November 2005
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Road Manager

Dealing With Winter Potholes
Injection patching picks up the pace of permanent winter patching.

by Ruth W. Stidger, Editor-in-Chief

Agencies with frequent winter freeze-thaw cycles suffer from the most winter potholes. But any area with freezing winter weather faces the problem of how to deal with repairs as the temperature drops.

Methods generally used include throw-and-roll, edge-seal, semi-permanent, and spray injection.

Originally viewed as an expensive method, spray injection has been gaining favor because the patches are more likely to remain in place than some other methods, which can actually mean a lower-cost repair over the long haul.

The conventional method of winter pothole repair is a temporary method — throw-and-roll, with the crew placing material in the hole and compacting it by rolling over the repair several times with truck tires. Unfortunately, this repair may last only weeks, days, or even hours.

Semi-permanent patching can be done during the winter, although hot-mix materials cannot be used below 40 degrees F. In this method, crews remove water and debris from the pothole using a broom, shovel, compressed air, or other means. They straighten the edges of the hole, making them as vertical as possible, using a jackhammer, paving saw,  milling machines, or other device. Next, they place the mix by hand using a shovel and rake. Placement should be in 3-inch or smaller lifts. The patch is compacted from the center of the repair to the edges to provide better compaction at the edges and corners. Crews may use a vibratory plate compactor or single-drum vibratory roller for this step. The result  is a tightly compacted, semi-permanent repair.

Edge seal uses a cold-mix throw-and-roll patch sealed around the edges with an asphalt-based sealant.

Spray injection is a good winter repair method because it is highly mechanized. When using a self-contained patcher, the repair machine operator completes the whole repair job in four steps, working from a heated cab.

Materials help

High-quality aggregates in repair mixes provide a common way to improve winter pothole repairs.

In Lawrence, Kansas, crews go a step further, adding geosynthetics. A small layer of geosynthetic material is placed in the hole, says Public Works Field Supervisor Bryce Campbell. This material costs from $1 to $5 a square yard, but can prevent water from eroding the repair.

After geosynthetic placement, the winter pothole is filled with a high-quality cold-mix. The average pothole repair cost is $6.06, including labor and materials.

In Arlington County, Virginia, asphalt-covered cement bases cause winter potholes because the two materials expand and contract at differing rates. Repeated pressure from plowing adds to the stress.

The county also cites winter water-main breaks as a pothole causer since many local mains are old and made of brittle cast-iron.

Cold-mix temporary repairs are used until warmer weather allows for semi-permanent repairs.

In Colorado Springs, a high-performance cold-mix asphalt patch is used in the winter. It costs five times as much as a hot-mix patch and lasts a shorter length of time.

Dickinson County, Michigan was one of the agencies to switch to spray-injected patching soon after its development. The county uses a self-propelled Rosco (Leeboy) unit that lets them repair to 30 degrees F.

The method includes four steps:

1. The hole is cleaned. A high-volume blower provides a blast of air to remove loose rock and debris.

2. A tack coat of hot emulsion is applied to the area to be patched.

3. Aggregate and hot emulsion are combined with forced air and shot into the hole.

4. A dust coat of aggregate is applied. Traffic can be returned to the road immediately.

A single-operator unit applies patching material.

No extra crew is needed with self-contained injection patching.

Injection Patching Steps

1 Clean the hole with a high-volume blower to remove loose rock and debris.

2 Apply a tack coat of hot emulsion to the area to be patched.

3 Shoot aggregate and hot emulsion combined with forced air into the hole.

4 Top the patch with a dust coat of aggregate.

Miller-Bradford & Risberg in Negaunee, Michigan, completed studies showing that repairs made with automated injection patchers last two to three times longer than repairs made by traditional methods. On average, the firm reports, repairs stay in place for 43 months.

Injection patching

Agencies are turning to spray injection patching for winter pothole repairs. Used all year, the units also improve crew safety. In Dickinson County, for instance, the operator never leaves the truck cab. A flashing-arrow panel at the rear of the truck keeps traffic informed as to how to move around the repairing unit. On two-lane roads, flaggers are used in conjunction with the patcher.

Proprietary, self-contained patchers are the top of the spray injection patching line. Other models include trailer units or units modified for the agencies’ own trucks.

Trailer units require more workers’ exposure to the weather, but cost less initially than self-contained patchers. Since the operator of a trailer unit is standing at the pothole operating the sprayer, he or she can hold the hose and nozzle close to the damaged area to reduce overspray.

Systems using air delivery stand up to abrasible aggregates better than those using auger delivery, according to a report by  Andrew Griffith, P.E., for the Oregon Department of Transportation.

Self-contained units cost around $125,000, Griffith says, while trailer units and modified units to fit on agency trucks cost about $40,000 to $45,000.

The number of potholes repaired annually can help the agency determine which unit is the more economical for their use.

Reprinted from Better Roads Magazine
November 2005

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