RE: S.P (T.H. 210) in Crow Wing County Located on T.H. 210 from Brainerd (R.P ) to Ironton (R.P )

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1 District 3 Administration 7964 Industrial Park Road Baxter, MN Memo To: Dan Anderson Transportation District Engineer From: Scott Zeidler Senior Engineering Specialist Date: December 11, 2017 RE: S.P (T.H. 210) in Crow Wing County Located on T.H. 210 from Brainerd (R.P ) to Ironton (R.P ) DESIGN RECOMMENDATION REPORT Project Manager: Luke Wehseler Programmed Letting Date: March 22, 2019 Programmed Cost Estimate: $6,000, Chapter 3 Bonding Funds I. GENERAL PROJECT INFORMATION A. Project Scope This is a Full Depth Reclamation (FDR) project on T.H 210 from 710 ft East of Pine Shores Road NE in Brainerd (R.P ) to 1,155 ft East of Wood Lane Road in Ironton (R.P ). The existing roadway (mainline and turnlanes) in this area will be milled 4.5 followed by a 8 FDR. The mainline and turn lanes will then be paved with 5.5 of bituminous. The existing bituminous shoulder will be removed. The shoulder will be brought up with 1-2 of Shoulder Base Aggregate and then paved with 3.5 of bituminous. The Hydraulics Recommendation on file shows cleaning of some culverts and culvert aprons, tie joints, apron replacement and culvert replacement. The ride ability performance ratings have been slowly decreasing on this portion of T.H The travel lanes are experiencing some rutting and transverse & longitudinal cracking. This roadway is showing signs of premature stripping believed to be caused by a dry mix placed in The Surface Performance Ratings from R.P to are as follows: 1

2 R.P to R.P RQI SR PQI YEAR The primary goals of this project are to improve the ride and pavement quality and to reduce the number of required maintenance activities on this portion of T.H The project will also provide a 20 year anticipated fix for this segment of T.H Any changes made to the scope of this project that could affect this design recommendation shall be brought to the attention of the District Soils Engineer. This will ensure that any changes made after the submittal of this recommendation will be incorporated into the as-built version of this document. 2

3 B. Project Background Information 1. Existing Conditions RP to R.P Functional Class Rural Principal Arterial Driving Lane Width Two 12 Bituminous Lanes Shoulder Width 8 Bituminous Posted Speed 60 MPH 2. Construction History R.P to R.P Year SP Number Work Type Width Depth Grading 40 NA Aggregate Base Bituminous Surface Bituminous Overlay Bituminous Overlay Mill Bituminous Bituminous Overlay R.P to R.P Year SP Number Work Type Width Depth Grading 65 NA Aggregate Base Bituminous Surface Bituminous Overlay Bituminous Overlay Mill Bituminous Bituminous Overlay Mill Bituminous Bituminous Overlay Traffic Data & Analysis Gerry Buscher from the District 3 Materials Office developed a detailed traffic forecast for the project. This section of TH 210 has projected AADT volumes for 2019 of 11,940. For design purposes, it has been assumed that the 2019 and 2039 AADT volumes are 11,940 and 14,610 respectively. Based on the 20-year projected AADT, the Bituminous Equivalent Single Axle Load (BESAL) forecast used for bituminous design is 3,278,000. For this same section, the 20-year projected Concrete Equivalent Single Axle Load (CESAL) forecast is 5,075,000. The report (Forecast No. F3-1715) was approved by the Traffic Forecasting and Analysis Unit on October 2, The report is available for review at the District 3 Materials Office in Baxter and in Projectwise. 3

4 C. Soils Information Existing Grading Material MnDOT auger crews from the Baxter office completed soil borings and made field classifications of the soils encountered within the project limits. The borings indicate that the in place sub-soils vary greatly and fall into the textural classification categories of Sand & Gravel (S & G), Loamy Sand & Gravel (LS & G), Sand (S), Sand & Fine Gravel (S & FG), Loamy Sand (LS), Sandy Loam slightly plastic (SL slpl), and Loam (L). An assumed R-Value of 30 was used for design purposes. This R-Value was based on soil classifications made by the auger crew. D. Pavement Field Data Deflection Measurements R.P to R.P Deflection measurement (FWD) data for this section of roadway was obtained in The data indicates the roadway is structurally sound, as the 85 th percentile was rated 10-ton or greater. Core Data (Bituminous Depths) T.H. 210 Location Range of Depths Average Depths Mainline Shoulder Turn Lanes Structurally speaking, mainline in-place depths of competent bituminous will allow for a 4.5 milling and 8 FDR. The mainline cores taken indicate minimal stripping of the bituminous. 4

5 E. Project Analysis As per the MNDOT Pavement Design Manual, a Life Cycle Cost Analysis (LCCA) was performed on this project. Three designs were analyzed for this project and included the following: 1) 4.5 Mill (Mainline & Turn Lanes), 8 FDR (Mainline & Turn Lanes) with 5.5 HMA (Mainline & Turnlanes) and 3.5 HMA (Shoulders). 2) 7 PCC mainline with 3 HMA (Shoulders). 3) 4.5 Mill (Mainline and Turn Lanes) with 6 White-Topping (Mainline and Turn Lanes) and 3 HMA (Shoulder). Upon running the LCCA, it was determined that the low cost option was the the 4.5 Mill (Mainline & Turn Lanes), 8 FDR (Mainline & Turn Lanes) with 5.5 HMA (Mainline & Turnlanes) and 3.5 HMA (Shoulders). The 7 PCC with 3 HMA shoulders was determined to be 151% of the low cost option and the 6.5 White-Topping (Mainline and Turn Lanes) and 3 HMA (Shoulder) was determined to be 174% of the low cost option. A hard copy of the LCCA is available for review in the District 3A Materials Office and in Projectwise. II. DESIGN RECOMMENDATIONS A. Removal, Salvage & Disposal Existing Structures All culvert sections, aprons and miscellaneous structures that are removed may be recycled in accordance with applicable MnDOT Specifications. Materials not utilized on the project will become the property of the Contractor and shall be disposed of outside the right-of-way in accordance with Specification C, unless specifically detailed otherwise in the plan and provisions. 5

6 Pavements Existing concrete and bituminous pavements that need to be removed may be recycled in accordance with applicable MnDOT Specifications. Materials not utilized on the project will become the property of the Contractor and shall be disposed of outside the right-of-way in accordance with Specification C. Topsoil In accordance with Specification D, the existing topsoil in any disturbed areas shall be salvaged and subsequently placed on any disturbed areas following the completion of the grading operations. Existing topsoil has an average depth of 5 and ranges from 3.6 to 6.0. B. Excavation & Embankment Construction Grading Soil Definitions See the MNDOT Spec. Book for Grading Soil Definitions Grading Grade The grading grade is hereby defined as the bottom of the Class 6 Aggregate Base. Embankment and Backfill Material Placement Where connecting to intersecting roads and at the project termini, cut vertically to the bottom of the proposed surfacing design, then at a 1(V):4(H) taper to the bottom of the subgrade excavation. To ensure consistency and compaction of grading material, provide for a sub-cut as shown in the typical sections, at all grading locations and backfill with Select Granular Material. Shrinkage Factors The shrinkage factors of 110% and 130% shall be used for materials taken from the existing highway embankment and imported borrow materials, respectively. Compaction Requirements All embankment material shall be compacted as required by the Penetration Index Method except for specific portions of the embankment as described in Mn/DOT Specification C. Pavement Structure Aggregate Base Compaction Requirements Compaction of the Class 6 Aggregate Base shall be obtained by the Penetration Index Method in accordance with Mn/DOT Specification C3 except for the bottom 3 which shall be compacted in accordance with the Quality Compaction Method. Bituminous Surfacing Recommendations All bituminous mixtures shall meet the requirements of the most current version of the 2360 Plant Mixed Asphalt Pavement Specifications and shall be constructed as indicated in the pavement design sections below. Full Depth Reclamation Compaction Requirements 6

7 Compaction of the Full Depth Reclamation material shall be in accordance with Mn/DOT Standard Spec B.7. Maximum lift thickness shall be modified to allow for an 8 maximum depth of reclaimed material. Mainline TH 210 Sta to Sta Sta to Sta Location, Material Thickness Mix Design Mill Bituminous (Mainline & Turn Lanes) 4.5 NA Full Depth Reclamation (Mainline & 8.0 NA Turn Lanes) Superpave Wear (Mainline & 3.5 SPWEA440F Turn Lanes) Superpave Non-Wear (Mainline & 2.0 SPNWB430B Turn Lanes) Shoulder Base Aggregate-(Shoulder) Var. CL. 6 Superpave Wear (Shoulder) 3.5 SPWEB230C 7

8 Mainline TH 210 Sta to Sta Location, Material Thickness Mix Design Mill Bituminous (Mainline & Turn Lanes) 4.5 NA Full Depth Reclamation (Mainline & 8.0 NA Turn Lanes) Superpave Wear (Mainline & 3.5 SPWEA440F Turn Lanes) Superpave Non-Wear (Mainline & 2.0 SPNWB430B Turn Lanes) Shoulder Base Aggregate-(Shoulder) Var. CL. 6 Superpave Wear (Shoulder) 3.5 SPWEB230C 8

9 Temporary Widening Location, Material Thickness Mix Design Remove Existing Shoulder Pavement 4.0 NA Superpave Wear (Temp. Widening) 5.0 SPWEB340B Aggregate Base Cl. 6 - (Temp. Widening) 8.0 CL. 6 Select Granular Subcut (Temp. Widening) 15.0 Select Granular 9

10 Mainline TH 210 Culvert Replacement Locations Location R.P R.P

11 D. Miscellaneous Bituminous and Shouldering Items Bituminous Items Pavement smoothness will be evaluated using IRI Equation A contained in the latest version of Special Provision D. The compaction of all bituminous mixture placed shall be subject to the requirements of Mn/DOT Specification D.1 Maximum Density. Special Provision (2016) Quality Management-Paver Mounted Thermal Profile (PMTP) Method will be required on this project. Special Provision (2016) Quality Management Special-Intelligent Compaction (IC) Method will be required on this project for the bituminous layer only. Special Provision (2360) Plant Mixed Asphalt Pavement (MSCR) and (3151) Bituminous Material (MSCR) will be required on this project. Prior to any bituminous surfacing, a bituminous tack coat shall be applied to existing bituminous surfaces and between all bituminous lifts. Application rates shall be in accordance with Section 2357 Bituminous Tack Coat of The Standard Specifications for Construction 2016 Edition. Safety Edge The contractor shall construct a Safety Edge where required and in accordance with Technical Memorandum No T-01. Aggregate Surfacing Special The Aggregate Surfacing Special shall be modified such that it consists of 100% bituminous millings from the project. The only gradation requirement is that 100% must pass the 1½ sieve and % must pass the 1 sieve. The material shall be free from clumps when placing on the shoulder. This may require screening and/or crushing before placement. If millings need to be imported to meet the established grade-line and cross-section prior to millings being available from this project, the millings shall consist of 100% salvaged bituminous material (which meets the above gradation requirements, has a minimum bitumen content of 4.0%, and is approved by the Engineer). If millings are not available, Aggregate Surfacing Class 1 Modified shall be utilized instead of Aggregate Surfacing Special. Compaction of the Aggregate Surfacing Special shall be in accordance with Mn/DOT Specification C Quality Compaction Method. The Aggregate Surfacing Special shall be compacted until there is no further evidence of consolidation using a pneumatic-tired roller. There will be no minimum moisture content requirement at the time of placement and compaction of the Aggregate Surfacing Special. Following the placement of the Aggregate Surfacing Special, a bituminous material for shoulder tack shall be applied to a width of 3 and in accordance with Special Provision (2357) Bituminous Material for Shoulder Tack. 11

12 E. Aggregate and Borrow Source The following MNDOT owned Aggregate Source is available for this project. SHPO clearance was obtained on November 2, Pit # Owner County Legal Description Material Available MN/DOT Crow Wing NW ¼, SE ¼ of Sec. 30 T45N R29W Aggregate, Borrow cc: G. Engstrom MS 645 T. Andersen/S. Henrichs MS 645 J. Garrity MS 645 P. Merchlewicz MS 692 T. Swanson MS 692 C. Puttbrese Baxter D. Nelson Baxter B. Miller Baxter T. Grater/T. Highum Baxter J. Hukriede Baxter L. Wehseler Baxter T. Hughes Baxter T. Dumont St. Cloud 12