Solving a Hard Problem For The NYC DOT With a High Performance Thin Overlay
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1 Solving a Hard Problem For The NYC DOT With a High Performance Thin Overlay NEAUPG Annual Meeting Portsmouth, NH October 24, 2013 Ronald Corun Director- Asphalt Technical Services NuStar Asphalt LLC
2
3 1 st Avenue in NYC 1 st Avenue in Manhattan is 30 year old 18 thick PCC pavement Pavement was built with huge fanfare in 1983 projecting 40 year life Utilities beneath the pavement Gas lines Water lines Sewer lines Steam line
4 1 st Avenue in NYC Removing the PCC would most likely damage the utilities NYC DOT tries not to use compaction with vibration when paving streets After paving projects are completed NYC DOT tests utilities for leaks Funding not available to replace PCC pavement and the utilities
5 1st Avenue in NYC PCC pavement is in very poor condition Curb clearances prevent use of a thick overlay
6 1st Avenue in NYC NYC is planning to improve bus service with an new bus lane on 1 st Avenue Question How to Rehabilitate 1 st Avenue? To come up with an answer you certainly must Think Harder
7 1st Avenue in NYC
8 1st Avenue in NYC
9 1st Avenue in NYC
10 1st Avenue in NYC
11 1st Avenue in NYC NYC DOT contacted NuStar Asphalt and asked for suggestions Research at Rutgers University had developed a High Performance Thin Overlay (HPTO) Mix
12 Paulsboro HPTO 5 years old Original After 5 years
13 NJ I-295 HPTO Project
14 NJ I-295 HPTO Project
15 NJ I-295 HPTO Project
16 1st Avenue in NYC Search to improve HPTO performance under severe conditions by beefing up the asphalt binder Highly Modified Asphalt (HiMA) developed by Kraton Polymers Specialty SBS material with lower viscosity increase Allows up to 7.5% polymer loading with workability
17 1st Avenue in NYC Research at Rutgers University comparing HPTO mix with conventional PMA binder and Highly Modified Asphalt (HiMA)
18 1st Avenue in NYC Conventional PMA binder had continuous grade of PG HiMA binder had a continuous grade of PG
19 Flow Number 2,500 2,000 AMPT Flow Number (cycles) 1,500 1,000 1, , NuStar Flexgard (Unaged) NuStar HiMA (Unaged) NuStar Flexgard (Aged) NuStar HiMA (Aged)
20 Texas Overlay Tester
21 Texas Overlay Tester Hot Mix Asphalt Overlaid on PCC PCC PCC Horizontal Tensile Stress due to Expansion/Contraction of PCC from Temperature Horizontal Stress/Strain is modeled using Overlay Tester
22 Texas Overlay Tester 6,000 Overlay Tester Fatigue Life (cycles) 5,000 4,000 3,000 2,000 1,000 > 5,000 4,750 2,541 1,665 - STOA LTOA STOA LTOA HiMA Flexgard Binder and Aging Condition
23 Flexural Beam Fatigue Flexural Beam Fatigue Testing Measure number of cycles to failure
24 Flexural Beam Fatigue Fatigue Life, N f,50% (Cycles) 100,000,000 10,000,000 1,000, ,000 10,000 N f,50% = k1 1 ε Flexgard - LTOA HiMA - LTOA 2 k 3 O 12.5mm PG LTOA t k 1 E 1, ,000 10,000 Micro-strain (µs)
25 1st Avenue in NYC HPTO mix containing each binder was placed on 1 st Avenue on September 25, 2012 HiMA placed between 100 th and 101 st Street Conventional PMA placed between 101 st and 102 nd Street 1 1/2 thick overlay
26 1st Avenue in NYC
27 1st Avenue in NYC
28 1st Avenue in NYC Both sections performed well through August 2013 NYC DOT selected HiMA based on laboratory testing and field performance
29 1st Avenue in NYC Rehabilitation Design Micro-mill existing PCC pavement Patch areas as required Crack seal as required Place PG tack coat and Mirafi PGMG4 fabric Overlay with 1 ½ HPTO mix with HiMA asphalt binder Added Evotherm warm mix additive to lower mix temperatures and improve workability Produced mix at 300 F
30 1 st Avenue Micro-Milling
31 1 st Avenue Micro-Milling
32 1 st Avenue Micro-Milling
33 1 st Avenue Crack Sealing and Patching
34 1 st Avenue Crack Sealing and Patching
35 1 st Avenue Tack Coat and Fabric
36 1 st Avenue Tack Coat and Fabric
37 1 st Avenue Paving
38 1 st Avenue Paving
39 1 st Avenue Paving
40 1 st Avenue Paving
41 1 st Avenue Finished Pavement
42 1 st Avenue Finished Pavement
43 1 st Avenue Finished Pavement
44 1st Avenue Finished Pavement
45 Summary Combination of HPTO mix and HiMA gives a thin overlay solution for hard pavement rehabilitations NYC DOT and NuStar Asphalt will monitor pavement performance
46 Questions?
47
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