Project File From: Robert Cody, PE Stantec Consulting Services Inc File: 4531.07 Date: November 19, 2013 (Update March 11, 2014)
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Memo To: Project File From: Robert Cody, PE Stantec Consulting Services Inc File: 4531.07 Date: November 19, 2013 (Update March 11, 2014) Reference: NYS Route 531 Terminus Improvement Project Pavement Evaluation Treatment Selection Report (PETSR) Introduction The purpose of this memorandum is to summarize the PETSR associated with the proposed Route 31 pavement rehabilitation, as well as the design and pavement type (flexible vs. rigid) selection process associated with Route 31 and 531 roadway segments that will require full depth reconstruction. Background The project involves the proposed reconfiguration of the roadways and ramps within or near the existing Route 531/36/31 interchange in order to improve safety and capacity. The New York State roadways that will be involved and the corresponding length of the proposed work are summarized below (Note: lengths are based on future route number designations): Route 531: 900 linear feet Route 31: 10,075 linear feet Route 36: 1,700 linear feet The attached plan illustrates the current/future ownership jurisdiction for the various roadway segments involved. The feasible alternatives currently under consideration include: • Alternative 2 – Route 531/Route 36 At-grade conventional signalized intersection with traffic calming and safety improvements to Route 31 • Alternative 3 – Route 531/Route 36 At-grade signalized superstreet median crossover with traffic calming and safety improvements to Route 31 • Alternative 5 – Route 531/Route 36 Full diamond interchange with traffic calming and safety improvements to Route 31 dtc u:\192500227\correspondence\doc\mem004_531 pavt selection report_20140311.docx November 19, 2013 (Updated March 11, 2014) Project File Page 2 of 5 NYS Route 531 Terminus Improvement Project Pavement Evaluation Treatment Selection Report (PETSR) A common component to each of the alternatives is the proposed work on Route 31. With the objective of improving safety by way of introducing traffic calming techniques, the Route 31 segment will be altered significantly from a potential pavement preservation standpoint. The horizontal and vertical alignments, as well as cross- slope/superelevation rates will be adjusted throughout the corridor, thereby precluding the possibility of applying a consistent pavement rehabilitation treatment on long full- width segments of Route 31. The primary segments where full-width Route 31 pavement may be rehabilitated will be at the far western end of the corridor and the segment from Route 36 to the eastern project limit. Due to roadway realignment, most of the remaining segments will most likely require reconstruction. Route 531 and Route 36 are similar in that due to proposed connecting roadway reconfigurations that include horizontal/vertical alignment adjustments, new roads and roadway removals, relatively little of the existing pavements will be suitable for rehabilitation. Roadway History and Condition Route 531 terminus and its connecting ramps to Route 31 and Route 36 were originally constructed in 1994 under Contract D253893. The primary affected Route 36 segment was reconstructed as part of the 1994 Route 531 terminus project, and included significant widening and an overlay across the entire riding surface. Both Route 531 and Route 36 consist of flexible pavement sections that include multiple hot mix asphalt courses over granular subbase. Considering its age, the pavement appears to be in relatively good condition. Route 31 was originally constructed in 1915 under Contract SH5539, then reconstructed and updated in 1926 to Portland cement slabs under Contract RC1567. Since then, the pavement has been maintained, widened with flexible pavement and overlaid with an asphalt riding surface. Based on a pavement evaluation (see attached) that was performed by NYSDOT for the Route 31 segment between Salmon Creek Road and Route 36 (MM 1076 to 1096), the pavement is considered to be in fair to poor condition. NYSDOT therefore recommends that consideration be given to two (2) potential levels of pavement rehabilitation. The first option consists of pavement milling with a single 2” overlay, while the second option consists of pavement milling w/ a 3” (or more) multiple course overlay (assumed herein to be 1.5 inches of top and 2” of binder for a total of 3.5”). dtc u:\192500227\correspondence\doc\mem004_531 pavt selection report_20140311.docx November 19, 2013 (Updated March 11, 2014) Project File Page 3 of 5 NYS Route 531 Terminus Improvement Project Pavement Evaluation Treatment Selection Report (PETSR) Full Depth Pavement Design (Flexible and Rigid) In accordance with the NYS Comprehensive Pavement Design Manual (CPDM), an appropriate pavement section was developed for both flexible and rigid pavements, for use in estimating and performing a Life Cycle Cost Analysis so that a direct comparison can be made. The process included the application of an 80-kN ESAL calculation, and for the flexible pavement design, coupled with the subgrade soil modulus (Mr) value. The ESAL calculations, in large part was based on vehicular traffic volumes, is attached. For the flexible pavement, the pavement section will experience a 32.3 million 80-kN ESAL count, while for the rigid pavement section, the 80-kN ESAL count is 44.3 million. The Regional Geotechnical Engineer has indicated that the Mr for this project is 34 MPa, which is applicable for flexible pavement designs. Based on the ESAL calculations and Mr, the flexible pavement section will be comprised of 10 inches of asphalt concrete over a 12 inch course of subbase material, while the rigid pavement will consist of a 9 inch thick concrete slab over 12 inches of subbase. A 4-inch permeable base course is included with the flexible section, however based on current Department Guidelines; the permeable base course is not included with the rigid pavement section. Life Cycle Cost Analysis (LCCA) Based on the aforementioned pavement thicknesses, an estimate of the cost to construct 11,300 linear feet of new pavement was developed. Using “Transport Estimator” as the basis throughout this entire analysis, the estimated cost to construct full depth flexible pavement is approximately $9.3 million, while the estimated cost to construct rigid pavement is approximately $10.2 million. The estimated cost of rehabilitating a nominal 845 linear feet of Route 31 pavement using either of NYSDOT’s recommended treatment is as follows: Option 1: Mill, Patch with 2 inch overlay Estimated Cost = $56,800 Option 2: Mill w/ 1.5 inch top and 2 inch binder Estimated Cost = $88,300 Given the recommended periodic maintenance activity that is based in large part on the NYSDOT CPDM Chapter 5: Appendix 5A “Pavement Rehabilitation Manual”, but coupled also with input from the Regional Materials Engineer, a LCCA was performed for each pavement treatment option. It is assumed that the recommended maintenance activities will be performed over the estimated 50-year life span of the pavement. The LCCA allows for the direct comparison of each pavement option by computing the dtc u:\192500227\correspondence\doc\mem004_531 pavt selection report_20140311.docx November 19, 2013 (Updated March 11, 2014) Project File Page 4 of 5 NYS Route 531 Terminus Improvement Project Pavement Evaluation Treatment Selection Report (PETSR) Present Worth of all current and future costs to construct and maintain the pavement during the design life of the facility over the same 50-year period. NYSDOT provided the recommended periodic maintenance activities for the two (2) rehabilitation options, and is summarized in the attached Route 31 Pavement Evaluation. The following summarizes the Present Worth Life Cycle Cost (LCC) associated with full depth flexible pavement and full depth rigid pavement, as well as the LCC associated with the two (2) recommended pavement rehabilitation treatment options: Flexible Pavement: $12.8 million LCC Rigid Pavement: $12.1 million LCC Rehab Option #1: $210,000 LCC Rehab Option #2: $198,000 LCC Recommendation Based solely on the above Present Worth LCC comparison, it is recommended that a rigid pavement section for all full depth/full width constructed or reconstructed roads within the project limits be progressed. However from a sensitivity analysis perspective, it should be noted that the LCC of the flexible pavement section, as listed, includes a major mill and fill rehabilitation treatment every 12 years, as recommended by the Regional Materials Engineer. Should this interval be increased to 15 years (as suggested in the CPDM), the LCC for the flexible pavement would be approximately $11.9 million, thus making its LCC lower and therefore more desirable than the rigid pavement section. Regardless though, for major high volume signalized intersections that will require total reconstruction, it is recommended that a rigid pavement be considered for the following reasons: • Rigid pavement is more resistant to rutting caused by slow moving and repeated channelized traffic • Rigid pavement is more resistant to shoving, raveling, corrugations and slippage caused by vehicular starting/stopping and turning maneuvers • Construction operations associated with the construction of rigid pavement may simplify work zone traffic control requirements, as it involves only a single placement of PCC pavement as opposed to the multiple courses required for flexible pavement. dtc u:\192500227\correspondence\doc\mem004_531 pavt selection report_20140311.docx November 19, 2013 (Updated March 11, 2014) Project File Page 5 of 5 NYS Route 531