Resin Modified Pavement Demonstration Project.pdf

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Chapter 3 - Construction of Resin Modified PavementResin Modified Pavement (RMP) is a composite paving material that combines the rutresistance of a concrete pavement with the lower initial cost of an asphalt pavement.An open graded 2” thick lift of hot-mix asphalt is constructed with approximately 30%air voids. After the mat has been allowed to cool to ambient temperature, a highlyfluid cement grout is poured onto the mat. The grout must penetrate the entire 2”depth of the open graded asphalt and fill all of the internal voids in the mat.This paving technique was developed in France in the 1960’s and has been widelyutilized throughout Europe. To date most of the UTW in the United States have beenpavements constructed for military applications.The United States Army Center for Public Works published a “User’s Guide: ResinModified Pavement” in 1996 which is included in Appendix G. This document wasutilized as a guide during the construction of Mississippi’s RMP test sections.In addition, the Mississippi DOT contracted the services of Dr. Randy Ahlrich. Dr.Ahlrich is an employee of Burns, Cooley and Dennis, a Jackson MississippiGeotechnical engineering firm. Dr. Ahlrich gained extensive experience with RMPduring his former employment with the United States Army Engineer WaterwaysExperiment Station.Since the Mississippi DOT has no previous experience with the RMP pavement, it wasdecided that a 100’ x 12’ test strip should be constructed off site in a “mill and fill”application as would be utilized on site. A location at the APAC – Corinth asphaltplant was utilized for the test section.On April 2, 2001 construction of the RMP test strip began. The strip was milled to theapproximate 2” depth at 8:00 am. At approximately 2:00 pm on a sunny 78 degree Fafternoon, the open graded mix was laid into the freshly milled section. It requiredapproximately 15 tons of asphalt to construct the strip. The mat temperature wasapproximately 290 degrees F at laydown. After approximately 1 hour, when the mattemperature had reached 140 degrees F, a small 2-ton steel wheel roller in static modemade one roller pass on the mat to smooth any imperfections in the mat.After examining the gradations from the truck samples that were taken from the teststrip material, it was determined not to accept the first test strip. For unexplainedreasons the mix gradation had “fined” during production with too much materialpassing the #4 sieve, hence our air voids in the mat were at the 25% minimum limit.Rather than risk attempting to add the grout to the strip, APAC was told they mustremove the mat, make adjustments to the gradation to “coarsen” the mix and place themat again.12
On April 5, 2001, construction of RMP test strip 2 began. At 9:20 am on an overcast63-degree F morning, the open graded mix was laid into the milled section. Onceagain 15 tons of asphalt was required to construct the test strip. For test strip 2 the mattemperature was approximately 240 degrees F at laydown. After approximately 20minutes, when the mat temperature had reached 140 degrees F, the small 2-ton steelwheel roller was utilized in static mode to smooth any imperfections in the mat.The gradations were examined from the truck samples that were taken from the teststrip material and they were well within the Job Mix Formula tolerances. The mat wasdeemed acceptable and was covered with a tarp to prevent any excessive moistureinfiltration until the grout could be added.On April 9, 2001 after a three day delay due to mechanical difficulties with the fly ashsilo auger at B & B Concrete’s Corinth plant, the cement grout was batched at 11:00am. It is important to note that prior to batching grout into cement trucks, care shouldbe taken to ensure that the drum of the truck is clean. Contamination of the grout withother material can be detrimental to the grout. During the plant batching process for a4 cubic yard load of grout, initially half of the water or 1550 gallons was added to thecement truck. Next, the Silica Sand, 2280 lbs dry weight is added to the truck. Afterthe sand has been added, 4556 lbs of Type 1 Cement is added to the truck. Next, theType F Fly Ash, 2280 lbs, is added. And finally the remaining water with theexception of ten gallons was added. It is important to note that during loading andtransport of the mixture the drum of the cement truck must be agitating. For thisproject, the resin additive PL7, was added to the truck at the project site. The concretetruck arrived at the project site at 11:30 am on a sunny 76-degree F morning. A smallpump was used to pump the PL7 from its 55-gallon drum into the concrete truck.After all of the additive had been pumped out of the drum, the remaining 10 gallons ofwater was used to rinse out the drum and pumped into the concrete truck. The groutmixture should undergo the maximum rotations of the concrete truck for no less than10 minutes to insure that the PL7 is thoroughly mixed. For construction of the RMPtest strip 2 at APAC-Corinth’s plant, only 3 cubic yards of the grout was batched.Therefore, all of the mixture quantities detailed in the previous paragraph werereduced by 25%.At 11:50 am after adding the PL7 and mixing for 10 minutes, the grout was ready tobe poured into our mat of open graded asphalt. Before pouring the viscosity of thegrout must be checked using a Marsh flow cone. The Marsh cone is used to measurethe length of time it takes for 1 liter of grout to flow through the cone. Too high of aflow time would mean that the grout is too viscous and might not penetrate the opengraded asphalt layer completely. If the flow time was too low, the grout may not gainthe strength required. For this project an acceptable flow time is between 7 and 10seconds. The flow of the grout that was used in RMP test strip 2 was checked andtimed out to 8.72 seconds which was acceptable.13
Page 1: Construction, Testing and Performan
Page 4 and 5: ACKNOWLEDGMENTSThe study reported h
Page 6 and 7: LIST OF FIGURES AND TABLESFigurePag
Page 8 and 9: LIST OF FIGURES AND TABLES (Continu
Page 10 and 11: Figure 3 - Plan view intersection o
Page 12 and 13: Figure 5 - Intersection of US 72 an
Page 14 and 15: Chapter 2 - Construction of Ultra-T
Page 16 and 17: After the white pigmented concrete
Page 18 and 19: Figure 12 - Whitetopping is given a
Page 22 and 23: Using 2” grout cube molds, six gr
Page 24 and 25: cubic yards remaining in the last t
Page 26 and 27: Figure 16 - APAC Corinth “drum”
Page 28 and 29: Figure 20 - B & B Concrete Corinth
Page 30 and 31: Figure 24 - 2” mortar cubes are m
Page 32 and 33: Figure 28 - “Working the grout”
Page 34 and 35: Figure 32 - Entire mat did not get
Page 36 and 37: Attached in Appendix H is a complet
Page 38 and 39: Figure 37 - Finish rolling30
Page 40 and 41: were also utilized in the 75’ fai
Page 42 and 43: of 72 or lower should be considered
Page 44 and 45: Chapter 7 - ConclusionsUsing constr
Page 46 and 47: APPENDIX ATRAFFIC DATA
Page 48 and 49: Figure A2 - Yearly Itemized Project
Page 50 and 51: Figure A4 - Year 2020 Projected 24
Page 52 and 53: Figure A6 - Year 2020 Projected 24
Page 54 and 55: Table B1 - Preconstruction Rut Data
Page 56 and 57: Table B3 - Preconstruction Friction
Page 58 and 59: Figure C1 - Ultra-Thin Whitetopping
Page 60 and 61: Truck No 24 hour break 48 hour brea
Page 62 and 63: Table C7 - UTW Smoothness Data coll
Page 64 and 65: Table C10- Long Term Data for Ultra
Page 66 and 67: APPENDIX DMDOT UTW STANDARD SPECIFI
Page 68 and 69: design. Documentation presented mus
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Payment will be made under:907-501-
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Figure E1 - UTW 24 hour test report
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Figure E5 - UTW 48 hour test report
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Figure E9 - UTW 7 day test report (
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Figure E12 - UTW 28 day test report
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Figure E17 - UTW 24 hour test repor
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Figure E21 - UTW 48 hour test repor
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Table F1 - Gradations, AC Contents
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Figure F4 - Aggregate Gradation Cha
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Table F7 - RMP Open Graded Mix Mat
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Table F11 - Air Voids in Mat @ Cass
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Table F15 - Thickness of Resin Modi
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Table F17 - Thickness of Resin Modi
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Table F19 - RMP grout design chartF
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Table F22 - RMP Grout Construction
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Table F28 - RMP Friction Data Colle
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APPENDIX GUSER’S GUIDE: RESIN MOD
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G - 2
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Technology Components and Sources..
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1 Executive SummaryDescriptionResin
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stances, the RMP also provides cost
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2 PreacquisitionDescription of Resi
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In 1987, the U.S. Army Corps of Eng
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Table 1RMP Project Locations in the
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Table 2Open-Graded Mixture Aggregat
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The slurry grout mix design is cond
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Resin modified groutThe resin modif
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Table 4Slurry Grout Viscosity Requi
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G - 24
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G - 26
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CostsThe initial construction costs
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A quick comparison of the construct
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equired to support logistical opera
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Procurement SchedulingNormal constr
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PersonnelThe personnel normally req
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ReferencesAhlrich, R. C., and Ander
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APPENDIX HPG 82-22 HMA DATA
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Table H2 - PG 82-22 Designs with di
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Table H4 - PG 82-22 Gradation Chart
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Table H6 - PG 82-22 Inspectors Dail
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Figure H8 - PG 82-22 Quality Contro
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Figure H10 - PG 82-22 Truck Tickets
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Table H13 PG 82-22 Rut Measurements
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Table H15 - PG 82-22 Smoothness Dat
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APPENDIX ICOST DATA
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Table I2 - Resin Modified Pavement
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