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Innovative Alternatives to Paving: Day County's Successful Road Rehabilitation Methods

Mr. Chuck Fromelt, Day County Highway Superintendent, discusses two effective methods for road rehabilitation in South Dakota. The first method involves recycling old pavements, enhancing the base with new aggregates, and applying Otta Seal surfacing, sometimes using geotextiles. The second approach reshapes existing roads into unpaved "RAP Roads" by adding virgin gravel and establishing a crown. The presentation highlights three specific projects showcasing these methods, emphasizing the importance of surface treatment and cost-effectiveness in maintaining rural roads.

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Innovative Alternatives to Paving: Day County's Successful Road Rehabilitation Methods

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  1. Success with Alternatives to Paving Mr. Chuck Fromelt Day County Highway Superintendent Webster, South Dakota

  2. Two Methods • Recycle old blotters or pavements, add virgin base aggregate, and place Otta Seal surfacing. Sometimes a geotextile (fabric) is used for base improvement. • Recycle old blotters or pavements, add virgin gravel, reshape and compact the surface, establish 4% crown, and treat it as an unpaved road – we call the “RAP Roads”.

  3. Three Examples • Day County Rd 12– Rural Major Collector Classification with ADT at 150 – recycled and rehabilitated with an Otta Seal/Cutback Seal. • Day County Rd 4 – Rural Major Collector Classification with ADT ranging from 500 to 600 – same as above, but 1.75 inch overlay placed over past two years. • Day County Rd 12-A – Rural Road Classification with ADT at 50 – recycled, reshaped, one inch of virgin gravel added, is now a “RAP Road”.

  4. Base repair is critical where needed:

  5. Day County Rds 12 and 12-A – Recycle Process Virgin base course added on roadway prior to recycling.

  6. Recycle Process (Con’t)

  7. Finishing base – extremely important for surface seals

  8. Surfacing: Initial surface on an Otta Seal is a very heavy coat of high float emulsion covered by clean, crushed, coarse 5/8 minus aggregate.There is no prime coat.

  9. Initial surface is very coarse, but durable. A second shot of cut-back asphalt and 3/8 minus pea stone provides a good driving surface.

  10. Final surface – thickness approx one inch

  11. Oil and Aggregate Rates • Co Rd 12 (first seven miles) – • 2.5 inches of virgin base aggregate added. • First shot of oil: HFMS-2S shot at .48 gal per sqyd • Second shot was MC 3000 shot at .30 gal per sqyd • Co Rd 12 (next five miles) – • 2.5 inches of virgin base aggregate added. • First shot of oil: MC-800 shot at .35 gal per sqyd • Second shot will be MC-3000 shot at .3 gal per sqyd

  12. Oil and Aggregate Rates (con’t) • Co Rd 4 (entire 12 mile section) • Built on 10 inches of virgin base on new grade • First shot of oil: HFMS-2S shot at .48 gal per sqyd • Second shot: MC-3000 shot at .30 per sqyd • Initial construction in 2008, entire 12 miles was overlayed with 1.75 in of hot-mixed asphalt (five miles in 2011, seven in 2012)

  13. Co Rd 12-A Condition prior to rehabilitation

  14. Virgin gravel added prior to recycling

  15. Reclaiming process and reshape

  16. Finished section in bottom of slide – work continues at top

  17. Recently performed for three weeks in harvest with 200 trucks per day! No blade maintenance done to date. Finished surface – very tightly bound “RAP Road”

  18. Before and After

  19. Aggregate added and process • Co Rd 12- A five mile section • One inch of virgin gravel added • Reshape to unpaved road crown at 4% • Aggressive use of water and compaction • No further work done

  20. We have previous experience with this: turn-back from asphalt to gravel in 2007 here. It has performed well.

  21. Cost Data • Co Rd #12 (2012) • Add 2.5 inch base course - 25 mile haul • Mill, shape, compact • $18,414/mile • (2009) Otta seal • 5/8" Clean crushed aggregate • HFMS-2S • $19,174/mile • Chip seal • 3/8" pearock • MC-800 • $20,215/mile

  22. Cost Data (con’t) • Co Rd #04 • (2008) Otta seal • $18,609/mile • (2012) 1.75 inch Asphalt Overlay • $122,000/mile • MC 3000 Chip Seal 2012 Avg Cost • #15,000/mile

  23. Cost Data (con’t) • Co Rd #12A (2012) • Add 1.5 inch base course - 40 mile haul • Mill, shape, compact • $19,524/mile

  24. Thank You

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