Research Report KTC-95-25 IMPACTS OF THE EXTENDED-WEIGHT COAL HAUL ROAD SYSTEM by Jerry G. Pigman Research Engineer Joseph D. Crabtree Research Engineer Kenneth R. Agent Research Engineer R. Clark Graves Research Engineer and John A. Deacon Professor Kentucky Transportation Center College of Engineering University of Kentucky Lexington, Kentucky in cooperation with Kentucky Transportation Cabinet Commonwealth of Kentucky and Federal Highway Administration U.S. Department of Transportation The contents of this report reflect the views of the authors, who are responsible for the facts and accuracy of the data presented herein. The contents do not necessarily reflect the official views or policies of the University of Kentucky, the Kentucky Transportation Cabinet, or the Federal Highway Administration. This report does not constitute a standard, specification, or regulation. December 1995 Commonwealth of Kentucky James C. Codell, Ill Transportation Cabinet Paul E. Patton Secretary of Transportation Frankfort, Kentucky 40622 Governor T. Kevin Flanery November 4, 1996 Deputy Secretary Mr. Paul Toussaint Division Administrator Federal Highway Administration 330 West Broadway Frankfort, Kentucky 40603-0536 Subject: IMPLEMENTATION STATEMENT- Research Study; "Impacts of the Extended­ Weight Coal Haul Road System" (KYHPR-93-151) Dear Mr. Toussaint: The Extended-Weight Coal Haul Road System was created by the Kentucky Legislature in 1986 and consists of roads which carry over 50,000 tons of coal in a calendar year. Trucks hauling coal on this system are authorized to exceed normal weight limits through the payment of an annual decal fee. A research study was initiated in July 1992 to analyze the impacts of the system and this is the final report from that effort to document the results. An interim report was prepared and distributed in October 1993. Results from the evaluation indicate that the extended-weight system has apparently been successful in accomplishing the objective of enhancing the competitiveness and economic viability of the Kentucky coal industry. From the safety standpoint, overall accident rates did not increase; however, fatal and injury accident rates were significantly higher on the system and for trucks operating with a coal decal. Considering the economics of the system, the decal-fee structure results in a net annual loss to the Road Fund of approximately $2 million and heavier weights of coal trucks add approximately $9 million annually to the pavement overlay costs. The primary recommendation for implementation was that the extended-weight system should evolve into a comprehensive trucking network. Further consideration will be given by the Transportation Cabinet to: 1) limitation of mileage to contain cost; 2)designation of a permanently connected continuous state-wide network for the system to promote efficient management; and 3) secure additional funding commensurate with increased costs and lost revenue attributed to the system. The eventual goal would be to provide a trucking highway network that is fully compatible with the dimensions and characteristics of the extended-weight trucks. If the problems of the extended-weight system can be resolved, it could serve as a model for a resource and commodity highway system which could accommodate large trucks carrying other commodities as well as coal trucks currently operating with decals on the extended-weight system. · KENTUCKY TRANSPORTATION CABINET "PROVIDE A SAFE, EFFICIENT, ENVIRONMENTALLY SOUND, AND FISCALLY RESPONSIBLE TRANSPORTATION SYSTEM WHICH PROMOTES ECONOMIC GROWTH AND ENHANCES THE QUALITY OF UFE IN KENTUCKY.' "AN EQUAL OPPORT1JNITY EMPLOYER M/F/0' Technical Report Documentation Page 1. Report No. 2. Government Accession No. 3. Rocipiont"s Catalog No. KTC·95-25 4. Title and Subtitle 5. Report Date December 1995 Impacts of the Extended-Weight Coal Haul Road System 6. Performing Organization Code 8. Performing Organization Report No. 7. Author(s) KTC-95-25 J. Pigman, J. Crabtree, K. Agent, C. Graves, J. Deacon 9. Performing Organization Name and Address 10. Work UnH No. [TRAIS) Kentucky Transportation Center College of Engineering University of Kentucky 11. Contract or Grant No. Lexington, KY 40506-0043 KYH PR-93-151 13. Type ol Report and Poriod Covorod Final 12. Sponsoring Agency Name and Address Kentucky Transportation Cabinet State Office Building 14. Sponsoring Agency Code Frankfort, KY 40622 15. Supplementary Notes Study Title: Impacts of the Extended-Weight Coal Haul Road System 16. Abstract The ExtendedM Weight Coal Haul Road System, created by the Kentucky Legislature in 1986, consists of all roads which carry over 50,000 tons of coal in a calendar year. Trucks hauling coal on lhis system are authorized to exceed normal weight limits through tbe payment of an annual decal fee. A research study was initiated in July of 1992 to analyze the impacts of the extended-weight system. Analyses in this report are based on the following: historical data on coal production and transportation: data from coal decaJ applications; interviews of legislators. transportation officials. coal company representatives. and coal trucking representatives: newspaper articles; vebicle classification data: analyses of pavement costs: pavement rideability data; and accident data. Primary conclusions include: I) The extended-weight 5)'Stem has apparently been somewbat successful in accomplishing the objective of enhancing the competitiveness and economic viability of the Kentucky coal industry: 2) Overall accident rates did not increase as a result of implementation oflhe extended-weight system. but the fatal accident injury rates were significantly higher on the extended-weight system and for trucks operating with the coal decal: 3) Advance-warning flashers have been evaluated and recommended as a means of reducing intersection accidents involving heavy/coal trucks: 4) The coal-decal fee structure results in a net annual loss in Road Fund revenue of approximately S2 million; 5) Forty percent of revenue from decal fees are allocated to counties even though county-maintained roads comprise only eight percent of the extended- weight system: 6) Heavier weights of coal-decal trucks add approximately $9 million annually to the pavement overlay costs; 7) Road users throughout the state are subsidizing the movement of Kentucky coal by participating in the cost of maintaining and improving tile highway system: and 8) Possibly reflecting the increased funding of extended-weight roads., the rideability index. has risen to a level above the statewide average. The primary recommendation was that the extended-weight system should evolve into a comprehensive trucking network. A "Resource and Commodity Highway System" was evaluated as a separate study and found to be a feasible and desirable means of providing a trucking llighway network th.at is fully compatible with the dimensions and characteristics of large trucks. 17. Key Words 18. Distribution Statemont Coal Pavements Trucks Highways Taxes Transportation Unlimited with Transportation Safety Weight Cabinet Approval Economics Revenue 19. Security Classif. (of this report) 20. Security Classif. (of this page) 21. No. of Pages 22. Prloo Unclassified Unclassified 130 Form DOT 1700.7 (8-72) Reproduction of completed page authorized TABLE OF CONTENTS Executive Summary . v Acknowledgments ................................................ xii Introduction . 1 The Coal Industry in Kentucky ..................................... 5 History of Coal Transportation . 6 Economics of Coal Transportation . 10 Perceptions . 12 The Population of Coal Trucks ...................................... 21 Revenue and Cost Analysis ........................................ 25 Accident Analysis . 33 Evaluation of Advance Warning Flashers ............................. 37 Pavement Condition Analysis ...................................... 39 Conclusions . 40 Recommendations . 43 References . 44 Figures ......................................................... 45 Tables .......................................................... 55 Appendix A: Issues Surrounding the Trucking of Kentucky Coal in the 1990's .......................................... 77 Appendix B: Sampling of Newspaper Articles Related to Extended Weight Coal Haul Road System .................. 89 Appendix C: Details of Revenue and Cost Analysis for Extended Weight Coal Haul Road System .................. 93 11 LIST OF FIGURES Figure 1. Coal Production by Transportation Mode (1895-1990). Figure 2. Coal Production by Transportation Mode (1970-1990). Figure 3. Percentage of Coal Hauled by Truck and by Rail (1970-1990). Figure 4. Coal Production by Type of Mine (1950-1990). Figure 5. Highway Mileage of Coal Haul System. Figure 6. Highway Mileage of Extended-Weight System. Figure 7. Ton-Miles of Coal Transported by Highway in Kentucky. Figure 8. Tons of Coal Shipped by Highway in Kentucky. Figure 9. Breakdown of Extended-Weight System--1991 Data. Figure 10. Gross Weight Distribution of Three-Axle, Single-Unit Trucks. Figure 11. Gross Weight Distribution of Four-Axle, Single-Unit Trucks. Figure 12. Gross Weight Distribution Five-Axle, Semi-trailer Trucks. Figure 13. Gross Weight Distribution Six-Axle, Semi-trailer Trucks. Figure 14. Annual Average Rideability. Figure 15. Percent Increase/Decrease ofRideability. iii LIST OF TABLES Table 1. Number of Producing and Impact Counties by Year. Table 2. Highway Mileage. Table 3. Coal Ton-Miles. Table 4. Tons of Coal Shipped by Highway in Kentucky. Table 5.