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Pavement PreservationMaintenance Strategies

& Budgeting

John CalvertDirector - Tennessee Public Works Institute

Consultant - Pavement Technology, Inc.

Education Chairman - APWA Tennessee Chapter

2006 APWA International Public Works Congress & Exposition

September 12, 2006 - Kansas City, MO

What is Pavement Preservation?

Why should an agency use it?

What strategies does it include?

How much annual funding shouldagencies budget for pavement

maintenance?

Pavement PreservationWhat is it?

Simply stated, Pavement Preservationis the process of utilizing time provenand lower cost preventive maintenanceactivities to extend the useful life ofasphalt pavements and thereby lowerannualized resurfacing costs as well asfuture resurfacing costs.

Pavement Preservation

Why should agencies use it?

Pavement Preservation

Why should agencies use it?

Image fromAPWA’s Publication “The Hole Story”

The Hole Story

Available from theAPWA Bookstore hereat the conference!

Includes information provided byseveral pavement maintenanceprofessionals, TransportationResearch Board, USACOE,Michigan DOT and Federal

Highway Administration.

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Pavement PreservationWhy should agencies use it?

TDOT Bituminous (AC) IndexJanuary 2000 - August 2006

$130.00

$150.00

$170.00

$190.00

$210.00

$230.00

$250.00

$270.00

$290.00

$310.00

$330.00

$350.00

$370.00

$390.00

$410.00

Month-Year

Co

st

TDOT Bituminous (AC) IndexJanuary 2000 - August 2006

$130.00

$150.00

$170.00

$190.00

$210.00

$230.00

$250.00

$270.00

$290.00

$310.00

$330.00

$350.00

$370.00

$390.00

$410.00

Month-Year

Co

st

Since January 2000, the cost of Asphalt Cement hasincreased approximately 160%.

The cost of AC has increased 100.8% in the past 24 months. In 2005, the cost of AC increased 22.42%, which was asubstantial increase from a typical increase of 4% to 10%

2005

During the past 12 months it has increased 95.8%

Historically, hot-mix andresurfacing prices have followedthe same “trendline” as that of

the cost of asphalt cement.

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From 2000 thru July 2005 the price of Asphalt Cementremained constant with fluctuations of 5% to 12% a year

It was possible to estimate future AC prices as theyremained somewhat close to the trendline.

Also, from 2000 thru July 2005 the cost of resurfacingremained constant with fluctuations of 4% to 10% a year

Then, in 2005 Katrina hit and crude oil prices soaredcausing Asphalt Cement prices to escalate.

Katrina

In the past 12 months the price of asphalt cement hasescalated from $195 to $390 per liquid ton.

$195

$390

In one ton of asphalt there is typically 120 pounds ofasphalt cement.

A liquid ton price of $390 per ton equates to a price of19.5 cents per pound, which means the AC alone inone ton of hot-mix now cost $23.40.

In 2005 when AC was $195 per liquid ton, the cost ofAC in one ton of hot-mix was $11.70

Thus, the increase in AC cost alone has caused hot-mix to increase $11.70 per ton over 2005 prices.

Factor in increases in fuel costs, aggregate, labor andequipment, it becomes easy to understand why resurfacing

costs have increased from a 2005 average cost of $40 per ton tothe current cost of $65 per ton.

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What does this have to do withPavement Preservation?

Be patient, we’re getting there.......

As noted earlier when AC cost wereconsistent, trendline projections could be

used to somewhat project future costs.

There was a general correlation between theAC trendline and resurfacing costs trendlines.

These graphs show AC and resurfacing cost from 2000-2005.

Notice the similarity between the AC trendline and the cost ofresurfacing.

Now, the good news...

and the bad news.

The good news......

Trendlines are still somewhatuseful in predicting future

costs........

The bad news................

The trendline projections donot look good...

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Using AC cost for the 24 month period of August 2004through August 2006, a trendline projects an August2007 AC cost of about $405 per liquid ton. $405

Using the costs for the past 12 months, a trendlineprojects an August 2007 AC cost of $545 per liquid ton.

$545

This equates to a cost of $32.70 for AC alone in 1 ton ofhot-mix.

This and increases in fuel and other cost could result withresurfacing cost of $85-$95 per ton and maybe higher.

What does this mean for cities & counties?

Typical Cost for Resurfacing on 1 mile

of 22’wide roadway with 1.5” overlay:

2005 @ $40 per ton = $42,600

2006 @ $65 per ton = $69,225

2007 @ $85 per ton = $90,525

Further escalation of resurfacing costswhich agencies cannot keep up with!

This is bad news for cities and countiesas most have historically been 30% to50% underfunded in resurfacingbudgets for many years,...... and werealready in trouble with high amountsof deteriorated pavements.

Continued increases in AC and hot-mix costs could further cause theseagencies to be 70% to 125%underfunded or worst.

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Many cities have not provided adequatefunding for resurfacing for various reasons.

Many that once had adequate levels fellbehind as they did not increase budgetsto keep up with higher resurfacing costs.

And many agencies apparently just do notunderstand about pavement deterioration andtherefore do not have a real clue of howmuch annual funding they should have.

Pavement deterioration is notreally rocket science and not that

difficult to understand!

Pavement surfaces have a typicalcost-effective useful life of 12-15years.

As such, annual funding levelsshould allow for replacing pavementsurfaces on a 12-15 year cycle.

To determine approximate funding levels adequatefor proper maintenance agencies simply need todivide their total centerline miles of streets by 15 todetermine the minimum number of miles they needto resurface annually.

Then multiply those miles by the average cost ofresurfacing one mile of street 25’ wide.

Formulas to use:

CL Miles / 15 x Cost Per Mile

or

CL Miles x .066 (6.6%) x Cost Per Mile

Annual 1990 1995 2000 2005 2006 2007CL Miles Rsrf Miles @ $25tn @ $ 30 tn @ $34 tn @ 40 tn @ $65 tn @ $85

50 3.33 $100,833 $121,000 $137,133 $161,333 $262,167 $342,833100 6.67 $201,667 $242,000 $274,267 $322,667 $524,333 $685,667150 10.00 $302,500 $363,000 $411,400 $484,000 $786,500 $1,028,500200 13.33 $403,333 $484,000 $548,533 $645,333 $1,048,667 $1,371,333250 16.67 $504,167 $605,000 $685,667 $806,667 $1,310,833 $1,714,167300 20.00 $605,000 $726,000 $822,800 $968,000 $1,573,000 $2,057,000400 26.67 $806,667 $968,000 $1,097,067 $1,290,667 $2,097,333 $2,742,667500 33.33 $1,008,333 $1,210,000 $1,371,333 $1,613,333 $2,621,667 $3,428,333750 50.00 $1,512,500 $1,815,000 $2,057,000 $2,420,000 $3,932,500 $5,142,5001000 66.67 $2,016,667 $2,420,000 $2,742,667 $3,226,667 $5,243,333 $6,856,6672000 133.33 $4,033,333 $4,840,000 $5,485,333 $6,453,333 $10,486,667 $13,713,333

Resurfacing Budget for 15 Year Cycle at Various Costs Per Ton

Cities that do not provideadequate funding will be

allowing their averagepavement conditions to drop

each year.

These cities will eventually endup having to borrow money at

some point to play catch-up andresurface many streets and

possibly rebuild others.

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Ideally, agencies will have an equal amountof pavements with the same age.

This city would resurface6.6% or 10 miles ofstreet every year andincrease budgets to keepup with increasingresurfacing costs

Problems occur when inadequatefunding is provided, i.e. in this graph for 10 years

15 years of inadequate funding and increasedresurfacing costs = Major Problem & Borrowing This is a problem because of this..

The poorer the pavement condition, the higher the cost to get itback in good condition or back to the top of the curve. Pavement Preservation

Now.......this is wherePavement Preservationcomes into play...

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Pavement Preservation

Rejuvenators

Surface Seal

Slurry Seal

Micro-surfacing

Crack Filler

Lower costactivities

performed whilepavements arenear the upper

part of the curve.

Pavement PreservationREJUVENATORS can be used on good pavements (1 to 5 yearsold) to keep them in good condition and aid in preventing themfrom cracking and raveling. By replenishing lost asphaltic oilsthey rejuvenate the asphalt cement and restore the pavement’sflexibility and ability to retain fines. They can extend pavementlife by 5 to 10 years and cost approximately $4200 per lane mile.

Reclamite® rejuvenator application

Pavement PreservationBlack coating SURFACE SEALS, SLURRY SEALS ANDMICRO-SURFACING can be used on severely raveledpavements to add an extra 3-5 years before the pavementneeds to be resurfaced with a hot-mix overlay. These typicallycost approximately $5200 to $10,000 per lane mile dependingon the type of seal used.

Micro-surface application

Pavement PreservationPreventive Maintenance activities bring pavements backtoward the top of the condition curve for a fraction ofnormal resurfacing costs.

The useful life of the pavement is thereby extended,essentially “re-starting” the deterioration curve.

Micro-surface application

Image fromAPWA’s

Publication

“The Hole Story”

Thin Hot-Mix OverlaysUsing fine-graded surface mixes, agencies can use 1/2”,3/4” and 1” hot-mix overlays on many streets dependingon surface condition and at a less expensive cost per lanemile than a conventional 1-1/2” overlay.

OverlayDepth LBS/SY TONS/LM Cost @ $65 tn

1/2" 56 181 $11,7453/4" 84 271 $17,6181" 112 361 $23,490

1.5" 168 542 $35,235

RESURFACING COST COMPARISONS PER LANE MILE

Thin Hot-Mix Overlays

1/2” Hot-mix Overlay Application

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Pavement PreservationUses the

RIGHT TREATMENT

on the

RIGHT PAVEMENT

at the

RIGHT TIME

Some agency officials maythink their resurfacing budgets

do not include funding forPavement Preservation,... sothey think can’t afford to

implement a program.

The truth isagencies can’t afford to notimplement a program, especially nowthat resurfacing costs are escalating atthe current record rates and beyond whattheir budgets can keep up with.Any agency can afford to implement aPavement Preservation program bysimply deferring the resurfacing of oneor more streets and then use this moneyto fund and implement a pavementpreservation program.

Regardless of their budget levels, agenciesneed to annually address as many miles of

pavement as their funding allows.

By deferring the resurfacing of a few miles ofstreet and using the saved funds for

implementing pavement preservationactivities, agencies will be able to overalladdress more miles of pavement with the

same amount of funding.

Using conventional 1.5” resurfacing only, this agencywould spend $680,000 and address 10 miles of street.

By deferring resurfacing of 1 mile of street the agency canuse those funds for rejuvenating 6.6 miles of streets and stillresurface 9 miles. For the same $680,000, the agency has

now addressed 15.6 miles of street.

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By deferring resurfacing of 2 miles of street the agency canuse those funds for rejuvenating 13.24 miles of streets andstill resurface 8 miles. For the same $680,000, the agency

has now addressed 21.2 miles of street.

By deferring conventional resurfacing of 2 miles of street theagency can use those funds for rejuvenating 13.24 miles of

streets and thenuse both 1” and 1.5”overlays to resurface 10miles. For the same $680,000, the agency has now addressed

23.24 miles of street.

23.24 MilesAddressed

1” OL

Pavement Conditions BeforePavement Preservation Implemented

0 5 10 15 20 25 30 35

VERY POOR

POOR

GOOD

VERY GOOD

EXCELLENT

Co

nd

ition

Per Cent of Streets

Pavement Conditions 8-10 Yrs. AfterPavement Preservation Implemented

0 5 10 15 20 25 30 35

VERY POOR

POOR

GOOD

VERY GOOD

EXCELLENT

Con

diti

on

Per Cent of Streets

Pavement Conditions 4-6 Yrs. AfterPavement Preservation Implemented

0 5 10 15 20 25 30 35

VERY POOR

POOR

GOOD

VERY GOOD

EXCELLENT

Co

nd

itio

n

Per Cent of Streets

Pavement Preservation Can Aid in Improving An Agency’s

Pavement Conditions & Reduction in Future Resurfacing Miles Summary

To address the escalating resurfacing costsagencies need to....“Think Outside of the Box”

It appears resurfacing costs will continue to increase.

SummaryLower cost and time proven Pavement

Preservation activities can allow agencies toaddress more miles of pavement each year and

extend pavement life by 5 years or more.

Extending pavementlife aids in reducingfuture resurfacing

costs!

Any Questions?

For more information contact:

John CalvertConsultant - Pavement Technology, Inc.

Director - Tennessee Public Works Institute

Education Chairman - APWA Tennessee Chapter

jgcalvert@comcast.net

(865) 803-4721