Airport project proves advanced condition analysis + advanced materials + advanced testing = best practices for asphalt paving

In August 2023, the BATT Team wrapped up a project that combined in-depth pavement condition analysis with a unique blend of advanced materials and advanced quality assurance (QA) testing to create a strategy that could well become the standard-bearer for changing best practices in asphalt pavements.

All project features are part of a Special Note for General Aviation (GA) Airports that is being developed by Gary Sharp (Palmer Engineering), Phil Blankenship (BATT), and Scott Quire (E&B Paving) for the Kentucky Department of Aviation (KDA). American Engineering Inc. (AEI) (Glasgow, KY) managed the engineering of the project, which included repaving a worn, 5,000-foot runway and taxiway.

Project Features

The Central Kentucky Airport project was unique for four reasons:

1.     It utilized BATT Vision, an advanced, AI-based system for analyzing pavement conditions.

2.     It incorporated advanced materials, including PG 76-22 (SBS) and aramid fibers in the overlay mix to achieve improved performance with superior cracking resistance.

3.     It designed the mix using Balanced Mix Design (BMD) testing and constructed the pavement with BMD testing every 500 tons of asphalt mix.

4.     It tied BMD Quality Assurance test results to the contractor’s pay factor — the first of its type (to the author’s knowledge) for a general aviation project.

The project applied the known industry best practices mentioned above in addition to echelon paving and cut back joints to improve the joint life. A Void Reducing Asphalt Membrane (VRAM) was also placed to evaluate for airports in conjunction with the National Center for Asphalt Technology (NCAT) research team.

Problem and Solution

The project included a thorough assessment of the pavements’ condition using BATT Vision, an advanced combination of photography and AI learning developed by Tiger Eye Engineering.  The aged pavement had extensive surface cracking, several full-depth cracks, and numerous pop-outs that could create Flying Object Debris (FOD) hazards that required isolation and treatment prior to applying a the new surface.

Since there were no clearance concerns and added structure is desirable for airports, the treatment strategy called for the use of a CRS-2P emulsion chip seal layer to isolate and seal the underlying cracking and a 2-inch overlay. VRAM from Asphalt Materials/Heritage Research Group was applied to the joints to further reduce cracking in these areas.  The two-inch asphalt overlay contained PG 76-22 reinforced with 2.1 oz/ton of Surface Tech’s ACE XP polymer fibers to add tensile strength and additional structure to the existing pavement.

Construction

Minimizing downtime was crucial for this general aviation airport that provides critical services to the Eastern Kentucky University (EKU) Aviation Program which is experiencing record enrollment this year.

The Allen Company served as the local contractor that produced and placed asphalt mix. The project was completed within a three-to-four week time frame and ahead of schedule thanks to the contractor’s dedication of additional resources to construct this project, which required more than 9,000 tons of asphalt. The Allen Company employed two paving crews and completed the project in four days, placing 6,000 tons in a 36-hour window.

AEI turned to BATT for the BMD-required QA testing during the paving process.  BATT provided QA testing of 13 mix samples at four-hour intervals. Test results revealed a 100 percent success rate in meeting or exceeding IDEAL-CT and Hamburg testing parameters.

“This was an intense project with extensive coordination among the contractor and lab personnel. We were glad to play an integral role in moving innovation from the lab to the pavement!” said Phil Blankenship, president of BATT.

Result

The unique strategies employed on the project now provide a blueprint for creating an improved method for specifying pavement performance — rather than simply relying on a mix design recipe. BATT plans to evaluate the project on an annual basis to track performance. There are always a few tweaks to make with any specification, but the blueprint is solid for a more sustainable pavement solution.

For more information on how the unique aspects of the Central Kentucky Airport project can be applied to your next pavement design, contact BATT at info@blankenshipasphalttech.com, or visit our website.