Two-Coat Bituminous Seal Design – Spray Rate Only

Project: McPhee Creek Iron Ore Project (PRJ0172) – GC job number: GC25013
Prepared for: Adi Suryawiraman from Corps
Date: 21/05/2025

Project Overview

*This project provides spray rate calculations and seal design recommendations based on the provided project specifications (PRJ0172-ATL-0000-CI-SPC-0001) and MRWA standards. 

Ground Civil provided seal design, surface texture and quality control requirements and helped with construction methodology.

Ground Civil requested the below information to validate final design:

1. Site-specific traffic data (e.g., ESALs, vehicle types).
2. Laboratory testing of materials (aggregate PSV, binder rheology).
3. Field verification of surface conditions prior to application.

1. Executive Summary

The final report outlines the design for the spray rate for a two-coat polymer-modified bituminous seal for Areas MC60 (39,060 m²) and MC61 (18,039 m²), per MRWA Specifications and project requirements. Key features:

• Binder: S45R polymer-modified bitumen (high-traffic grade).
• Aggregate: 16mm (1st coat) + 10mm (2nd coat) crushed rock.
• Traffic Assumption: Medium/heavy (T2-T3, 500–2,000 ESALs/day).
• Texture: MTD 1.2–1.8 mm for skid resistance.