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COLD IN PLACE ROCK CRUSHING AND STABILIZATION OFNORTHERN LOW VOLUME ROADS:A CASE STUDY APPLICATION OF GROUND PENETRATINGRADAR FOR COLD-IN-PLACE RECYCLED ROAD SYSTEMSPrepared By:Curtis BerthelotAssistant Pr<strong>of</strong>essor <strong>of</strong> Civil Eng<strong>in</strong>eer<strong>in</strong>gUniversity <strong>of</strong> SaskatchewanRon Gerbr<strong>and</strong>tPreservation Eng<strong>in</strong>eerSaskatchewan Highways <strong>and</strong> TransportationLarry SafronetzArea ManagerSaskatchewan Highways <strong>and</strong> TransportationGordon SparksPr<strong>of</strong>essor <strong>of</strong> Civil Eng<strong>in</strong>eer<strong>in</strong>gUniversity <strong>of</strong> SaskatchewanPresented at80 th Annual Meet<strong>in</strong>g, Transportation Research BoardWash<strong>in</strong>gton D.C.CDROM Proceed<strong>in</strong>gs Paper #01-2615January, 2001


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 1ABSTRACTSaskatchewan Department <strong>of</strong> Highways <strong>and</strong> Transportation (SDHT) is responsible for ma<strong>in</strong>ta<strong>in</strong><strong>in</strong>gapproximately 6500 kilometers <strong>of</strong> northern gravel surfaced roads. Many <strong>of</strong> these northern gravel roads are built onpoorly graded s<strong>and</strong> subgrades <strong>and</strong> may conta<strong>in</strong> protrud<strong>in</strong>g bedrock <strong>and</strong>/or large boulders. Because <strong>of</strong> this,washboard<strong>in</strong>g, protrud<strong>in</strong>g rocks, rutt<strong>in</strong>g <strong>and</strong> potholes are common performance problems <strong>of</strong> many northern gravelroads. Rout<strong>in</strong>e blad<strong>in</strong>g <strong>of</strong> these roads is <strong>of</strong>ten <strong>in</strong>effective because unstable s<strong>and</strong> does not ma<strong>in</strong>ta<strong>in</strong> its shape <strong>and</strong>compaction, protrud<strong>in</strong>g bedrock <strong>and</strong> boulders damage motor grader blades, boulders may become dislodged leav<strong>in</strong>gholes <strong>in</strong> the road, <strong>and</strong> dislodged boulders are a safety hazard when w<strong>in</strong>drowed along road side-slopes. Clay capp<strong>in</strong>g<strong>and</strong> base stabilization have been used to provide a stable wear<strong>in</strong>g surface, cover protrud<strong>in</strong>g bedrock <strong>and</strong> largeboulders, <strong>and</strong> reduce traffic dust. However, the long-term performance <strong>of</strong> clay capp<strong>in</strong>g <strong>and</strong> base stabilization can behighly variable <strong>and</strong> the associated costs can make these conventional solutions untenable. As a result, SDHT<strong>in</strong>vestigated the use <strong>of</strong> <strong>in</strong>-place rock crush<strong>in</strong>g <strong>and</strong> stabilization/modification for northern gravel roads withsignificant proportion <strong>of</strong> boulders <strong>in</strong> the grade us<strong>in</strong>g a rotomixer/stabilizer. Based on the f<strong>in</strong>d<strong>in</strong>gs <strong>of</strong> this study, <strong>in</strong>placerock crush<strong>in</strong>g <strong>and</strong> stabilization/modification is a technically feasible solution for elim<strong>in</strong>at<strong>in</strong>g protrud<strong>in</strong>gbedrock <strong>and</strong> boulders conta<strong>in</strong>ed near the surface. However, <strong>in</strong>-place crush<strong>in</strong>g <strong>of</strong> boulders with unconf<strong>in</strong>edcompressive strengths over 50,000 psi resulted <strong>in</strong> significant damage to the rotomixer m<strong>and</strong>rel result<strong>in</strong>g <strong>in</strong> anapproximate cost <strong>of</strong> just under $13,684 CDN per kilometer. <strong>in</strong> situ rock crush<strong>in</strong>g with subgrade stabilization <strong>and</strong>double seal was found to cost approximately $52,017 CDN per kilometer.


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 21 INTRODUCTIONSaskatchewan Department <strong>of</strong> Highways <strong>and</strong> Transportation (SDHT) is responsible for ma<strong>in</strong>ta<strong>in</strong><strong>in</strong>gapproximately 6500 kilometers <strong>of</strong> northern gravel roads. Many <strong>of</strong> these gravel roads are built on poorly graded s<strong>and</strong>subgrades <strong>and</strong> may conta<strong>in</strong> protrud<strong>in</strong>g bedrock <strong>and</strong>/or large boulders. Because <strong>of</strong> this, these roads may exhibit washboard<strong>in</strong>g, protrud<strong>in</strong>g rocks, rutt<strong>in</strong>g <strong>and</strong> potholes which results <strong>in</strong> decreased service level <strong>and</strong> potential driv<strong>in</strong>g hazards.Rout<strong>in</strong>e blad<strong>in</strong>g is <strong>of</strong>ten <strong>in</strong>effective because unstable s<strong>and</strong> does not ma<strong>in</strong>ta<strong>in</strong> its shape <strong>and</strong> compaction, protrud<strong>in</strong>gbedrock <strong>and</strong> boulders damage motor grader blades, boulders may become dislodged leav<strong>in</strong>g holes <strong>in</strong> the road, <strong>and</strong>dislodged boulders are a safety hazard when w<strong>in</strong>drowed along road side-slopes.In the past, clay capp<strong>in</strong>g <strong>and</strong> base stabilization have been used to provide a stable wear<strong>in</strong>g surface, coverprotrud<strong>in</strong>g bedrock <strong>and</strong> large boulders, <strong>and</strong> reduce traffic dust (1). However, the long-term performance <strong>of</strong> clay capp<strong>in</strong>g<strong>and</strong> base stabilization can be highly variable <strong>and</strong> the associated costs can make them untenable. As a result, significantbenefits could result from a more effective ma<strong>in</strong>tenance <strong>and</strong> upgrade treatment for northern gravel roads characterized byprotrud<strong>in</strong>g boulders <strong>and</strong> bedrock <strong>and</strong>/or comprised <strong>of</strong> unstable s<strong>and</strong> subgrades. In the search for more appropriatemethods for ma<strong>in</strong>ta<strong>in</strong><strong>in</strong>g northern gravel roads, an <strong>in</strong>-place rock crush<strong>in</strong>g <strong>and</strong> stabilization pilot project was undertakenon Highway 918-01 <strong>in</strong> 1999 between kilometers 12.80 <strong>and</strong> 21.84.Historic performance problems with Highway 918-01 <strong>in</strong>clude rough road surface due to severe potholes,rutt<strong>in</strong>g, protrud<strong>in</strong>g boulders <strong>and</strong> washboard<strong>in</strong>g. Rout<strong>in</strong>e blad<strong>in</strong>g <strong>of</strong> Highway 918-01 has been relatively <strong>in</strong>effective dueto unstable subgrade conditions <strong>and</strong> protrud<strong>in</strong>g boulders. Commercial traffic on Highway 918-01 is limited to suppliesto the Patunak First Nations Reservation, which is comprised <strong>of</strong> approximately 1500 residents. There is no residential orcommercial development along Highway 918-01.2 PRELIMINARY SITE INVESTIGATIONA prelim<strong>in</strong>ary site <strong>in</strong>vestigation <strong>and</strong> visual site survey was performed along Highway 918-01 <strong>in</strong> early summer1999. Figure 1 <strong>and</strong> Figure 2 show protrud<strong>in</strong>g boulders <strong>and</strong> unstable s<strong>and</strong> subgrade conditions common to Highway918-01.


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 3FIGURE 1 Highway 918-01 Typical Boulders In Grade <strong>and</strong> Along Road EdgeFIGURE 2 Highway 918-01 Typical Unstable S<strong>and</strong> Subgrade


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 4In situ subgrade soil samples were retrieved from Highway 918-01. The result<strong>in</strong>g gra<strong>in</strong> size analysis from eachsample is illustrated <strong>in</strong> Figure 3. As seen <strong>in</strong> Figure 3, Highway 918-01 subgrade is comprised <strong>of</strong> uniform s<strong>and</strong> withapproximately 15 to 20 percent f<strong>in</strong>es. Atterburg limit characterization <strong>of</strong> the f<strong>in</strong>es portion determ<strong>in</strong>ed the f<strong>in</strong>es portion tobe non-plastic. AASHTO classification determ<strong>in</strong>ed the subgrade to be non-plastic f<strong>in</strong>e s<strong>and</strong> (A-3) <strong>and</strong> the Unified SoilClassification System determ<strong>in</strong>ed the subgrade to be poorly graded s<strong>and</strong> with high non-plastic f<strong>in</strong>es content (SM).St<strong>and</strong>ard Proctor moisture density characterization was performed as per ASTM protocols <strong>and</strong> is shown <strong>in</strong> Figure 4. Ascan be seen <strong>in</strong> Figure 4, the optimum st<strong>and</strong>ard proctor density was found to be approximately 2070 kg/m 3 at 7.5 percentmoisture content <strong>and</strong> the optimum modified proctor density was found to be approximately 2160 kg/m 3 at 6.5 percentmoisture content.100908070% Pass<strong>in</strong>g6050403020100.075 .25.15.425.852.04.75 6.3Sieve Size 0.45 (mm)9.512.519.0Kilometer 10 Kilometer 20FIGURE 3 Highway 918-01 <strong>in</strong> situ Subgrade Gra<strong>in</strong> Size Distribution


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 52180215521302105Dry Density (kg/m 3 )2080205520302005198019551930190518803 4 5 6 7 8 9 10Moisture Content Percent11Modified ProctorSt<strong>and</strong>ard ProctorFIGURE 4 St<strong>and</strong>ard <strong>and</strong> Modified Proctor Moisture-Density <strong>of</strong> SDHT Highway 918-01 SubgradeIn situ boulders were sampled from Highway 918-01, were identified as to their type, <strong>and</strong> characterized withrespect to unconf<strong>in</strong>ed compressive strength. The rock type identification <strong>and</strong> unconf<strong>in</strong>ed compressive strengthmeasurements are summarized <strong>in</strong> Table 1 <strong>and</strong> illustrated <strong>in</strong> Figure 5. As seen <strong>in</strong> Table 1 <strong>and</strong> Figure 5, the <strong>in</strong> situboulders exhibited mean unconf<strong>in</strong>ed compressive strengths rang<strong>in</strong>g from 121.1 MPa (24.0 ksi) for weathered granitoidto 358.1 MPa (51.9 ksi) for f<strong>in</strong>e-gra<strong>in</strong>ed metamorphic basalt.


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 6TABLE 1 Highway 918-01 <strong>in</strong> situ <strong>Rock</strong> Unconf<strong>in</strong>ed Compressive Strength Measurements<strong>Rock</strong> TypeSampleLength(mm)SampleWidth(mm)SampleL/DRatioLoad(KN)UCS(ksi)UCS(MPa)F<strong>in</strong>e Gra<strong>in</strong>ed Metamorphic A 80.7 38.5 2.10 431 53.8 370.7F<strong>in</strong>e Gra<strong>in</strong>ed Metamorphic B 84.3 38.5 2.37 402 50.1 345.5Granite A 82.1 38.5 2.13 318 39.7 273.7Granite B 80.7 38.6 2.09 316 39.2 269.8Pegamite A 74.9 38.5 1.95 281 35.0 241.4Pegamite B 80.7 38.5 2.10 243 30.3 208.9P<strong>in</strong>k Granitoid A 82.8 38.6 2.15 185 23.0 158.6P<strong>in</strong>k Granitoid B 82.5 38.6 2.14 241 29.8 205.6Weathered Granitoid A 76.7 38.6 1.99 185 22.9 157.8Weathered Granitoid B 80.6 38.6 2.09 214 26.5 182.5Weathered Granitoid A* 82.5 38.5 2.14 82 10.2 70.1Weathered Granitoid B 84.9 38.5 2.21 200 25.0 172.0Grey Granitoid A 81.1 38.6 2.10 160 19.9 136.9Grey Granitoid B 81.2 38.6 2.10 234 29.0 199.8* Sample conta<strong>in</strong>ed <strong>in</strong>ternal fracture plane.MeanUCS(MPa)358.1271.8225.1182.1170.2121.1168.4400350358Mean UCS (MPa)300250200150100271225182170168121500F<strong>in</strong>e Gra<strong>in</strong>ed MetamorphicGranitePegamiteP<strong>in</strong>k GranitoidWeathered GranitoidGrey GranitoidWeathered Granitoid FracturedFIGURE 5 SDHT Hwy 918-01 <strong>in</strong> situ <strong>Rock</strong> Unconf<strong>in</strong>ed Compressive Strength Measurements


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 73 TEST SECTION DESIGN, LAYOUT, AND CONSTRUCTIONThe test sections constructed on SDHT Hwy 918-01were designed <strong>and</strong> constructed around the objective toevaluate the effectiveness <strong>of</strong> crush<strong>in</strong>g protrud<strong>in</strong>g boulders <strong>in</strong>-place, <strong>and</strong> stabiliz<strong>in</strong>g the <strong>in</strong> situ gravel road s<strong>and</strong> subgrade.The stabilizers considered <strong>in</strong> this study <strong>in</strong>cluded low plastic clay, calcium chloride, DL10 Special asphalt emulsion, <strong>and</strong>SS-1 asphalt emulsion. The <strong>in</strong>-place rock crush<strong>in</strong>g <strong>and</strong> stabilization test sections constructed as part <strong>of</strong> the Highway918-01 test site <strong>in</strong>clude:a) In-place rock crush<strong>in</strong>g, reshap<strong>in</strong>g, <strong>and</strong> recompaction with no stabilization (control section).b) In-place rock crush<strong>in</strong>g, reshap<strong>in</strong>g, recompaction <strong>and</strong> surface modification with low plastic clay.c) In-place rock crush<strong>in</strong>g, reshap<strong>in</strong>g, recompaction <strong>and</strong> stabilization/modification with calcium chloride.d) In-place rock crush<strong>in</strong>g, reshap<strong>in</strong>g, recompaction <strong>and</strong> stabilization/modification with low plastic clay <strong>and</strong>calcium chloride.e) In-place rock crush<strong>in</strong>g, reshap<strong>in</strong>g, recompaction <strong>and</strong> stabilization with DL-10 asphalt emulsion.f) In-place rock crush<strong>in</strong>g, reshap<strong>in</strong>g, recompaction <strong>and</strong> stabilization with SS-1 asphalt emulsion.Stabilizer concentrations <strong>and</strong> layer thicknesses were based on the characterization results <strong>of</strong> the subgrade <strong>and</strong>the properties <strong>of</strong> the alternative stabilizers/modifiers considered <strong>in</strong> this study. The stabilized test sections aresummarized <strong>in</strong> Table 2. As seen <strong>in</strong> Table 2, the asphalt emulsion stabilized test sections considered <strong>in</strong> this study<strong>in</strong>cluded the addition <strong>of</strong> DL10 Special <strong>and</strong> SS-1 at concentrations <strong>of</strong> 2.5, 4.5 <strong>and</strong> 6.5 percent. Given a residual asphaltcement content <strong>of</strong> approximately 60 percent, the residual asphalt cement content <strong>in</strong> the field was 1.5, 2.7 <strong>and</strong> 3.9 percentby dry weight <strong>of</strong> soil respectively. Table 3 summarizes <strong>and</strong> Figure 6 illustrates the Marshall stability after a seven-daycure <strong>and</strong> the reta<strong>in</strong>ed Marshall stability after a seven-day cure <strong>and</strong> a 48 hour soak <strong>of</strong> each SDHT Hwy 918-01 stabilizedmaterial system. Marshall stability was chosen as the relative measure <strong>of</strong> stability because it is commonly understood<strong>and</strong> well referenced. As also seen <strong>in</strong> Table 3 <strong>and</strong> Figure 6, the Marshall stability <strong>of</strong> the Highway 918 subgrade soil wassignificantly improved with the addition <strong>of</strong> asphalt emulsion whereas the addition <strong>of</strong> the calcium chloride <strong>and</strong> clay onlymarg<strong>in</strong>ally <strong>in</strong>creased Marshall stability. When soaked for 48 hours, the reta<strong>in</strong>ed stability <strong>of</strong> the unmodified Highway918 subgrade <strong>and</strong> that <strong>of</strong> the Highway 918 subgrade with clay <strong>and</strong>/or calcium chloride modification was negligible.However, the reta<strong>in</strong>ed stability <strong>of</strong> the Highway 918 subgrade modified with asphalt emulsion was found to be onlyslightly less than that observed from the unsoaked samples, illustrat<strong>in</strong>g the moisture resistance <strong>of</strong> the asphalt emulsionstabilized soil.


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 8Cha<strong>in</strong>ageStart (km)Cha<strong>in</strong>ageEnd (km)TABLE 2 Highway 918-01 Test SectionsSectionLength(m)Stabilizer Type <strong>and</strong> AmountSurfac<strong>in</strong>gGravel(Tonnes)Surfac<strong>in</strong>gDoubleSeal (m)12.80 13.44 640 none 100 013.44 13.94 500 20% clay (150 tonnes) 100 013.94 14.44 500 20% clay (150 tonnes) 100 014.44 15.44 1000 15% clay (200 tonnes) 100 015.44 15.90 460 15% clay (100 tonnes) 100 015.90 16.40 500 10% clay (75 tonnes)100 016.40 16.60 200210% clay (25 tonnes) 1 l/m 2 25 016.60 16.80 200 10% clay (25 tonnes) 2 l/m 2 25 016.80 17.00 200 10% clay (25 tonnes) 3 l/m 2 25 017.00 17.20 200 3 l/m 2 CaCl 25 017.20 17.40 200 2 l/m 2 CaCl 25 017.40 17.60 200 1 l/m 2 CaCl 25 15017.60 17.75 150 None 0 15017.75 18.55 800 None 150 020.34 20.49 150 2.5% DL10 Special 0 020.49 20.64 150 6.5% DL10 Special 0 020.64 20.72 80 4.5% DL10 Special 0 7520.72 20.87 150 2.5% SS-1 0 15020.87 21.02 150 6.5% SS-1 0 15021.02 21.18 160 4.5% SS-1 0 15021.18 21.84 660 none 108 0Totals 7250 1008 825TABLE 3 Highway 918-01 Subgrade Marshall Stability Across Stabilizer Types <strong>and</strong> ConcentrationsStabilizer Type <strong>and</strong>Concentration7-Day CuredMarshall Stability(KN)7-Day Cured <strong>and</strong> 48-Hour Soak MarshallStabilityUnmodified 1.9 010% Clay 3.1 015% Clay 82.1 020% Clay 3.7 010% Clay 11/m 2 CaCl 3.6 010% Clay 21/m 2 CaCl 3.4 010% Clay 31/m 2 CaCl 3.0 01 1/m 2 CaCl 2.4 02 1/m 2 CaCl 2.0 03 1/m 2 CaCl 1.8 02.5% DL10 Special 18.6 9.84.5% DL10 Special 14.3 12.56.5% DL10 Special 9.2 10.32.5% SS-1 19.1 19.14.5% SS-1 28.4 23.46.5% SS-1 25.2 17.2


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 9Mean Marshall Stability (KN)302520151050Unmodified10% Clay15% Clay20% Clay10% Clay 11/m2 CaCl10% Clay 21/m2 CaCl10% Clay 31/m2 CaCl1 1/m2 CaCl2 1/m2 CaCl3 1/m2 CaCl2.5% DL10 Special4.5% DL10 Special6.5% DL10 Special2.5% SS-14.5% SS-16.5% SS-17-Day Cure7Day Cure-48 Hour SoakFIGURE 6 Marshall Stability <strong>of</strong> SDHT Highway 918-01 Stabilized SystemsFigure 7 through Figure 14 show the process used to construct the Highway 918-01 test sections. The process<strong>in</strong>cludes primary <strong>in</strong>-place rock crush<strong>in</strong>g with a rotomixer/stabilizer CMI650 with m<strong>and</strong>rel cutt<strong>in</strong>g down (Figure 7).Although the CMI R/S 650 did crush almost all <strong>in</strong> situ boulders, it provided on average a 200 mm m<strong>in</strong>us crush, whichrequired rak<strong>in</strong>g with a motor grader to remove the larger pieces <strong>of</strong> crushed rock out <strong>of</strong> the grade to achieve effectiveshap<strong>in</strong>g <strong>and</strong> compaction (Figure 8). Follow<strong>in</strong>g the <strong>in</strong>-place rock crush<strong>in</strong>g process; primary shap<strong>in</strong>g <strong>and</strong> compaction <strong>of</strong>subgrade (Figure 9); secondary <strong>in</strong>-place rock crush<strong>in</strong>g <strong>and</strong> <strong>in</strong>jection <strong>of</strong> stabilizers us<strong>in</strong>g the CMI R/S 650 with m<strong>and</strong>relcutt<strong>in</strong>g up (Figure 10); f<strong>in</strong>al shap<strong>in</strong>g <strong>and</strong> compaction (Figures 11 <strong>and</strong> 12); <strong>and</strong> application <strong>of</strong> surface coarse traffic gravelor double seal (Figures 13 <strong>and</strong> 14) was performed.


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 10FIGURE 7 Primary <strong>Rock</strong> Crush<strong>in</strong>gFIGURE 8 W<strong>in</strong>drow<strong>in</strong>g <strong>and</strong> Separat<strong>in</strong>g Crushed <strong>Rock</strong>s


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 11FIGURE 9 Clay ModificationFIGURE 10 Asphalt Emulsion <strong>Stabilization</strong>


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 12FIGURE 11 F<strong>in</strong>al Shap<strong>in</strong>g <strong>and</strong> Compaction <strong>of</strong> GradeFIGURE 12 Typical Compacted F<strong>in</strong>al Grade


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 13FIGURE 13 Typical Gravel Wear<strong>in</strong>g CoarseFIGURE 14 Typical Asphalt Emulsion Stabilized Wear<strong>in</strong>g Coarse


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 144 CONSTRUCTION COST EVALUATIONThe total construction cost for each test section was equilibrated to a per kilometer basis segmented with respectto labor; equipment; gravel; stabilizer/modifier; miscellaneous costs <strong>in</strong>clud<strong>in</strong>g fuel, teeth, <strong>and</strong> hous<strong>in</strong>g for the crew; <strong>and</strong>double seal surfac<strong>in</strong>g as summarized <strong>in</strong> Table 4 <strong>and</strong> illustrated <strong>in</strong> Figure 15. As seen <strong>in</strong> Table 4 <strong>and</strong> Figure 15, asignificant portion <strong>of</strong> the cost to crush boulders <strong>in</strong>-place was equipment costs. Because the CMI R/S 650 employed <strong>in</strong>this project is designed to rotomix asphalt concrete with an unconf<strong>in</strong>ed compressive strength <strong>of</strong> one to five MPa at roomtemperature, boulder unconf<strong>in</strong>ed compressive strengths as 358 MPa <strong>in</strong>flicted severe m<strong>and</strong>rel damage when highconcentrations <strong>of</strong> boulders were encountered. Dur<strong>in</strong>g the 7.25 kilometers <strong>of</strong> rotomixed road, $13,222 <strong>of</strong> m<strong>and</strong>rel teethwas consumed. However, this pilot was <strong>in</strong>tended to be a “worst case scenario” <strong>and</strong> therefore, sections <strong>of</strong> Highway 918-01 with high concentrations <strong>of</strong> boulders were selected <strong>in</strong> order to provide an extensive field evaluation <strong>of</strong> the <strong>in</strong>-placerock crush<strong>in</strong>g process. It is believed that redesigned m<strong>and</strong>rel will improve efficiency, reduce teeth costs, <strong>and</strong> result <strong>in</strong>fewer equipment breakdowns. Figure 16 illustrates the mean total construction cost by test section type. As seen <strong>in</strong>Figure 16, the mean construction cost per kilometer ranged from $13,684 for <strong>in</strong>-place rock crush<strong>in</strong>g <strong>and</strong> a gravel wear<strong>in</strong>gcoarse to $52,017 for <strong>in</strong>-place rock crush<strong>in</strong>g, asphalt emulsion stabilization <strong>and</strong> a double seal wear<strong>in</strong>g coarse.TABLE 4 Highway 918-01 Test Section Construction Cost Per Kilometer by Cost TypeTestSection(m)GravelCost($/Km)Stab.Cost($/Km)SealCost($/Km)Misc.Cost($/Km)TotalCost($/Km)Labor EquipTest SectionCost CostNo <strong>Stabilization</strong> 640 3,127 11,931 1,844 0 0 3,220 20,12220% Clay 500 3,104 11,407 2,185 0 0 3,022 21,29620% Clay 500 3,353 12,320 2,360 0 0 3,264 21,29615% Clay 1000 1,617 7,542 2,360 0 0 3,263 14,78215% Clay 460 3,515 16,613 2,565 0 0 3,263 25,95610%Clay-2/3l/m 2 CaCl 500 2,453 10,122 2,360 5,409 0 2,596 22,94010%Clay-1l/m 2 CaCl 200 6,133 25,304 1,475 2,823 0 2,595 38,33510%Clay-2l/m 2 CaCl 200 6,133 25,304 1,475 4,397 0 2,595 39,90510%Clay-3l/m 2 CaCl 200 4,662 20,128 1,475 5,971 0 2,595 34,8303l/m 2 CaCl 200 4,662 20,128 1,475 5,971 0 2,595 34,8302l/m 2 CaCl 200 4,662 20,128 1,475 4,397 0 2,595 33,2601l/m 2 CaCl & Seal 200 4,662 20,128 1,475 2,823 6,719 2,595 38,405No <strong>Stabilization</strong> & Seal 150 0 7,206 0 0 8,959 2,593 18,760No <strong>Stabilization</strong> 800 954 4,286 1,967 0 0 2,769 9,3522.5% DL10 Special 150 6,410 21,874 0 6,456 0 2,593 37,3336.5% DL10 Special 150 6,410 21,874 0 19,369 0 2,593 50,2474.5% DL10 & Seal 80 7,125 22,888 0 12,106 6,463 2,600 51,1812.5% SS-1 & Seal 150 7,117 22,894 0 6,706 6,467 2,593 45,7806.5% SS-1 & Seal 150 7,117 22,894 0 16,766 6,467 2,593 55,8404.5% SS-1 & Seal 160 6,672 21,464 0 10,365 6,063 10,706 55,269No <strong>Stabilization</strong> 660 1,457 4,971 1,931 0 0 2,595 10,954


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 1560,000Construction Costs ($/Km)50,00040,00030,00020,00010,0000No Stab (control)20% Clay20% Clay15% Clay15% Clay10% Clay-2-3l CaCl10% Clay-1l CaCl10% Clay-2l CaCl3l CaCl10% Clay-3l CaCl2l CaCl1l CaCl SealNo Stab & SealNo Stab (control)2.5% DL10SLabor Equipment Gravel Stabilizer Misc.6.5% DL10S4.5% DL10S Seal2.5% SS1 SealSeal Coat6.5% SS1 Seal4.5% SS1 SealNo Stab (control)FIGURE 15 Highway 918-01 Test Section Construction Cost per Kilometer by Cost Type$60,000Construction Cost ($/Km)$50,000$40,000$30,000$20,000$10,000$13,684$18,759$24,448$34,002$35,497$38,403$43,790$52,017$0GravelGravel w/ SealClay StabilizedClay/CaCl ModifiedCaCl ModifiedCaCl Modified w/ SealAsphalt Emulsion StabilizedAsphalt Emulsion Stabilized w/ SealFIGURE 16 Mean Total Construction Cost per Kilometer Grouped by Test Section Type


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 165 POST CONSTRUCTION PERFORMANCEInspection <strong>of</strong> the Highway 918-01 test sections was performed immediately after construction <strong>and</strong> one yearafter construction. For comparative purposes, a control test section comprised <strong>of</strong> <strong>in</strong>-place rock crush<strong>in</strong>g with a gravelwear<strong>in</strong>gsurface coarse <strong>and</strong> no stabilizers added to the subgrade was constructed. After one year <strong>of</strong> performance, theclay modified test sections were determ<strong>in</strong>ed to exhibit improved stability <strong>of</strong> the subgrade, assisted <strong>in</strong> ma<strong>in</strong>ta<strong>in</strong><strong>in</strong>gmoisture after ra<strong>in</strong>falls, <strong>and</strong> assisted <strong>in</strong> reta<strong>in</strong><strong>in</strong>g gravel <strong>in</strong>to the wear<strong>in</strong>g coarse. However, the clay modified test sectionsproduced <strong>in</strong>creased traffic dust <strong>in</strong> dry weather conditions <strong>and</strong> became slippery <strong>in</strong> wet weather conditions when comparedto other test sections.Calcium chloride modified test sections were constructed at concentrations <strong>of</strong> one liter/m 2 , two liter/m 2 <strong>and</strong>three liter/m 2 to a depth <strong>of</strong> 150 mm. To evaluate the relative <strong>in</strong>fluence that clay has on the retention <strong>and</strong> performance <strong>of</strong>calcium chloride modification, test sections with <strong>and</strong> without ten percent clay by dry weight <strong>of</strong> subgrade soil wereconstructed. It was determ<strong>in</strong>ed that calcium chloride provided improved compaction properties <strong>of</strong> the s<strong>and</strong> subgrade,assisted <strong>in</strong> moisture retention with<strong>in</strong> the grade, <strong>and</strong> assisted <strong>in</strong> embedd<strong>in</strong>g gravel <strong>in</strong>to the wear<strong>in</strong>g coarse. The calciumchloride modified test sections significantly reduced dust <strong>in</strong> dry weather conditions when compared to other test sections.Clay modification <strong>of</strong> the calcium chloride treated subgrade <strong>in</strong>creased the amount <strong>and</strong> duration <strong>of</strong> moisture retention. Itwas concluded that with ten percent clay added to the subgrade, one liter/m 2 <strong>of</strong> calcium chloride provided the optimalbalance <strong>of</strong> moisture retention <strong>and</strong> stability. Calcium chloride concentrations <strong>of</strong> two liters/m 2 <strong>and</strong> three liters/m 2 with tenpercent clay resulted <strong>in</strong> surface pond<strong>in</strong>g, potholes, rutt<strong>in</strong>g, <strong>and</strong> slippery driv<strong>in</strong>g surface after ra<strong>in</strong>falls. It was alsodeterm<strong>in</strong>ed that the calcium chloride without clay was less sensitive to ra<strong>in</strong>fall <strong>and</strong> only exhibited m<strong>in</strong>or surface pond<strong>in</strong>g<strong>and</strong> potholes after ra<strong>in</strong>fall up to concentrations <strong>of</strong> three liters/m 2 .SS-1 <strong>and</strong> DL10 Special asphalt emulsion was used to stabilize test sections at respective concentrations <strong>of</strong> 2.5,4.5 <strong>and</strong> 6.5 percent by dry weight <strong>of</strong> soil to a design depth <strong>of</strong> 150 mm. SS-1 is a slow set anionic asphalt emulsion thatemploys medium residual penetration asphalt designed to <strong>in</strong>crease the stability <strong>and</strong> strength <strong>of</strong> granular materials. DL10Special is an anionic s<strong>of</strong>t pen residual asphalt emulsion designed to provide added stability, improved environmentaldurability <strong>and</strong> surface workability <strong>in</strong> hot weather.Based on the observations <strong>of</strong> the SS-1 <strong>and</strong> DL10 Special asphalt emulsion stabilized test sections immediatelyafter construction, the test sections with <strong>in</strong>creas<strong>in</strong>g concentrations <strong>of</strong> asphalt emulsion <strong>in</strong>creased the s<strong>and</strong> subgradestability, provided a tighter surface wear<strong>in</strong>g coarse <strong>and</strong> reduced dust as would be expected. It was found that the asphalt


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 17emulsion stabilized test sections required m<strong>in</strong>or shap<strong>in</strong>g for a period <strong>of</strong> approximately two weeks after placement untilthe emulsion fully cured. M<strong>in</strong>or wheel path abrasion was also observed two months after placement with no wear<strong>in</strong>gsurface coarse placed on the stabilized s<strong>and</strong> subgrade after construction. To m<strong>in</strong>imize wheel path abrasion, it isrecommended that a th<strong>in</strong> layer <strong>of</strong> crushed rock or traffic gravel be embedded <strong>in</strong>to the wear<strong>in</strong>g surface immediately afterplacement <strong>and</strong> prior to the asphalt emulsion cur<strong>in</strong>g. In addition, a residual pen asphalt emulsion <strong>and</strong>/or faster sett<strong>in</strong>gemulsion may help reduce wheel path rutt<strong>in</strong>g <strong>and</strong> abrasion <strong>and</strong> elim<strong>in</strong>ate the need for blad<strong>in</strong>g dur<strong>in</strong>g cur<strong>in</strong>g. Double sealwear<strong>in</strong>g coarse was also placed on select portions <strong>of</strong> the asphalt emulsion stabilized test sections, one-year afterconstruction the sealed test sections constructed on the asphalt emulsion stabilized subgrade was found to be perform<strong>in</strong>gwell with only m<strong>in</strong>or edge breaks present.6 SUMMARY, CONCLUSIONS AND FUTURE RECOMMENDATIONSSDHT is responsible for ma<strong>in</strong>ta<strong>in</strong><strong>in</strong>g approximately 6500 kilometers <strong>of</strong> northern gravel roads. Many <strong>of</strong> thesegravel roads are built on poorly graded s<strong>and</strong> subgrades <strong>and</strong> may conta<strong>in</strong> protrud<strong>in</strong>g bedrock <strong>and</strong>/or large boulders.Furthermore, many <strong>of</strong> these roads exhibit washboard<strong>in</strong>g, protrud<strong>in</strong>g rocks, rutt<strong>in</strong>g <strong>and</strong> potholes, which result <strong>in</strong> severeroad roughness <strong>and</strong> a potential driv<strong>in</strong>g hazard. Rout<strong>in</strong>e blad<strong>in</strong>g is <strong>of</strong>ten <strong>in</strong>effective because unstable s<strong>and</strong> does notma<strong>in</strong>ta<strong>in</strong> shape <strong>and</strong> compaction, protrud<strong>in</strong>g bedrock <strong>and</strong> boulders damage motor grader blades, boulders may becomedislodged leav<strong>in</strong>g holes <strong>in</strong> the road, <strong>and</strong> dislodged boulders are a safety hazard when w<strong>in</strong>drowed along road side-slopes.SDHT undertook an <strong>in</strong>-place rock crush<strong>in</strong>g <strong>and</strong> subgrade stabilization pilot project on sections <strong>of</strong> Highway918-01. The objective <strong>of</strong> this project was to evaluate cold <strong>in</strong>-place rock crush<strong>in</strong>g to reduce protrud<strong>in</strong>g boulders <strong>and</strong> toevaluate the feasibility <strong>of</strong> <strong>in</strong>-place modification/stabilization to stabilize s<strong>and</strong> subgrades. The construction <strong>of</strong> theHighway 918-01 test sections determ<strong>in</strong>ed that <strong>in</strong>-place rock crush<strong>in</strong>g with the CMI R/S 650 is technically feasible <strong>and</strong>provides a workable surface free <strong>of</strong> large boulders. The addition <strong>of</strong> clay <strong>and</strong> calcium chloride <strong>and</strong> asphalt emulsion tothe uniform s<strong>and</strong> subgrade resulted <strong>in</strong> <strong>in</strong>creased stability <strong>and</strong> reduce traffic dust. The construction costs for this pilotproject ranged from $13,684 for <strong>in</strong>-place rock crush<strong>in</strong>g <strong>and</strong> a gravel wear<strong>in</strong>g coarse to $52,017 for <strong>in</strong>-place rockcrush<strong>in</strong>g, asphalt emulsion stabilization <strong>and</strong> a double seal wear<strong>in</strong>g coarse.Based on the results <strong>of</strong> this study, further <strong>in</strong>vestigation <strong>of</strong> <strong>in</strong>-place rock crush<strong>in</strong>g <strong>and</strong> s<strong>and</strong> stabilization shouldconsider:a) A roto mixer m<strong>and</strong>rel specifically designed for <strong>in</strong>-place rock crush<strong>in</strong>g.


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 18b) <strong>Stabilization</strong> designs should be based on fundamental subgrade soil behavior <strong>in</strong>clud<strong>in</strong>g physical <strong>and</strong>mechanical properties <strong>of</strong> alternative stabilization systems to quantify the performance related behavior <strong>of</strong>these systems.REFERENCES1. Safronetz, J., Berthelot, C., Sparks, G., <strong>and</strong> Gerbr<strong>and</strong>t, R. Alternative Ma<strong>in</strong>tenance Treatments for<strong>Northern</strong> Saskatchewan Gravel Roads. Proc., Canadian Society <strong>of</strong> Civil Eng<strong>in</strong>eers, pp. 449-458, Reg<strong>in</strong>a,June 1999.


Berthelot, Gerbr<strong>and</strong>t, Safronetz, <strong>and</strong> Sparks. Page: 19LIST OF FIGURESFIGURE 1 Highway 918-01 Typical Boulders In Grade <strong>and</strong> Along Road EdgeFIGURE 2 Highway 918-01 Typical Unstable S<strong>and</strong> SubgradeFIGURE 3 Highway 918-01 <strong>in</strong> situ Subgrade Gra<strong>in</strong> Size DistributionFIGURE 4 St<strong>and</strong>ard <strong>and</strong> Modified Proctor Moisture-Density <strong>of</strong> SDHT Highway 918-01 SubgradeFIGURE 5 SDHT Hwy 918-01 <strong>in</strong> situ <strong>Rock</strong> Unconf<strong>in</strong>ed Compressive Strength MeasurementsFIGURE 6 Marshall Stability <strong>of</strong> SDHT Highway 918-01 Stabilized SystemsFIGURE 7 Primary <strong>Rock</strong> Crush<strong>in</strong>gFIGURE 8 W<strong>in</strong>drow<strong>in</strong>g <strong>and</strong> Separat<strong>in</strong>g Crushed <strong>Rock</strong>sFIGURE 9 Clay ModificationFIGURE 10 Asphalt Emulsion <strong>Stabilization</strong>FIGURE 11 F<strong>in</strong>al Shap<strong>in</strong>g <strong>and</strong> Compaction <strong>of</strong> GradeFIGURE 12 Typical F<strong>in</strong>al GradeFIGURE 13 Typical Gravel Wear<strong>in</strong>g CoarseFIGURE 14 Typical Asphalt Emulsion Stabilized Wear<strong>in</strong>g CoarseFIGURE 15 Highway 918-01 Test Section Construction Cost per Kilometer by Cost TypeFIGURE 16 Mean Total Construction Cost per Kilometer Grouped by Test Section TypeLIST OF TABLESTABLE 1 Highway 918-01 <strong>in</strong> situ <strong>Rock</strong> Unconf<strong>in</strong>ed Compressive Strength MeasurementsTABLE 2 Highway 918-01 Test SectionsTABLE 3 Highway 918-01 Subgrade Marshall Stability Across Stabilizer Types <strong>and</strong> ConcentrationsTABLE 4 Highway 918-01 Test Section Construction Cost Per Kilometer by Cost Type

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