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. #: 1234.56 Project Desc.: Project Name (cont'd.) XXXX County Date: Rev'd - 7/8/09 Mainline and Ramp Reconstruction INPUT PARAMETERS: Construction Year 2010 1. Design Life (use 50 years for determining pavement thickness) 50 2. Projected Construction Year AADT 2500 3. Percent Heavy Trucks Class 4 or greater 70.0 4. Percent Trucks in Design Direction 50 5. Percent Trucks in Design Lane 100 6. Truck Equivalency Factor (avg. ESAL per truck) 1.35 7. Truck Volume Growth Rate 2.00% 8. Annual Truck Weight Growth Rate 0.50% Mr Value 34 08 Enter the Functional Classification Code of the highway YES Does this road have full or partial access control? Partial NO Is there a possibility of damaging homes, historic sites, etc., due to excessive vibration during compaction. NO Will there will be less than 2000 MT of each course placed? NO Is the highway located in either Dutchess, Orange, Rockland, Putnam, Westchester, Nassau, Suffolk, Sullivan County or the City of New York? Rens. County NO Is the highway located in either Orange, Rockland, Putnam, Westchester, Nassau, Suffolk CountIes or the City of New York? NO Are there are more than 3 lanes on this road? RESULTS: AADT for Design Year 2060 6,597 Use asphalt series for low volume roads. Total 80 kN ESAL Count for the Design Life 44,651,609 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 44,651,609 Total HMA Thickness 250 mm enter number from table at right SELECT GRANULAR SUBGRADE GRAVEL BASE BINDER TOP (enter # from table at right) 80 Kn ESALs Total HMA Thickness Select Granular Subgrade mm mm mm mm mm over Design Life Thickness 150 300 145 65 40 millions mm mm < 4 165 0 4 - 7 175 0 ACTUAL PAVEMENT THICKNESSES TO USE > 7 - 13 200 0 > 13 - 23 225 0 THICKNESS > 23 - 40 250 0 SELECT GRANULAR SUBGRADE 150 mm > 40 - 70 250 150 GRAVEL 300 mm > 70 - 130 250 300 BASE 150 mm > 130 - 235 250 450 BINDER 65 mm > 235 - 300 250 600 TOP 40 mm 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. #: 1234.56 Project Description: Project Name Date: Rev'd - 7/8/09 INPUT PARAMETERS: Construction Completion Year 2010 1. Design Life (years) 20 2. Initial AADT 2500 3. Percent Heavy Trucks Class 5 or greater 70 4. Percent Trucks in Design Direction 50 5. Percent Trucks in Design Lane 100 6. Truck Equivalency Factor (avg. ESAL per truck) 1.35 7. Truck Volume Growth Rate 2.00% 8. Annual Truck Weight Growth Rate 0.50% #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. RESULTS: AADT for Design Year 2030 3,642 Use asphalt series for low volume roads. Total 80 kN ESAL Count for the Design Life 11,119,144 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 ***** 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. SPECIAL NOTE ATTENTION SUPERPAVE Item Number Descriptions 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) SUPERPAVE 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 Y Z Q 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 8 - Miscellaneous Items (T & L, Optional Flexible Shoulders, Pavement Shoulder Course) 4 - Pavement Smoothness Quality Adjustment (> 8,000 AADT on 2 or 3 lane and > 13,000 on 4 or more lanes) (> 8,000 AADT on 2 or 3 lane and > 13,000 on 4 or more lanes) (< 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 M Metric Spec. 2 - Pavement Density Quality Adjustment 3 - Longitudinal Joint Density Quality Adjustment 4 - Pavement Smoothness Quality Adjustment FUNCTIONAL CLASSIFICATION RURAL Functional Functional Classification Classification Code Description Code 1 Principal Arterial - Interstate 11 2 Principal Arterial - Other 12 6 Minor Arterial 14 7 Major Collector 16 8 Minor Collector 17 9 Local 19 FUNCTIONAL CLASSIFICATION URBAN Description Principal Arterial - Interstate Principal Arterial - Expressway Principal Arterial - Other Minor Arterial Collector Local ROADWAY INFORMATION 8 01 01 - Rural Principal Arterial - Interstate 02 02 - Rural Principal Arterial - Other 06 06 - Rural Minor Arterial 07 07 - Rural Major Collector 08 08 - Rural Minor Collector 09 09 - Rural Local #N/A 11 11 - Urban Principal Arterial - Interstate 12 12 - Urban Principal Arterial - Expressway 14 14 - Urban Principal Arterial - Other 16 16 - Urban Minor Arterial 17 17 - Urban Collector 19 19 - Urban Local 0 has yes This road will have full or partial access control. is no no There is a possibility of damaging homes, historic sites, etc., due to excessive vibration during compaction. more no There will be less than 2000 MT of each course placed. is not no The highway is located in either Dutchess, Orange, Rockland, Putnam, Westchester, Nassau, Suffolk, Sullivan county or the City of New York. less than 4 no There are more than 3 lanes on this road. 3,642 Design Year AADT no Hi Volume? 11,119,144 Total 80 kN ESAL Count for Design Life PAVEMENT TYPE SECTION 402 XX A B TOP 5 2 BINDER 5 9 BASE 6 9 50 YEAR PAVEMENT THICKNESS SHEET QUALIFIERS TABLE A Mr = 28 Mpa 80 Kn ESALs Total HMA Thickness Select Granular Subgrade 80 Kn ESALs over Design Life Thickness over Design Life millions mm mm millions < 2 165 0 < 4 2 - 4 175 0 4 - 7 > 4 - 8 200 0 > 7 - 13 > 8 - 13 225 0 > 13 - 23 > 13 - 23 250 0 > 23 - 40 > 23 - 45 250 150 > 40 - 70 > 45 - 80 250 300 > 70 - 130 > 80 - 140 250 450 > 130 - 235 > 140 - 300 250 600 > 235 - 300 TABLE C Mr = 41 Mpa 80 Kn ESALs Total HMA Thickness Select Granular Subgrade 80 Kn ESALs over Design Life Thickness over Design Life millions mm mm millions < 6 165 0 < 8 6 - 11 175 0 8 - 16 > 11 - 20 200 0 > 16 - 30 > 20 - 35 225 0 > 30 - 50 > 35 - 60 250 0 > 50 - 85 > 60 - 110 250 150 > 85 - 160 > 110 - 200 250 300 > 160 - 300 > 200 - 300 250 450 TABLE E Mr = 55 Mpa 80 Kn ESALs Total HMA Thickness Select Granular Subgrade 80 Kn ESALs over Design Life Thickness over Design Life millions mm mm millions < 12 165 0 < 15 12 - 20 175 0 15 - 30 > 20 - 40 200 0 > 30 - 50 > 40 - 65 225 0 > 50 - 90 > 65 - 115 250 0 > 90 - 150 > 115 - 215 250 150 > 150 - 300 > 215 - 300 250 300 SPECIAL NOTE SECTION 01 - Rural Principal Arterial - Interstate 64-28 64-28 02 - Rural Principal Arterial - Other 06 - Rural Minor Arterial 07 - Rural Major Collector 08 - Rural Minor Collector 11 - Urban Principal Arterial - Interstate 12 - Urban Principal Arterial - Expressway 14 - Urban Principal Arterial - Other Yes 16 - Urban Minor Arterial Yes 17 - Urban Collector No There is a possibility of damaging homes, historic sites, etc., The highway is located in either Dutchess, Orange, Rockland, Putnam, Westchester, Nassau, Suffolk, Sullivan county PAVEMENT AGGREGATE SIZE 402 XX XX TOP 12 BINDER 25 BASE 37 TABLE B Mr = 34 Mpa Total HMA Thickness Select Granular Subgrade Thickness mm mm 165 0 175 0 200 0 225 0 250 0 250 150 250 300 250 450 250 600 TABLE D Mr = 48 Mpa Total HMA Thickness Select Granular Subgrade Thickness mm mm 165 0 175 0 200 0 225 0 250 0 250 150 250 300 TABLE F Mr = 62 Mpa Total HMA Thickness Select Granular Subgrade Thickness mm mm 165 0 175 0 200 0 225 0 250 0 250 150 <30 FHWA VEHICLE CLASSIFICATION Vehicle Class Number Description Sample 1 Motorcycles 2 Passenger cars 3 Other two-axle, four-tire single-unit vehicles 4 Buses 5 Two-axle, six-tire single-unit trucks 6 Three-axle single-unit trucks 7 Four-or-more-axle single-unit trucks 8 Four-or-less-axle single-trailer trucks 9 Five-axle single-trailer trucks 10 Six-or-more-axle single-trailer trucks 11 Five-or-less-axle multi-trailer trucks 12 Six-axle multi-trailer trucks 13 Seven-or-more-axle multi-trailer trucks