21st Century Pavement Construction, Rehabilitation and Maintenance Alternatives Chris Robinette September 14, 2009 APWA International Public Works Congress & Exposition 1 XXXXXXXXXX 2 1
XXXXXXXXXX 3 XXXXXXXXXX 4 2
5 Outline Introduction G Green Construction C t ti Alternatives Alt ti Savings Price Environmental Impact Savings Energy, Emissions and Resources y Summary 6 3
Outline Introduction Green Construction ti Alternatives ti Savings Price Environmental Impact Savings Energy, Emissions and Resources Summaryy 7 Change in State/County/City Agencies 8 4
Inflation Adjusted Monthly Crude Oil Prices $140 $130 $120 $110 $100 $90 $80 $70 $60 $50 $40 $30 Crude Oil Price, $/bbl $20 $10 $0 Nominal Crude Oil Price Dec 1979 Monthly Ave Oil Price $106.86 in June 2009 Dollars Dec 1979 Nominal Monthly Ave Oil Price $38.00 in June 2009 Dollars June 2008 Monthly Ave Oil Price $124.53 in June 2009 Dollars 1946 1950 1954 1958 1962 1966 1970 1974 1978 1982 1986 1990 1994 1998 2002 2006 Time (Years) Inflation Adjuect Crude Oil Price $140 $130 $120 $110 $100 $90 $80 $70 $60 $50 $40 $30 $20 $10 $0 Sources of Information: Oil Prices: Illinois Oil & Gas Assoc. CPI: Bureau of Labor Statistics Crude Oil Price, $/bbl 9 Price Trends Year Material Crude Oil, Asphalt HMA, $/ton $/bbl Binder, $/ton 1970 3.39 20.00 8.04 1980 37.42 160.00 25.29 1990 23.19 142.00 24.52 2000 27.39 200.00 35.15 2005 50.04 232.00 45.56 2008 125.00 850.00 100.00 10 5
Binder Availability? 11 Permitting Facilities 12 6
Energy and Environment 13 Environmental Awareness Ref. US EPA 14 7
Environmental Policies Global Kyoto Protocol - 1997 Federal Energy Policy Act of 2005 California AB 32 Global Warming Solutions Act 2006 15 Where are we on the curve? Economic Cycle 16 8
Funding 17 Historical Perspective Concerns 1970 s 2000 s Price of Asphalt X X Binder Availability of Asphalt X X Binder Environmental X X Concerns Energy Concerns X X Global Warming X Limited Funds X X Available Inflation X? 18 9
Outline Introduction Green Construction ti Alternatives ti Savings Price Environmental Impact Savings Energy, Emissions and Resources Summaryy 19 Federal Recycling Policy February 7, 2002 Fredrick Wright, Jr. Memo Formal Policy on the Use of Recycled Materials Recycling and reuse can offer engineering, economic and environmental benefits Recycled materials should get first consideration Use of recycled materials should include review of engineering and environmental stability Economic benefits assessment should be conducted Restrictions on recycled materials without technical basis should be removed from specifications 20 10
Cold In-Place Recycling (CIPR) CIPR Full Depth Reclamation (FDR) Depth of Cut HMA Agg Base Depth of Cut 21 CIPR and FDR CIPR FDR 22 11
CIPR and FDR: Advantages Stretch Dollars Further Lower Energy Required Improved Air Quality Material Hauling Minimized Most Pavement Distress Treated Significant Structural Improvements Ride Quality Improved 23 Requirements for CIPR and FDR Requirements CIPR FDR Low to Moderate Traffic Rural Road Application Requires Significant Section Requires Wearing Course No underground conflicts X X X X X X X 24 12
States Use of CIPR Red = 4+ Projects Blue= Low/limited use Green = No use White = No response 25 HIPR Recycling Train Infrared Heater Scarified Surface Finished Surface 26 13
Hot In-Place Recycling (HIPR) Attributes Surface Remix Repave Heat Surface X X X Scarify or Mill X X X Add Recycling X X X Agent Add HMA (15 to 20%) X Pave X X X New HMA Lift X Compaction X X X 27 Hot In-Place Recycling: Advantages Material hauling minimized Reduced traffic interruption Aged asphalt is rejuvenated Delays reflective cracking Rutting, shoving and bumps corrected Improve surface frictional resistance Aggregate gradation and asphalt content can be modified Pavement geometrics preserved 28 14
Requirements for HIPR Best for rural areas due to long recycling train Ideal for AADT s between 1,000 and 10,000 Pavement should not exhibit extensive cracking Limited presence of surface treatments Limited foliage concerns 29 States Use of HIPR 10 States specify on a regular basis 32 States have placed experimental sections 30 15
RAP Material Alternatives for HMA Components Asphalt Shingles 31 Recycled Materials: Advantages Provides asphalt binder Provides aggregate Reduces trucking of materials Preserves landfills Reduces greenhouse gas emissions 32 16
States Use of Recycled Materials RAP 75-percent of States allow at least 10- percent RAP in surface course mixes Shingles 14 States allow up to 5-percent of either manufactured and/or tear-off shingles in HMA 33 Alternative RAP Uses Aggregate base Conserves natural resources Increased strength over conventional AB Cementitious properties Reduce structural section? Easier to process/crush Materials met HMA specifications 34 17
Alternative RAP Uses (cont d) Shoulder backing Material removed from roadway Material pushed up to roadway shoulder when construction finished Value = eliminates transportation + cost conventional shoulder material Credit to City/County DOT gives to City/County t for transportation t ti programs Value = cost of dust palliative + transportation savings 35 Use of RAP as Shoulder Backing 36 18
Definitions for Asphalt Shingles Post Industrial (manufactured shingles) rejected asphalt shingles or shingle tabs that are discarded in the manufacturing process of new asphalt shingles. Post Consumer (tear-offs) shingle scrap derived from re-roofing projects whereby the old shingle layers are removed to prepare the roof surface for new shingles and/or other roofing materials. Recycling Tear-Off Asphalt Shingles: Best Practices Guide, CRMA, 2007. 37 Asphalt Shingles Must be processed Introduced same as RAP 38 19
Warm Mix Asphalt 39 Demonstration - Loadout Water Injection Method Control WMA Temp = 320 o F Temp = 270 o F 40 20
WMA Demonstration Projects From NCHRP 9-47 41 New Publication 42 21
Outline Introduction G Green Construction C t ti Alternatives Alt ti Savings Price Environmental Impact Savings Energy, Emissions and Resources y Summary 43 XXXXXXXXXX PCI<55 Poor Condition 44 22
Rehabilitation Options Standard rehabilitation Remove and replace? Thick overlay? Thin overlay? Chip seal? Do nothing? Alternative rehabilitation Cold in-place recycling full depth? Cold in-place recycling partial depth? Hot in-place recycling? Other? 45 46 23
Pavement Condition Survey Distresses Raveling Flushing & Rutting Thermal Cracking Longitudinal Cracking Fatigue Cracking Patching 47 Purpose of a Pavement Preservation Distress 48 24
Treatment Selection Distress Type OGFC HMA Overlay Remove & Replace (HMA Surface) Reconstruct y Thin Overlay ( 1.25-in) CAPM ( 3-in n) Structural Ov verlay Hot In-Place Recycle Partial Depth CIPR IPR Full Depth C Hot Central Plant Recycle Mill & Fill (F Full Depth) Full Depth Reclamation Rutting Raveling Flushing Alligator Cracking Longitudinal Cracking Transverse Cracking rials Virgin Mater Candidate Treatment Marginal Treatment 49 Pavement Preservation Concept Condition Original Pavement Optimal Timing Preventive Trigger Rehabilitation Trigger Time 50 25
Estimated Price Operations Rep. Range Rep. Value New Construction and Rehabilitation, $/yd 2 -in Cold Milling Asphalt Pavement 0.30-0.70 0.51 Hot Mix Asphalt 2.75-5.60 3.65 CIPR - Partial Depth 0.80-1.20 1.24 CIPR - Full Depth 0.30-0.80 0.55 HIPR - Remixing 2.81 Conventional Aggregate g Base 0.50-1.05 0.79 Recycled Aggregate Base 0.43 Emulsion Stabilized Aggregate Base 3.80-5.60 3.89 Cement Stabilized Aggregate Base 0.30-1.90 1.01 Cement Treated 0.10-0.50 0.27 Lime Treated 0.23 51 PCI<55 Poor XXXXXXXXXX Condition 52 26
Poor Pavement Condition Price Analysis Operation 50i 5.0-in HMA on 11-in Conventional AB (Remove & Replace) Mill and Fill 3.0-in and 2.8-in Overlay CIPR-Full Depth w/ 6.0 0-in cut and 4.0-in HMA Overlay Price, $/yd 2 % Savings 35.08-18.35 47.7 16.79 52.1 53 PCI 55 to 70 Fair Condition 54 27
Fair Pavement Condition Price Analysis Operation Mill and Fill 4.0-in and 1.8-in Overlay CIPR-Partial Depth w/ 3.0-in cut 3.3-in HMA Overlay Price, $/yd 2 % Savings 17.47-14.34 17.9 3.5-in HMA Overlay 12.95 25.9 2.0-in Mill, 2.0-in HIPR-Remix, 2.0-in Fill, 2.0-in Overlay 16.59 5.1 55 PCI >70 Good Condition 56 28
Good Pavement Condition Price Analysis Operation Mill and Fill 2.0-in and 2.0-in Overlay Price, $/yd 2 % Savings 12.84-2.5-in HMA Overlay 9.25 28.0 2.0-in HIPR-Remix, and 2.0-in Overlay 11.96 6.9 57 New Construction 58 29
Recycled Materials in HMA Price Analysis Material / Process Recycled Material Content, % Recycled Asphalt Binder Content, t % Price, $/ton Savings, % Conventional HMA 0 0 64.87 - RAP Post Industrial Shingles Post Consumer Shingles 15 4 61.17 5.7 25 4 58.70 9.5 5 18 60.57 66 6.6 5 32 57.12 12.0 WMA 0 0 64.37 0.8 59 Treatment of Materials Price Analysis HMA 5.0-in HMA 5.0-in HMA 5.0-in HMA 5.0-in HMA 5.0-in HMA 5.0-in Conv. AB 11.0-in Rec. AB 9.5-in Emul. Stab AB 7.0-in Cement Stab AB 7.0-in Cement Stab 9.5-in Lime Stab 10.0-in Price, $/yd 2 26.95 22.32 45.48* 25.32 20.79 20.51 % Savings Over Conventional Materials - 17.2-68.8* 6.0 22.8 23.9 60 *Based on limited quantities 30
Question Should all pavement construction, reconstruction, rehabilitation and maintenance activities be based on cost? 61 Outline Introduction Green Construction ti Alternatives ti Savings Price Environmental Impact Savings Energy, Emissions and Resources Summaryy 62 31
Considerations Energy consumption Emissions generation Natural resource consumption Aggregate Asphalt Binder 63 Information Sources Energy Consumption NCHRP 214 Colas Group PaLATE Contractor Data 1980 2003 2003 2009 X X X X Emissions Generation Conservation of fresources X X X 64 32
Operation Estimated Energy Consumption Rep. Value Operations Representative (Rep.) p) Range (Value Used in Analysis) Construction and Rehabilitation, Btu/yd 2 -in Cold Milling Asphalt Pavement 1,000 2,500 1,500 Hot Mix Asphalt 27,000 34,000 30,000 CIPR - Partial Depth 3,000 24,000 7,300 CIPR - Full Depth 2,700 20,000 17,000 HIPR Remixing 9,000 27,000 16,100 Conventional Aggregate Base 5,000 12,000 7,300 Recycled Aggregate Base 4,000-8,000 5,700 Emulsion Stabilized Aggregate Base 15,000 33,000 18,900 Cement Stabilized Aggregate Base 14,000-21,000 14,100 Cement Treated 5,600 Lime Treated 3,000-10,200 5,100 65 Recycled Materials in HMA Energy Analysis Material / Process Recycled Material Content, % Recycled Asphalt Binder Content, t % Energy, Btu/ton Savings, % Conventional HMA 0 0 520,000 - RAP Post Industrial Shingles Post Consumer Shingles 15 4 488,400 6.1 25 4 467,400 10.1 5 18 480,400400 76 7.6 5 32 451,300 13.2 WMA 0 0 497,600 4.3 66 33
Operations Operation Estimated Emissions Generation Representative (Rep.) Range Rep. Value (Value Used in Analysis) Construction and Rehabilitation, CO 2eq /yd 2 -in Cold Milling Asphalt Pavement 0.080-3.500 1.730 Hot Mix Asphalt 5.500-10.500 7.500 CIPR - Partial Depth 3.712 CIPR - Full Depth 1.000-8.500 2.552 HIPR Remixing 5.065 Conventional Aggregate Base 1.400-5.100 6.051 Recycled Aggregate Base 2.642 Emulsion Stabilized Aggregate Base 7.072 Cement Stabilized Aggregate Base 5.200-11.600 8.361 Cement Treated 2.780 Lime Treated 4.636 67 Recycled Materials in HMA Emissions Analysis Material / Process Recycled Material Content, % Recycled Asphalt Binder Content, t % Emissions, CO 2eq /ton Savings, % Conventional HMA 0 0 133.33 - RAP Post Industrial Shingles Post Consumer Shingles 15 4 127.03 4.7 25 4 122.83 7.9 5 18 127.38 45 4.5 5 32 123.53 7.4 WMA 0 0 131.33 1.5 68 34
Outline Introduction G Green Construction C t ti Alternatives Alt ti Savings Price Environmental Impact Savings Energy, Emissions and Resources Summary 69 XXXXXXXXXX PCI<55 Poor Condition 70 35
Poor Pavement Condition Environmental Analysis* Operation Energy, CO 2eq, Btu/yd 2 Btu/yd 2 Asphalt, ton/yd 2 Aggregate, ton/yd 2 5.0-in HMA on 11-in Conventional AB (Remove & Replace) Mill and Fill 3.0-in and 2.8-in Overlay CIPR-Full Depth w/ 6.0-in cut and 4.0-in HMA Overlay - - - - 43.3 70.3 4.8 71.4 29.0 69.5-12.3 75.9 *percent savings in comparison to conventional alternative 71 PCI 55 to 70 Fair Condition 72 36
Fair Pavement Condition Environmental Analysis* Operation Mill and Fill 4.0-in and 1.8-in Overlay CIPR-Partial Depth w/ 3.0-in cut, 3.3-in HMA Overlay 3.5-in HMA Overlay Energy, CO 2eq, Btu/yd 2 Btu/yd 2 Asphalt, ton/yd 2 Aggregate, ton/yd 2 - - - - 17.6 25.5 7.8 26.4 15.9 30.4 20.9 20.8 2.0-in Mill, 2.0-in HIPR-Remix, 2.0-in Fill, 2.0-in Overlay 9.2 9.8 17.8 24.5 *percent savings in comparison to conventional alternative 73 PCI >70 Good Condition 74 37
Fair Pavement Condition Environmental Analysis* Operation Mill and Fill 2.0-in and 2.0-in Overlay Energy, CO 2eq, Btu/yd 2 Btu/yd 2 Asphalt, ton/yd 2 Aggregate, ton/yd 2 - - - - 2.5-in HMA Overlay 19.6 31.3 25.5 25.0 2.0-in HIPR-Remix, and 2.0-in Overlay 12.3 13.5 24.5 32.5 *percent savings in comparison to conventional alternative 75 New Construction 76 38
Recycled Materials in HMA Environmental Analysis* Material / Process Recycled Material Content, % Recycled Asphalt Binder Content, t % Asphalt, ton/ton Aggregate, ton/ton Conventional HMA 0 0 - - RAP 15 4 11.5 15.2 25 4 19.2 25.3 Post Industrial Shingles 5 18 17.3 43 4.3 Post Consumer Shingles 5 32 30.1 3.6 WMA 0 0 0.0 0.0 *percent savings in comparison to conventional alternative 77 Treatment of Materials Environmental Analysis HMA 5.0-in Conv. AB 11.0-in HMA 5.0-in Rec. AB 9.5-in HMA 5.0-in Emul. Stab AB 7.0-in HMA 5.0-in Cement Stab AB 7.0-in HMA 5.0-in Cement Stab 9.5-in HMA 5.0-in Lime Stab 10.0-in Energy, % Savings (measured in Btu/yd 2 ) - 11.3-23.3-8.24 11.8 12.7 Emissions, % Savings (measured in CO 2eq /yd 2 ) - 8.5 16.4 7.7 45.5 35.6 78 39
Treatment of Materials Natural Resource Analysis HMA 5.0-in Conv. AB 11.0-in HMA 5.0-in Rec. AB 9.5-in HMA 5.0-in Emul. Stab AB 7.0-in HMA 5.0-in Cement Stab AB 7.0-in HMA 5.0-in Cement Stab 9.5-in HMA 5.0-in Lime Stab 10.0-in Asphalt Binder, % Savings (measured in ton/yd 2 ) - 0.0-52.8 0.0 0.0 0.0 Aggregate, % Savings (measured in ton/yd 2 ) - 9.3 25.8 24.9 68.4 68.4 79 Life Cycle Assessment Format Reconstruction IC CS CS M&F M&F M&F CS CS CS 0 7 11 14 19 23 28 32 37 40 IC = Initial Cost CS = Crack Seal M&F = Mill & Fill Salvage 80 40
Life Cycle Assessment Similar approach to previously presented Considerations Estimated life Price of rehabilitation/maintenance Discount rate Analysis period Salvage value Additional savings seen in LCA 81 Outline Introduction Green Construction ti Alternatives ti Savings Price Environmental Impact Savings Energy, Emissions and Resources Summaryy 82 41
Summary Not all decisions based on price Numerous green construction alternatives available Operations Materials Stabilization Environmental benefits abound Emissions i Energy Natural resources Consider LCA to analyze alternatives 83 Construction Operations - % Savings* Operation Price, $/yd 2 Energy, Btu/yd 2 CO 2eq, Btu/yd 2 Asphalt, ton/yd 2 Aggregate, ton/yd 2 Conventional - - - - - CIPR Partial Depth 9.0 9.3 15.3 2.0 17.6 CIPR Full Depth 52.1 29.0 69.5-12.3 75.9 HIPR - Remix 69 6.9 12.3 13.5 24.5 32.5 Overlay 28.0 19.6 31.3 25.5 25.0 *percent savings in comparison to conventional alternative 84 42
Treatment of Materials - % Savings* Operation Price, $/yd 2 Energy, Btu/yd 2 CO 2eq, Btu/yd 2 Asphalt, ton/yd 2 Aggregate, ton/yd 2 HMA on Conventional AB - - - - - HMA on Recycled AB 17.7 11.3 8.5 0.0 9.3 HMA on Emulsion Stab. AB -68.8-23.3 16.4-52.8 25.8 HMA on Cement Stab. AB 60 6.0-8.24 824 77 7.7 00 0.0 24.9 HMA on Cement Treated Sub 22.8 11.8 45.5 0.0 68.4 HMA on 23.9 Lime Treated Sub *percent savings in comparison 12.7 35.6 0.0 68.4 to conventional alternative 85 Recycled Materials in HMA - % Savings Material / Process Conventional HMA RAP Post Industrial Shingles Post Consumer Shingles WMA Recycled Material Content, % Recycled Asphalt Binder Content, % % Content, Price Energy CO 2eq AC Agg 0 0 - - - - - 15 4 5.7 6.1 4.7 11.5 15.2 25 4 9.5 10.1 7.99 19.2 25.3 5 18 6.6 7.6 4.5 17.3 4.3 5 32 12.0 13.2 7.4 30.8 3.6 0 0 0.8 4.3 1.5 0.0 0.0 86 43
Questions 87 44