MONTANA AVIATION SYSTEM PLAN 2012 UPDATE - PAVEMENT CONDITION INDEXES A.I.P. 3-30-0000-010-2012 prepared for: Aeronautics Division 2630 Airport Road P.O. Box 200507 Helena, Montana 59620-0507 (406) 444-2506 prepared by: Stelling Engineers, Inc. 614 Park Drive South Great Falls, MT 59405 February, 2013 Montana Aviation System Plan – 2012 Update TABLE OF CONTENTS CHAPTER 1 INTRODUCTION Page No. 1.1 Project Description.................................................................................................. 1-1 1.2 The Pavement Management System ....................................................................... 1-5 1.3 Scope of Services .................................................................................................... 1-6 CHAPTER 2 PROJECT APPROACH 2.1 Historical Data Collection....................................................................................... 2-1 2.2 Network and Sample Definition ............................................................................. 2-1 2.3 Pavement Condition Surveys .................................................................................. 2-5 2.4 Pavement Condition Index (PCI) ............................................................................ 2-7 2.5 PCI Calculations ..................................................................................................... 2-7 2.6 Pavement Families .................................................................................................. 2-8 2.7 Family Analyses.................................................................................................... 2-10 CHAPTER 3 RESULTS AND RECOMMENDATIONS 3.1 Family Analysis Curves .......................................................................................... 3-1 3.2 PCI Predictions ....................................................................................................... 3-3 3.3 System-Wide Pavement Conditions ....................................................................... 3-4 3.4 Maintenance Priorities .......................................................................................... 3-13 3.5 Maintenance Practices .......................................................................................... 3-17 3.6 Maintenance and Rehabilitation Planning ............................................................ 3-18 3.7 Other MicroPAVER Reports ................................................................................ 3-23 3.8 Continued Micropaver Implementation ................................................................ 3-23 CHAPTER 4 AIRPORT REPORT SUMMARIES 4.1 Introduction ............................................................................................................. 4-1 4.2 Inspection Report Summaries ................................................................................. 4-1 4.3 Maintenance Report Summaries ............................................................................. 4-1 4.4 Inspection Photos .................................................................................................... 4-2 4.5 FAA Form 5320-1................................................................................................... 4-2 4.6 Reports .................................................................................................................... 4-2 APPENDIX i Montana Aviation System Plan – 2012 Update LIST OF TABLES AND FIGURES TABLES Page No. 1.1 Montana’s Pavement Management System - 2009 Update .................................... 1-2 2.1 Selection of Minimum Number of Sample Units ................................................... 2-2 2.2 Example Sample Unit Selection ............................................................................. 2-3 2.3 Section Category Criteria ........................................................................................ 2-9 2.4 Section Properties and Family Assignments ......................................................... 2-12 2.5 PCI vs. Age - Allowable Extremes/Boundaries .................................................... 2-21 3.1 Summary of PCI Ratings ........................................................................................ 3-5 3.2 Pavement Projected to Go Subcritical, by Pavement Area ................................... 3-14 3.3 Pavement Projected to Go Subcritical, by % of Each Airport’s Pavement Area . 3-15 3.4 Percent of Each Airport’s Pavement with 2012 Subcritical PCI .......................... 3-16 3.5 First Year Localized Maintenance Policies .......................................................... 3-21 3.6 First Year Localized Maintenance Costs .............................................................. 3-22 3.7 Example First Year Repair Consequences ............................................................ 3-22 3.8 Global Maintenance Costs and Consequences ..................................................... 3-22 3.9 Effective Major M & R Priorities ......................................................................... 3-22 A.1 Pavement Distresses A.2 Sections Omitted from 2012 PCI Survey A.3 First Year Repair Consequences FIGURES 1.1 Montana Airports’ Pavement Database Map .......................................................... 1-4 2.1 Concrete and Asphalt Pavement Inspection Sheets ................................................ 2-4 2.2 PCI Calculation Steps ............................................................................................. 2-6 Family Life Cycle Curves: 2.3 ACPL Asphalt Pavements With Less Than 12,500 lb. Load Rating .................... 2-21 2.4 STPA Bituminous Surface Treated Pavements of All Load Ratings ................... 2-22 2.5 ACAH Asphalt Aprons With Higher Than 30,000 lb. Load Rating ..................... 2-22 2.6 ACRH Asphalt Runways & Taxiways With Higher Than 30,000 lb. Load Rating ........................................................................................................... 2-23 2.7 ACRML Asphalt RWs & TWs, Load Rating 12,500 to 30,000 lb, 5000 or Fewer Ops. ........................................................................................................ 2-23 2.8 ACRMU Asphalt RWs & TWs, Load Rating 12,500 to 30,000 lb, Over 5000 Ops. ..................................................................................................... 2-24 2.9 ACAM Asphalt Aprons With Load Rating From 12,500 to 30,000 lb.. .............. 2-24 2.10 PCAA Portland Concrete Cement - All Sections ................................................. 2-25 2.11 Pavement Life Cycle ............................................................................................. 2-25 3.1 MicroPAVER PCI Prediction Process .................................................................... 3-3 3.2 System-wide Pavement Condition Ratings ........................................................... 3-12 3.3 Extended Pavement Life Cycle ............................................................................. 3-17 3.4 Cost by PCI Assumptions ..................................................................................... 3-19 A.1 Family Comparisons A.2 Pavement Distresses by Causes ii Montana Aviation System Plan – 2012 Update ABBREVIATIONS AAC Pavement surface type - structural asphalt overlays of asphalt AC Pavement surface type - asphalt I bot mix I plant mix bituminous surface course ACAH Pavement Family- Asphalt Aprons With Higher Than 30,000 lb. Load Rating ACAM Pavement Family- Asphalt Aprons With Load Rating From 12,500 to 30,000 lb. ACPL Pavement Family- Asphalt Pavements With Less Than 12,500 lb. Load Rating ACRH Pavement Family- Asphalt Runways & Taxiways With Higher Than 30,000 lb. Load Rating ACRML Pavement Family- Asphalt RWs & TWs, Load Rating 12,500 to 30,000 lb, 5000 or Fewer Ops. ACRMU Pavement Family- Asphalt RWs & TWs, Load Rating 12,500 to 30,000 lb, Over 5000 Ops. Agg Aggregate / gravel as a manufactured structural layer of a pavement section AlP Airport Improvement Program- FAA funding for airport maintenance and construction APC Pavement surface type - structural asphalt overlays of concrete BST Pavement surface type - bituminous surface treatments I single shot I double shot I triple shot FAA Federal Aviation Administration FAAAC Federal Aviation Administration, Advisory Circular FOD Foreign object debris. Loose material on a pavement surface that could cause aircraft damage Form 5320-1 FAA-format for an airport pavement map with construction and maintenance history GA General Aviation Global Maintenance policy applied to the whole pavement (e.g. fog seals, overlays) H High - degree of severity for an asphalt defect HLNIADO FAA's Helena Airports District Office L Low - degree of severity for an asphalt defect L&TCR Longitudinal and transverse cracking LF Linear foot (unit of length) Local Maintenance policy applied to small sections of a pavement (e.g. crack seal, patching) M Medium - degree of severity for an asphalt defect M&R Maintenance and rehabilitation MAD Montana Aeronautics Division Major<Crit Reconstruction of a pavement after its condition has dropped below the critical PCI Major>Crit Reconstruction of a pavement before its condition has dropped below the critical PCI MDT Montana Department of Transportation N No degree of severity for an asphalt defect is defined, the defect is either present or not NWM FAA's Northwest Mountain Region Ops Aircraft operations (takeoff or landing) P-152 FAA designation for compacting native soils P-154 FAA designation for subbase