Beneficial Use of Coal Combustion By By-Products Products in the Rehabilitation of Failed Asphalt Pavements

William Wolfe, Willi W lf Tarunjit T ji Butalia, B li Harold H ld Walker W lk Alexis Semach, James Howdyshell, Rachael Pasini The Ohio State University

Objective

Demonstrate effective use of Class F fly y ash in combination with lime or lime kiln dust ( (LKD) ) in Full Depth p Reclamation of asphalt pavements.

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Full Depth p Reclamation (FDR) ( )

FDR is a flexible pavement reclamation process. The full pavement section (wearing ( g surface, base / subbase, and a p pre-determined p portion of underlying soil) is uniformly pulverized, blended with chemical additives (e.g. cement, fly ash, lime, emulsion) and compacted to construct a new stabilized base. An asphalt overlay can then be placed. Short Sh t of f conventional ti l re-construction, t ti FDR i is only l cost-effective t ff ti pavement t rehabilitation procedure that corrects base and subbase problems.
Construction Instrumentation Monitoring Conclusions

Introduction

Coal Use Facts

Nationally: 52% of Electricity is Generated by Combustion of Coal 1.1 Billion Tons were consumed in 2005.

State of Ohio: 90% of Ohios Electricity is Generated by Combustion of Coal Coal Use: 30 Million Tons/Yr. (Ohio Coal) 30 Million Tons/Yr. (Non-Ohio Coal)

1.5 Tons of Coal Combustion By-products generated in Ohio / Person / Yr.

Construction Instrumentation Monitoring Conclusions

Introduction

Coal Fired Fly Ash Generating Power Plants

25 mile radius Introduction Construction Instrumentation Monitoring Conclusions

Role of Fly Ash in FDR Work

Fly ash provides Silica and Alumina needed for cementious reaction with lime to increase strength strength, stiffness, and durability of stabilized base layer. Fly ash act as mineral filler to fill the voids in the granular pulverized pavement mix, thus reducing permeability of the FDR stabilized layer.

Introduction

Construction

Instrumentation

Monitoring

Conclusions

2006 FDR Sites

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Section Line Rd. Station Layout D l Delaware C County t

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Delaware County Pavement Sections (4.1 miles) ( )

Nine sections constructed using the following six mixes:
Station 1: 2% Cement with 1.6 1 6 gallons per square yard emulsion emulsion, , 8 inch stabilization depth (0.3 mile) Station 2: 5% Cement Cement, , 12 inch stabilization depth (0.8 mile) Station 3: 3% Lime Kiln Dust with 1.4 gallons per square yard emulsion emulsion, , 8 inch stabilization depth (0.7 mile) Station 4: 5 inch Mill and Fill (Two 0 0.1 1 mile sections at the north and south ends of the project, and a 0.7 mile as well as 0.1 mile sections near the middle of the project) Station 5 5: 5% Lime Kiln D Dust st with ith 5% Fly Fl Ash Ash, , 8 inch stabili stabilization ation depth (0.6 mile) Station 6: 4% Lime with 6% Fly Ash, Ash, 8 inch stabilization depth (0.7 mile)
Introduction Construction Instrumentation Monitoring Conclusions

Long Spurling Rd. Station Layout Warren County

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Warren County Pavement Sections (0.4 miles)

Station 1: 5 inch Mill and Fill (0.08 mile) Station 2: 4% Lime with 6% Fly Ash, Ash, 12 inch stabilization depth (0.32 mile)

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Pavement Instrumentation Plan

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Asphalt overlaying on South bound lanes of Section Line Road

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Delaware Pavements February 12, 2009

Section 1: Cement + Emulsion

Section 2: Cement

Section 3: LKD + Emulsion

Section 4: Control (Mill & Fill)

Section 5: Fly Ash + LKD

Section 6: Fly Ash + Lime

Delaware Pavements February 12, 2009

Section 1: Cement + Emulsion

Section 2: Cement

Section 3: LKD + Emulsion

Section 4: Control (Mill & Fill)

Section 5: Fly Ash + LKD

Section 6: Fly Ash + Lime

Falling g Weight g Deflectometer (FWD) ( ) Testing g by y Ohio DOT

Delaware site before f FDR

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Falling Weight Deflectometer (FWD) Testing Dates

Delaware County Section Line Rd Rd. July 10, 2006 Pre-Reclamation October 26, 2006 April 25, 2007 July y 30, , 2007 October 22, 2007 April 9, 2008 July 21, 2008 September 25, 2008

Warren County Long Spurling Rd. July 11 11, 2006 Pre-Reclamation Pre Reclamation September 5, 2006 November 21, 2006 April 17, 2007 July 3, 2007 October 16, 2007 April 8, 2008 July 22, 2008 September 16, 2008

Introduction

Instrumentation

Monitoring

Conclusions

Sensor Data Collection Dates

Delaware County Section Line Rd. November, 2006 December, 2006 January, 2007 March, 2007 May, 2007 June, 2007 July, 2007 October, 2007 April, 2008 July, y 2008 September, 2008

Warren County y Long g Spurling p g Rd. December, 2006 January, 2007 March, 2007 April, 2007 June, , 2007 July, 2007 October, 2007 April, 2008 July, 2008 September, 2008

Introduction

Instrumentation

Monitoring

Conclusions

Average Backcalculated Moduli of FDR Layer from FWD Testing (Delaware County)
1600
07/06 - Before FDR 10/06 - 3 Weeks 04/07 - 7 Months 07/07 - 10 Months 10/07 - 13 Months 04/08 - 19 Months 07/08 - 22 Months 09/08 - 24 Months

1400

Elastic Modu E ulus of base l layer (ksi)

1200

Open graded cement stabilized aggregate

1000

800
Soil cement

600

400

Lime stabilized soils or unstabilized dense

200

0 S1, Cement + Emulsion S2, Cement S3, LKD + Emulsion S4, Control S5, LKD + fly ash S6, Lime + fly ash

Section
Typical Resilient Modulus values (Mechanistic Empirical Pavement Design Guide 2004, FHWA) Outlying data points removed

Average Backcalculated Moduli of FDR Layer from FWD Testing (Warren County)
1600

Elastic Modulus of f base layer r (ksi)

1400 1200 1000 800

Soil cement

Open graded cement stabilized aggregate

07/06 - Before FDR 09/06 - 3 Weeks after FDR 11/06 - 3 Months 04/07 - 8 Months 07/07 - 11 Months 10/07 - 14 Months 04/08 - 20 Months 07/08 - 23 Months 09/08 - 25 Months

600 400 200 0

Lime stabilized soils or unstabilized dense graded aggregate

S2, fly ash and lime

Section

S1, control

Typical Resilient Modulus values (Mechanistic Empirical Pavement Design Guide 2004, FHWA) Outlying data points were removed

Longitudinal Strain Data from Delaware County 12/06 45 mph

0.00008 0 00007 0.00007 0.00006 0.00005

Longit tudinal Strain

Station 1 - Cement & Emulsion Station 2 - Cement Station 3 - LKD & Emulsion Station 4 - Control Station 5 - LKD & Fly Ash Station 6 - Lime & Fly Ash

0.00004 0.00003 0.00002 0.00001 0 0 -0.00001

2 sec) Ti Time (10-2 )

850

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Transverse Strain Data from Delaware County 12/06 45 mph

0.00009
Station 1 - Cement & Emulsion Station 2 - Cement Station 3 - LKD & Emulsion Station 4 - Control Station 5 - LKD & Fly Ash Station 6 - Lime & Fly Ash

0.00007

0.00005
Tran nsverse Strain

0.00003

0.00001

-0.00001

700

-0.00003 Time (10-2 sec)

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Structural Layer Coefficients

D l Delaware C County t -S Section ti Li Line Rd. Rd Section 1
Cement & Emulsion

2
Cement

3
LKD & Emulsion

4
Mill & Fill

5
LKD & Fly Ash

6
Lime & Fly Ash

Date 07/06 Before FDR 10/06 3 Weeks 04/07 7 months 07/07 10 months 10/07 13 months 04/08 19 months 07/08 22 months 09/08 24 months

MR (psi) 10,173 364,033 276 630 276,630 188,288 375,183 272,050 187,438 309,406

ai 0.10 0.32 0 29 0.29 0.26 0.32 0.29 0.26 0.30

MR (psi) 5,900 755,692 818 369 818,369 922,125 886,315 937,500 935,938 1,232,625

ai 0.08 0.41 0 42 0.42 0.44 0.43 0.44 0.44 0.48

MR (psi) 22,598 251,896 271 244 271,244 247,354 459,375 343,125 194,027 310,292

ai 0.13 0.28 0 29 0.29 0.28 0.35 0.32 0.26 0.31

MR (psi) 14,174 61,306 36 309 36,309 11,559 58,785 51,809 27,529 70,803

ai 0.11 0.18 0 15 0.15 0.10 0.18 0.17 0.14 0.19

MR (psi) 9,029 477,772 476 889 476,889 810,037 948,722 699,152 517,047 834,750

ai 0.09 0.35 0 35 0.35 0.42 0.44 0.40 0.36 0.42

MR (psi) 17,785 205,180 301 933 301,933 767,857 1,154,670 536,025 854,833 1,014,972

ai 0.12 0.27 0 30 0.30 0.41 0.47 0.37 0.43 0.45

AASHTO: ai = 0.14*(MR/30,000)1/3

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Structural Layer Coefficients

Source: Pavement Analysis and Design, 2nd ed., Yang H. Huang

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Structural Layer Coefficients

Warren County - Long Spurling Rd. Section 1
Mill & Fill

2
Lime & Fly Ash

Date 07/06 Before FDR 09/06 3 Weeks 11/06 3 months 04/07 8 months 07/07 11 months 10/07 14 months 04/08 20 months 07/08 23 months 09/08 25 months

MR (psi) 7,408 4,966 24,063 16,725 4,827 6,331 27 104 27,104 7,789 17,416

ai 0.09 0.08 0.13 0.12 0.08 0.08 0 14 0.14 0.09 0.12

MR (psi) 3,124 494,545 744,513 223,695 564,059 1,742,470 620 975 620,975 546,037 898,196

ai 0.07 0.36 0.41 0.27 0.37 0.54 0 38 0.38 0.37 0.43 AASHTO: ai = 0.14*(MR/30,000)1/3

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Delaware County - Structural Layer Coefficients

0.5

0.4 Structural l Layer Coeffic cient (ai)

Sec. 1 - Cement & Emulsion

0.3

Sec. 2 - Cement Sec. 3 - LKD & Emulsion Sec. 4 - Mill & Fill Sec. 5 - LKD & Fly Ash Sec. 6 - Lime & Fly Ash

02 0.2

0.1

0 0 6 12 18 24 30 Months After Construction

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Warren County - Structural Layer Coefficients

0.6

0.5 Structural l Layer Coeffic cient (ai)

0.4

0.3

Sec. 1 - Mill & Fill Sec. 2 - Lime & Fly Ash

0.2

01 0.1

0 0 6 12 18 24 30 Months After Construction

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Environmental Objectives j
Demonstrate CCPs can be incorporated into FDR mixes in an environmentally sound manner manner.
Characterize environmental properties for various mixes
Elemental composition TCLP/SPLP Leachate Warren County Delaware County

Field Monitoring

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Analysis y Techniques q
Inductively Coupled Plasma Atomic Emissions Spectrometry (ICP)
Analytes: Al Al, Ba Ba, Ca Ca, Cd Cd, Cr Cr, Cu Cu, Fe Fe, Pb Pb, K K, Mg Mg, Mn Mn, Mo Mo, Ni Ni, Si Si, Na Na, Sr, S, Zn

Graphite Furnace Atomic Absorption Spectrometry (GFAAS)

Analytes: As, As Se

Cold Vapor Atomic Absorption Spectrometry (CVAAS)

Analyte: Hg

Ion Chromatography C ( (IC) C)

Analytes: SO42-, Cl- and NO3-

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Toxicity Characteristic Leaching Procedure Data

Warren County
Analyte Arsenic (Limit=5.0 mg/L) Cadmium (Limit=1.0 (Li it 1 0 mg/L) /L) Chromium (Limit=5.0 mg/L) Lead (Limit=5.0 mg/L) Mercury (Limit=0.2 mg/L) Selenium (Limit=1.0 mg/L) CCP 0.015 Control 0.002 Section 1 0.003

Delaware County
Section 3
0.014

Section 5
0.004

Section 6 0.006

BDL

BDL

BDL

BDL

BDL

BDL

BDL

BDL

BDL

BDL

BDL

BDL

0.028

0.045

ND

ND

ND

ND

<0.001

<0.001

<0.001

<0.001

<0.001

<0.001

0.005

0.003

0.004

0.014

0.004

0.003

All values given in units of mg/L. BDL= Below Detection Limit ND= Not Determined

Limits = Hazardous Waste Limit

Synthetic Precipitation Leaching Procedure Data

Warren County Analyte Arsenic (Limit=5.0 mg/L) Cadmium (Limit=1.0 (Li it 1 0 mg/L) /L) Chromium (Limit=5.0 mg/L) Lead (Limit=5.0 mg/L) Mercury (Limit=0.2 mg/L) Selenium (Limit=1.0 mg/L) CCP <0.001 Control 0.002 Delaware County Section 1 Section 6 <0.001 <0.001

BDL

BDL

BDL

BDL

BDL

BDL

BDL

BDL

0.032

ND

ND

ND

<0.001

<0.001

<0.001

<0.001

<0.001

<0.001

<0.001

<0.001

All values given in units of mg/L. BDL= Below Detection Limit ND= Not Determined

Limits = Hazardous Waste Limit

Field Sampling Results

Site W Warren Control C t l Warren CCP Section Delaware #1 Delaware #2 Delaware #3 Delaware #4 Delaware #5 Delaware #6
Introduction Construction

Samples Obtained 5 1 3 0 3 2 0 0
Instrumentation

Trips 12 12 13 7 13 13 7 13
Monitoring Conclusions

Warren County Sampling Data

Analyte Arsenic Cadmium Chromium Lead Mercury Selenium EPA MCL 0.010 0.005 0.100 0.015 0 002 0.002 0.050 CCP Section 0.002 BDL BDL BDL <0 001 <0.001 BDL Control <0.001 BDL BDL BDL <0 001 <0.001 <0.001

All data given in units of mg/L. Maximum values obtained over the course of sampling. BDL= Below Detection Limit ND= Not Determined

MCL = Maximum Contaminant Level

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Delaware County Sampling Data

Analyte
Arsenic Cadmium Chromium Lead Mercury Selenium

EPA MCL
0.010 0.005 0.100 0.015 0 002 0.002 0.050

Section 1
0.020 BDL 0.020 BDL <0 001 <0.001 0.001

Section 2
-

Section 3
0.003 BDL BDL BDL <0 001 <0.001 0.002

Section 4
<0.001 BDL BDL BDL <0 001 <0.001 <0.001

Section 5
0.002 <0.001

Section 6
0.003 <0.001

All data given in units of mg/L. Maximum values obtained over the course of sampling. Sections 2, 5, and 6 never produced enough water to do all the analysis procedures. BDL= Below Detection Limit ND= Not Determined MCL = Maximum Contaminant Level

Runoff Data: Warren/Delaware County

Warren County Delaware County

Analyte y
Arsenic Cadmium Chromium Lead Mercury y Selenium

EPA MCL
0.010 0.005 0.100 0.015 0.002 0.050

CCP
-

Control
0.001 BDL BDL ND <0.001 <0.001

Section 1
-

Section 2
-

Section 3
0.001 BDL BDL ND <0.001 <0.001

Section 4
<0.001 BDL BDL ND <0.001 <0.001

Section 5
0.003 BDL BDL ND <0.001 <0.001

Section 6
0.014 BDL BDL ND <0.001 0.001

All values given in units of mg/L. Maximum values obtained over the course of sampling. BDL= Below Detection Limit ND= Not Determined MCL = Maximum Contaminant Level

Conclusions
Pavement sections stabilized with fly ash (+LKD/lime) showed comparable stiffness and strength to the cement stabilized sections after 2 years of monitoring. The use of fly ash (with LKD or lime) as substitute for traditional additives can result in substantial cost savings as well as additional significant environmental benefits Fly ash can be easily mixed and compacted using standard FDR construction equipment Longer-term testing data are still necessary

Introduction

Construction

Instrumentation

Monitoring

Conclusions

Acknowledgements
Ohio Coal Development Office / Ohio Air Quality Development Authority D l Delaware C County t E Engineers i Office Offi Warren County Engineer's Office Ohio DOT Base Construction Fly Ash Direct Headwater Resources Carmeuse NA Mintek Resources EDP Consultants Asphalt Recycling and Reclamation Association American Coal Ash Association