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. #:
Project Desc.:
(cont'd.)
Date:

1234.56
Project Name
XXXX County
Rev'd - 7/8/09
Mainline and Ramp Reconstruction

INPUT PARAMETERS:
Construction Year
Design Life (use 50 years for determining pavement thickness)
1.
2.
Projected Construction Year AADT
3.
Percent Heavy Trucks Class 4 or greater
4.
Percent Trucks in Design Direction
5.
Percent Trucks in Design Lane
6.
Truck Equivalency Factor (avg. ESAL per truck)
7.
Truck Volume Growth Rate
8.
Annual Truck Weight Growth Rate
Mr Value
08
YES
NO
NO
NO
NO
NO

Enter the Functional Classification Code of the highway

Does this road have full or partial access control?
Is there a possibility of damaging homes, historic sites,
etc., due to excessive vibration during compaction.
Will there will be less than 2000 MT of each course placed?
Is the highway located in either Dutchess, Orange, Rockland, Putnam,
Westchester, Nassau, Suffolk, Sullivan County or the City of New York?
Is the highway located in either Orange, Rockland, Putnam,
Westchester, Nassau, Suffolk CountIes or the City of New York?
Are there are more than 3 lanes on this road?

2010
50
2500
70.0
50
100
1.35
2.00%
0.50%
34

Partial

Rens. County

RESULTS:
AADT for Design Year 2060

Use asphalt series for low volume roads.

Total 80 kN ESAL Count for the Design Life

6,597

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
Total HMA Thickness
SELECT GRANULAR SUBGRADE
(enter # from table at right)
mm
150

44,651,609
250
mm
GRAVEL

BASE

BINDER

TOP

mm
300

mm
135

mm
65

mm
50

ACTUAL PAVEMENT THICKNESSES TO USE

SELECT GRANULAR SUBGRADE

GRAVEL
BASE
BINDER
TOP

enter number from table at right

THICKNESS
150 mm
300 mm
150 mm
65 mm
50 mm

80 Kn ESALs
over Design Life
millions
<4
4-7
> 7 - 13
> 13 - 23
> 23 - 40
> 40 - 70
> 70 - 130
> 130 - 235
> 235 - 300

Total HMA Thickness

mm
165
175
200
225
250
250
250
250
250

Select Granular Subgrade

Thickness
mm
0
0
0
0
0
150
300
450
600

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. #:
Project Description:
Date:

1234.56
Project Name
Rev'd - 7/8/09

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

2010
20
2500
70
50
100
1.35
2.00%
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

Use asphalt series for low volume roads.

Total 80 kN ESAL Count for the Design Life

3,642

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 Nu
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)

PAVE Item Number Descriptions

Reference to the Coarse Aggregate Friction Requirement

. XX

vement Shoulder Course)

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

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 Adjustmen
4 - Pavement Smoothness Quality Adjustment

ction Requirement

lume Pavements
000 on 4 or more lanes)
me Pavements
000 on 4 or more lanes)

000 on 4 or more lanes)

der, and T & L Courses

M
Metric
Spec.
Currently 1

ty Adjustment Items

Item (Core Item)

n Quality Adjustment
sity Quality Adjustment
nt Density Quality Adjustment
othness Quality Adjustment

FUNCTIONAL CLASSIFICATION

RURAL
Functional
Classification
Code
1
2
6
7
8
9

Description
Principal Arterial - Interstate
Principal Arterial - Other
Minor Arterial
Major Collector
Minor Collector
Local

Functional
Classification
Code
11
12
14
16
17
19

CATION

URBAN

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

ROADWAY INFORMATION
8

01
02
06
07
08
09
11
12
14
16
17
19

#N/A

01 - Rural Principal Arterial - In

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

0
has
is no

yes
no

more
is not

no
no

less than 4

no

3,642
no

11,119,144

This road will have full or partial access control.

There is a possibility of damaging homes, historic sites, etc.,
due to excessive vibration during compaction.
There will be less than 2000 MT of each course placed.
The highway is located in either Dutchess, Orange, Rockland,
Putnam, Westchester, Nassau, Suffolk, Sullivan county
or the City of New York.
There are more than 3 lanes on this road.

Design Year AADT

Hi Volume?

Total 80 kN ESAL Count for Design Life

PAVEMENT TYPE SECTION

402 XX
TOP
BINDER
BASE

50 YEAR PAVEMENT THICKNESS SHEET QUALIFIERS

B
5
5
6

2
9
9

80 Kn ESALs
over Design Life
millions
<2
2-4
>4-8
> 8 - 13
> 13 - 23
> 23 - 45
> 45 - 80
> 80 - 140
> 140 - 300

80 Kn ESALs
over Design Life
millions
<6
6 - 11
> 11 - 20
> 20 - 35
> 35 - 60
> 60 - 110
> 110 - 200
> 200 - 300

80 Kn ESALs
over Design Life
millions
< 12
12 - 20
> 20 - 40
> 40 - 65
> 65 - 115
> 115 - 215
> 215 - 300

TABLE A
Mr = 28 Mpa
Total HMA Thickness
mm
165
175
200
225
250
250
250
250
250
TABLE C
Mr = 41 Mpa
Total HMA Thickness
mm
165
175
200
225
250
250
250
250

TABLE E
Mr = 55 Mpa
Total HMA Thickness
mm
165
175
200
225
250
250
250

Select Granular Subgrade

Thickness
mm
0
0
0
0
0
150
300
450
600

80 Kn ESALs
over Design Life
millions
<4
4-7
> 7 - 13
> 13 - 23
> 23 - 40
> 40 - 70
> 70 - 130
> 130 - 235
> 235 - 300

Select Granular Subgrade

Thickness
mm
0
0
0
0
0
150
300
450

80 Kn ESALs
over Design Life
millions
<8
8 - 16
> 16 - 30
> 30 - 50
> 50 - 85
> 85 - 160
> 160 - 300

Select Granular Subgrade

Thickness
mm
0
0
0
0
0
150
300

80 Kn ESALs
over Design Life
millions
< 15
15 - 30
> 30 - 50
> 50 - 90
> 90 - 150
> 150 - 300

Rural Principal Arterial - Interstate

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
Urban Minor Arterial
Urban Collector

SPECIAL NOTE SECTION

64-28

64-28

Yes
Yes
No

storic sites, etc.,

Orange, Rockland,
ullivan county

PAVEMENT AGGREGATE SIZE

402 XX
TOP
BINDER
BASE

XX
12
25
37

TABLE B
Mr = 34 Mpa
Total HMA Thickness
mm
165
175
200
225
250
250
250
250
250
TABLE D
Mr = 48 Mpa
Total HMA Thickness
mm
165
175
200
225
250
250
250

TABLE F
Mr = 62 Mpa
Total HMA Thickness
mm
165
175
200
225
250
250

Select Granular Subgrade

Thickness
mm
0
0
0
0
0
150
300
450
600

Select Granular Subgrade

Thickness
mm
0
0
0
0
0
150
300

Select Granular Subgrade

Thickness
mm
0
0
0
0
0
150

<30

FHWA VEHICLE CLASSIFICATION

Vehicle Class
Number
1
2
3
4
5
6
7
8
9
10
11
12
13

Description
Motorcycles
Passenger cars
Other two-axle, four-tire single-unit vehicles
Buses
Two-axle, six-tire single-unit trucks
Three-axle single-unit trucks
Four-or-more-axle single-unit trucks
Four-or-less-axle single-trailer trucks
Five-axle single-trailer trucks
Six-or-more-axle single-trailer trucks
Five-or-less-axle multi-trailer trucks
Six-axle multi-trailer trucks
Seven-or-more-axle multi-trailer trucks

Sample