,578.40

3 Base, Type B Class 2 Asphalt Cement 577 Tons 9. 17 5,291.09 Concrete

4 Base, Bituminous Concrete Class 2 3,381 Tons 9 .17 31,003.77

5 Asphalt-Sand Surface Course 160 Tons 30.00 4,800.00

6 Base, Binder Bitumen HFMS-2 27,823 Gals. .90 25,040.70

7 Base, Binder Bitumen CSS-1 9,966 Gals. .90 8,969.40

8 Base, Binder Bitumen MC-3000 7,619 Gals. 1.25 9,523.75

9 Base, Binder Bitumen SC-800 6,940 Gals. 1. 15 7,981.00

10 Asphalt Cement 50 Tons 232.00 11,600.00

Grand Total $110,469.81

PAGE 30 Contract Quantities Co. Rd. A-46

ITEM jquANTITY UNIT I UNIT PRICE I AMOUNT ,_

1. Base, Cleaning & Preparation of 6.988 Miles l 00. 00 698.80 l 2. Primer Or Tack-Coat Bitumen 7,313 Gals 1.00 7,313.00

3. Base, Type B Class 2 Asphalt Cement Concrete 1,437 Tons 9.07 13,033.59

4. Base, Bituminous Concrete Class 2 8,483 Tons 9.07 76,940.81

5. Asphalt-Sand Surface Course 70 Tons 30.00 2,100.00

6. Asphalt Cement 99 Tons 232.00 22,968.00 I ,

7. Base, Binder Bitumen HFMS-2 70,918 Gals .90 63,826.20 I )

8. Base, Binder Bitumen CSS-1 24,439 Gals .90 21,995.10

9. Base, Binder Bitumen MC-3000 24,354 Gals 1.25 30,442.50

10. Base, Binder Bitumen SC-800 17, 190 Ga 1 s 1.15 19,768.50

Grand Total $259,086.50

Alternate Construction Quantities

1. Base, Cleaning & Preparation of 4. 981 Mil es

2. Primer or Tack-Coat Bitumen 7,313 Gals

3. Base, Type B Class 2 Asphalt Cement Cone. 1,437 Tons

4. Base, Bituminous Concrete Class 2 5,713 Tons

5. Asphalt-Sand Surface Course 50 Tons

6. Asp ha 1t Cement 99 Tons

7. Base, Binder Bitumen HFMS-2 67,057 Gals

8. Base, Binder Bitumen CSS-1 20,588 Gals

9. Base, Binder Bitumen MC-3000 21,367 Gals

10. Base, Binder Bitumen SC-800 14,491 Gals

11. Aggregate, For Bituminous Mix 969 Tons

12. Planing & Milling Existing Base 25, 911 Sq. Yds.

13. Mixing & Relaying Bituminous 25. 911 Sq. Yds. Concrete Base

IOWA DEPARTMENT OF TRANSPORTATION Ames, Iowa

Special Provisions for

ACC PROJECTS

Osceola County Projects: FM-72 (7)--55-72 SN-69 (1) --51-72

May 27, 1981

PAGE 31 SP-358

THE STANDARD SPECIFICATIONS, SERIES OF 1977, ARE AMENDED BY THE FOLLOWING ADDITIONS AND MODIFICATIONS. THESE ARE SPECIAL PROVISIONS AND SHALL PREVAIL OVER THOSE PUBLISHED IN THE STANDARD SPECIFICATIONS.

358.01 GENERAL. The work shall consist of the construction of two Type B asphalt cement concrete base sections and various compacted bituminous concrete base courses as specified on the ·plans. Section 2203 of the Standard Specifications will apply to Division 1 {Type B ACC base) and Section 2204 of the Standard Specifications Will apply to Divisions 2, 3., 4, and 5 {various compacted bituminous concrete base courses) except where modified by these special provisions or other DOT current special provisions. Section 1109.03 of the Standard Specifications shall not apply to asphalt-sand mix, SC-800, or primer or tack coat. All or any part of the work may be eliminated at the discretion of the engineer.

:t is intended that some wheel-track distortion be corrected by placing a heavy tack coat, blading a hot asphalt-sand mix into the areas, and rolling it up to six times W.1.th a rubber-ti;;-,"}d roller. The areas to be corrected, mix designs, and construction procedures Will be determined during construction.

It is proposed that two miles of Project RS-69(1) will be milled, mixed, and laid cold, if found feasible. This work may be done before other work is started and therefore need not delay other work. If the alternate is not found feasible, as determined by the engineer, these are.::s will be constructed according to the original plani however milled depths other than the proposed l~ inches will be considered if the contractor and engineer can reach agreement on construction methods and payment.

358.02 MATERIALS.

A. Primer or Tack-Coat Bitumen - MC-70 meeting requirements of Section 4138 shall be used.

B0 Division 1 - AC-5 meeting requirements of AA.SETO M 226-78, Table 2, .shall be used.

c. Division 2 - Anionic high-float emulsified asphalt meeting requirere:ents of ASTM D 977 shall be used. Residue from the distillation test of this material shall be a minimum 140 penetration at 77°F. (25°c.) with lOOg. for 5 seconds. The anionic high-float emulsified asphalt shall contain a minimum of 5% oil distillate. HFHS-2 ~s intended, but the grade will depend on the design and job-mix formula determinations.

D. Division 3 - cationic emulsified asphalt meeting requirements of AASHTO M 208-72 shall be used. Residue from the distillation test of this material shall be a ~inimu~ 140 penetration at 77o F (2s0c.) with lOOg. for 5 seconds. 'I'he cationic <..::!mulsi:':.!.0d asphal.t shall contain a minimum of 5% oil distillate. CSS-1 is intended, but thE:: gro.de ·Hill depend on the design and job-mix formula determinations.

E. Division 4 - Medium curing cut-back asphalt meeting requirements of AASH.TO :.1 82-75 shall be used. Residue from th'e distillation test of this material shall be a minimum 140 penetration at 77°F. (25°c) with lOOg. for 5 seconds. MC-3000 furnished in the upper half of the viscosity range is intended, but the grade will depend on the design and job-mix formula determinations.

F. Division 5 - Slow curing liquid asphalt meeting requirements of ASTM D 2026 shall be used. sc.-800 is intended, but the grade will depend on the design and job-mix formula determinations.

PAGE 32

G. 1:1;.lJ.I.Q.CJ.£tl:.£ - The z199re,Ja!.:e incorpor<Jtcd in t11e Type B, Class 2 asphalt cement concr.i:'.:1_• {;.;.:;ph.Jltio:: cor.cl: 8 tt:) base und the v.1r:i.ous types of bituminous concrete bases, inclu(!ing virgin aggregate to be. in mixtures for. the milled areas, shall meet require­ment~; of section 4126 and Gradation No. 19, Si.::ct1on 4109, except Paragraph 4126.04C shall be deleted. hll pit-run material passing an 8-inch screen shall be crushed and inccrporated in the aggregate.

T:,., 0 ~\q';~egate 3.nc:orporated in the asphal tic-s~tnd mix s1)all meet requirements of Spoc~~ication 4129 end Gradation No. 22, Section 4109.

H. fl._~91 Mixture -· Refer to general notes on plans.

358.0?- EQUIPM..Et=!T.

A. ~:·i•:.1.sions 2, 3, 4, and 5 - J\rti.cle 2001.19 of the Standard Specifications shall apply·wherc the material is 'puver lnid.

358. 0·1 CQHSTRUCTION

A. Divisions 2, 3, 4, and 5 - It is intended the various bituminous concrete base courses shali-S::~ oa·J8r laid ·.-·ith the option to spread \o,/ith motor patrols, if so approved by the engi:v.·c::..-.' i\rticlcs 2203,09, 2203.10, 2203.lJ., 2203.13, and 2203.15 of the Standard Specifi­cati()r:s zhall apply \<he::e the material is paver laid, except the second paragraph of • 2203. lC sh~ll not apply. Article 2204.07 wJ.11 not apply .

. B. ?:.-.~ditional Construi:;_ti.£J.:i_i'l'ork. on Project RS-62__{.JJ. The following additional construction worY. _i.s intended on this project.

~·l.~lling - 'Jlhis work shall include all labor and equipment for milling or planing :-: :, , 911 square yards, 1·1'i inch in depth, :if the existing bi tumino\is· concrete base on ;"rojcct RS-69(1). rnt·~HHl•:)d wroas to be milled are from stzition 26+50, Division 2, tu station 79+50, Divis.ion 3, and from station 133+00, Division 4, to station 186+00, :;_L•;ision 5. Over 'JS~,(, of this milled mate.r.ial must pass a 1-inch sieve; large pieces ;iot incorporated in the mix will be loaded on county trucks.

~·lL'.~~ and Rc~:!:_!},.9_ - 'l'hi.s wot"'k shall include all labor and equipment for mixing <.-:nd relaying the mill~d bituminous concrete base. 'l'his work shall include adding ~ virgin aggregate to the milled material so that a 2~-inch lift will be re-laid hy tacking the milled surf.:tce, adding asphalt to the combined mix, and re-laying •~nd compacting the m.ix on the same areas. It is preferred that a traveling pug b·_: used for mixing and that a luydown m21ch.ine be used for laying; however other c'.·,.-·.~thods producin9 acceptable resuJ.ts may be used, if acceptable to the engineer.

This ndr:1itional work and the revised quantitiE:,<; within this area are identified on the plans as alt.ornate construction. Payment for nll work in this area, if constructed as intended, will h·:: r;:ade on the l:>at-.:if.; of the contra.ct qunntities for items identified on the plans as quot-E:".: construction, •,.;5th no meitsurcrnent for payment, as noted on the plans. This payment '"ill he f:ull compensation for furnishing ~11 •2quipment, labor, and materials necessary to do t~·i.is additional con5tructi.on work •,.;ithin the ;:ireti designated.

\

Appendix B

Aggregate Test Reports

PAGE 33

' ... :

:UJl,1(1 Dl::l't1l(lllD< l OF' Tl(l'1NSl''Dl~T{1TION

Ol''FTCi:C 01· i·l(1TEl\I(1LS fESf REPURl - Bl1UMINOUS MATEFIALS

LAB LOCATJON AMES

PAGE 34

:j TNllcN\/ED USL I 0· 1 'i/. f1Dl>ED TO ::41 ::!,i1 1'1GfJl'iE:GATI': M SN·-29(3)

COUNTY OSCI OLr~ Pl'W,J IW. .FM-72 ( 'l l

DESIGN

PRODUCER FLOYD RIVER SAND & GRAVEL

SOURCE

CONTl(ACT NO. 1 fl(:,21;), 1861 '? 1B61 B

CONTRACTOR ROHLIN CONST.

UNIT OS MATl':RIAL 3 SACKS FROM SfOCKPILE ;.>,'.'JOO TON

SAMPl.l':D BY BOB FREY Sl:'.NDEH' S NU. HF-5

DATE SAMPLL0 8-14-81 REPORTED 9-25-81

I I

I

I

I I

............................ - ......... - .... -- --- ·----· ,l ..

1 l

SIEVE ANALYSIS - PER CENl PASSING I I /2' 1 " ~\/Al " j ( '') , ,; .. ' :·'.J./Hu 1 {;)G

If r) • ;\ .... , '"') ,;~ ~ ...

r~ _i ' u 1 .. )

l·'U I 6 1 0 HI: 30 0 . 9 /,Ui 50 ('1 . H on 1 00 0

.... . ' Nf..1 2()0 (i . 7

Y. PSG, HU. 8 Al''LR 16 CYCLl':S F & T, WATER-ALCO. SOL X PSG. NU. 8 Ai"fER 25 CYCLES F & T, WAlER SOLUTION j~ r__.·.· 1,.,![1'.:·1F~, LO.s; ,~·cf~GFLI~~.::.; ,:~nr;~P1SIDJ~, DF<PiDING

1 ... 1c.1:.1.rn L.Ii'i r r f'l .. 11STIC L. lMIT PLASl'ICITY INDEX

CDP IE.'': BlT ,, t"1ULi .. ..! • BUMI'' F':':UI... SCHl·lf.'d(l :um L .. ZF.J,m_;:y F'lil.IJECTS LIS Ii r; MHJVI:'.

DISPOSITION· SIGNED: BERNARD C. DROWN

i[;.'TTiW ',1(;'\lll"F'I::

101.,1() lll \'r'ilnMEN ·1 ur Tl((iNSPDlnt.T HJN UFFJCE OF MATEl~IALS

TFST ;:::[F'Dl':f' - n.: ilJMINDUS MATE!'OAL.S LAD LOCAllUN AMES

~ATERlAL 3/4' CRUSHED AGGREllA'fE LAB NO. AAT1-591

. iNTENDLD USE TYPE B CLASS 2 & BIT. CONL. BASE

PAGE 35

SN-·6?(!,) :OUNT'i OSCEDl.J; PROJ NO. SN-2?(3)

DESIGN CONTF\t.r.:T !10.

'RODUCER MAUDLIN CONST. CONTRACTOR ROHLIN CONST.

~OURCE NE-1/4 28-98-42 OSCEDl..P1 CU.

JNIT OF MATLRIAL 2 SACKS t fl, 000 T.

:AMPLED BY BUB FREY SENDER'S NU. 7/31-1 A&B

DATE S1iMl"LEl) REPORTED 9-25-81 ''°' '">.::" .... 0'>• OOM ··- .. .. M OOM 0••• ........ "" ·- M .. OOM M'' - M•O ·- p '"' .... M•• '"' 000' .... "'' o•'' om··- MO• 0'0 '" .... ••M M'O OMo MM - - - - - - - - - -~ "'

~IEVE ANALYSIS - PER CENT PASSING ·1 1/20 ·1 t!

~5/ .i"\ • 1 00 1 /:? " n1..':'

'T ... }

3/U • DI NI.I

' 4 .. ? 1 NU "' ~i [! " 0

f·! I ·; l .:;, 4''• N,,

" :rn 2r;· NI' ~:>o 1 4 l'-l\,I ! 00 D •J . . ,1: •

NO . ~:~oo 6 ' 1;>

X PSG. NO. D AFlER 16 CYCLES E & T, WAfER-ALCO. SUL. X P~G •. NU. 8 AElER 25 CYCLES F & T, WATER SOLUTION x ilF vJl'.:;~il(' l..OS 1'1NCiLl...ES {)[ii((,;; I 01<' GF(r~D .[NG

1... I Q\.I I l) 1...1 ll l. T 1::·Lt1STIC LIMIT F'U)STICITY IND(C>'.

r:oP IES: r::i r. r.nu. ,J. HUl1P P. SCHl·.lfil\TING L. ZEM<l . .EY PROJECTS l.ISTED ABOVE

'lISPIJSITIDN: SIGNED: BERNARD C .. DROWN

TF'STTl~U !"·~f'.!f:"~Tt~~··i:·:i:·

IOWA DEPARTMEN"I OF lRANSPORTATION UFF I CE or ilATEI;: 11;1 ... S

TEST REPORT - Bl JIJMINOUS MATERIALS LAB LOCATION AMES

MAl~R!AL 1/2' CRUSHED AGGREGATE LAD NO. AAll-592

INTENOLD USE BI·r. CONC. DASE OVERLAY

C 0 LJ i< T \' 0 SC E (]I._,; PROJ NU. FM-72(71

DESI i'i·i

PAGE 36

!:ONTRACfOR ROl1LIN CONST.

~OLJRCE NE-114 28-98-42, OSCEOLA CO.

ONIT UF MATERIAL 4 SACKS 4,000 T.

SAMPLED BY BOB FREY SENDER'S NO. 7/31-2

DATE SAMPLED 7-31-81

SIEVE ANALYSIS - PER CENT PASSING ~ 1 /'2 It

1 " 3i' f 11 ·100 "1 ~:,~ n 'i B ~1-/B u ~?(·)

i ! 4 1·il) . H 1'·;, ; I (:~

NU . ~:;o

i·J' ~) () ·\ 4 I"\!;,_! . 1. or:, "' D •'

iiD . 200

~·: r·.\-·},, NCi .. n (1r- f"EH i{~ LYCL.r::~ F C1 Ti l1J(iTEF~·-~1~LCO,, .'.~()L~

% P~G. ND 8 AFTER 25 CYCLES F & T, WAlER SDLUTION X IJF:· WEAl~, LOS ANGE!_l~:s ADF~AS:[ClN, GRADJ.Nl3

l._I()!JID LJ1:1.T F"Lt1,;r1c LTMIT PLASTIC IT, INDI'~\

COPIE.-': _BJ;·, 1V31·

,J. CUMP I''. SCHl0Jl•1i': IINCi L. ZEt1l::I LY ~M: /2(7), OSCEUL0

DISF"DSITH>H:

'! : , '· :. 'T. ,,

I I I

PAGE 37

r '

Appendix C

Test Section Layout

Test Section Layout

A-46

SECTION 1 Plant Mix AC-5

I I I I

s6+oo

150+00

SECTION 5 Road Mix css-1

'

SECTION 9 Road,Mix sc-800

I

187+70 bk.; 0+00 ahd.

SECTION 6 Plant Mix cs11-1

I I

100+00

SECTION 10 Plant Mix SC-800

I I I

2ob+oo

SECTION 2

' 1 Plant

1Mix MC,3000

I

1od+oo

SECTION 3 SECTION 4 Plan

50+0

SECTION 7 SECTION 8 Plant Mix MC-3000

I ! ' Roa? Mix ~C-800

1 so'+oo '

-cl )> G) rn

w 00

\ J

( \_

Test Section Layout

A-34 ,----------------------------- ---------

Plant Mix SECTION 111 SECTION 12

Plapt Mix , ' ' ' ' ' I

150+00 I '

HFMS-2 I 200+00 AC-5

SECTION 13 SECTION 14 l Plant Mix MC-3000 Plant Mix SC-800

- ------ -------------------------1--------- ------ ------- ' ! j ! I l I ! I

I 250+00 300+00

------ I .... ·- ------------.-.!.

\ )

" )> G> .,, w <.O

PAGE 40

Appendix D

Mix Design Reports

\

I

' ' I .

\ i

' MIX, l(PE AND CLASS•

i ' 1.NTE::Nni:::o USi:i ..

PAGE 41 IOWA DEPARTMEN OF TRANSPORTATION

OFFICE C!I Mt1TERit1LS 1•\SPHtr! .. T CONC!.T:TE MIX ])[SIGN

LAB LUCATlON AMES

lYF'L D CL.(·,ss J L.i"d'I NO .• l1BD1 .... l.<JO

! ' .·'IZE ~':)/ 4 II SPEC .. f.IU. DAlE RLPURTED 9/15/81 I .

I' ' COUNTY o.:;·c 1: OL.r"1 i F'hC:1 . .JFCT ~6? < 3 'i ·-·····~5·1 .... 7:?

CONTRhCTOR RUHLIN

Pi'ULJ •. :..CiC::·1,jTiJN

1AGG,. ::~ .·1uh:ci:::s ~3/.;} 11 UF'.t·1t.)FL F'Et, r::;1:;,:1, 1)1":L

,JCJD Mi F!Jl':i·1UL1:\ (1!<1.!l':EC'i1''1 IE

t1SHTUi·I PIT FLOYD F: I t)EF:

l'l':OPOl<:TJONS:

,JOB MI/ 1'0Vi1U/(:, 't .. ~ i / ~.:.'. ' ·t !I ·.'./.4 II

I (-) (-)

i /) 11

('\" "l'Q

'/

NIJ.4 64

FM .... 1::.~ ( "l) ·······'.5~:>· .. ·7:?

DSCECIL(i CD. ; s· (1 j">.! D ()( Gr:: {1l)1;:: L

U~:~'.;:; P1f1T ·1 .... 4B?1

COMBINED GRADATION N0.16 N0.30 N0.50

~·::'fl :.:.~ ~'.> ·} '.~.~

1;·· .. .>

/:1SPH/:1L f snt:i, ;·~F (:,i-..J'!I (·1PF'F~U :·:li''it"1TF 1.)JS'COSI"f\( .·1...t,sr;; JTt 11'1D1:-·

KOCH 537 i'llISES N, 1::· ..

/ t·1SF·'h., Ji·· .. l l'il>'. -~Ul''/f\F:·r·· OF i ''··1h'.S'H(:·,\. 1 .. :ULCJl,..JS l""itd:;:,:;.·hiH .. i ... .'·}'"i1""d3ILJ ,· ( L.:us J"'.L.D~ .. ; () ... ()1 .;.i-/,, i)'P,.t·:;r: :u·y J)J;'.'PL.f'.:'JL.l.:.MFNT(! .. (1)J :OFi"',J:.~: :·· .dULJZ: SI·''. GI·' . CUi'J: . DF:Y t,i;i,; .. SP. C ASPH. @ 71 F :'AL(::~ SOL.:El) ~;:),,(31·~.

F{ I Cr: .... ' ., G Fi ·, VOJI>,\' · f.:; LE X l~.1,;·1 !·. {:~·1.0S(JF~F'TJf'!,-.. ! f:':1CG!·\:EC-Jt1·1··c

\.)()JJ)S lN i·i .. IF i"f ! ·lL!?{·11... tr'._,;:.!r;;Fi3(1'rL. X V.H ·,. FILLED W[fH ASPHALl' l''.f'1L.CUL.ClTFD 1,,;,'l"'H 'I '! M THI Ci<NE:ss ( ,., ::: Cl':ONS) FILL[ \<JTUi"il:'.N ru:,1 JO

5 .·. ()

n.,u ·j ... 3H i D ... H

~::;o

iH17

;:: ,. l):-54 ·i "0~?2 2.,44 , ... ,

\';) " ,;-; 2 .. 4~3 ~:> ,, a ·\ .3U i fl·' 3

<:')'.::; /, ·1) ? ,, 6 () ·• r;

A CONlENT OF 6.'iOX ASPHALf JS RECOMMENDED TO START THL JOB.

cor:·T 1•:::, (:i,\·, ~:., i'--1I>": UF;.~.'Ji.·;1,!

F"F:u .1i:::c·r.-:_., ;_. Is···r i:::o t-1l:ilJl)L L "'UiiF

F' ~ ::; Cl .. J!:J(1i·.:·r J NC:i D., .l•lf(DJ.>Ji' ;::: , .:111 u;1u1sr I. . .·'Lt11'\L!.:·'/ l·:U;; .HI C, ...!ON!.'..S

NO. 1 00 ... , !. 1' .. I

7 ·' ~) '.~; (-)

2047

::.~ ~ t:) ;3 4 ·1 "()~?2

;_~ ., 41

i , .. iB 1 a,. 1 79 .,B 1 ·j •' '.5

NO. 20<1 1::- , ~>,. Q

" , •i

1

·I ' ~j j ~

' ' '

I "

I :)

!

SIZE :;:;!"

COUNTY osc1:0L1'1

CONTRAClOR ROHLfN

I' rrn.J' LDC1Yr; • .. 11·1

PAGE 42

lOklil 1.iLl''(rl'(fi'il'.::N' DF ·TFU'1NSPOl:(ff'1TION ur FICE u:: h;:'1T[F;:It1LS

ASPftALT CONCFLf[ MIX Dl:':SIGN LAB LOCATION AMES

SPEC. i-IU.

1'1SHTON PIT

LAB NO. ABD1-13i

DATE REPORTED 9/15/81 .S' N ···· ~.;~ "? ( :.~> ) ........ '.5 1 .... "l ~,:~

F'!(DJECT ~·6'i' ( :'> l ··· ··~;1 .. 7;:?, Ff·'i· .. ·72 ( .l) ....... '.::;5 .... ·l:?

DSCEOLP1 CU •

............. ,.,_ ........ , ···-·····-······-···········-· .. ·-·-········---·-·-"··-·-···················"'''""'''"''''''''''""'""-"''""''"---····-·----..JOB MI>: 1:: Uh'.MU/.J\

'l ""· 1 /;,:.'.JI ., II ·./ .. :'.}II

1()0 i / ,.~ !!

I ,; ..

10LER~~1 DE: '8/100 ·15 BLU~ MARSftALL DENSITY

:J .. iH 11 NU ... '+ N(J.,D ?O 6~i ~:)<;>

.....

n:~:l'"H:':' ; suu;:..,,;[ (1HD t1F'Pl!O:>< :r i\f'1TE \) T scos I TY r:·Lf:1ST ,,··1Tr INDEX

t1sr:·1-1. :rN >·1···>:: i'IUMHi.:.: l'IF ;;,:H:.:.~'11(11 I .. BL.DIAS •:f'll'~SH(:if .. J. S, <rf .. Il" LBS, r LD•·J ), 01 l1L

P.GR. BY n•~PLALFMENT<LAD DENS. .:::UL!'\ ·:·r· ,, cm,•, COh;i" \)!'(( l1GC" <.·1::·.. 01\ .. ris·r:·H m ,;- ;.i r 1 •• P1L.C ... ::'DLIL T ,Ci!·':. '.~; \,J C1 J ;:•. ·,.' -· ('· r~i i .. C ., rucr:: :cF'. DI·;. ~~ t,..r C1 I r ·1 ·:;· .... h: :;: C.. L. '"~ lAJi~)TFi:: fiH:::·; '~'Pl] (1!·~ (1i...i13F'.t::C·Jt·1TF. .; l.J!IT,.o,' J.N IHL h;;!FIU'iL '""·IU::Glili:::

;.; <..! ... IL1·L F''ll 1.FD 1°.J:i.TH (1SPHt1LT 1..J1LLU' .YfE:O i'.:.T'H .. 1 ;LM THli;J:.:~-IL5'S(i1JCl'WNSl i":l:LLLh/BITUiil::1; r;J1 I JU

CDMBINFD MO. i 6

4·:>

GI'~;>, I)(:, TI ON N0.30 NIL'.'\()

;:>(i 14

'.,·:. ·' ;.:.~? KOCH - 572 POISES '') ,;.,

'.5.,('l 6,,() '.::; 0 ~:> (i :?(-)'"?'.? '..'li.)i~.3

fJ H

1 ,. 02:.:? 'i •. o;.~~2 2.,4f~ :?.,45 9,.(-) 6~(";)

'.,? ·' lf fj '.,:.~ ~ 4 ~-~ B ., (_r' '.:> .. 7 ·1 "~:~.:;~ i; ,, 3 ,'.,;! 1B .. 7 11'1.H ~:} ·t ·' .s (:1 .:) ;, <:~

6., 6 D., '.?

(1 CCI•! ;rNT OF "'" f'';}; ('ISl'lltil.T rs r;:1::C!lMMLNJ1F)) TD STM~T THF .JOB,

COl"'II ,;: t1SF:H ... j'·,t:r l"i[,\" J:i,i·J

i::·1;:, ·:·els L .. LS r: I) 1.YfliJl)E ..J .• ::11.IMI' I'' SCH\,!(,,., I ::: NC~

D .. ·tJh'..OISUi°'! h: .. ;.·i'IEIJ)1l:ST L. ., :"1.::t1Fi'.I ... : "/ F:t.;l··ii :t.N C.. .IONES

ND.100 B. ·1

7,()

'.\O 1?07 f:~

::.: ·' ;?9 2.64\

2 '· ~'56 :LI i ":3:,:: l 9" 4 73 JI

9 .,B

N0.200

3

Fohl in C. Jones

llH\,\ DU'ARlil\f::-:1 Of lRANSf'ORTAl!ON HIGHW·\Y DIVISION

IMJ\ rERI ," H' PAfHM~NT 1

ASPHALT cor 'CRETE MIX DESIGN AMES L\BORATORY

PAGE 43 Asph. Mix Design Projects Listed Below J. Bump P. Schwarting D. Jordison R. Shelquist

.... size._.3/:±''. _____ ~;b. ~:~1li£1-:=.,;1~5L7._ ___ _

lnlended Use : _ __:S:..C::..-_8 O O Co 1 d Mix ------ Spec • No. ---------.Dale Re ported __ 9.:../_2_8-'-/_8_1 __ _ SN-29(3)--51-72

county : ___ O"'§_c::_eo la,,_ ____ Pro i . No. _ _,S,,.'M"'.,_,;,6'-'9'--'-( "'3.;_)_-_-_5=1_-_,7..:2=---· contraclor __ ._,R"'o"h"'l"'i"'· "'n~------FM-72 ( 7) --55-72

Proj. Location: ________________ _

Agg. Sources: 3/4" _<;:;ravel -: .... ..£8--98-42 Osceola .-"c"'o'-'.--------------'-----

Job Mix formula Aggregate Proportions: __ ,, __ 1.00o/LAAT 1-5_';.?_l __________ -····---·-----

JOB MIX FORMULA COMOl!llEO GRADATION . 1 v.·, 1 " 3/4" \fz" .• 3/8" U4 U8 ff16 #30 #50 HTOO H200

100 95 87 71 58 45 29 14 8.2 6.5 Tolerance

-· Asphalt Source and Approximate Viscosity Algona --------% Asph. tn Mix

___ =J 5.0 6.0

Number of Ma:rshall blows 50 50

Marshall Stability· Lbs. 2242 2300 ----------·-

Flow· 0.01 In. 8 9

Sp. Gr. By Oi~p!acem(>nt (Lab Dens,) 2.26 2. 27 "--· ··--------

Bulk Sp. Gr. Comb. Dry Agg. 2.634 2.634 1--~-----

Sp. Cr, Asph. @• 77 f . 0.9744 0.9744 ._.... Cale. Solid Sp. Cr. 2.43 2.39 ~

% Voids - Cale 6.9 5.0 -----··---···--·--··---·· ... ···-·---------- Mixing Temp. 180° I;i.

Ri<:e Sp, Gr, Cure - 16 hrs. @ 140° F. --···-----·-------··- ·-··------- Molding Temp. 140° F.

% Vnids - Rice Testing Temp. 77° F. --------·-·---· -·---··--·--

% Water Absorption ~Aggregate -- --------- -·· ""

% Voids in the Mineral AggrC'gate 18. 5 19.0 ..

~,.;. v M.A. Filled with Asphalt 62.7 73.6

Calculated Asph. Film Thick..lwss (Microns) 7.8 9.4

A content of 5.50% SC-800 is recommended .-~!'.\?.art tl).e, job. ?- •.. .> ~/?' ~ SIGNED: .. ~ • --... ·;, .. ~ ( .... ~

!TESnNG ENG!Nf~Rl · ·

Form 9!>6 1. 7[) Rohlin Constr.

c. Jones

PAGE 44 Asph. Mix Design 11i1\'\ DIPARTMI: 1 ell TRANSl'ClRTAT!oN Projects Listed Below

UIGlfW ,y OIVISION (M/\,T! fll/• cJ! PARtMfN1 I J. Bump

ASPHALT cm CRETE MIX DESIGN AMES U\BORATORY

P. Schwarting D. Jordison R. Shelquist L. zearley

Mix, Typl.' and Cl,1ss: . __ ':fype B ~.1:<3..f?.1? ..... ?.--··---··-- _____ Size __ l/_2_'.' ____ Lab. No. ABDl-159

Intended Use: SC-800 Cold Mix 9/28/81 ·----~~~~ Sµ,ec. t-{e -~~------ Date Re p:>rted'--------SN-29 (:;1--::il-=

Osceola . ~-69 (3)--51-72 Rohlin --------- Pro1. No. -~~--~-~--- Contractor-------------

~FM- 72 ( /) --55-12 County

Proj. Location: _______ _

Agg. Sources: 1/2" Gravel 28-98-42 ----------Osceola co.

----· -~---------------····· ··-------·- --·-------------------------Job Mtx Formula Aggrcgat!." Proportions: _______ l:.:c .. :.:.: .. :Ac:A:.:::T_-_:5:_9::2: __________________________________________ _

JOB MIX FORMULA· COMBINED GRADATION , 'Ii" l" 3 / 4" 'Ii''·· 3/8" #4 #8 #16 #30 #50 #100 #200

100 98 90 69 56 42 26 14 8.7 7. :

Tol!."rance

Asphalt Source and Algona - SC-800 Approximate Viscosity ------ ·-

% A~ph. fn Mi,,_ 5.0 6.0 f-------·· --

Number of Marshall blows 50 50 f--·----·----·------- ... ··-·-·--

Marshall Stability· Lbs. 1940 1960 ---·------------·-----·-----·---- --

Flow - 0.0·1 In. 8 10 -----

Sp. Gr. By OispJ.1ce;nent (Lab Dens.) 2.24 2. 25 ----------

Bulk Sp, Gr. Comb. Dry Agg. 2. 641 2. 641 --------

Sp. Gr. Asph. r~ 77 F. 0.9744 0.9744

Cale.. Solid Sµ. Gr. 2.43 2.40 ----·--

'~ Voids - Cale. 7. 9 6. 1 --·--------

Rice Sp. Gr. Mixing Temp. 180° F.

--· _· --------~ cure - 16 Hrs. 140° F.

% Voids - Rice Molding Temp. 140° F.

-------·-··-·-.. -·--- __ .... ___ ,,. ____ ···---·-- Testing Tenp. 77° F. % Water Absorption -Aggregate -- --% V~ids in the Mineral Aggregate 19.4 19.9

-% V M.A. filled with Asphalt 59.2 69.6 ---- ·-

Calculated Asph, Film Thickness (Microns) 7. 6 9.2

A content of 5.25% SC-800 is recorrunended ;9:)31~ th~~ ,,:-:;;;:::::;:::::> SIGNED: ,,/ .. ··"'-'·""'"-----;r C... £..~~

!TESTING ENG!NEERI

Form 9f>li 1-75

Mix, lype and ct.1s~: __ rl~YJ?_~. -~

PAGE 45 IOWA DLPAR1MU:f OF lRANSf'ORfAT!ON

HIGHW \y OlVlSlON (MATEHIA·:, O~PAAfMfNfl

ASPl!ALT COt'CRETE MIX DESIGN AMES LABORATORY

Asph. Mix Design SN-29(3)--51-72

-81"l-69 (3) --51-72 FM-72(7)--55-72; Osceola ,J. Bump, Schwarting D. Jordison, R. Shelquist L. Zearley, Rohlin

_,_l .. ..ca_ . .cs .. c8.-'2'--· . ____ Size_. 3/ 4" Lab. No. ABDl-156

lnternled Use: MC-3000 Cold Mix ·--- Spet·. No. ------ Dale Re port•d __ 9_-_2_8_-_-_:;:8.:;;lc__ SN-29(3)--51-72

County _ Osceola _____ Pro;. No.J3_N-:-69 (3) --51-72 FM-72(7)--55-72

_ Contractor __ R_o_h_l_i_n _______ _

Proj. locution: ______ .

Agg. Sources: ___ 3~/_4_''. Gra_ve:I,_ - 28-98-42 Osceola Co.

-----·----

---·-'"·.,-------·-·· -----·-----····---- - - -·· ··-

JOB MIX FORMULA -COMBINFD GRADATION -- -·----·---' 1 v~" 1" 314" '11''·· 3/8" 114 118 1116 1130 I/SO 11100 #200 ---·-·

100 95 87 71 58 45 29 14 8.2 0 •. 5 . ··----

Tolerance

Asphalt Source and Algona MC-3000 93.7"/o Residue Approximate Viscosity ·----

% A~ph, In Mix 5.0 6.0 ~· .. - .. ,.----

Number of M.:ushall blows 50 50 -----·--·--·-···-. -·

Marshall Stability - lbs. 2955 3450 ..

Flow· 0.01 In. 13 17

Sp. Gr. By Displacement {lab Dens.) 2.10 2.14 !----··--~-·----·-----:---

Bulk :.;p. Gr. Comb, Ory Agg. 2.634 2.634 -------·-·--·----...

Sp. Gr. Asph. i:o 77 F. 1.020 1.020 ~ .. -------------·-

CJlc. Solid Sp. Gr. 2.44 2.41 -·

% Voids - Cale. 14.0 11.0 -··----·---·-· . --·------ Mixing temp. 180°F.

Rice ~p. Gr. Clire-16 hrs_ @ 140°F. .. -----··---·---- Molding Temp. 140°F .

% Voids - Ric€' Testing Temp. 77°F. ·---·-------·-·- -------, . ··-

% Waler Absorption -Aggregate -- ---... _ -·-·-------·-·- -------

% Voids in the Mineral AggregJ.t(.' 24. 3 23.6 -

% V M.A. Fillt>d with Asphalt 42.4 53.3 --·- ·-

Calculated Asph. Film Thick .. ness (Microns) 7 Q 9 4

A Content of 5.5"/o MC-3000 is re comme nrl '"tL.l;;o --sl: a r~, +:he • ...;i o:P~-::::;:::::> SIGNED:'}_? -----..__/',.;:;..>"' G p.-. ..:.,~

rTESTl'NG ENGINfER1

Fo,rrn 9!,,-, , -75

Rohlin Constr. Co. c. Jones

PAGE 46 Asph. Mix Design IOW'\ IH!'.·\Rll.\!' ! or lRANSPllR!AllON Projects listed below

HIGHW •Y OIVISION tMA1rniti1 ,.,(PARJMFN11 J. Bump

ASPHALT COt CRETE MIX DESIGN AMES Lt\BORATORY

P. Schwarting D. Jordison R. Shelquist L. zearley

_____ Size_l/'.2.'_' ___ · _Lab.No. ABD1-.el~5'-'8"------

MC-3000 cold Mix 9/28/81 Intended Use:__________ --------Spec .No. -------Date Re{X)rted--------

County Osceola SN-29 (3)--51-72

Proj, No._.:.~-69 (3) --51-72 FM-72(7)--55-72

Contractor __ R_o_h_l~i_n _______ _

Proj. Local ion: ________ _

Agg. sources: __ li.2" Gravel - .. Z.8-98-4_? Osc_e_o_l_a_C_o_. ____________________ _

Job Mix Formula Aggregate Pro port ions: _. __ c::cc:._:c_Lo-'AA=:::T_,l,-.. _5::..=,9:::2: __ . _______ ·------·-·-----·---------

)08 MIX FORMULA· COMBINED GFADATION

1 \'i" 1" 314" %' '·• 3/8" 114 118 1116 1130 1150 11100 11200

100 98 90 69 56 42 26 14 8.7 7.3 ·-Tolerance

'

Asphalt Source and Algona - MC-3000 Approx'1ma1e Vi SCOS'ity

% Asph. fn Mix 5.0 6.0 '

,,, ___ , Number of Marshall blows 50 50

·--··--·---- --·--~-

Mar:;hall Stability· Lb$. 3180 3480 - --

Flow-0.01 In. 10 14 ------

2.10 ,·

2. 11 Sp. Gr. By Oisp!.icement (lclb DE.>ns.) -· --·--

Bulk Sp, Gr. Comb. Dry Agg. 2.641 2.641 --

Sp, Gr. Asph. E~ 77 f. l. 020 1. 020 -·-·--

Cale. Solid Sp. Gr. 2. 45 2.41

% Voids - Cale. 14.2 12. 5 . ·-

Rice :Jp. Gr. Mixing Temp. 180° F. Cure - 16 Hr. @ 140° F. --

% Voids - Rire Molding Temp. 140° F.

f-------··-·· .. ---"-·"-----··-- .. ·-·· -·· ' - ·---·-··-·--- Testing Temp. 77° F. "lo Water Abs()rplion ~Aggregate -- --

r % V~ids in the ~~ncra~-Aggrega-t~-- l 24.5 24.9

% V .+rt.A. Filled with Asphalt 42. l 49.8

Calculated Asph. Film Thick..ness (Microns) 7.6 9.2

A Content of 5.25% MC-3000 is

Form 956 1-75

PAGE 47 l\Sph. Mix Design SN-29(3)--51-72

10\liA Df:PARTM[~1l Of TRANSPORfATION HIGHW·\V DIVISION -&N"-69 (3)--51-72·

tMATERIA: ;;neA~TM<NT> FM- 72 (7)--55-72, Osceola ASPHALT C0~1CRETE MIX DESIGN J. Bump, schwart.ing

AMES L·\BORATORY D. Jordison, R. Shelquist L. zearley, Rohlin

Mix, Type and CIJSS: __Type_J3 ___ c:_l_~§S 2 · 3/4'' ABDl-160 .. ··----Size _______ Lab. No.-'="'-----------

Intended Use: HFMS-2 Cold Mi<!;,______ Spec. No.=-------- o.ie le ported 9-28-81 SN-29(3)--51-72 --'"--"--"--"'-"'----

County Osceola rroj. No._§_N-69 (3)--51-72 FM-72(7)--55-72

Contractor Roh 1 in

Proj. location:

Agg. Sources: 3/4" Gravel. - 28-98-42 Osceola Co. .~~~-~-~~-~~--------------------

JOU MIX FORMULA -COMBINED GRADATION

1%" 1" 314" Yi''·· 3/8" U4 #8 #16 "30 #50 HIOO #200

100 95 87 71 58 45 29 14 8.2 6.5 -·

Tolerance

Asphalt Sour'ce and Algona HFMS-2 (65. 6% Residue) Approximate Viscosity -------·-

~~~~~Emulsion in Mix 5_5 6.5 ·--------

Nuinbt>r of Marshall blows 50 50 __ . ._ __ .

Marshall Stability ·Lbs. 2175 2470

Flow· 0.01 In. 12 11 -·--------·

Sp, Gr. By Displacement (lab Dens.) 2.07 2.08

Bulk Sp, Gr. Comb. Dry Agg, 2.634 2.634 --···-----·

Sp. Gr. Asph. ~ 77 f, 1.020 1.020 -··---··-

Cale. Solid Sp. ~r. 2.42 2. 3 9 .. --

% Voids - Cale. 14.6 12.9 -,---·-· ------------- 5. 5% water added to agg. before mixing

Rice Sp, Gr. Mixing temp. 130°F. '-ured 16 hrs. @ 130°F.

% Voids - Rice Molding temp. 130°F. •··----·--·--··------ resting temp. 77°F.

% V1ater Absorption -Aggregate -- ---------·----·-

% Voids in the Mineral Aggregate 25.7 26.2

% \.' }l...A. Filh~d with Asphalt 43.4 50.7 ---- -· Calculated Asph. Film Thickness (Microns)

" G 10.3 A content of 7.0 HFMS-2 emulsion

fo.rm 95;; 1·75

PAGE 48 10\'vA DfPARTMEt:J OF TRANSPORTATION

HIGttWr\y DIVISION PvlATfRlll.• (lfPARTM!:N11

ASPMALT C01•Cl1ETE MIX DESIGN AMES L\BORATORY

Asph. Mix Design SN-29(3)--51-72

....&N"-69(3)--51-72 FM-72(7)--55-72~ Osceola J. Bump Schwarting, D. Jordison R. soelquist, L. zearley Rohl in

Mix, Type and Class:__1Jp~ __ B . .. ~.-i_?~_.§_) ______ ______ Size ___ l/~_" ___ Lab. No. ABDl-163

Intended Use:-'H'-"F"-• ..,M,,,S,_-~2~~C~o,_l=-d=-.=-M,_,i"'· x,_,_ ______ ~ Spec . No.--------- D•te Re ported 9- 2 8- 8 l SN-29(3)--51-72

Count~ Osceola r - N -~~=~------ to). o. S_'-N~--6_9_(,_3~),_-__ -_5_1_-_7_2 ____ conlractor Rohl in FM-72(7)--55-72

Proj. Location: __ _

Agg. Sources: l_/2" gravel_ - 28- 98-4 2 Osceo_l_a_c"--o_. ________________ _

Job Mix Formula Ai;gregate Proportions: __ . 100% AA'rl-592 -----·-----------------

JOB MIX FORMULA • C'OMBINED GRADATION

l '!z" 1" 314" Yl"·• 318" 114 #8 1116 1130 #50 #100 #200

100 98 90 69 56 42 26 14 8.7 7.3

Tolerance

Asphalt Source and Approximate Viscosity Algona - HFMS-2 (65. 6% residue)

% Total Emulsion---rn Mix :i@IMMliJfill/M*I: 5.5 6. 50

-------·-Number of Marshall blows 50 50

------··--·-··"

Mat!:>hall Stability - Lbs. 2060 2362 f-- - --

Flow· 0.01 In. 11 11 --

Sp. Gr. Sy Oi~placement (lab Dens.) 2.04 2.09 ----·--·--~---

Bulk Sp. Gr. Comb. Ory Agg. 2.641 2.641 -- --

Sp. Gr. Asph.@ 77 F. 1.020 1.020

CJ! c. Solid Sp. Gr. 2.43 2.39

% Voids - Cale. 16.0 12.7 -- -- 5.5% water added to Agg. before

R'1cr. ~;p. Gr. mixing -- -- Mixing 130°F Temp. % Voids· Rice cured 16 hrs. @ 130°F

-·-· -------- ·····- --·- ·--·-· Molding temp. 130°F % Water Absorption ~Aggregate 'J:~sting Temp. 77°F --

..

% Voids in the Mineral Aggregate 27.0 26.0 -- - - --

% v .M.A. Filled with A$phalt 40.7 51.2

Calculated Asph. Film Thickness (Microns) p /[ in.a A content of 7.0% HFMS-2 emulsion 1s recommen_cl~sl to start the job. ___.-:-.: ... = ~ _..,:::::-.:.:.:._,,._ __ , _,,,..-?'" ~

SIGNED:~- -_,· C..-~ 11rsn\<:;1 tl\ll:;1NEfA1 -..

Form 951> 1-75

PAGE 49 l\JWI\ OD'ARJMU<f Of TRANSPORTATION

HIGllW-W DIVISION (MATFfllfl.: ·., ~H PARTMENT)

ASPHALT cor CRETE MIX DESIGN AMES L,\BORATORV

Asph. Mix Design SN-29(3)--51-72 ~69(3)--51-72 FM-72(7)--55-72, Osceola J. Bump, Schwarting D. Jordison, R. Shelquist L. zearley, Rohlin

Mix, Type and Class: -~-yf)e _!3 _____ S'.~-~'3-~~ ____ Size ___ _:J_.'.'.'. 4 ·~--Lab. No. _A_B_D_l_-_1_6_1 _____ _

Intended Use: ---=Cc=S:.::S:__-_::l:__..::C::o:..'.l::d:_ Mix 9 2 8 81 ··-------SN-29 (3) 5~".:'5~<:;.,--.-,-------D•le ftepcrted - -

Count Y --"O..:s:..:c:..:e::.o=l-=a ______ Pro; . No. ____§> N - 6 9 ( 3 ) - - 51- 7 2 FM 72(7)--55-72

Contractor Roh 1 in

Proj. Location: ____ _

3/4'' Gravel - 28-98-42 Agg. Sources: __ ___: osceola Co.

Job Mix Formula Aggregate Proportions: __ . ___ l_O_:_O<;.::Yo AA'l11-59_1 ____ _

)OD MIX FORMULA COMBINED GRADATION -11/1" 1" 314" %''·• 3/8'' U4 #8 U16 U30

100 95 87 71 58 45 29

Tolerance

.

------------

#50 #100 #200

14 8.2 6" 5

Asphalt Source and Algona - css-1 (67. 3% Residue) Approximate Viscosity

~ToU'i"l-Bmu L sYoTi J:nJl'fiX-5~5 6.5

XJl!J<WDi!l{Ml-!i ---------·---

Number of Marshall blows 50 50

---

Marshall Stability· lbs. 2320 2825 --------

flow. 0.01 In, 16 15

Sp, Gr. By Displacement (lab Dens.) 2.03 2.07 ---

Bulk Sp. Gr. Comb. Ory Agg, 2.634 2.634 ....__ ___

Sp. Gr. Asph. 9 77 F. 1.020 1.020 -- - --

Cale. Solid Sµ. Gr. 2 .42 2. 3 9

% Voids - Cale. 16.2 13.3 5.5% water added to agg. before test in

Rice Sp. Gr. mixing Temp. 130°F. - -- Cured 16 hrs. @ l30°F.

% Voids • Ric(' Molding Temp. 130°F. ------ ---~----- Testing temp. 77°F.

% WJter Absorption ~Aggreg.lt~ -- --

% Voids in the Mineral Aggrt>gate 27.2 26.5 ---

% V M.A. fill(.ld with Asphalt 40.3 49. 7

Calculated Asph. film Thic~less (Microns) 8.6 10.3 A content of 7 .. o~':} CSS-1 emulsion is re commended to sta t the oh.

Form 9M.> 1.75

PAGE 50 IOWA D[PARTMf~.11 OF TRANSl'ORTATtON

HIGHW'\Y DIVISION (MATfRl/l Ul-PARTMFNl I

ASPHALT COtJCRETE MIX DESIGN AMES LABORATORY

Asph. Mix Design SN-29(3)--51-72

-sr:r::-69(3)--51-72 FM-72(7)--55-72, Osceola J. Bump, Schwarting D. Jordison, R. Shelquist L. zearley, Rohlin

Mix, Type and Class: _.'.f:Y£C. _B ___ <;:1"-l5~-·- .. ·---size _J_L2.'~--- lab. No. --1illl2J-~-~1~6~2~-----

lntende1 us~SS-1 Cold Mix 9-28-81 -------- Spec. No.=-------- Date Re Ported _______ _ SN-29(3)--51-72 S,.:N:_-_6,::..::.9-;(_,,3,+)_-_-_5::..-=l_-_,,7.;2c_ ___ Contractor __ R_o_h_l_i_n ______ _ FM-72(7)--55-72

county , ---'O'-s"-c-'--'e-'o-'l~a"-·--- rroj. No.

Proj. Location: _________ ---------------------------------

Agg. Sources: 1/2" gravel - 28-98-42 Osceola Co. ·------------·---------------------- -·-----------

Job Mix Formula Aggregate Propan\ons: ____ l_0'-0% AA'rl-592

JOU MIX FORMULA· COMBINED GRADATION

1%" 1 " 3/4" %"·· 3 /8" U4 #8 #1& #30 HSO #100 #200

100 98 90 69 56 42 26 14 8.7 7.3

Tolerance

Asph.11t Source and Algona css-1 (67. 3% Residue) Approximate Viscosity -

-- -% Asph. tn Mix 5.5 6.5

--------·-------Nur.1ber of Marshall blows 50 50

- --·-·. ··------~"-

Marshall Stability· lbs. 2190 2392 -· ----·- --

Ftow. 0.01 lri. 17 22

Sp. Gr. By Dis!>lacement (lab Dens.) 2.03 2.03

Bulk Sp. Gr. Comb. Dry Agg, 2.641 2.641 -----

Sp. Gr. Asph. «~ 77 F. 1.020 1.020

Calr. Solid Sp, Gr. 2.43 2. 3 9 -

% Voids - Cale. 16.4 15.2 5.5% water added to agg. before mixing

Rice Sp. Gr. Mix in~- Temp .. l30°F. - Cured 16 hrs. @ 130° F. % Voids· Ri(e Molding Temp • 130°F. -------·· .. --·--·--·-· - . --·--"- ···--" .. _ % Water Absorption ·Aggrcga!e

Testing rremp .. 77°F. -- ---

·----···----·-~----

% Voids in the Min~tal Aggn•µ,ate 27.4 28.l --

% V M.A. Filled with Asphalt 40.0 46.0

Calculated Asph. Film ihicl<Ir•ss (Microns) 8 Ll 10.0 A content of 7.0% CSS-.L emu.Ls 1.on 1S recommenaea to start tne JOO. ,_,. __

Mix, Type and Cl.a~s; _ _Typ§! B

PAGE 51 IOWA D£PA~1MfrJT or TRANSPORTATION

HIGHW W DIVISION (MATf:RI/".:, l)f.PARTMENTl

ASPHALT cm,CRETE MIX DESIGN AMES L\BORATORY

Asph. Mix Design SN-29(3)--51-72 ~69 (3)--51-72 FM-72(7)--55-72; Osceola J, Bump, Schwarting

Class 2 ··---Size

R. Shelquist, D. Jordison

314.,L. zearley, Rohlin

____ Lab. No. ABDl-1658

Intended Use: cold-Mix ·-----=~~~ S N 9-28-81 SN-29 (3) _£"sl-"J_,-------- D•le Reported'--------

county : __ _,0,,_s=c:::e:::Oc:.cl;;.a:::_ __ _

Proj. Location:_

Proj. No.SN-:-69(3)--51-72 FM 72(7)--55-72

Contractor Rohl in

Agg. sources: Aggregate F'rorn roadway after milling and addition of new aggregate

Job Mill. Formula Aggregate Proportions:_ 100% ABCl-293 (Contains 3 .0% Asphalt) -------- ., ------

JOB MIX FORMULA COMBINED GRADATION -1%" 1" 3/4" Yi''·• 3/8" #4 #8 #16 #30 #50 #100 #200

100 94 86 66 50 38 26 15 11 9.2

Tolerance

Asphalt Source and cssl-H Emulsion Approximate Viscosity

"'° ~ 1.•gti, 1 '.Mli.ill.aion._Acl!i.fi.d. ___ 6.5 7.2 7.9 5.0 6.0 7.0

Number of Mar!>hall blows 50 50 50 ---------

Marshall Stability - Lbs. 680 650 540

Flow - 0.01 !n. 21 19 19

Sp, Gr. By Displacement (lab Dens.) 2.11 2.10 2.12

Bulk Sp. Gr. Comb. Ory Agg. 2.65 2.65 2.65 --

Sp. Gr. Asph.@ 77. F. 1.02 1.02 1.02 - -

Cale. Solid 5:J. Gr. 2.39 2.37 2.34

% Voids - c:1lc. 11.8 11.3 9.6 ·--·-----·-·-----

Ril"t' Sp. Gr. ·-

% Voids - Rice ··----- ... ----·---

% Water Ab!iorption -Aggrep,ate -- -- ---·---------------··-

% Voids in lhe Mineral ~grt•gatc 25.5 26.5 26.3 L--.. - .

% V lit.A.. Filled with Asphalt 53.7 57 .1 63 .6 , ____ Calculated Asph. Film Thic~ss (Microns) 9.0 10.0 11.0

n . mixed at room tern . - Mixture cured 20 hrs. at: roe Emuls10 & Agg P Temp. and compacted at room Temp.

m ----~:.'C ·:::.::::.. ~

SIGNED:~ c7 . ·· lTfST!i<lGENGJNR1 ~

Asph. Mix Design IOWA DEP1\RTMU;r or TRANSPORTATION s 29 (3) 51 72

HIGHW \V OlVISION N- -- -

PAGE 52

(MATERlf"; o~PARTMFNll ~-69 (3) --51-72 ASPHALT (Qt,CRETE MIX DESIGN FM-72 (7)--55-72; Osceola

AMES Li\BORATORY ,J. Bump, Schwarting D. Jordison, R. Shelquist L. zearley, Rohlin

Mix, Type and Class: _'!'Yl26 . B ___ Cl_a_s_s_2 ______ ·····- Sile_.::lft_• ___ lab. No. ABD1-165A

I nd Cold-Mix . 1 nle ed Use: _ _c=.=.::=..==----------- Spec. No. oc-------D•te Reported __ 9c...-_;;;2.;:8_-_:8'-'---SN-29 (3) --5l-72

cou 01 y : -.:O:..s.:..c.:...;:e..:o..:l:..:a::.-____ .

Proj. Location: __ _

Proj. No .. SN-69 (3)--51-72 FM-72(7)--55-72

Contractor Roh 1 in

Agg. Sources: Aggregate from roadway after milling and addition of new aggregate

Job Mi< Formula Aggregate Proportions: ___ 1_0_0_% ABC_l_-_2_9_3 ___ .:..(C_o_n_t_a_i_·n_s_ 3 .0% Asphalt) .... c-::----~--- =::;~~~:;::;;;:;~~;;:;:::

JOB MIX FORMULA ·COMBINED GRADATION

l 'lz" 1 .. 314'' Yi''·· 318" •4 #8 #16 #30 •so #100 #200

100 94 86 66 50 38 26 15 11 9.2 ---

Tolerance

. Asphalt Soµrce and Approximate Viscosity MC-800 SC-800 HFMS-2 Emu ls on

.

"~,h~~Ph .• .Jn ¥.,iJ_ , 4.9 5.25 5.5 6.0 6.5 7.2

. c ". . "i s, an .or.....Rl:lh&cr k 2.5 3.0 2.5 3 . 0 5.0 6.0 Number of Marshall blows 50 50 50 50

··-----~------·~---- -·

Marshall Stability - Lbs. 680 515 650 640 540 460 -

flow· 0.01 In. 21 23 20 19 19 19 ---

Sp. Gr. By Displacement (lab Dens.) 2.02 2.08 2.06 2.07 2.14 2.15 ·-

Bulk Sp. Gr. Comb. Dry Agg. 2.65 2.65 2.65 2.65 2.65 2.65

Sp, Gt, Asph.@ 77 F. 1.00 1.00 1.00 1.00 1.02 1.02 . --

Cale. Solid Sµ. Gr. 2.45 2.44 2.43 2.41 2.39 2.37 <-- ·----

% Voids - Cale. 17.6 14.7 15.2 14.2 10.6 9.2 ... ------·---

Rice Sp. Cr, -··-----

% Voids - Rice ~-----···------- -·----·-·-----

% Water Absorption -Aggrep,ate -- -- -- -- -- ----

% Voids in the Mineral Aggregate 27.5 25.6 26.5 26.6 24.5 24.7 ·-

% V ."ti.A. Fi!l~d with Asphalt 35.9 42.6 42.7 46.7 56.8 62.6

Calculated Asph. Film Thick..ness (Micron!:i) 6.6 7.1 7.5 8.2 9.0 10.0 0 w h A . room Tern . Emu1sio n cutbacks heated to 160 F before mixing it gg @ P

& agg. ml. xcd at t.oom tern. - mixture cured 2.0 hrs~-.--"' t r~o temp and SIGNED: ,/ .. · ····:·;.::.....;- __ ~ compacted ff/ room temp. ,,.... m:N4/'G"Ndf~ -

PAGE 53

Appendili: E

Asphalt Penetrations and Viscosities

PENETRATION/VISCOSITY TEST RESULTS

Extracted Binder From 3/4" Mixes

Asphalt Penetration

AC-5 126

MC-3000 148

SC-800 -*

HFMS-2 133

CSS-1 78

Extracted Binder from 1/2" Mixes

Asphalt Penetration

MC-3000 139

SC-800 -* HFMS-2 108

CSS-1 83

Extracted Binder from Road Mix

Asphalt Penetration

Existing Asphalt 40

MC-800 68

SC-800 145

HFMS-2 64

CSS-1 56

*To soft to test

PAGE 54

Absolute Viscosity

891

763

-*

767

1610

Absolute Viscosity

777

-*

1050

1490

Absolute Viscosity

11 ,630

2,840

682

3,640

3,860

Note: Penetration at 77°F .. 100 gms., 5 sec.

Absolute Viscosity at 140°F., 300 mm. HG(Poises)

Appendix F

Density Test Resu.lts

PAGE 55

PAGE 56

Lab Density1 Fiel9 Density2 Percent Section No·. Binder Field Voids

1 AC-5 2.39 2.26 7.4

2 MC-3000 2.22 2.07 16.6

3 HFMS-2 2.22 2.06 17. 6

4 HFMS-2 2 .11 2.09 13. 0

5 CSS-1 2.11 2.03 15.3

6 CSS-1 2.21 1.96 22.2

7 MC-3000 2.24 2.06 16.6

8 MC-800 2.00 1. 90 21.6

9 SC-800 2.03 1. 93 20.2

10 SC-800 2.29 2.09 15. 1

11 HFMS-2 2.25 2.07 18. 3

12 AC-5

13 MC-3000 2.22 2. 16 13. 6

14 SC-800 2.36 2.22 11. 3

1. Lab densities for section 4, 5, 8 and 9 by Modified Proctor.

2. Field densities for section 1 by cores.

Field densities for other section by nuclear gauge.

PAGE 57

Appendix G

Maintenance Work and Seal Coat Construction

PRO.ll!CT FM-72(7)~55-72 "RESEARCH PROJECT NO. HR229

COUNTY ROUTE NO. A-34 .

Note: The Type B and Bituminous Mats are !:;" Gravel Mixes.

N

§ t ~ ~ ~..!: g ;!; "'

Nominal Thickness

Asphalt Content

N .... ;t ~ ....

11:;"

6.4'

0

"" + <X> ..... .... ., ... "'

" l 3/4" 1 1/8"

6.6% 5.2%

0 0

"' 0 + + M .... "' ..... N .... N N

+ "' ., 0 .. ... N ...

0 .... oJ; """' ~ ""'" "''"' "'

1 1/8"

5.3%

"' * .... M

.. ... "' "' "' ' . ; ., ...

"'

.. 0 .. ... ....o ... "' "' "'

; 6_,11~1 ' -""'9 ~ ~ --- ,~uf-1-"'•""f,}""<ct="=--'•-M_>!.u.,n .. o,·o~ " '16~- - I' b ""r ', . 0 0 + "' .,.. + M ,_, ... ~ "' 0 0 .... ;; .... ... "' . " 0 u N

"' "' ....

.. ... ti:>

.. ... «> CSS-1 Bit. Mat Removed by County

~-----1 Type B Cl. 2·AcC .Base l" Nom. Thick. (Control ·Section), . I .

Paver Laid Asphalt Sand Mix To Correct Wheel Distortion

Blade Laid Asphalt Sand Mix To Correct Wheel DistortiQn

Se<l.l Coated (,26 Gal./Sq.Yd. MC-800 & 200 of 3/8" Pea Gravel/Sq.jd.)

-0

if; ,.,, U'I 00

.....

g .... ... u ~ ... .. .. g u N

"' "' ..;

PROJECT SN-69(3)~51-72 RESEARCH PROJECT NO. llll22 9

COUNTY ROUTE NO. A-46

,,-·,~.---

11 .., .., <

Note: The Type B and Bituminous Concrete Mater'ials are 3/4 11 Gravel Mixes~

N

t 211 Bituminous Concrete Mat 2" Type B Cl. 2 Asph. Cone. Mat

(Control Section) ..----lHot Plant Mix - Paver Laid 1--,~--------,

6.6% 5.7% 5.3% 6.4% 4.7% 4.9% 6.5% 5.5% 2.9% 2.8%

-- - - ·-"' ~ " u"I 0 0 0 + M CO ..0 0

1= _ ~;"''·;''\}.~: ~~''"'d1 • " , :i~~.,,,,b-,~~L. rd llr Ac-s I ::: .. ,,MC/:"'' '~-·' ·'-··:'11"' . '' 'i-.l'\~-.:)91).Q·:,,.,.,;1~.c-:- - I r;i 1 I "' o-r J ""

101 M < 0 0 I M ~ rf<C "' I + +< + + +

-t-..a </"I 0 "° °' , .., ... - co a..a o ~ -M\O 0 o-l .... NQ'I.

M ~O ~ ~ I + .;:r . "a)

C$ ..J ,..... t 2~11 Bituminous Concrete .Mat-" c:J :=t t) .- ~ ~ (l~~' C~ld ·Milled, Mate'i"ial Mixed I · ~~

In Place with 327. Virgin Aggregate

0

~ "' .. ... "'

000 000

:t6;t N"' M

and Additional Asphalt)

00 00

6$ "' "'

tl-1•!

0 0

6 "' " ... "'

0

~ 0 ..; . " ... "'

.. .,, +

"' ..,. ... ..

. .. .. ... ~ ... .. ... Type B Cl. 2

Paver Laid Asph. 6.5% AC-5

Mat!-~~~~~'--'--~-'---'

Asph. Sand Mix Blade Laid ll:t;0 ± Mat ::::::';.,.~-~~

Seal Coated With 0.22 Cal./Sq.Yd. MC-3000 & 20# of 3/8" Pea Rock/Sq. Yd.

6 +· ·..; 0 N

" ... "'

I "" ii=; fT'I

"' '°

PAGE 60

Appendix H

Rut Depth Measurements

PAGE 61

Appendix H

Average Rut Depths

Section w.o. W. I. E.I. E.O. AVE.

1 0.11 0.11 0.13 0.07 0.10 2 0.08 0.09 0.14 0.08 0.10 3 0.07 0.10 0.11 0.08 0.09 4 0.08 0.06 0.11 0,19 0.11 5 0.06 0.06 0.06 0.07 0.06 6 0.10 0.06 0.10 0.08 0.08 7 0.08 0.08 0.09 0.05 0.07 8 0.16 0.23 0.20 0.32 0.22 9 0.16 0.19 0.12 0.16 0.16

10 0.06 0.09 0.09 0.06 0.07

11 0.08 0.15 0.14 0.09 0.11 12 0.11 0.10 0.09 0.06 0.09 13 0.10 0.13 0.16 0.12 0.12 14 0.06 0.08 0.16 0.12 0.10

w .. o. = Westbound, outside wheelpath W. I. = Westbound, inside wheelpath E •I. = Eastbound, inside wheelpath E .. O .. = Eastbound, outside wheelpath

Measurements taken 12-21-87

Appendix I

Crack Survey Results

PAGE 62

' /'

Gra 602 5601 214/88

100

90

10 •

60

50

10

•

•

. •

•

• • •

• •

• •

. •

• • .

• •

• •

. •

• • • • •

Section 1 2 ---3 ------4 .... 0 011

5 6 7 1111111111111

8 ,,,,,,.,,. 9 DODOO

10 000000

o-1-~----....... ~----..-~----.~--~....,,.--~---v-------s-2a-s2 11-1-ss s-20-a4 8-14-85 4-27-87 12-21-87

10

• 2

. • .

• •

Section I 11 ------13 ..... . 14

•• ..

O-+-~----...-------..-~~--..----~--.-------.

6-23-82 11-1-83 6-20-84 8-14-85 4-27-87 12-21-87 Date

Gra_ 602" 560\ 214168

100

90

80

70

60

.. 50

'f

" " 'f

40

30

20

10

... " .. ..

'f

... ...

Section 1 2 ..... ·. 7 ------

10 * * * * 11 1111111111

O-ll-~~--......-~~......-~~~,,-.~----.-~~--.--~~-

6-23-82 11-1-83 6-20-84 8-14-85 4-27-87 12-21-87 Date of Survey

Appendix J

Road Rater Results

PAGE 66

2.25

0')2.00 c ·--«J a:: ]! 1.75 :I ti ::::s :... -0

1.50

1.25

• • ... ,

• • .

• • •

• •• • •

................... ~

•

Road Rater Structural Rating Results (80°/o Structural Rating)

•

• •

• • •

• Oooooooeo.,.,

• • • •

Aug. 17, 1981 -­May 5, 1982 -----­May 23, 1984 • .. · · · April 27, 1987 ---

/"<.., '1 ... ... ...... _ ~ .

""'-- ... ~\, 00 • • •

• • • • i\'\:\ ·· .. • • • ...-........

\' . . ~' ·. -...: ' ' . • .

• • . • • •

·,- ........ -......... , ".,

' ' . I ' •" , ' ', ·. . . /

I ' • , '/- ---... ' . / , \ ' . ; . I ' • /

/ '"' \ '\ ... ,. .... \ ', ,,' ,- ' /

/ / \ ',..., ...... ' \ \~ /,1 \ /----\\ ,,,. I °" \\ / / \ / \ \.... ...... \ ,,, \ ,,, 'V ' / ' .... \ ,.

' .... ...

1.00..-.......-~~..--~--.------.-~---r~---.------.-~~......-----.,---~r--

1 2 3 4 5 6 1 8 9 10

Section No.

Gra. 602 5601 214 88

m 1.75 c .... -ca a:

~ 1.50 ~ t) 2 -00

1.25

1.00

Road Rater Structural Rating Results (80°/o Structural Rating) Aug. 17, 1981 .......,_,.,,...,

May 5, 1982 ............. . April 27, 1987 .............. ..

··-·-·-·-·-·-·-·-·-·-·-·-·-·-·-··

....... . ... ...................................... .. ........ .. ''''''''''•e,,111

• ••• ,,,, ..

0.75-'-----,-------ir--~-,---'-----,----

11 12

---. ~. ;e ---·

(

Section No.

13 14