Bonded Asphalt Concrete Friction Course

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Bonded Asphalt Concrete Friction Course
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Where are BFCs used?

• Over PCC or asphalt pavements
• 50 of projects over PCC, 50 over asphalt
• Preventive maintenance
• Ex Protecting joints, sealing the pavement
• Corrective maintenance
• Ex Frictional characteristics
• Surface for new pavements
• Ex Perpetual pavement, sacrificial surface, Curb
  Gutter areas for Cities Counties

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A Little History. . .

• 1988 - First Trial in France
• 1992 - Introduced in U.S
• 1992 - Projects in TX AL
• 1993 - Projects in NJ PA
• 1993-97 - Projects in Northeast
• 1998 - Process adapted spread throughout U.S.

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States with Bonded Friction Course Surfaces
Over 125,000,000 yd2 in U.S.
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FDOT UF Evaluation of Thick Open Graded and
Bonded Friction Courses for Florida

• 2002 US 27, Highlands County
• 6.2 Mile Section to study Raveling, Rutting,
  Cracking Permeability.
• Modified binders improve tensile strength
• The presence of a bonded polymer-modified tack
  coat appears to improve both the cracking and
  rutting resistance of friction course mixtures.

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Who has used it in Florida?

• Counties
• Alachua County
• Bay County
• Escambia County
• Hillsborough County
• Lake County
• Okaloosa County
• Orange County
• State DOTs
• Districts 1,2,5,7 have used BACFC
• District 2 I-10 project bid in July
• Turnpike project bids in July 08
• Districts 1,2,4 have projects in design

Kings Avenue, Hillsborough County 2003
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Why Polymer Modified Emulsion?

• Controls migration into mix
• Superior bonding
• Allows 1-inch or less lifts without delamination
• Seals existing pavement
• Prevents water intrusion

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What are the Application Rates?

• Emulsion membrane
• 0.13 - 0.3 gal/yd2
• Typically 0.20 gal/yd2
• BFC hot mix asphalt overlay
• FC-5 Mix

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The Process
The emulsion membrane wicks up around the HMA
aggregates
The emulsion cures, bonding the mix pavement
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The Process
Click to run video clip
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Spray Bar distributing Emulsion Membrane
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HMA Applied Directly Behind Spray Bar
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Uniform Coating of Emulsion Membrane
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Roller Directly Behind Spray Paver
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Roller Operator Directly Behind Spray Paver
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Paving System - Equipment
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Midland Paver
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RoadTec Paver
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Vogele Paver
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Spray Paver Features

• Ultrathin mat,
• 60-100 ft/min
• No traffic on emulsion
• Uniform application of emulsion

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Pavement Preparation

• Clean pavement
• Seal existing cracks ¼ inch
• Dont overfill
• Fill surface deformities ½ inch deep
• Protect manhole covers, drains, etc.
• Standard Paving Procedures

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BFC Features

• Fast paving, 4-6 lane miles/day
• Quick release to traffic
• thin lift with emulsion membrane cools quickly
• Bonds to existing
• pavement
• 4X binder vs tack
• Cost effective (life
• cycle cost)
• 2-3 additional years

US 281 San Antonio, TX after 12 years
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Bonded Friction CourseSurface Over Reconstruction

• I-35, north of Albert Lea, MN
• Seals and protects construction joints

Cracks forming in unprotected construction joint
on adjacent highway without BFC
Centerline construction joint protected by BFC
seal
I-35 after 2½ years
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Night Paving
San Antonio, Texas
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I-20/59 Birmingham, AL160,000 ADT
After 3 years
Before surfacing
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Other Benefits

• Protects pavement
• Seals out water
• Resists wear rutting
• Thin lift retains clearances, curbs
• Fast construction reduces user delays
• Night construction
• Lower life cycle costs

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What Support does SemMaterials Offer?

• Technical Marketing Support
• Field Engineering On-Site
• Mix Design Support
• Pre-Con Meetings / Quality Workshops
• Workshops to Educate on the Process
• Facilitate/ Support Contractors wanting to enter
  the Spray Applied Business

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Where?Site Selection Guidelines over Asphalt
Pavements

• Structurally sound pavement
• Rut depth
• Minor to moderate severity transverse
  longitudinal cracking
• Minor to moderate severity patches bleeding
• Raveling polished aggregate to high severity

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Where?Site Selection Guidelines over PCC

• Structurally sound pavement
• Low severity D cracking
• Minor to moderate transverse longitudinal
  cracking
• Minor to moderate severity corner breaks
• Minor to moderate severity joint spalling
• Map cracking
• Faulting
• No blowups, water bleeding or pumping

I-40 North Carolina
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Project SelectionPoor Candidates
High severity alligator cracking
High severity block cracking
High severity D cracking
Rutting
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Other BFC Mixes

• Process open to other mix types
• PFC - Permeable/porous friction course (TX)
• Wet process crumb rubber open graded mixes (FL)
• FC-5 PG 76-22 (FL)
• Terminal blend crumb rubber open graded and gap
  graded mixes (CA)

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Summary
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Thank you.
Stephan Romanchak Account Manager sromanchak_at_semgr
ouplp.com Cell 727-748-5310
Jeff Butt Account Manager jbutt_at_semgrouplp.com Cel
l 813-777-4181
Robert Basgall Account Manager rbasgall_at_semgrouplp
.com
Ivann Harnish Field Engineer iharnish_at_semgrouplp.c
om
SR 26 Gainesville, FL