80 kN ESAL calculation Work Sheet

Version 3.1 4-18-03 Updated 05/10/2006 kaw

This work sheet is used for the purpose of calculating the 80 kN ESAL using the "simple" method.
These calculations were taken from Figure 4-1 of the NYS Comprehensive Pavement
Design Manual (June 2000). Enter the parameters for items 1 through 8 below in the blue blocks.
The 80 kN ESAL count is calculated based on a compound traffic growth rate and
should be used for SUPERPAVE.
Enter data also in pavt. thickness sheet. Print this sheet + pavt thickness + item numbers + special note.

P.IN. #: 1234.56
Project Desc.: Project Name
(cont'd.) XXXX County
Date: Rev'd - 7/8/09
Mainline and Ramp Reconstruction
INPUT PARAMETERS:
Construction Year 2010
1. Design Life (use 50 years for determining pavement thickness) 50
2. Projected Construction Year AADT 2500
3. Percent Heavy Trucks Class 4 or greater 70.0
4. Percent Trucks in Design Direction 50
5. Percent Trucks in Design Lane 100
6. Truck Equivalency Factor (avg. ESAL per truck) 1.35
7. Truck Volume Growth Rate 2.00%
8. Annual Truck Weight Growth Rate 0.50%
Mr Value 34

08 Enter the Functional Classification Code of the highway

YES Does this road have full or partial access control? Partial
NO Is there a possibility of damaging homes, historic sites,
etc., due to excessive vibration during compaction.
NO Will there will be less than 2000 MT of each course placed?
NO Is the highway located in either Dutchess, Orange, Rockland, Putnam,
Westchester, Nassau, Suffolk, Sullivan County or the City of New York? Rens. County
NO Is the highway located in either Orange, Rockland, Putnam,
Westchester, Nassau, Suffolk CountIes or the City of New York?
NO Are there are more than 3 lanes on this road?

RESULTS:

AADT for Design Year 2060 6,597

• Use asphalt series for low volume roads.

Total 80 kN ESAL Count for the Design Life 44,651,609

• The 'Estimated Traffic' level should be < 100.0 million 80 Kn ESALs.

***** Don't forget the SPECIAL NOTE required in the Proposal *****
PAVEMENT THICKNESS TABLE
enter blue numbers
TOTAL ESAL VALUE 44,651,609
Total HMA Thickness 250 mm enter number from table at right

SELECT GRANULAR SUBGRADE GRAVEL BASE BINDER TOP

(enter # from table at right) 80 Kn ESALs Total HMA Thickness Select Granular Subgrade
mm mm mm mm mm over Design Life Thickness
150 300 145 65 40 millions mm mm
<4 165 0
4-7 175 0
ACTUAL PAVEMENT THICKNESSES TO USE > 7 - 13 200 0
> 13 - 23 225 0
THICKNESS > 23 - 40 250 0
SELECT GRANULAR SUBGRADE 150 mm > 40 - 70 250 150
GRAVEL 300 mm > 70 - 130 250 300
BASE 150 mm > 130 - 235 250 450
BINDER 65 mm > 235 - 300 250 600
TOP 40 mm
80 kN ESAL calculation Work Sheet
Version 3 3-28-02

This work sheet is used for the purpose of calculating the 80 kN ESAL using the "simple"
method. These calculations were taken from Figure 4-1 of the NYS Comprehensive Pavement
Design Manual (June 2000). The 80 kN ESAL count is calculated based on a compound
traffic growth rate and should be used for SUPERPAVE.

P.IN. #: 1234.56
Project Description: Project Name
Date: Rev'd - 7/8/09

INPUT PARAMETERS:
Construction Completion Year 2010
1. Design Life (years) 20
2. Initial AADT 2500
3. Percent Heavy Trucks Class 5 or greater 70
4. Percent Trucks in Design Direction 50
5. Percent Trucks in Design Lane 100
6. Truck Equivalency Factor (avg. ESAL per truck) 1.35
7. Truck Volume Growth Rate 2.00%
8. Annual Truck Weight Growth Rate 0.50%

• #N/A
• This road has full or partial access control.
• There is no possibility of damaging homes, historic sites,
etc., due to excessive vibration during compaction.
• There will be more than 2000 MT of each course placed.
• ESALS are greater than 0.3 million.
• The highway is not located in either Dutchess, Orange, Rockland, Putnam,
Westchester, Nassau, Suffolk, Sullivan County or the City of New York?
• There are less than 4 lanes on this road.

RESULTS:

AADT for Design Year 2030 3,642

• Use asphalt series for low volume roads.

Total 80 kN ESAL Count for the Design Life 11,119,144

• The 'Estimated Traffic' level should be < 30.0 million 80 Kn ESALs.

Recommended SUPERPAVE Item number

• TOP: 402.125201 M
• BINDER: 402.255901 M
• BASE: 402.376901 M
• Confirm with the Regional Materials Engineer
• Remember to add the appropriate Quality Payment Items

***** Don't forget the SPECIAL NOTE required in the Proposal *****
 SPECIAL NOTE

ATTENTION
SUPERPAVE HOT MIX ASPHALT, 12.5 mm / 25.0 mm, NOMINAL MAX. SIZE

The Contractor should be aware that this is a performance-related specification in which the Contractor is
responsible for compacting the pavement within a specified density range. In order to successfully compact
the pavement to the specified density range, the Contractor must be prepared to select, operate, and control
the paving and compaction equipment, to monitor the results, and to make necessary adjustments (without
direction from the Engineer) to achieve the desired results. Written instructions for determining pavement
density and core locations are available from the Regional Materials Engineer or the Director, Materials
Bureau.

The Performance Graded asphalt binder used in the production of SUPERPAVE Hot Mix Asphalt mixtures
shall be a 64-28 as defined by AASHTO Provisional Standard MP1 - Standard Specification for
Performance Graded Asphalt Binder.

The mixtures designs should be developed in accordance with the criteria specified in the SUPERPAVE
Hot Mix Asphalt Items that is appropriate for an "Estimated Traffic" level of <30
"Million 80 kN ESALs". Under no circumstances shall the Performance Graded Binder content be less than
5.6% for a 9.5 mm design, less than 5.0% for a 12.5 mm design, less than 4.3% for a 19.0 mm design or
less than 4.0% for a 25.0 mm design.

When crushed gravel is to be used in the production of SUPERPAVE Hot Mix Asphalt mixtures, the
minimum percent of crushed particles shall be as follows: for particle sizes greater than 12.5 mm, 75% one
crushed face; for particle sizes between 12.5 mm and 2.36 mm, 85% two crushed faces.
 SUPERPAVE Item Num
Reference to Mixture
Nominal Max Aggregate Size

� 37 = 37.5 mm Base Course

� 25 = 25.0 mm Binder Course (for use when ESALs > 3 million)
� 19 = 19.0 mm Binder Course (for use when ESALs < 3 million)
� 19 = 19.0 mm Binder Course (for use when ESALs between 3 - 10 million)
� 12 = 12.5 mm Top Course
� 09 = 9.5 mm Top Course

402 .
Reference to Standard
Specifications Sub-Section

Reference to Construction Details

Compaction Requirements

• 5 - Daily Coring with Payment Adjustments (HD)

• 6 - Nuclear Gauge Monitoring with Core Verification (RA)
• 7 - Nuclear Gauge Monitoring only (Standard)
• 8 - Miscellaneous Items (T & L, Optional Flexible Shoulders, Pavement Shoulder Course)
E Item Number Descriptions
Reference to the Coarse Aggregate Friction Requirement

• 1 - F1 Aggregates for use on Downstate High Volume Pavements

(> 8,000 AADT on 2 or 3 lane and > 13,000 on 4 or more lanes)
• 2 - F2 Aggregates for use on Upstate High Volume Pavements
(> 8,000 AADT on 2 or 3 lane and > 13,000 on 4 or more lanes)
• 3 - F3 Aggregates for use on Low Volume Pavements
(< 8,000 AADT on 2 or 3 lane and < 13,000 on 4 or more lanes)
• 9 - F9 - No Friction Requirement - For Base, Binder, and T & L Courses

XX Y Z Q R
Revision
Number
Currently 1

Reference to Quality Adjustment Items

• 0 - Specified HMA Item (Core Item)

• 1 - Plant Production Quality Adjustment
• 2 - Pavement Density Quality Adjustment
• 3 - Longitudinal Joint Density Quality Adjustment
houlder Course) • 4 - Pavement Smoothness Quality Adjustment
 or more lanes)

or more lanes)

or more lanes)
T & L Courses

M
Metric
Spec.

y Adjustment
y Quality Adjustment
Quality Adjustment
 FUNCTIONAL CLASSIFICATION

RURAL

Functional Functional
Classification Classification
Code Description Code
1 Principal Arterial - Interstate 11
2 Principal Arterial - Other 12
6 Minor Arterial 14
7 Major Collector 16
8 Minor Collector 17
9 Local 19
CATION

URBAN

Description
Principal Arterial - Interstate
Principal Arterial - Expressway
Principal Arterial - Other
Minor Arterial
Collector
Local
 ROADWAY INFORMATION

8 01 01 - Rural Principal Arterial - In

02 02 - Rural Principal Arterial - O
06 06 - Rural Minor Arterial
07 07 - Rural Major Collector
08 08 - Rural Minor Collector
09 09 - Rural Local
#N/A 11 11 - Urban Principal Arterial - I
12 12 - Urban Principal Arterial - E
14 14 - Urban Principal Arterial - O
16 16 - Urban Minor Arterial
17 17 - Urban Collector
19 19 - Urban Local
0

has yes This road will have full or partial access control.
is no no There is a possibility of damaging homes, historic sites, etc.,
due to excessive vibration during compaction.
more no There will be less than 2000 MT of each course placed.
is not no The highway is located in either Dutchess, Orange, Rockland,
Putnam, Westchester, Nassau, Suffolk, Sullivan county
or the City of New York.
less than 4 no There are more than 3 lanes on this road.

3,642 Design Year AADT

no Hi Volume?

11,119,144 Total 80 kN ESAL Count for Design Life

PAVEMENT TYPE SECTION

402 XX A B
TOP 5 2
BINDER 5 9
BASE 6 9

50 YEAR PAVEMENT THICKNESS SHEET QUALIFIERS

 TABLE A
Mr = 28 Mpa
80 Kn ESALs Total HMA Thickness Select Granular Subgrade 80 Kn ESALs
over Design Life Thickness over Design Life
millions mm mm millions
<2 165 0 <4
2-4 175 0 4-7
>4-8 200 0 > 7 - 13
> 8 - 13 225 0 > 13 - 23
> 13 - 23 250 0 > 23 - 40
> 23 - 45 250 150 > 40 - 70
> 45 - 80 250 300 > 70 - 130
> 80 - 140 250 450 > 130 - 235
> 140 - 300 250 600 > 235 - 300

TABLE C
Mr = 41 Mpa
80 Kn ESALs Total HMA Thickness Select Granular Subgrade 80 Kn ESALs
over Design Life Thickness over Design Life
millions mm mm millions
<6 165 0 <8
6 - 11 175 0 8 - 16
> 11 - 20 200 0 > 16 - 30
> 20 - 35 225 0 > 30 - 50
> 35 - 60 250 0 > 50 - 85
> 60 - 110 250 150 > 85 - 160
> 110 - 200 250 300 > 160 - 300
> 200 - 300 250 450

TABLE E
Mr = 55 Mpa
80 Kn ESALs Total HMA Thickness Select Granular Subgrade 80 Kn ESALs
over Design Life Thickness over Design Life
millions mm mm millions
< 12 165 0 < 15
12 - 20 175 0 15 - 30
> 20 - 40 200 0 > 30 - 50
> 40 - 65 225 0 > 50 - 90
> 65 - 115 250 0 > 90 - 150
> 115 - 215 250 150 > 150 - 300
> 215 - 300 250 300
 SPECIAL NOTE SECTION

Rural Principal Arterial - Interstate 64-28 64-28

Rural Principal Arterial - Other
Rural Minor Arterial
Rural Major Collector
Rural Minor Collector

Urban Principal Arterial - Interstate

Urban Principal Arterial - Expressway
Urban Principal Arterial - Other Yes
Urban Minor Arterial Yes
Urban Collector No

storic sites, etc.,

Orange, Rockland,
ullivan county

PAVEMENT AGGREGATE SIZE

402 XX XX
TOP 12
BINDER 25
BASE 37
TABLE B
Mr = 34 Mpa
Total HMA Thickness Select Granular Subgrade
Thickness
mm mm
165 0
175 0
200 0
225 0
250 0
250 150
250 300
250 450
250 600

TABLE D
Mr = 48 Mpa
Total HMA Thickness Select Granular Subgrade
Thickness
mm mm
165 0
175 0
200 0
225 0
250 0
250 150
250 300

TABLE F
Mr = 62 Mpa
Total HMA Thickness Select Granular Subgrade
Thickness
mm mm
165 0
175 0
200 0
225 0
250 0
250 150
<30
 FHWA VEHICLE CLASSIFICATION

Vehicle Class
Number Description Sample
1 Motorcycles
2 Passenger cars
3 Other two-axle, four-tire single-unit vehicles
4 Buses
5 Two-axle, six-tire single-unit trucks
6 Three-axle single-unit trucks
7 Four-or-more-axle single-unit trucks
8 Four-or-less-axle single-trailer trucks
9 Five-axle single-trailer trucks
10 Six-or-more-axle single-trailer trucks
11 Five-or-less-axle multi-trailer trucks
12 Six-axle multi-trailer trucks
13 Seven-or-more-axle multi-trailer trucks