October 15, 2019

Full Depth Reclamation Case StudiesEnhancing Quality of Life for All Texans

October 15, 2019

October 15, 2019

Challenges in San Antonio

2

October 15, 2019

Why consider FDR?

Less curing time

Traffic can be returned onto lane sooner

to minimize lane closures

Not prone to shrinkage cracking

Less susceptible to fatigue damage under

heavy loads

Flexible to bridge softer and expansive soils

Better resistance to moisture prior to sealing

3

October 15, 2019

Why consider FDR?

4

Dallam Sherman Hansford Ochiltree Lipscomb

Hartley Moore Roberts Hemphill

Oldham Potter Carson Gray Wheeler

Deaf Smith Randall Armstrong DonleyCollings-

worth

Parmer Castro Swisher Briscoe Hall

Bailey Lamb Hale Floyd Motley

Dickens King KnoxHockleyLubbock

Crosby

GarzaLynnTerryYoakum

Gaines Dawson Borden Scurry Fisher Jones

Kent StonewallHaskell Throck-morton

Baylor

WilbargerWichita

WICHITAFALLS

Clay

Archer

Young Jack

Howard Mitchell NolanTaylor

CallahanEastland

GlasscockSterling Coke Runnels

ReaganIrion

Cooke Grayson Fannin

Lamar

Delta

Red RiverPARIS

Bowie

Wise Denton Collin Hunt Hopkins

Rains Wood UpshurMarion

CassTitus

Mor

ris

CampATLANTA

HarrisonSmith

VanZandt

Henderson TYLERRusk Panola

AndersonCherokee

Freestone

DallasDALLAS

RockwallPalo Pinto

Parker Tarrant

Shelby

SabineHouston LUFKIN

Angelina

TylerPolk

Trinity

Jasp

er

New

ton

SanJacinto

Walker

Leon

Navarro

Ellis

Hardin

FORTWORTH

Erath

Hood Johnson

HillBosque

McLennanHamilton

Coryell

Bell

FallsWACO

RobertsonMadison

MilamBrazos

Grim

es

Burleson

BRYAN

WashingtonLee

AustinFayette

Harris

Montgomery LibertyBEAUMONT

Orange

Jefferson

ChambersHOUSTON

FortBend

Brazoria

Matagorda

Wharton

Colorado

LavacaGonzales

Dewitt

YOAKUM

JacksonVictoria

CalhounGoliad

Bee Refugio

Karnes

LiveOak

JimWells

SanPatricio

NuecesCORPUSCHRISTIKleberg

Kenedy

WillacyHidalgo

BrooksJimHogg

Zapata

Starr

PHARR

DuvalWebb

LAREDO

La SalleDimmit

Zavala Frio Atascosa

McMullen

Guadalupe

Wilson

Bexar

MedinaUvalde

Real Bandera

KerrKendall

Gillespie Blanco

KinneySAN

ANTONIO

Edwards

Sutton Kimble

Mason LlanoBurnet

Williamson

TravisAUSTIN

BastropHays

CaldwellComal

BrownComanche

BROWNWOOD

Coleman

MillsMc

Culloch San Saba LampasasConcho

Menard

SANANGELO

Schleicher

TomGreen

Andrews Martin

Midland

Pecos

Ector

CraneWard

WinklerLoving

Crockett

Val Verde

Upton

Terrell

ReevesCulberson

Jeff Davis

BrewsterPresidio

Hudspeth

El PasoEL PASO

ODESSA

LUBBOCK

AMARILLO

ABILENE

Cottle Foard

CHILDRESS

Fran

klin

Cameron

KerrKendall

Bandera

Uvalde Medina

Frio

McMullen

Atascosa

Bexar

Comal

Guadalupe

Wilson

$411M

$37M

$309M

$110M

$91M

$255M

$30M$40M

$49M

$208M$309M$111M

$1.96 BILLION

October 15, 2019

Why consider FDR?

5

Dallam Sherman Hansford Ochiltree Lipscomb

Hartley Moore Roberts Hemphill

Oldham Potter Carson Gray Wheeler

Deaf Smith Randall Armstrong DonleyCollings-

worth

Parmer Castro Swisher Briscoe Hall

Bailey Lamb Hale Floyd Motley

Dickens King KnoxHockleyLubbock

Crosby

GarzaLynnTerryYoakum

Gaines Dawson Borden Scurry Fisher Jones

Kent StonewallHaskell Throck-morton

Baylor

WilbargerWichita

WICHITAFALLS

Clay

Archer

Young Jack

Howard Mitchell NolanTaylor

CallahanEastland

GlasscockSterling Coke Runnels

ReaganIrion

Cooke Grayson Fannin

Lamar

Delta

Red RiverPARIS

Bowie

Wise Denton Collin Hunt Hopkins

Rains Wood UpshurMarion

CassTitus

Mor

ris

CampATLANTA

HarrisonSmith

VanZandt

Henderson TYLERRusk Panola

AndersonCherokee

Freestone

DallasDALLAS

RockwallPalo Pinto

Parker Tarrant

Shelby

SabineHouston LUFKIN

Angelina

TylerPolk

Trinity

Jasp

er

New

ton

SanJacinto

Walker

Leon

Navarro

Ellis

Hardin

FORTWORTH

Erath

Hood Johnson

HillBosque

McLennanHamilton

Coryell

Bell

FallsWACO

RobertsonMadison

MilamBrazos

Grim

es

Burleson

BRYAN

WashingtonLee

AustinFayette

Harris

Montgomery LibertyBEAUMONT

Orange

Jefferson

ChambersHOUSTON

FortBend

Brazoria

Matagorda

Wharton

Colorado

LavacaGonzales

Dewitt

YOAKUM

JacksonVictoria

CalhounGoliad

Bee Refugio

Karnes

LiveOak

JimWells

SanPatricio

NuecesCORPUSCHRISTIKleberg

Kenedy

WillacyHidalgo

BrooksJimHogg

Zapata

Starr

PHARR

DuvalWebb

LAREDO

La SalleDimmit

Zavala Frio Atascosa

McMullen

Guadalupe

Wilson

Bexar

MedinaUvalde

Real Bandera

KerrKendall

Gillespie Blanco

KinneySAN

ANTONIO

Edwards

Sutton Kimble

Mason LlanoBurnet

Williamson

TravisAUSTIN

BastropHays

CaldwellComal

BrownComanche

BROWNWOOD

Coleman

MillsMc

Culloch San Saba LampasasConcho

Menard

SANANGELO

Schleicher

TomGreen

Andrews Martin

Midland

Pecos

Ector

CraneWard

WinklerLoving

Crockett

Val Verde

Upton

Terrell

ReevesCulberson

Jeff Davis

BrewsterPresidio

Hudspeth

El PasoEL PASO

ODESSA

LUBBOCK

AMARILLO

ABILENE

Cottle Foard

CHILDRESS

Fran

klin

Cameron

KerrKendall

Bandera

Uvalde Medina

Frio

McMullen

Atascosa

Bexar

Comal

Guadalupe

Wilson

$411M

$37M

$309M

$110M

$91M

$255M

$30M$40M

$49M

$208M$309M$111M

$1.96 BILLION

FY 2020

FY 2021

FY 2022

FY 2023

FY 2024

FY 2025

FY 2026

FY 2027

FY 2028

FY 2019

10 YRTOTAL

$111M $110M $110M $111M $111M $112M $113M $114M $115M $125M $1.1B

October 15, 2019

San Antonio District Candidate Projects

6

FM2924, Atascosa County

FM0099, Atascosa County

FM1099, Atascosa County

FM0117, Frio County

FM0140, Frio County

SH0055, Uvalde County

1

2

3

4

5

6

October 15, 2019

Site/Soil Investigation

7

October 15, 2019

Site/Soil Investigation

8

PI MAP GYPSUM MAP

October 15, 2019

Falling Weight Deflectometer (FWD) & Ground Penetrating Radar (GPR)

9

October 15, 2019

Sampling

10

October 15, 2019

Atascosa County

11

FM 2924

FM 1099

FM 99

October 15, 2019

Atascosa County

12

FM 2924

FM 1099

FM 99

October 15, 2019

FM 2924, From FM 791 to FM 99 (Rehab & Widen)

13

Issues:

CTB was not extended under the pavement edge

Tri-Ax Geogrid used (4” to 8” deep)

Poor quality existing base

Very poor high PI subgrade (PI=20-65)

Very heavy loads

Traffic Data:

ADT: 1,200 (2020), 2,100 (2040)

% Trucks: 28.9%

% Tandem Axles in ATHWLD: 50

October 15, 2019

FM 99, From Karnes CL to Live Oak CL (Rehab & Widen)

14

Issues:

Poor quality existing base

Very poor high PI subgrade

Very heavy loads

Weak edges

1.5 miles of 8” HMA maintenance work already starting to fail

Traffic Data:

ADT: 2,300 (2020), 3,900 (2040)

% Trucks: 22.4%

% Tandem Axles in ATHWLD: 60

2015 2019

October 15, 2019

FM 1099, From US 281A to FM 99 (Rehab & Widen)

15

Issues:

Poor quality existing base ( PI 12-23)

Very poor high PI subgrade (PI 27-66)

Very heavy loads

Traffic Data:

ADT: 900 (2021), 1,600 (2041)

% Trucks: 29.6%

% Tandem Axles in ATHWLD: 60

October 15, 2019

Frio County

16

FM 140

FM 117IH 35

October 15, 2019

FM 140, Zavala/Frio County Line to IH 35 (Rehab & Widen)

17

Issues:

A lot of patching

Some deflections exceed 100 mils

Similar to an adjacent road (SH 85)

Subgrade PI 8-29

Existing base PI 19-24

Traffic Data:

ADT: Pending

% Trucks: Pending

% Tandem Axles in ATHWLD: Pending

October 15, 2019

FM 117, From Zavala County Line to CR 4614 (Rehab & Widen)

18

Issues:

Last 8 miles NB visually ok

First 8 miles have received a lot of work and are in poor shape, especially North of FM 1588

Thick HMA overlay around 5” badly cracking

Traffic Data:

ADT: 2,800 (2021), 4,900 (2041)

% Trucks: 23.4

% Tandem Axles in ATHWLD: 70

October 15, 2019

FM 117, From Zavala County Line to CR 4614 (Rehab & Widen)

19

Issues:

Last 8 miles NB visually ok

First 8 miles have received a lot of work and are in poor shape, especially North of FM 1588

Thick HMA overlay around 5” badly cracking

Traffic Data:

ADT: 2,800 (2021), 4,900 (2041)

% Trucks: 23.4

% Tandem Axles in ATHWLD: 70

October 15, 2019

Uvalde County

20

SH 55

October 15, 2019

SH 55, From Real/Uvalde CL to US 83 (Rehab Existing Road)

21

Issues:

Very long project broken up into 4 CSJs

Worst section is 2nd Section (between CR 412 and Nueces River)

Variable soils (PI 7-50)

GPR showed wet localized areas

Most areas don’t have ditches

Traffic Data:

ADT: 1,000 (2023), 1,300 (2043)

% Trucks: 19.6

% Tandem Axles in ATHWLD: 40

October 15, 2019

Cost Comparison – Atascosa County

22

HWY LENGTH (MILES)

PRELIMINARY ESTIMATE

TRADITIONAL PAVEMENT DESIGN OPTIONS

TRADITIONALCOST

FOAMEDASPHALT EMULSION CEMENT IN HOUSE

FM2924 4.134 $4,107,252

a. 6” LTS, 6” CTB, 6” Flex Base, 5” HMAb. 8” LTS, 8” Flex Base, 5” HMAc. 8” LTS, 10” HMAd. 12” HMA

a. $5.3Mb. $4.7Mc. $5.4Md. $4.5M

$1.7M $2.0M $1.3M $1.4M

FM0099 9.368 $10,113,632 a. 8” LTS, 8” Flex Base, 5” HMAb. 8” LTS, 10” HMA

a. $10.6Mb. $12.0M $3.9M $4.6M $2.9M $3.2M

FM1099 7.649 $8,599,465

a. 10” LTS, 6” Flex Base, 5” HMAb. 8” LTS, 10” HMAc. 17” HMAd. 12” Flex Base, 6” HMAe. 9” Exist Flex Base, 8” HMA

a. $6.8Mb. $9.0Mc. $13.4Md. $8.4Me. $7.1M

$2.8M $3.3M $1.9M $2.2M

Costs do not consider imported materials

October 15, 2019

Cost Comparison – Frio County

23

HWY LENGTH (MILES)

PRELIMINARY ESTIMATE

TRADITIONAL PAVEMENT DESIGN OPTIONS

TRADITIONALCOST

FOAMED ASPHALT EMULSION CEMENT IN HOUSE

FM0117 16.56 $15,057,683

a. 8” CT Sub, 8” Flex Base, 6”HMA

b. 8” CT Sub, 10” HMAc. 13” HMAd. 1.5” Exist Flex Base, 8.5” HMA

a. $12.9Mb. $14.8Mc. $16.6Md. $11.6M

$7.0M $8.3M $5.1M $5.7M

FM0140 21.192 $19,968,965 a. 7” Flex Base,6” HMAb. 8” CT, 6” HMA

a. $17.2Mb. $14.4M $8.8M $10.4M $6.4M $7.2M

Costs do not consider imported materials

October 15, 2019

Cost Comparison – Uvalde County

24

HWY LENGTH (MILES)

PRELIMINARY ESTIMATE

TRADITIONAL PAVEMENT DESIGN OPTIONS

TRADITIONALCOST

FOAMED ASPHALT EMULSION CEMENT IN HOUSE

SH0055 16.614 $21,487,901

a. 8” LTS, 8” Flex Base, 5” HMAb. 8” LTS, 10” HMAc. 12” HMAd. 8” Flex Base, 5” HMAe. 8” LTS, 12” HMAf. 8” LTS, 9.5” Flex Base, 4.5” HMAg. 11.5” Flex Base, 4.5” HMA

a. $23.0Mb. $26.0Mc. $22.1Md. $16.0Me. $28.9Mf. $23.1Mg. $18.0M

$8.6M $10.2M $6.2M $7.0M

SH0055 17.25 $24,494,472

a. 8” LTS, 8” Flex Base, 3” HMAb. 8” LTS, 10” HMAc. 12.5” HMA

a. $12.2Mb. $17.7Mc. $19.0M $8.7M $10.4M $6.3M $7.1M

Costs do not consider imported materials

October 15, 2019

Current Challenges & Opportunities

25

Challenges:

Several Resources

TxDOT Lab, MNT, MTD, TTI, Consultant Design, Consultant Geotech

Road widening

Very poor subgrades

Poor quality existing base

Very dynamic projects

Opportunities:

Several Resources

Provides another tool in our toolbox

Learning process for SAT & partners

October 15, 2019

Thank you and Questions

Texas Transportation Institute

TxDOT - Materials & Tests Division

TxDOT - Maintenance Division

TxDOT – SAT Atascosa County Maintenance

TxDOT – SAT Frio County Maintenance

TxDOT – SAT Uvalde County Maintenance

TxDOT – SAT Contract Management Office

26

Design Consultants

– Consor

– Halff

– HDR

– Kimley-Horn

– LJA

– Pape-Dawson

– Tedsi

Geotech Consultants

– Arias

– Corsair

– Terracon