Base Stabilization
The purpose of base stabilization is to increase the bearing capacity
(or strength) of the roadbed materials. Adding an emulsified asphalt,
and possibly other fillers, increases the road’s firmness and resistance
to weather, while reducing movement or rutting in the base layer. Mix
design work performed in the lab seeks to maximize the strength of
the base materials and minimize the effects of moisture and
freeze/thaw cycles.
Design Criteria
In order to design a mix to satisfy the objectives of the project the
existing pavement must be investigated for structural adequacy,
thickness, slope and cross-fall as well as the visual appearance. Based
on these criteria a proper design can be developed. In most instances
the design procedure developed by Wirtgen is the accepted method
of design. This design procedure is well laid out in the Wirtgen Cold
Recycling Technology Manual.
The following is a guide to the design procedure:
Obtain representative samples of the base, sub-base
and sub-grade materials from field
Determine gradation and physical properties of
various granular materials
Select amount and type of additional aggregate if
required
Select type and grade of recycling additive
Estimate recycling, additive demand
Determine pre-mix moisture content for coating
Test trial mixtures, initial curing properties, final
curing properties, and moisture sensitivity
Establish job mix formula
Make adjustments in field
Materials – Recycling Additives
Asphalt Emulsions:
A number of different types and grades of asphalt emulsions can be
used in Base Stabilization. The proper emulsion to be used is based
on a number of factors; environmental conditions (temperature and
humidity), time of year, and the existing road conditions. All these
conditions affect the emulsion to be used. Typically the most common
emulsions used are CSS-1, CMS-2 (polymer versions included) as well
as proprietary products. Compatibility between the emulsion and the
reclaimed material is critical to make the system work.
Expanded (Foam) Asphalt:
The asphalt cement typically used in base stabilization is PG58-28.
Softer grades can be used if the specification requirements for tensile
strength can be met. To create the foam 2-3% water is injected into
the hot (150-170°C) asphalt.
Blended Material:
The blended material is created by the pulverization of the
underlying granular materials into a homogeneous mixture.
Virgin aggregate, RAP material, or crushed concrete can be
added to improve overall strength. Typically the maximum
particle size is 37 mm. The pulverizing machine can control
the gradation of the material through speed, milling head
direction as well as the added granulars.
Modifiers:
There are different modifiers that can be used in the FDR
process. Besides the asphalt emulsion or Expanded (Foam)
Asphalt, virgin aggregate may be added to improve gradation,
stability or cross slope. Portland cement or lime in dry or
slurry form as well as Type C Fly ash can be used to improve
early strength, cohesion and resistance to moisture damage.
Aggregate:
Aggregates used to improve the gradation or give extra
strength can be virgin crusher run, recycled crushed concrete
or recycled asphalt pavement (RAP). The virgin aggregate can
also be coarse aggregate if the gradation needs to be
corrected due to the fine nature of the pulverized material.
Performance Guidelines
In order to construct a proper well designed base stabilized mix the
following guidelines should be followed:
Ensure the existing structure is adequate to support
expected traffic
Evaluate existing structure for distresses and make
sure repairs completed prior to construction
Ensure that the base stabilization process is the
proper process to be used
Determine if a corrective aggregate or other
modifiers such as cement are needed
Ensure a proper mix design is done. Use mix design
as a guide only
Field adjustments may have to be made to water
content or recycling additive to achieve good
coating and workability
Proper equipment needed (reclaimer, grader, water
truck, compactors)
Use of vibratory footpad, pneumatic ,vibratory
rollers and static steel rollers used
If modifier used compaction begins as soon as mix is
placed
Breakdown rolling following by shaping and final
compaction
Rolling patterns should be established at start with
use of nuclear gauge
Curing of finished mat is required before placement
of wearing surface
Curing can vary depending on environmental
conditions and type of additive used. Typically 2 to 4
days for foam and 10-14 days for emulsions
A light fog seal may be needed to prevent surface
ravelling
Typically a HMA wearing surface is placed over the
stabilized base. Mix type governed by structural
requirements