County using new methods for paving rural roads
Staff reporter
Trying to "keep up" with the maintenance of paved roads in Marion County may seem like a never-ending task. But the Marion County Road and Bridge department is using a different resurfacing mixture these days that could significantly extend the life of the roads.
With the third largest number of miles of county roads in the state, Marion County Road and Bridge Superintendent Gerald Kelsey recognized the need to try something different.
There is a total of 1,606 miles of county roads in Marion County, which includes 768 miles of dirt roads, 650 miles of graveled roads, and 306 miles of paved roads.
"Marion County, like other counties, was following a five-year repair and replacement plan for the paved roads, but the roads weren't lasting that long," Kelsey said.
Most roads are in need of repair every two to three years with the traditional "chip and seal" method (limestone and emulsion oil) used by the county for the past 20 years.
Typically, the county would follow this process: cover the base with emulsion oil, cure it, then cover it with limestone and roll it until compressed. The base may be rock, or more recently millings (ground up pavement from old roads).
The superintendent from Clay County recommended that Kelsey try a polymer (synthetic oil that creates more elasticity) in the sealing oil and a Buildex aggregate (baked clay) in the chipping composite making the road reddish/brown in color. Clay County had used it for three years and was pleased with the results. McPherson County has also used this combination for several years with positive results.
By making these two changes in the materials, Kelsey is confident the county will see a significant increase in usage before considerable repairs are required.
"These materials cost more than the traditional emulsion oil and limestone rock," Kelsey said, "so fewer roads will be done in the future. But these roads should last longer before major repairs or replacement need to be done."
The elasticity of the polymer oil allows the road to expand and contract as the weather changes. The Buildex material is a lighter aggregate of baked clay which is less dusty than limestone.
In the past, the county has improved about 45 to 50 miles of paved roads per year. With the increase in the cost of materials, the county will do 10 to 15 fewer miles, or 30 to 35 miles per year.
The county issued a bond in 2000 for 68.5 miles of overlay, and road improvements continue to be a part of the road and bridge's annual budget.
With a six percent cut in the department's budget, Kelsey has had to decrease the department by one employee and reduce expenditures for materials and equipment. However, he is confident road projects will continue as the budget will allow.
Kelsey said that natural water springs cause the most damage to roads, with many roads being built over the drainage from the springs. The county tries to divert the drainage as much as possible by filling with large rocks or establishing a new "vein" for the water to flow.
Bridge replacement is also a necessity for Kelsey and his department.
"In the 10 years that I've been with the county, we've replaced probably 40 bridges," he said.
The county has a total of 301 bridges, which includes 213 on dirt and graveled roads, and 88 on paved roads.
The county hires an independent bridge inspector every two years, a requirement of the Kansas Department of Transportation, and follows the recommendations made at that time.
"State funds assist with the bridge replacements," Kelsey said. "The county generally matches the grant with 30 percent of the funds, and the state provides 70 percent."
When the bridges need to repaired or replaced, the planned process can take several years to complete.
Two bridge replacement projects are in progress, one by Durham and one east of the Marion Reservoir.
Spring and summer are the typical months for road improvements and replacement. This year, the department sealed 36 miles of roadway, and "fogged" 68 miles of roadway. (Fog is a thin layer of emulsion oil that allows traffic on it within an hour of being poured.)
Projects that are now being completed are blade patching, the replacement of three sets of boxed culverts, and a contract for a new bridge.
During the winter months, the department trims and removes trees that may be a road hazard, and responds to the weather with snow and ice removal.
