WMA A Contractors Experience. NAPA 56 th Annual Meeting February 5-9, 2011 Orlando, FL. Tony Limas Granite Construction Company

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1 WMA A Contractors Experience NAPA 56 th Annual Meeting February 5-9, 2011 Orlando, FL Tony Limas Granite Construction Company 1

2 Today's Discussion WMA By the Numbers Granite WMA Experience Observations 2

3 By the Numbers Over 60 HMA plants capable of producing WMA 21 (35%) asphalt plants retrofitted with WMA mechanical foaming units Astec Double Barrel Green Gencor Green Machine Ultrafoam GX Maxam AQUA Black Stansteel Eco-Blend 3

4 By the Numbers Produced 1,700 tons of WMA in 2008 Produced 115,617 tons of WMA in 2009 Produced 305,000 tons of WMA in 2010 Total tons to date = 422,317 tons* * December 31,

5 Bringing BAGT Together Up to 50% RAP Capable Multiple RAP/RAS Bins Paved Yard Dust / Moisture Control RAP/RAS RAP/RAS/WMA CRM/RAP/RAS RAP/WMA CRM/RAP CRM/WMA/RAP/RAS

6 WMA Technologies Experience WMA Technologies Used to Date Astec Double Barrel Green (Foam) Evotherm ET/DAT(Chemical) Maxam (Foam) Sasobit (Wax) Gencor Ultrafoam (Foam) Advera (TR Foam) Stansteel (Foam) Cecabase RT (Chemical) 6

7 Granite Experience - State DOT WSDOT- SR-12 Add Lanes (80,000 tons/20% RAP) WSDOT Nile Rd. (13,100 tons/20% RAP) WSDOT - SR 520 Sammamish PW (5,300 tons/20% RAP) WSDOT - I-5 Northbound 52nd Ave (6,000 tons/20% RAP) WSDOT - SR 101 SR 6 (4,400 tons/20% RAP) WSDOT - SR-12 Mitchell Rd (5,300 tons/20% RAP) WSDOT - SR-546 Guide Meridian (4,000 tons/20% RAP) WSDOT - SR-6 Grays Harbor Project (3,000 tons/20% RAP) WSDOT - SR-532 Starbird Road project (3,000 tons/20% RAP) WSDOT SR 410 Emergency Repair (13,000 tons/20% RAP) WSDOT SR-3 Near Anderson Hill (19,000 tons/20% RAP) WSDOT - US 12 FT. to Walla Walla (81,034 tons/18% RAP) 7

8 Granite Experience - State DOT WSDOT Valley Mall Blvd. Inter. (29,953 tons/20% RAP) WSDOT Indian John Hill (1,108 tons/20% RAP) WSDOT Keechelus Dam to CC (17,188 tons/20% RAP) WSDOT Naches to Mitchell (2,761 tons/20% RAP) WSDOT Washington National Parks (1,991 tons/20% RAP) WSDOT Terrace Heights Off Ramp (551 tons/20% RAP) WSDOT E. Wenatchee to Rock Island (4,200 tons/20% RAP) Caltrans - SR 70 Oroville (1,430 tons/15% RAP) Caltrans - SR 1 Fort Bragg (2,500 tons) Caltrans - SR 101 Scotia (2,600 tons RHMA) Caltrans Dist. 1 Maintenance (misc. tonnage/15% RAP) 8

9 Granite Experience - State DOT Caltrans - SR 1 near Albion (7,500 tons) Caltrans - Hwy 49 RWMA-O (7200 tons) UDOT- Wall Ave Region 1 (6,000 tons/15% RAP) Arizona- I-10 Houghton Rd to SR 183 (9,715 tons/20% RAP) 9

10 Granite Experience - Local Agencies Alaska - Anchorage International Airport (6,500 tons) Alaska - City of Anchorage (1,200 tons) Washington - City of Ocean City (40,000 tons/30% RAP) Washington City of Vancouver (2,000 ton/20% RAP) Washington- Clark county (4,000 tons/20% RAP) Washington - City of Yakima, K Park (215 tons/20% RAP) Washington - Yakima County, Insp. Dr (500 tons/20% RAP) Washington - Lincoln Ave Grade Sep. (283 tons/20% RAP) Washington - Town of Naches (745 tons/20% RAP) Washington - Yakima Nation, DL (7,360 tons/20% RAP) Washington - Yakima County, Hall Rd (2,800 tons/20% RAP) 10

11 Granite Experience - Local Agencies Washington - Camas Grind & Overlay (659 tons/20% RAP) Washington - Kittitas County, Parking (533 tons/20% RAP) Washington City of Yakima, 66 th Ave (254 tons/20% RAP) Washington - City of Richland, Shared Trail (864 tons) Oregon - City of Portland PP (10,000 tons/20% RAP) Oregon - City of Portland (11,000 tons/25% RAP) Nevada - City of Reno (100 tons/30% RAP) Nevada RTC Bravo Ave (6,700 tons/15% RAP) Nevada City of Reno, Chism St. (1,000 tons/15% RAP) Nevada - Washoe County/COE (450 tons/30% RAP) Nevada - City of Reno (100 tons/15% RAP) Nevada City of Reno, Taylor St. (6,800 tons/30% RAP) 11

12 Granite Experience - Local Agencies California - City of Coachella (1,000 tons/15% RAP) California - City of Palm Desert (400 tons/15% RAP) California Ventura County (2,000 Tons/15% RAP) California - City of Calabasas (1,100 Tons/15% RAP) California City of Folsom Bike Path (200 tons/25% RAP) California City of Roseville (230 tons/25% RAP) California - City Of Indio (1,000 tons/15% RAP) California - County of Kern right-of-way (100 tons/20% RAP) California County of Mendocino (27,000 tons/15% RAP) California City of Roseville (20 tons/25% RAP) California - El Dorado County Bike Path (250 tons/20% RAP) California City of Roseville, Douglas (20 tons/25% RAP) 12

13 Granite Experience - Local Agencies California - North Sacramento CHP (20 ton/25% RAP) Utah - City of Cottonwood Heights (240 tons/25% RAP) Utah - County of Salt Lake (1,200 tons/25% RAP) Utah - City of Kaysville (250 tons/25% RAP) 13

14 Granite Experience Private Owners Washington Selah Plant, Misc. Work (19,716 tons/20% RAP) Washington Selah Plant Ext. Sales (9,734 tons/20% RAP) Utah Granite Const. SLC (200 tons 15-40% RAP) Arizona - Granite Const. Tucson (225 tons/15% RAP) California - Cameron Airpark (9,200 tons/20% RAP) California- Blue Diamond Sacramento (900 tons 20% RAP) California - Geyser Industries (3,000 tons/15% RAP) California - Granite Const. Sacramento (250 tons/20% RAP) California - Granite Const. Bakersfield (225 tons/10% RAP) California - Granite Const. Indio (650 tons/15% RAP) California - Granite Const. Indio (250 tons/30% RAP) California - Glen Ellen Estates (35 ton/25% RAP} California Pacific Gas & Electric (200 tons/15% RAP) 14

15 Granite Indio Plant Access Road WMA Test Sections, Indio Ca Astec Double Barrel Green 15

16 Rubberized Crack Filler (No Swelling) 16

17 City of Indio, CA ½ Dense Graded Plant Temp: 270 F. (Astec Double Barrel) Job Temp/Breakdown Rolling: 230 F. Intermediate Rolling 175 F. Final Rolling: 160 F. Average Density: 93% RICE 17

18 City of Indio, CA 18

19 City of Indio, CA Warm Mix Hot Mix 19

20 City of Indio Test Sections Hot Mix 92.6% Warm Mix 92.9% 20

WSDOT SR-3 ½ Dense Graded PG 64-22 Plant Temp: 330 F (Gencor)

21 WSDOT SR-3 ½ Dense Graded PG Plant Temp: 330 F (Gencor) Job temp: 300 F Job Ambient Temp: 60 F Density: 92-95% RICE 21

22 Cameron Airpark, Cameron Park, CA ½ Dense Graded Plant Temp: 270 F. (Gencor) Job Temp: 245 F. Density: 92-96% RICE 22

23 Cameron Airpark, Cameron Park, CA Paving Fabric 23

24 Cameron Airpark, Cameron Park, CA Pick Up Machine 24

25 Cameron Airpark, Cameron Park, CA 25

26 Caltrans SR-101 Scotia, CA ¾ RWMA Type G Plant Temp: 250 F. (Evotherm) Job Temp: 230 F. Ambient Temp: 55 F. Density: RICE Notched Wedge Joint 26

27 Caltrans SR-101 Scotia, CA 27

28 Caltrans SR-101 Scotia, CA Material Transfer Device 28

29 WSDOT Nile Road Project 1/2 Dense Graded PG PM WMA Technology: (Gencor) Plant Temp: Haul: 45 min, (tarps) Project Temp: Job Ambient Temp: Cold. Density: 92-93% RICE 29

30 WSDOT - Nile Road Project 30

31 WSDOT - Nile Road Project 31

32 WSDOT - Nile Road Project 32

33 WSDOT - Nile Road Project 33

34 WSDOT Nile Road Project We had to work at getting everything started in the cold weather. There were very few problems, but it was a challenge to get things de-iced and going in the morning We were very successful using warm mix. The long hauls and the cooling mix could have caused a problem. By using the warm mix we were able to learn a lot about how well the mix compacts at lower temperatures. The job was able to pull the 3 rd roller. From this experience we are more confident about long hauls, and cool weather paving when using WMA 34

Caltrans SR-70 Oroville, CA 1400 tons of ½ DGAC w/ PG 64-16

35 Caltrans SR-70 Oroville, CA 1400 tons of ½ DGAC w/ PG Month Detour on SR 70 AADT 18,500, Trucks 15% on 5% Grade 35

36 Caltrans SR-70 Oroville, CA Plant Temp: 240 F. Job Temp: 230 F. (Evotherm) Density: 92-94% RICE Breakdown Roller Temp F. 92% RICE achieved at 160 F. 36

37 Caltrans SR-70 Oroville, CA Wheel Path 37

38 Local Green Pavement Examples Chism St. McCarran Blvd. Bravo Ave. Taylor St. Engineering Services

39 Bravo Ave Reconstruction 2010 In-Place Recycle Existing HMA + Base (partial depth HMA milling first) WMA w/ 15% RAP Surface Course Gencor Green Machine 39

40 Reno - Chism St WMA/RAP 40

41 Reno - Taylor St Reconstruction In-Place Recycle Existing HMA + Base (partial depth HMA cold milling first) WMA w/ 15% RAP Surface Course Gencor Green Machine 41

Anchorage International Echelon Paving ¾ Dense Graded PG 64-34

42 Anchorage International Echelon Paving ¾ Dense Graded PG Plant Temp: 235 F. (Evotherm) Job Temp: 230 F. Avg. Density: 95% RICE 42

43 Anchorage International 43

44 Anchorage International ¾ Dense Graded PG PM Plant Temp: 285 F. (Evotherm) Job Temp: 260 F. Avg. Density: 95% RICE 44

45 Anchorage International 45

46 Anchorage International Top Lift ¾ Dense Graded PG PM 46

47 So What Have We Learned? Rollers We were able to cut the pneumatic roller out. We were able to get compaction with just the two DD-130 steel wheel rollers. WMA Technology The amount of water injected in the binder (1.25 2%) may effect the duration of the tender zone P s and Q s Like HMA, moisture in the RAP must be considered when determining the amount of RAP in the mix 47

48 So What Have We Learned? Production The bid planned to lay 1450 tons per day. We were able to place an average of 1511 tons per day WMA Technology All HMA designs worked well with the addition of the WMA technology at the plant (no WMA additives in lab mix) Quality There was really no problem with quality. We were able to get great compaction with a long haul and poor weather conditions 48

49 So What Have We Learned? Mix Properties WMA RICE values are typically very close to HMA RICE values Compaction Nuclear gauge correlations can differ considerably from HMA Leadership In the absence of permissive specifications most local agency and private work is done at the behest of the Contractor (State DOT s need to lead the way) 49

50 We re Just Getting Started! 1,200,000 Projected WMA Tonnage 2011 Accumalative WMA Tons 1,000, , , , ,

51 Anchorage International Thank You Made For Warm Mix 51

Longitudinal Joint Construction. Mike Robinson, PE

Longitudinal Joint Construction Mike Robinson, PE Inherently weaker than surrounding pavement Prone to deterioration Often drives rehabilitation FOD Longitudinal Joints Two predictors of success Density