Selection of Claycrete Projects from 1995 - 2004 Re-visited (2006)

Ionic Soil StabiliserStabilisation ofHigher P.I. ClayBased Material

Claycrete Constructed Projects Re-visited January 2006

• Corrigin - Narembeen Road – Constructed April 2002

• Spurr Road, Kondinin – Constructed 1995

• Carstairs Road, Varley – Constructed 1996

• East Hyden Road, Hyden – Constructed Nov. 2001

• East Kalgarin Road – Constructed December 2001

• Bridge wash-away – Road re-constructed 2002

• Hyden – Southern Cross – constructed Dec. 2004

Corrigin - Narembeen Rd.

Re-constructed with

CLAYCRETE

April 2002

Photo Taken Sept. 2003Photo Taken May 2002

Re-constructed with Claycrete April 2002 and sealed within 4 weeks

Photo taken Jan. 2006


This area has a high clay material with high water retention. Major drainage required as

shown in photo.

When revisited the road looked as new, with the

shoulders and seal in un-marked condition

Travelling on this road at 110kph there was absolutely no undulations or suspension

vibrations


Spurr Road Kondinin Re-constructed with

CLAYCRETE October 1995

Road re-constructed October 1995 Nuclear Density CBR test October 1996

Test results, taken after 12 months, show a significant CBR

increase

Spurr Road section re-constructed with Claycrete by Shire of Kondinin—October 1995

Picture taken September 2003. Inspection shows road in excellent shape. NO Shire records of

any maintenance grading since construction.

Photo taken Sept. 2003

September 2003

January 2006

Loose material is easily brushed off to reveal a firm

well bound and solid pavement

Regular on-site inspections confirm NO

deterioration in the pavement or any rutting

and corrugations. In recent week there was rain on this road as the next slide will illustrate

This first section of Spurr Rd. was never stabilised

with Claycrete and has been re-sheeted and re-

constructed twice since 1995. This area received a

large downpour from cyclonic rains

The truck that travelled on this section of Spurr road also travelled on the Claycrete

constructed section adjoining approx 800m away. Next slide shows a dramatic difference.



Spurr Road Both photo’s taken the same day and the vehicle

MUST have travelled on both sections. January 2006

Constructed with Claycrete in 1995

Un-stabilised section adjoining the

Claycrete section

Carstairs Rd. Lake Varley Forestania Nickel Mine

28 km Haul Road Re-constructed

with CLAYCRETE October 1996

Carstairs Road – Lake Varley Haul road for Forestania Nickel Mine 28km re-constructed with Claycrete 1996 Mine decommissioned 2000 now sheep &

wheat farming traffic

An excellent grading of gravel stone & clay re-constructed with Claycrete

resulting in a first class tight & well bound pavement

Carstairs Road re-visited Jan. 2006 This area received cyclonic rains and flooding 2 weeks prior. Road still in

excellent trafficable & Roadworthy condition

Forestania Nickel Mine – Lake Varley - Western Australia – 1996Project: The haul route from mine to highway was used by light vehicles and school buses. Several near accidents caused the Local Government Shire to close the haul road during rain. This 28km haul road was re-constructed with Claycrete providing an ‘all weather’ pavement, with a view to safety for local & school bus traffic. Work was performed & controlled by the Shire of Lake Grace.Problem:For safety reasons, due to main school bus route, the road was closed to mine traffic during wet weather. The road was badly corrugated with un-ravelling and creating excessive dust, needing constant maintenance, also very slippery in the wet due to high clay content. The local Government Shire required an ‘All Weather’ road to safely accommodate the heavy mine hauling trucks as well as local and school bus traffic. Solution: The in-situ material had a high clay content with high plasticity and good stone content. This in-situ material was re-constructed with Claycrete resulting in considerable savings, compared with the need to import 20cm of new material for a complete re-sheeting program. The crew finished mixing one section on a Friday afternoon and decided to trim and finish the section on the following Monday. When they returned to site the road had set up with truck tyre marks in the surface. The Shire grader was unable to cut the surface and was forced to leave the marks on the pavement surface.

The tight well bound surface achieved by the Claycrete method of construction resulted with a significant reduction in ‘billowing dust’, meaning that the ‘strength’ material of the road was not blown away and lost. In an un-stabilised situation the continual loss of road ‘strength’ materials in the billowing dust blowing off the road would result with requiring re-sheeting & re-construction of the road every 18 to 24 months.

This road DID NOT require any major re-sheeting during the life of the road, also what was noticeable was NO LOSS of surface pavement material.

Conclusion:The road was never closed during wet weather for the life of the mine once the road had been re-constructed with Claycrete, also maintenance was not required on the road.

A nuclear density test for CBR increase was taken 12 months after the road was re-constructed and showed a large increase.

This road was re-visited January 2006 and photo’s & movies taken. The road, today, is still a very good trafficable AND ‘all weather’ surface

with evidence the road had sustained cyclonic rains in the last 2 weeks.A major issue with this road is that should the Authorities decide to upgrade

the road and maybe even sealing it there is no need to re-stabilise the material, even tho it was stabilised in 1996.

All that would be required is to rip the road and re-waterbind with ONLY 10% Claycrete added.

Still A Good Well Bound Surface with

Signs of only Minimal Wear, as in loose

material.

Photo’s January 2006

Re-constructed with Claycrete in 1996

East Hyden Bin Road Kondinin Western Australia

Re-constructed with

CLAYCRETE

Project Completed November 2001

Road was starting to deform and pothole with

the asphalt deteriorating. The road was ripped and the in-situ high clay gravel material was re-constructed using Claycrete. Project

completed November 2001

East Hyden Bin Road Section of Pavement Failure Across A Salt PanThe road Pavement was extensively rutted and undulating, with evidence of considerable movement under the seal. It was evident that the material was plastic and holding water. The decision was to re-work the section and stabilise with Claycrete. The existing seal was chopped & mixed into the re-worked in-situ material thus saving cost of disposal and cartage away.This photo is of the re-constructed and sealed Claycrete Pavement

Construction was undertaken by Manager of Works Shire of Kondinin, November 2001This Picture Taken September 2003.Details From CBH Show 2002-2003 Grain Haulage On This Road was 27,339 Tonnes In 365 (each way)Triple Road Train Movements Hauling An Average Of 75 Tonnes Per Load, Over & Above Local Farming Traffic Also Tourist Traffic To Wave RockThis Section of Road Is Now One Of The Main Connecting Routes To The Eastern States and used by heavy haulage interstate vehicles.

Photo taken Sept. 2003

Project re-visited October 2004 Road in first class condition with NO

Deformations or sign of damage

Photo taken Oct. 2004

Project re-visited January 2006

Crossed the road at 110kmh and there was NO sign of deformations or faults in the pavement. The asphalt is now showing

signs of ‘bleeding’ due to the current heavy haulage use


East Kalgarin Crossing re-constructed with

CLAYCRETE December 2001

East Kalgarin access roadSection of flood crossing re-constructed

with Claycrete by Manager of

WorksShire of Kondinin—December 2001

Project re-visited Sept. 2003 & Jan. 2006Inspection shows road in excellent shape.

Every year prior to the Claycrete re-construction this crossing was washed away & totally lost after every overflow

during a wet season.Pic taken after a flow over the crossing.

NO Maintenance has been required since re-constructed in December 2001

Evidence of Water Flow Over Road Is Clearly Seen

Photo taken Sept. 2003 and water flow from right to left clearly visible

September 2003 January 2006

Both photo’s show evidence of water flow over the crossing. The latest shows considerable silt

deposited on the road

January 2006

This photo clearly shows the heavy scouring caused by the large volume of water flowing

over the crossing

Bridge washaway - Kondinin

Cyclonic Rains January 2006

CLAYCRETE re-constructed

2002

Water reached here

The water flowed over this road to width of the arrow mark and a depth of 40cm over the

asphalt. The current was sufficient to wash away the bridge section

Water reached knee cap height

January 2006 Cyclone Clare dumped a record 223mm (in 24 hours) of rain on and

around Lake Grace & districts.

Reported as - A ‘once in 500 year event’

Lake Grace is located approx 200km South East of Kondinin.

The large volume of water dumped on Lake Grace has flowed to many

surrounding areas via the lake system & thus also caused flooding, even as far as

Kondinin.

This damage at Kondinin was caused by the water flow from Lake Grace’s deluge,

rather than directly from the cyclone.

Extract from West Australian newspaper Sat. 28th Jan. 2006

3 weeks after the cyclonic

rains roads and rail still remain submerged by the flooding.

Article from West

Australian newspaper 1st February

2006

The base course was a high clay gravel

material with good stone and

re-constructed with Claycrete. This photo

clearly shows the Claycrete material to

the right of the yellow line. When inspected the Claycrete section was dry, firm & well

bound with no scouring marks even tho water to 40cm deep washed

over this road. Material left of the line was

holding moisture. The flow of water started to

lift the asphalt seal. The area was totally

submerged for several days

Note

Next Slide

This photo shows the Claycrete clay gravel material still attached to the asphalt seal. This material has not broken down or washed away under the worst conditions of flooding & complete submersion for

several days.


Hyden – Southern Cross Road Re-

constructed with CLAYCRETE

December 2004

Photo taken January 2006

3km section of road re-constructed with Claycrete. Driving on this road at 110kpm was extremely

smooth with no vibrations thru the shock absorbers or steering wheel. This area received cyclonic rains

2 weeks prior to my visit.

The road is well constructed with excellent drainage and constructed with Claycrete from

shoulder to shoulder. Thus if a vehicle's tyres leave the asphalt they will not damage the un-

sealed areas nor the asphalt edge


16/100 Briggs Street16/100 Briggs StreetWelshpool 6106Welshpool 6106

Western AustraliaWestern Australia

Email : [email protected] [email protected]

TEL : +61(8) 9470 9117FAX : +61(8) 9472 4366

mailto:[email protected]

Selection of Claycrete Projects from 1995 - 2004 Re-visited (2006)

Technology

Transcript of Selection of Claycrete Projects from 1995 - 2004 Re-visited (2006)