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FHWA/TX-86/5l+359-3F
. Title ond Subtitle 5. Report Oate
October 1985
IMPLEMENTATION MANUAL FOR THE RAPID REPAIR
6. Performing Orgoni I.tion Code
OF WET ASPHALTIC CONCRETE
7. Author") 8. Performing Orgonilation Report No.
David Cherem-Sacal, David A. Price, Brian Osterndorf,
Research Report 359-3F
Alvin H. Meyer, and David W. Fowler
9. Performinll Organization N_e and Addre .. 10. Wo," Unit No.
19. S~curity Clalli f. (of "'I. report) 20. Socurltv CI.llff. (of thi. poool 21. No. of Pooe. 22. Prlc.
by
David Cherem-Sacal
David A. Price
Brian Osterndorf
Alvin H. Meyer
David W. Fowler
conducted for
by the
Center for Transportation Research
Bureau of Engineering Research
The University of Texas at Austin
October 1985
The contents of this report reflect the views of the
authors, who are responsible for the facts and the
accuracy of the data presented herein. Ihe contents
do not necessarily reflect the official views or
policies of the Federal Highway Administration. This
report does not constitute a standard, specification,
or regulation.
ii
PREFACE
iii
ABSTRACT
v
SUMMARY
vii
IMPLEMENTATION STATEMENT
ix
TABLE OF CONTENTS
Chapter Page
1 INTRODUCTION 1
1.1 The Pothole Problem. 1
2 MATERIALS 3
2.1 Background 3
2.2 Fly Ash 3
2.3 Commercial Asphalt Materials 4
xi
CHAPTER 1
INTRODUCTION
1
2
2.1 Background
During periods of wet and cold weather special
materials for making rapid repairs in asphalt must be
used. The material implemented in this report include
class C fly ash and three commercially available products.
3
4
2.3.1 Descriptions
The descriptions of the materials are taken from
the literature provided by the manufacturers.
2.3.2 Costs
Quantities of these three materials were
purchased for the purposes of beginning testing. Due to
the small quantities required, the products were purchased
in 5-gallon pails. Larger scale use of these materials
would require purchases of larger unit quantities for ease
of storage/stockpile and reduce unit costs. Table 2.1
presents price and quantity information, current as of
February 14, 1985.
TABLE 2.1 QUru~TITY/PRICE DATA (AS OF FEBRUARY 14, 1985)
...
N
Instant Road Repair 5 gallon (50 lb.) pall less than 10 pails: $15.00 each $ .)0
Distributor: 10 or more pails: $13.75 each .28
Safety lights Co.
Houston, Texas 55 gallon (667 lb.) drum I-l drums: $180.00 each .27
4 or more drums: $166.75 each .25
8ulk -- 1n hopper
FOB at factory
2000 lb. .25
6000 lb. .24
-.J
I liquid asphalt binder is available separately to districts desiring to use their own aggregates and to do their own batching.
CHAPTER 3
RESEARCH RESULTS - LAB
3.1 Background
This chapter contains the results of the formal
lab research, Le., that part of the investigations in
which the material origins are known. The testing
procedures followed the guidelines of ASTM except where
noted otherwise.
All of the fly ash initially tested came from
three plants in Texas located near the cities of San
Antonio, Amarillo, and Cason. After different kinds of
fly ash were examined, this portion of the research
centered around finding the optimum ratios of fly ash,
sand, coarse aggregate and water. Finally, different
additives to fly ash were investigated to see if fly ash
could be further improved as a road repair material.
In regard to the commercial repair materials, two
principal characteristics of a repair material were
selected as representative of how well the material
performs. First, the material should be "strong" in its
own right. It should be able to withstand expected
traffic loads. Also, the repair and this pavement should
behave as one unit: a repaired area subjected to wheel
loads should respond as an integral part of the
surrounding pavement. A repaired area that is more or
less rigid than the surrounding original pavement will
deform differently under the wheel load, accelerating
failure along the interface of the two materials. A
repair material with poor adhesive qualities, that does
not form a strong bond with the original pavement is that
9
10
~
til
AVERAGE *SCALED (1-10)
<:
...... COST 1 00 3.33
c:::
t.Ll
l-
S
..... WORKING TIME 3.15 4.75
"'0" CURING TIME 2.58 5.70
til
u
..... EASE OF HIX, PLACE, FINISH 3.55 4.08
I-
til
......
c::: PERFORMANCE 1.25 7.92
t:J
I-
U
~ COLOR 5.94 0.10
<:
U
200
I
'<ii
a.
-
J:!
0)
c
Q)
150
J:::a
en
a:I
'-
:::J 100
x
.m
u..
50
....
w
Fig. 3.1 Comparison of the of Deely Fly Ash at Different Temperatures
......
~
-
en
~ 400
~
(!J
Z
I.aJ
a: 300
I-
en
..J
a:
::l 200
)(
I.aJ
..J
b..
100
TIME
5000
I
VI
-
0..
:J:
I-
4000-
(,!)
Z
W
0::
t; 3000
w
>
(I)
fJ)
w 2000-
0:
0..
::E
0
u
1000
TIME
.....
Ul
Welch #2 r77777J
Welch #3 VHH/LHD..!
Deely
6000 3" x 6" Cylinders
Tested at 72 F
~ 5000 Age = 7 days
rn
rn
...
~
CI)
4000
Q)
.>
rn
3000
rn
Q)
E 2000
~
o
()
1000
o
1:0 1:1 1:2 2:1
Fly Ash: Sand Ratio, by Volume
Sto 1000
...E
.1 .2 .4 .5 .6 .7
Water : Fly Ash Ratio
1 :1 2: 1 1 :2
Fly Ash : Sand Ratio
'"a... ,
A Age - 12 days
500 ., 'v/Without Fibers
......'"'"
I ,
Q) I \
400 I \
rn }
...
Q) I
\
\
..0 300 I \
u::
,:.
I \
Q) \
E 200 \
...
...><
Q) J
I
\
\ With Fiber
100
W
Q2 %
Fig. 3.9 Fly ash mixed with various ratios (by weight)
of iron oxide compared to the cylinder of
asphalt concrete on the right
27
en 4000
a.
~
en
en
Q)
~ 3000C-~~-----:----------~
Q)
>
en
en
Q)
L.- 2000
a.
E
o
(,)
1000
o 1 2 3
Parts Coarse Aggregate
en 5000
a.
~
en
en 4000
CD
....
~
en 1:1:2
CD 3000
.-en> ~1:2:2
en
CD
~
2000
a.
E
0
() 1000
o ~--~----~--~----~----~--~----~-
.1 .2 .3 .4 .5 .6 .7
Water/Fly Ash Ratio, by Volume
Fig. 3.11 The Optimal Water - to - Fly Ash Ratio for
different ingredient ratios of Welch Fly Ash
32
-
CD
'-
CJ)
CD
2000
>
(J)
en
CD 1000
'-
0.
E
0
0
1 4 12 24
Time, hours
en
. 6000
en
...
(J)
..... 5000
en
(J) 4000
.:::en 3000
en
...a.
(J)
2000
E
0 1000
U
1 7 28
Time. days
w
-..J
38
Uncorrected Average
Uncorrected Average Average Corrected
Specimen Test Condition Stabl1 ity Flow Stabil ity Flow Stability
015 39
39
Uncorrected Average
Uncorrected Average Average Corrected
Specimen Test Condition Stabi I ity Flow Stabil ity Flow Stabi'ity
S4 9 Day Cure,
S5 Room Temperature 655 14.0 712.5 14.3 612.8
S6 765 14.6
015 ItO
40
Average Average
Uncorrected Uncorrected Average Corrected
Material Stabil tty Flow Stabtl tty Flow Stabtl tty
Trafftx 40.0
30.0 4.8 25.5 5.1 21.9
6.5 5.4
015 Itl
42
3.3.2.2 Strength
Instant Road Repair consistently yielded higher
values of strength and stability under all test conditions
than the other two repair materials. The SDHPT
requirement for stability for bituminous materials is 750
pounds for use on moderate volume roads, and 1,500 pounds
for high volume roads. Due to the different manner in
which the stability tests were conducted on the repair
materials (the SDHPT criteria changes are based on tests
conducted at 140 o F), direct comparisons of measured
stabilities with these requirements are not applicable.
The materials become stronger with increased cure
time at room temperature. The result indicate the Traffix
increases in strength at a rate greater than the other
two. The stability of Sylvax increases appreciably within
the first few days of increased cure time but remains
relatively unaffected by further increases in cure time.
The effect of water on the repair materials is
clearly different for each of the three materials. The
stability of Instant Road Repair decreased when specimens
43
Test
Material Condition Loads at Failure (lb) Mean S
Instant Road Repair Dry 56. 29, 49. 61, 44, 32 45.2 12.80
Instant Road Repair Wet 39, 45, 49. 52. 42. 25 42.0 9.55
015 ....
45
47
48
4.3 Cost
Fly ash in general is very inexpensive when
compared with other repair materials. A major portion of
the cost is for shipping. For this reason, it is
recommended that the fly ash obtained from the Welch plant
be used.
The three commercial products can be more easily
differentiated between in terms of cost than in terms of
effectiveness. Traffix is the most expensive of these
products. Moreover, Traffix is not available in bulk
quantity and storage would present a problem.
Instant Road Repair is more moderately priced and
is available in bulk. However, its sole distribution
point is located in Houston, remote from the regions in
Texas that most experience the adverse weather conditions
that justify the expense of these products.
50
51
TABLE 5.1 RATIO OF INGREDIENTS DATA U1
N
Fig. 5.1 The loose material is first swept from the base
of the pothole
57
Fig- 5.8 The material is hard, before the water has even
evaporated from ~he surrounding road surface
64
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