Pavement_Memo.pdf

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Form FHWA-201 (Rev. 11-67)

U.S. DEPARTMENT OF TRANSPORTATION

FEDERAL HIGHWAY ADMINISTRATION

Use this form in lieu of transmittal slips within Dept. of Trans. When message comment is to be retained as file material. Do not prepare carbons. Not to be used in lieu of Form FHWA- 121 for informal correspondence. MINUTE-MEMO

M:\PROJECTS\_FWS\IRRI\10(1)\Techserv\Pavement\Correspondence\IRRI 10(1) Pavement Memo.doc

SUBJECT: Pavement Recommendations for Project FWS IRRI 10(1)

TO MESSAGE/COMMENT FROM/DATE

R. Kotadia Project Manager

And:

C. Burnell Highway Design Manager

Pursuant to the scoping trip dated June 11-13, 2017 and pavement investigation performed on May 20, 2018, we’re submitting our findings and recommendations for FWS IRRI 10(1), Iron River National Fish Hatchery. The project site is in Iron River, Wisconsin. The project consists of the rehabilitation of the Main Entrance Road (Route 10AZ), Lower Lever Entrance Road (Route 10BZ), Main Hatchery Parking Lot (Route 900AZ), Lower Level Hatchery Parking Lot (900BZ), and Fish Loading and Parking Lot (Route 800). If the recommendations herein are revised due to additional design information, revisions will be included as an addendum to this memo.

Executive Summary The entire project will consist of rehabilitation of approximately 0.82 miles of roadway and 43,700 square feet of parking. The above-mentioned routes have low to high severity thermal cracking, oxidation, localized raveling and rutting.

We recommend crack sealing, full depth patching, and wedge and leveling to repair the distressed areas prior to pavement rehabilitation. Three pavement rehabilitation alternatives are recommended:

1. Option 1 – Double Chip Seal

2. Option 2 – 1-½-inch Asphalt Overlay

3. Option 3 – Single Chip Seal Stress Absorbing Membrane Interface

(SAMI), followed by a 1-½-inch asphalt overlay Additional details are discussed in the following sections.

Main and Lower Level Entrance Roads (Routes 10AZ & BZ) Main Entrance Road is an asphalt paved road that runs from Weidenaar Road to the Main Hatchery Parking lot (Route 900AZ). Lower Level Entrance Road, used for truck deliveries, extends from Route 10AZ to the Lower Level Hatchery Parking Lot (Route 900BZ) and Fish Loading and Parking Lot (Route 800). A portion of Route 10BZ which runs from Main Entrance Road to Lower Level Access Parking is also called Handicapped Access Road (Route 011). Route 10BZ from Route 900BZ to Route 800 is also known as Holding House Access Road (Route 0302). Refer to the attached map for further detail.

The roadways have low to high severity thermal cracking with minor alligator cracking on some of the transverse thermal cracks. The thermal cracking is causing noticeable roughness and bumping to drivers. Prior to rehabilitating the roadway, asphalt pavement cracks larger than ¼-inch would need to be cleaned and sealed. Otherwise, the pavement surface is in good shape with no rutting or fatigue related distresses.

During the pavement investigation, pavement cores P-1, 2, 3, 5,6,7, and 10 were performed along Routes 10AZ and 10BZ. At the core locations, approximately

3.5 to 6 inches of asphalt concrete over aggregate base course (crushed rock) was encountered. The thinner pavement sections of 3 and 4.5 inches were encountered at P-10 (along the section of Route 10BZ also known as Route 0302) and P-6 (at intersection with Route 900BZ), respectively.

K. Ngozi- Bullock Pavement Engineer

Through:

M. Elias (Acting) Pavement Team Leader

7/3/2018

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The as-built plans for the fish hatchery roadway dated February 1984 indicate the roadway was constructed 34 years ago. The pavement section consisted of 3 inches of asphalt concrete overlying 6 inches of fine aggregate, which in turn overly 8 inches of coarse aggregate. The current pavement investigation suggests that a 1.5 to 3-inch asphalt overlay was placed sometime after the initial construction. However, it is difficult to confirm the overlay placement by visual inspection of the pavement cores, as they are all primarily consistent in aggregate and coloring; suggesting the asphalt was placed in one construction season.

Main and Lower Level Hatchery Parking Lots (Routes-900AZ & BZ) The Main Hatchery Parking Lot is an asphalt parking lot in fair condition, with observed oxidation, significant raveling, heaving, alligator cracking and rutting.

Ponding and depressions were observed adjacent to the storm drain inlets.

Localized portions should be repaired with full depth patching prior to pavement rehabilitation.

The Lower Level Hatchery Parking Lot is an asphalt parking lot intersecting the Lower Level Entrance Road. This asphalt parking lot is in fair to poor condition and has a history of significant ponding that occasionally floods nearby facilities.

The asphalt pavement is oxidized with a substantial amount of raveling, minimal rutting and alligator cracking.

Core P-8 performed within the Main Hatchery Parking lot, revealed 4 inches of asphalt concrete over aggregate base course. Cores P-6 and P-7 revealed 4.5 to 5 inches of asphalt concrete over aggregate base course within the Lower Level Hatchery Parking Lot.

Prior to rehabilitating the asphalt pavement within parking areas, cracks larger than ¼-inch would need to be cleaned and sealed. In addition, current patching around utility manholes and drainage inlets is deteriorating and should be repaired. Positive drainage should be achieved by leveling with multiple lifts of asphalt or preservation material. Finally, joint filler should be considered between concrete aprons (at building delivery bays) and the asphalt paved parking areas.

Fish Loading and Parking Lot (Route-800) Route 800 is primarily covered in gravel, with minor portions covered in asphalt concrete, near the building delivery bays. As builts indicate that the area was prepared by installing a polypropylene fabric across a prepared subgrade, compacting 12 inches of gravel, then capping with 8 inches of roadway gravel.

Boring B11 collaborates the as-built information revealing 2.5 feet of gravelly sand overlying filter fabric and reddish-brown clay with sand. The Fish Hatchery wants to pave this area to provide better support for delivery truck traffic and to reduce the maintenance efforts associated with the gravel roadway.

In addition, the existing roadway alignment will be redesigned to allot for the

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The gravel roadway was observed to be well maintained. We recommend minor surface preparation or road reconditioning prior to placing 4 inches of asphalt concrete in two equal lifts. Additional recommendations are provided in subsequent sections of this memo.

Recommended Pavement Treatments Prior to pavement rehabilitation, several pavement treatments are recommended to include crack sealing, full depth patching, and wedge and leveling.

Crack sealing should be performed for all cracks that measure ¼-inch up to 1-inch in width. Cracks wider than 1-inch should be filled. Most of the cracks observed were less than 1 inch, however, minimal quantities should be considered (approximately 10% of crack sealing quantity) for crack filling.

Clean, seal or fill cracks in accordance with Section 414 of FP-14 Specifications.

Crack sealing quantities per Route are as follows:

Route 10AZ – 1,000 linear feet (lnft) Route 10BZ – 1,100 lnft Route 900AZ - 500 lnft Route 900BZ – 275 lnft

Full depth asphalt patch, type 1 will be required in localized areas of the Main Hatchery Parking Lot and Lower Level Hatchery Parking Lot. At Full Depth Patch, Type 1 (FDP-1) locations, the asphalt and aggregate base course should be removed to a depth of 10 inches. Prior to the placement of aggregate, a separation and stabilization geotextile should be placed over the prepared subgrade. The recommended patch section is as follows:

Table 1. Full Depth Asphalt Patch, Type 1

Layer Minimum Thickness

(in)

Comments

Asphalt Surface Course

Asphalt Concrete Pavement – Gyratory Method (GACP), 0.3 to 3 x 106 ESAL’s, PG 58-34, ½” NMSA, Type IV roughness

Asphalt Tack Coat -- AC Tack Coat as per Section 412 of the FP-14 Specifications

Asphalt Base Course 2 GACP, 0.3 to 3 x 106 ESAL’s, ½”

NMSA

Aggregate Base Course

Base Aggregate, Grading C or D, as per Section 301 of the FP-14 Specifications

Geotextile --- Separation and Stabilization

Geotextile Class 2 – Type E, per

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Section 207 of FP-14 Specifications

A polymer modified (PG 58-34) asphalt binder is recommended to minimize future thermal cracking.

Patching will be required within the Main Hatchery Parking Lot around existing drainage inlets and within the Lower Level Hatchery Parking around utility manholes. An estimated 150 square feet of patching is estimated within Route 900AZ and 250 square feet within Route 900BZ.

Asphalt wedge and level course will be required in parking areas to achieve final grades; is estimated to total 5,000 square feet, and may extend up to 4 inches in thickness. Wedge and level course should be placed in maximum 3-inch lifts using the same asphalt concrete used for full depth asphalt, type 1 patching.

Recommended Pavement Rehabilitation Alternatives As discussed, we recommend that following localized pavement treatments, the roadways should be rehabilitated to extend the service life of the asphalt pavement. The rehabilitation options consist of:

1. Option 1 – Double Chip Seal

2. Option 2 – 1-½-inch Asphalt Overlay

3. Option 3 – Chip Seal Stress Absorbing Membrane Interface (SAMI), followed by a 1-½-inch asphalt overlay

The rehabilitation options are discussed in further detail below.

Option 1 – Double Chip Seal The existing roadway can be preserved for an additional 5 to 7 years of service life with a double chip seal application. This pavement preservation would be applied after completion of crack sealing and full depth patching.

Table 2. IRRI Road Rehabilitation Option 1 – Double Chip Seal

Minimum Thickness

Double Chip Seal 2B

0.75 Double Course Chip Seal Type 2B, per

Section 407 of the FP-14 Specifications, Table 407-2

Asphalt Tack Coat

AC Tack Coat as per Section 412 of the

FP-14 Specifications It should be noted, that reflective cracking may be noticeable in 2 to 3 years and additional crack sealing may be required within 5 years. In addition, chip seal applications are not recommended in parking lots and other tight areas where vehicles will be turning at slow speeds.

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Option 2 – Asphalt Overlay To potentially extend the service life of the pavement, we recommend placing a 1-½-inch asphalt overlay. A polymer modified (PG 58-34) asphalt binder is recommended to minimize future thermal cracking.

Table 3. IRRI Road Rehabilitation Option 2 – Asphalt Overlay

Minimum Thickness

1.5

Asphalt Concrete Pavement – Gyratory Method (GACP), 0.3 to 3 x 106 ESAL’s, PG 58-34, ½” Nominal

Maximum Size Aggregate (NMSA), Type IV roughness

Asphalt Tack Coat

AC Tack Coat as per Section 412 of the

FP-14 Specifications

This recommendation will provide a rehabilitated pavement surface and will minimize further saturation and degradation of the pavement subgrade, with a design life of approximately 10-15 years. However, reflective cracking will be noticeable in 2 to 3 years and additional crack sealing may be required within 5 years.

Option 3 – SAMI & Asphalt Overlay To potentially reduce the potential for reflective cracking, we recommend placing a Stress Absorbing Membrane Interface (SAMI), consisting of a chip seal, prior to placing an asphalt overlay in accordance with the following table.

Table 4. IRRI Road Rehabilitation Option III – SAMI & Asphalt Overlay

Minimum Thickness

1.5

Asphalt Concrete Pavement – Gyratory Method (GACP), 0.3 to 3 x 106 ESAL’s, PG 58-34, ½” Nominal

Maximum Size Aggregate (NMSA), Type IV roughness

Asphalt Tack Coat

AC Tack Coat as per Section 412 of the

FP-14 Specifications

Chip Seal 1B --- Single Course Chip Seal Type 1B, per

Section 407 of the FP-14 Specifications, Table 407-2

Asphalt Tack Coat

AC Tack Coat as per Section 412 of the

FP-14 Specifications This option will extend the service life of the pavement an additional 10 to 15

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New Construction and Construction Considerations Route 800 will be reconstructed as an asphalt paved loading dock, parking and drive. It is our understanding that the horizontal alignment for the roadway will be modified to allow for proper truck turning radius. This will involve grading and earthwork. To prepare the existing ground for new pavement, sod, topsoil and any other organic and deleterious materials should be removed, the ground compacted and scarified. The new pavement section should be constructed in accordance with Table 1. This will raise existing grades up to 10 inches. To reduce grade raise, we recommend removing existing surface material prior to construction.

During construction, the following items should be considered:

1. Crack sealing/filling should be performed at least 5 days, prior to chip seal or asphalt placement. To allow for proper adherence of tack coat, avoid over-banding of crack sealant during placement.

2. Care should be taken in placing asphalt along Route 10BZ (a.k.a. Route

302) where monitoring wells were observed within the asphalt pavement.

An extension collar will likely be required.

3. Care should be taken during construction of Route 800 around existing utilities and drainage inlets. An extension collar will likely be required.

Rerouting of utilities may be required.

Refer to attached map, photographs and summary table for more details.

Attachments:

Site Map Core Summary Table Boring Log B11 Project Photographs feet meters

Chris.Burnell Callout Rte 10AZ

Chris.Burnell Callout Rte 10BZ

Chris.Burnell Callout Rte 900AZ

Chris.Burnell Callout Rte 900BZ

Chris.Burnell Callout Rte 800

Core No. Latitude Longitude Route/Location Asphalt Thickness (inches) Notes

P-1 46.646333° -91.363430° Route 10AZ 6 intact core, drilling water retained in core hole

P-2 46.644805° -91.360545° Routes 10AZ/BZ

Intersection

1.5 + 3.0 + 0.5 = 5.0 broken core

P-3 46.643211° -91.357512° Route 10BZ 5.0 + 1.0 = 6.0 core broken during removal

P-4 46.642063° -91.357352° Residence Driveway not performed proposed location not included in project scope

P-5 46.642372° -91.358857° Route 10BZ 5 P-6 46.643128° -91.359867° Routes 10BZ/900BZ 4.5 P-7 46.643498° -91.359722° Route 900BZ 5

P-8 46.643752° -91.359432° Storage Bldg Access

Road

P-9 46.644152° -91.360235° Route 900AZ 3.0 + 1.0 = 4.0 core broken P-10 46.644183° -91.361738° Route10BZ 3.5

B11 46.645027° -91.362077° Route 800 NA 5-foot boring in gravel roadway, see boring log B11

Notes:

2) Asphalt thickness based on field observations.

Iron River National Fish Hatchery - IRRI 10(1)

1) Core locations are based on approximate latitude and longitude as depicted on Google Earth. Refer to location map for further details.

Summary of May 2018 Pavement Investigation

J-1

2.5

5.0

0.9 8-8-3-4

Red and brown with gray, dry to moist, poorly-graded, gravelly SAND, some silt.

Bore cave-in at 2.0 ft.

Reddish brown, wet, CLAY, with f-m sand. Filter fabric at top and bottom of clay.

Bottom of Bore at 5.0 ft.

(Blows / ft)

2.0 ft

2.0 ft

Groundwater Depth:

At Completion:

La ye r D ep th ft)

D ep th S ca le ft)

Completed:

Hole Diameter:

Boring Method:

Rock Core Diam:

Vane Shear

Density, Color, Plasticity, Size, Proportions, Moisture T yp e

Boring Location:

Boring No.:

MATERIAL DESCRIPTION

Liquid Limit

Standard Penetration Test Data

B11

Weather:

Operator:

Inspector:

R ec

SAMPLE

Iron River National Fish Hatchery

Iron River, Wisconsin hrs

B lo w s p e r in

Remarks:

G ra p h ic L o g

Auger Cuttings UD

30 in.

20 60 80

140 lbs/Auto

2.0 ft

3.0 in.

Caved at:

Hammer Drop:

Hammer Wt. & Type:

Surface Elevation: Boring Began: 5/20/18

SFA

NA

5/20/18 G. Moody

D. Hutchins clear, sunny

Project Name:

E le va tio n (f ee t)

Water Content % Plastic Limit

IRRI-0800 Fish Loading and Parking Lot

Sheet: 1 of 1

U. S. DEPARTMENT OF TRANSPORTATION

FEDERAL HIGHWAY ADMINISTRATION

EASTERN FEDERAL LANDS HIGHWAY DIVISION

BORING LOG

Bottom of Boring 5.0'

SPT Rock Core Penetrometer

N o.

Sample Types:

Encountered at:

After

Project Location:

B O

R

IN

G L

O G

IR

R I

(1

G

P J

F H

W A

_V A

.G D

T

6/

/1

Main Entrance Road– Route IRRI‐10AZ

(a)

(b) (c)

(d)

(a) Route 10AZ in June 2017 showing typical thermal cracking.

(b) Core hole P‐1 showing sidewalls and aggregate base course.

(c) Core P‐1 showing intact 6‐ inch asphalt pavement.

(d) Close up of typical temperature crack > ¼ inch.

Lower Entrance Road– Route IRRI‐10BZ

(b) (c)

(d)

(a) Route 10BZ in May 2018 showing typical conditions.

(b) Close up of core hole P‐3, showing sidewalls and aggregate base course.

(c) Core P‐3 showing intact 6‐inch asphalt concrete.

(d) Route 10BZ in May 2018 showing typical conditions.

Note observation well cover in bottom of photo (center of roadway).

Main Hatchery Parking Lot– Route IRRI‐900AZ

(b)

(c)

(a) Route 900AZ showing typical conditions in June 2017.

(b) 4‐inch asphalt pavement core P‐9.

(c) Route 900AZ showing typical conditions observed May 2018. Close up of pavement distress:

cracking, raveling, and delamination of surface treatment. Possible chip seal

Lower Level Hatchery Parking Lot– Route IRRI‐900BZ

(b)

(a) Route 900BZ looking west, showing typical conditions in May 2018.

(b) Route 900BZ looking east, showing typical conditions in May 2018.

(c) Close up of concrete pad shown in photo (b).

(d) Close up of patch deterioration adjacent to concrete pad shown in photos

(b) and (c).

(e) 5‐inch intact asphalt pavement core P‐7.

(c)

(d) (e)

Fish Loading and Parking Lot– Route IRRI‐800

(a) Route 800 looking south showing typical conditions.

(b) Route 800 showing area in front of fish loading bays.

(c) Route 800 gravel roadway and gravel stockpile in background.

(d) Note existing inlets within grass.

(e) Close up of gravel roadway and borehole B11.

(a) (b)

(c) (d)

(e)