80 kN ESAL calculation Work Sheet Version 3.

1 4-18-03 Updated 05/10/2006 kaw This work sheet is used for the purpose of calculating the 80 kN ESAL using the "simple" method. These calculations were taken from Figure 4-1 of the NYS Comprehensive Pavement Design Manual (June 2000). Enter the parameters for items 1 through 8 below in the blue blocks. The 80 kN ESAL count is calculated based on a compound traffic growth rate and should be used for SUPERPAVE. Enter data also in pavt. thickness sheet. Print this sheet + pavt thickness + item numbers + special note. P.IN. #: Project Desc.: (cont'd.) Date: 1234.56 Project Name XXXX County Rev'd - 7/8/09 Mainline and Ramp Reconstruction 2010 50 2500 70.0 50 100 1.35 2.00% 0.50% 34

INPUT PARAMETERS: Construction Year Design Life (use 50 years for determining pavement thickness) 1. 2. Projected Construction Year AADT 3. Percent Heavy Trucks Class 4 or greater 4. Percent Trucks in Design Direction 5. Percent Trucks in Design Lane 6. Truck Equivalency Factor (avg. ESAL per truck) 7. Truck Volume Growth Rate 8. Annual Truck Weight Growth Rate Mr Value 08 YES NO NO NO NO NO Enter the Functional Classification Code of the highway Does this road have full or partial access control? Is there a possibility of damaging homes, historic sites, etc., due to excessive vibration during compaction. Will there will be less than 2000 MT of each course placed? Is the highway located in either Dutchess, Orange, Rockland, Putnam, Westchester, Nassau, Suffolk, Sullivan County or the City of New York? Is the highway located in either Orange, Rockland, Putnam, Westchester, Nassau, Suffolk CountIes or the City of New York? Are there are more than 3 lanes on this road?

Partial

Rens. County

RESULTS:
AADT for Design Year 2060 Use asphalt series for low volume roads. 44,651,609 6,597

Total 80 kN ESAL Count for the Design Life

The 'Estimated Traffic' level should be < 100.0 million 80 Kn ESALs.

***** Don't forget the SPECIAL NOTE required in the Proposal *****

PAVEMENT THICKNESS TABLE enter blue numbers TOTAL ESAL VALUE Total HMA Thickness SELECT GRANULAR SUBGRADE (enter # from table at right) mm 150 44,651,609 250 mm GRAVEL mm 300 BASE mm 145 enter number from table at right BINDER mm 65 TOP mm 40 80 Kn ESALs Total HMA Thickness over Design Life millions mm <4 165 4-7 175 > 7 - 13 200 > 13 - 23 225 > 23 - 40 250 > 40 - 70 250 > 70 - 130 250 > 130 - 235 250 > 235 - 300 250 Select Granular Subgrade Thickness mm 0 0 0 0 0 150 300 450 600

ACTUAL PAVEMENT THICKNESSES TO USE THICKNESS 150 mm 300 mm 150 mm 65 mm 40 mm

SELECT GRANULAR SUBGRADE GRAVEL BASE BINDER TOP

80 kN ESAL calculation Work Sheet Version 3 3-28-02 This work sheet is used for the purpose of calculating the 80 kN ESAL using the "simple" method. These calculations were taken from Figure 4-1 of the NYS Comprehensive Pavement Design Manual (June 2000). The 80 kN ESAL count is calculated based on a compound traffic growth rate and should be used for SUPERPAVE. P.IN. #: Project Description: Date: INPUT PARAMETERS: Construction Completion Year 1. Design Life (years) 2. Initial AADT 3. Percent Heavy Trucks Class 5 or greater 4. Percent Trucks in Design Direction 5. Percent Trucks in Design Lane 6. Truck Equivalency Factor (avg. ESAL per truck) 7. Truck Volume Growth Rate 8. Annual Truck Weight Growth Rate #N/A This road has full or partial access control. There is no possibility of damaging homes, historic sites, etc., due to excessive vibration during compaction. There will be more than 2000 MT of each course placed. ESALS are greater than 0.3 million. The highway is not located in either Dutchess, Orange, Rockland, Putnam, Westchester, Nassau, Suffolk, Sullivan County or the City of New York? There are less than 4 lanes on this road. 1234.56 Project Name Rev'd - 7/8/09

2010 20 2500 70 50 100 1.35 2.00% 0.50%

RESULTS: AADT for Design Year 2030 3,642

Use asphalt series for low volume roads. 11,119,144

Total 80 kN ESAL Count for the Design Life

The 'Estimated Traffic' level should be < 30.0 million 80 Kn ESALs.

Recommended SUPERPAVE Item number TOP: 402.125201 M BINDER: 402.255901 M BASE: 402.376901 M Confirm with the Regional Materials Engineer Remember to add the appropriate Quality Payment Items

***** Don't forget the SPECIAL NOTE required in the Proposal *****

SPECIAL NOTE
ATTENTION
SUPERPAVE HOT MIX ASPHALT, 12.5 mm / 25.0 mm, NOMINAL MAX. SIZE The Contractor should be aware that this is a performance-related specification in which the Contractor is responsible for compacting the pavement within a specified density range. In order to successfully compact the pavement to the specified density range, the Contractor must be prepared to select, operate, and control the paving and compaction equipment, to monitor the results, and to make necessary adjustments (without direction from the Engineer) to achieve the desired results. Written instructions for determining pavement density and core locations are available from the Regional Materials Engineer or the Director, Materials Bureau. The Performance Graded asphalt binder used in the production of SUPERPAVE Hot Mix Asphalt mixtures shall be a PG 64-28 as defined by AASHTO Provisional Standard MP1 - Standard Specification for Performance Graded Asphalt Binder. The mixtures designs should be developed in accordance with the criteria specified in the SUPERPAVE Hot Mix Asphalt Items that is appropriate for an "Estimated Traffic" level of <30 "Million 80 kN ESALs". Under no circumstances shall the Performance Graded Binder content be less than 5.6% for a 9.5 mm design, less than 5.0% for a 12.5 mm design, less than 4.3% for a 19.0 mm design or less than 4.0% for a 25.0 mm design. When crushed gravel is to be used in the production of SUPERPAVE Hot Mix Asphalt mixtures, the minimum percent of crushed particles shall be as follows: for particle sizes greater than 12.5 mm, 75% one crushed face; for particle sizes between 12.5 mm and 2.36 mm, 85% two crushed faces.

SUPERPAVE Item Num

Reference to Mixture Nominal Max Aggregate Size 37 = 37.5 mm Base Course 25 = 25.0 mm Binder Course (for use when ESALs > 3 million) 19 = 19.0 mm Binder Course (for use when ESALs < 3 million) 19 = 19.0 mm Binder Course (for use when ESALs between 3 - 10 million) 12 = 12.5 mm Top Course 09 = 9.5 mm Top Course

402 .
Reference to Standard Specifications Sub-Section Reference to Construction Details Compaction Requirements 5 - Daily Coring with Payment Adjustments (HD) 6 - Nuclear Gauge Monitoring with Core Verification (RA) 7 - Nuclear Gauge Monitoring only (Standard) 8 - Miscellaneous Items (T & L, Optional Flexible Shoulders, Pavement Shoulder Course)

VE Item Number Descriptions

Reference to the Coarse Aggregate Friction Requirement

1 - F1 Aggregates for use on Downstate High Volume Pavements (> 8,000 AADT on 2 or 3 lane and > 13,000 on 4 or more lanes) 2 - F2 Aggregates for use on Upstate High Volume Pavements (> 8,000 AADT on 2 or 3 lane and > 13,000 on 4 or more lanes) 3 - F3 Aggregates for use on Low Volume Pavements (< 8,000 AADT on 2 or 3 lane and < 13,000 on 4 or more lanes) 9 - F9 - No Friction Requirement - For Base, Binder, and T & L Courses

XX

R
Revision Number Currently 1

Reference to Quality Adjustment Items 0 - Specified HMA Item (Core Item) 1 - Plant Production Quality Adjustment 2 - Pavement Density Quality Adjustment 3 - Longitudinal Joint Density Quality Adjustment 4 - Pavement Smoothness Quality Adjustment

houlder Course)

or more lanes)

or more lanes)

or more lanes) T & L Courses

M
Metric Spec.

y Adjustment y Quality Adjustment Quality Adjustment

FUNCTIONAL CLASSIFICATION

RURAL Functional Classification Code 1 2 6 7 8 9 Functional Classification Code 11 12 14 16 17 19

Description Principal Arterial - Interstate Principal Arterial - Other Minor Arterial Major Collector Minor Collector Local

CATION

URBAN

Description Principal Arterial - Interstate Principal Arterial - Expressway Principal Arterial - Other Minor Arterial Collector Local

ROADWAY INFORMATION 8 01 02 06 07 08 09 11 12 14 16 17 19 0 has is no more is not yes no no no This road will have full or partial access control. There is a possibility of damaging homes, historic sites, etc., due to excessive vibration during compaction. There will be less than 2000 MT of each course placed. The highway is located in either Dutchess, Orange, Rockland, Putnam, Westchester, Nassau, Suffolk, Sullivan county or the City of New York. There are more than 3 lanes on this road.

#N/A

01 - Rural Principal Arterial - In 02 - Rural Principal Arterial - O 06 - Rural Minor Arterial 07 - Rural Major Collector 08 - Rural Minor Collector 09 - Rural Local 11 - Urban Principal Arterial - I 12 - Urban Principal Arterial - E 14 - Urban Principal Arterial - O 16 - Urban Minor Arterial 17 - Urban Collector 19 - Urban Local

less than 4

no

3,642 no

Design Year AADT Hi Volume?

11,119,144

Total 80 kN ESAL Count for Design Life

PAVEMENT TYPE SECTION 402 XX TOP BINDER BASE A 5 5 6 B 2 9 9

50 YEAR PAVEMENT THICKNESS SHEET QUALIFIERS

80 Kn ESALs over Design Life millions <2 2-4 >4-8 > 8 - 13 > 13 - 23 > 23 - 45 > 45 - 80 > 80 - 140 > 140 - 300

TABLE A Mr = 28 Mpa Total HMA Thickness mm 165 175 200 225 250 250 250 250 250 TABLE C Mr = 41 Mpa Total HMA Thickness mm 165 175 200 225 250 250 250 250

Select Granular Subgrade Thickness mm 0 0 0 0 0 150 300 450 600

80 Kn ESALs over Design Life millions <4 4-7 > 7 - 13 > 13 - 23 > 23 - 40 > 40 - 70 > 70 - 130 > 130 - 235 > 235 - 300

80 Kn ESALs over Design Life millions <6 6 - 11 > 11 - 20 > 20 - 35 > 35 - 60 > 60 - 110 > 110 - 200 > 200 - 300

Select Granular Subgrade Thickness mm 0 0 0 0 0 150 300 450

80 Kn ESALs over Design Life millions <8 8 - 16 > 16 - 30 > 30 - 50 > 50 - 85 > 85 - 160 > 160 - 300

80 Kn ESALs over Design Life millions < 12 12 - 20 > 20 - 40 > 40 - 65 > 65 - 115 > 115 - 215 > 215 - 300

TABLE E Mr = 55 Mpa Total HMA Thickness mm 165 175 200 225 250 250 250

Select Granular Subgrade Thickness mm 0 0 0 0 0 150 300

80 Kn ESALs over Design Life millions < 15 15 - 30 > 30 - 50 > 50 - 90 > 90 - 150 > 150 - 300

SPECIAL NOTE SECTION 64-28 64-28

Rural Principal Arterial - Interstate Rural Principal Arterial - Other Rural Minor Arterial Rural Major Collector Rural Minor Collector

Urban Principal Arterial - Interstate Urban Principal Arterial - Expressway Urban Principal Arterial - Other Urban Minor Arterial Urban Collector

Yes Yes No

storic sites, etc.,

range, Rockland, ullivan county

PAVEMENT AGGREGATE SIZE 402 XX TOP BINDER BASE XX 12 25 37

TABLE B Mr = 34 Mpa Total HMA Thickness mm 165 175 200 225 250 250 250 250 250 TABLE D Mr = 48 Mpa Total HMA Thickness mm 165 175 200 225 250 250 250

Select Granular Subgrade Thickness mm 0 0 0 0 0 150 300 450 600

Select Granular Subgrade Thickness mm 0 0 0 0 0 150 300

TABLE F Mr = 62 Mpa Total HMA Thickness mm 165 175 200 225 250 250

Select Granular Subgrade Thickness mm 0 0 0 0 0 150

<30

FHWA VEHICLE CLASSIFICATION

Vehicle Class Number 1 2 3 4 5 6 7 8 9 10 11 12 13

Description Motorcycles Passenger cars Other two-axle, four-tire single-unit vehicles Buses Two-axle, six-tire single-unit trucks Three-axle single-unit trucks Four-or-more-axle single-unit trucks Four-or-less-axle single-trailer trucks Five-axle single-trailer trucks Six-or-more-axle single-trailer trucks Five-or-less-axle multi-trailer trucks Six-axle multi-trailer trucks Seven-or-more-axle multi-trailer trucks

Sample