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HomeMy Public PortalAboutPerma-Zyme Instruction Manual.pdf i isle: 1 1 . 4:' . .-.0,'.1:: , .... - .j . INSTRUCTIO i i ,. .:, ._. , MANUAL , pERmA. zymE SUBSTRATA.US I +1 (702) 825-5200 7330 Eastgate Rd #150 Henderson NV, 89011 • • • PURPOSE OF MANUAL 2 PERMA-ZYME OVERVIEW 3 Perma-Zyme Description 3 Uses of Perma-Zyme 3 Storage 3 Handling 4 Disposal 4 DESIGN PARAMETERS 5 Soil Requirements 5 Perma-Zyme Amount Calculation 6 Water and Perma-Zyme 7 Equipment Required 8 Weather Requirements 8 UNPAVED ROAD CONSTRUCTION Design Parameters 9 Application Procedure 11 PAVED ROAD CONSTRUCTION 13 Design Parameters 13 Application Procedure 17 TROUBLESHOOTING 20 Washboarding 20 Excessive Dust 21 Wet Soil 21 Soil Wont Harden 22 Superficial Cracking 23 Large Cracking 24 COPYRIGHT AND LEGAL INDEX 26 TABLE OF CONTENTS 1 SUBSTRATA® Version 1.0 Copyright O 2022 Substrata,LLC.All Rights Reserved . . 11 • LA AL A . ;. . This manual is intended to detail the use of Perma-Zyme when used as a soil stabilizer.This manual will detail how Perma- Zyme works and the various applications in which Perma-Zyme can be used, including unpaved roads, paved roads, and pond lining. This manual can be used as a guide for application, however, the construction of finished road surfaces in case of paved roads shall be carried out according to its relevant standards and practices. Information about product safe handling, disposal and general precautions can be found on Perma-Zyme Safety Precautions and Disposal. The purpose of this manual is to assist users for application of the soil stabilizer i.e. Perma-Zyme, as well as identify phases in the whole procedure of application and their effect to achieve appropriate results. It is important to follow all safety precautions and manufacturers' warnings when operating heavy equipment. This manual is not a guide for using heavy equipment, please consult the manufacturer's manual. Users of this document will be able to: • Gain understanding of moisture content for soil and its importance for road construction • Understand the compaction and its contribution to surface strength • Recognize the parameters for correct road profile and water drainage • Review the procedure before they commence road work • Prepare in advance for necessities during application and final finish PURPOSE OF MANUAL 2 - SUBSTRATA® Version 1.0 Copyright O 2022 Substrata,LLC.All Rights Reserved • • F T - r - +` 'f F . F ! 4 Y f 1 _ { r v • • *i • • M' 4Yx t,. f • { - - • wr a. P. i • - • dJ ■ ,• k 1 1 • • PERMA-ZYME DESCRIPTION Perma-Zyme is an enzyme-based soil stabilizer. Perma-Zyme interacts with the organic content in the soil and permanently bonds the soil particles together to create a concrete-like surface that will last over 10 years. Perma-Zyme is used for unpaved roads, the base layer of paved roads, and pond lining. Since Perma-Zyme is an enzyme-based product, the solution is 100% non-toxic, non-hazardous, and environmentally friendly. USES OF PERMA-ZYME UNPAVED ROADS Using Perma-Zyme to construct unpaved roads is the most popular use of Perma-Zyme. When using Perma-Zyme to construct an unpaved road, the roadway can become concrete-like for over 10 years and resilient in all climates including rain and snow.This is highly effective because this substantially reduces maintenance costs tied to traditional unpaved roads. PAVED ROADS Perma-Zyme treated subbases for paved roads are unique and offer a substantial cost savings to the end user. The cost savings is immediate because the construction costs can be decreased by up to 80%. This is because with Perma-Zyme subbases there is often no need to import traditional aggregate subbase and asphalt requirements may be decreased. Using Perma-Zyme as the subbase allows rural areas the opportunity to have paved roads that were not once an option because of budget. POND LINING Lining ponds with Perma-Zyme will decrease seepage and erosion. Prior to filling the pond, apply Perma-Zyme with the typical method and allow for the soil to cure. Because Perma-Zyme is environmentally friendly and non-toxic, the water and ecosystem will not be harmed. STORAGE Temperature Range: 40°F- 100°F (Room temperature) Shelf-Life: 2-3 years Avoid storing Perma-Zyme near areas that produce extreme heat, cold, or moisture (such as steam vents) or other conditions that could warp the container material and/or compromise the air-tight seal. Store containers upright to avoid leakage. PERMA-ZYME OVERVIEW 3 SUBSTRATA. Version 1.0 Copyright O 2022 Substrata,LLC.All Rights Reserved HANDLING Perma-Zyme is a non-toxic solution and is NOT classified as posing any significant risk to human health, personal protection, or physical hazard and is not flammable. However, it is recommended that the following general precautions be observed: EYE PROTECTION Always wear proper eye protection. This product may splash during normal use. If contact with eyes is made,flush eyes with clean water immediately,for 10 minutes. If any adverse reaction occurs, seek medical attention. SKIN Avoid prolonged skin contact by wearing gloves and long sleeves. If contact with skin is made, remove contaminated clothing and wash skin thoroughly with clean water and mild soap. In the rare case that Perma-Zyme causes skin irritation, seek medical attention. INGESTION If swallowed, nausea or upset stomach may occur. Do not induce vomiting. Drink plenty of water to dilute. Immediately consult your physician. For more handling information see the Perma-Zyme Safety Data Sheet. DISPOSAL CLEAN UP Avoid spills and clean up immediately. Prevent product from spreading by using sand,earth,clay,or containment material to absorb spilled material. Slippery when spilled. MATERIAL DISPOSAL Recover or recycle if possible. Do NOT dispose into drains, bodies of water, or environment in concentrated form. Solidify product and dispose in approved landfill. Check with local, regional, and/or national regulations for appropriate methods of disposal. DISPOSAL Containers may be offered for recycling. For more disposal information see the Perma-Zyme Safety Data Sheet. PERMA-ZYME OVERVIEW 4 SUBSTRATA. Version 1.0 Copyright O 2022 Substrata,LLC.All Rights Reserved A A SOIL REQUIREMENTS In order for Perma-Zyme to work effectively,the soil must meet certain requirements. The most important requirement for soil compatibility with Perma-Zyme is that there must be organic content in the soil.This usually means there must be clay in the soil. The best way to determine if there is organic content is to find out if the soil is plastic or not. If the soil is plastic,then the soil will be compatible with Perma-Zyme. If the soil is not plastic then it will most likely not be compatible with Perma-Zyme unless another additive is added. The next factor to consider for the soil is the sieve sizes. It is good to have a variety of different sizes in the soil. If the soil has all fines or majority rocks it is recommended to import other material so the material can compact properly and the Perma-Zyme can cure properly. RECOMMENDED SOIL TESTS ASTM C117, C136- Sieve Analysis The ASTM C117 and C136 are standard sieve analysis tests. It is vital to have a sieve analysis done prior to the Perma- Zyme application to ensure that the soil has at least 20%passing the#200 sieve.Soils outside with less than 15%are NOT compatible. It is also ideal to have a variety of other sieve sizes inside the soil. This gives the Perma-Zyme something to bond to. ASTM D1557- Proctor Test The ASTM D1557 (Proctor Test) measures the soil's optimum moisture content which allows the soil to reach optimum density.This test is important to ensure the likelihood the soil will reach optimum density and will be as strong as possible once fully cured. ASTM D4318-Atterberg Limits The Atterberg limits are a basic measure of the critical water contents of a fine-grained soil: its shrinkage limit, plastic limit, and liquid limit. Depending on its water content, a soil may appear in one of four states: solid, semi-solid, plastic and liquid. In each state, the consistency and behavior of a soil is different and consequently, so are its engineering properties. Thus, the boundary between each state can be defined based on a change in the soil's behavior.The Atterberg limits can be used to distinguish between silt and clay, as well as distinguish between different types of silts and clays. The water content at which the soil changes from one state to the other are known as consistency limits or Atterberg limit. The Atterberg Limits test will determine the soil's plasticity,thus the soil's compatibility with Perma-Zyme. DESIGN PARAMETERS 5 SUBSTRATA. Version 1.0 Copyright O 2022 Substrata,LLC.All Rights Reserved HAND COMPATIBILITY TEST The best way to determine if the soil is plastic is to conduct a laboratory test (see RECOMMENDED SOIL TESTS). If a laboratory test is unavailable,a hand test may be performed.Although this test is not the most accurate, it is a good test to run as a quick determination if the soil might be compatible or not. * IMPORTANT: The Hand Compatibility Test might show the soil is plastic. A laboratory test might show different results. W: O Use this QR code to be directed to Substrata's at home Soil Test Kit PERMA-ZYME AMOUNT CALCULATION Perma-Zyme is used on a soil consumption basis, this means that the amount of soil you are treating is dependent on how much Perma-Zyme you will use. For general applications the usage rate is 1 gallon of Perma-Zyme will treat 160 cubic yards of soil. To determine how much Perma-Zyme the project requires, you must calculate the number of cubic yards of soil to be treated. Follow the steps below. STEP 1 Determine cubic yardage of project. STEP 2 Determine amount of Perma-Zyme needed. ROAD DIMENSIONS Length = 5280 feet Width = 20 feet Depth = .5 feet (5280 X 20 X 0.5) Soil Cubic Yardage = 27 = 1955.56 cubic yards 1955.56 Perma-Zyme Required (Gallons) _ 160 = 12.22 Gallons of Perma-Zyme DESIGN PARAMETERS 6 SUBSTRATA Version 1.0 Copyright 0 2022 Substrata,LLC.All Rights Reserved WATER AND PERMA-ZYME The ratio between water and Perma-Zyme is of utmost importance because there is no dilution rate throughout the Perma- Zyme application process. Substrata recommends that the amount of water that is added towards the application be dependent on the level of the soil's current moisture level and the soil's optimum moisture level. Substrata recommends that the soil's moisture level be at optimum moisture or as close to optimum moisture as possible prior to compaction. With all of this in mind, there are many factors that will dictate how much water will need to be added to the soil. These include the soil's current moisture content,the soil's optimum moisture content, and the climate (i.e. hot, humid, cloudy, etc). If the Proctor Test was performed by a laboratory,then the soil's current and optimum moisture content is known. With that information, an estimate on the amount of water needed can be calculated. See the example below. SOIL PROPERTIES Optimum Moisture = 14% Soil Moisture = 4% Soil Weight = 3105 pounds/cubic yards Soil Cubic Yardage = 1955.56 cubic yards aai - 4% Water% Required = 27 = 10%water required 1955. X X 10% Water Required = 8.34 = 72,805 Gallons of Water Performing these calculations will give you a rough idea of how much water and how many water trucks you will need. It is also important to consider additional factors for construction day such as: • What is the temperature? Is it sunny? • How far is the water source for the job site? • What is the humidity like? • How far off is the soil's moisture from optimum moisture? All the factors above will impact the soil and its ability to take on more water. It is very common for jobsites to have two or three water trucks because water is that vital to the success of Perma-Zyme. While on site, the moisture content should be constantly monitored in various locations throughout the jobsite by performing the hand test detailed below. Pick up a handful of soil. Squeeze it in your hand. Open your hand. If the soil is powdery and will not retain the shape made by your hand, it is too dry. If it shatters when dropped, it is too dry. If the soil is moldable and breaks into only a couple of pieces when dropped, it has the right amount of moisture for proper compaction. If the soil is plastic in your hand, leaves small traces of moisture on your fingers and stays in one piece when dropped, it has too much moisture for compaction. DESIGN PARAMETERS 7SUBSTRATA. Version 1.0 Copyright©2022 Substrata,LLC.All Rights Reserved EQUIPMENT REQUIRED OPTIONAL 11.1.116) AL rio ® ® �i� 1 ii o Q o o • •• �� '■ 'II. ® ®.� ^III WATER TRUCK GRADER SMOOTH WHEEL PADFOOT RECLAIMER ROLLER COMPACTOR MOTOR GRADER Substrata recommends using two (2) Cat 140G Motor Graders or equivalent. The prevailing features that will be utilized are the grading and the ripping attachments. It is important to note that the ripper attachment should have the capability to go at least 6 inches deep. WATER TRUCK For most Perma-Zyme projects, two (2) 3,000-gallon water trucks or larger are recommended. Although Perma-Zyme is a non-toxic and non-hazardous product,the water trucks should be for non-potable water use. SHEEPSFOOT COMPACTOR/ PADFOOT COMPACTOR Although a Sheepsfoot or Padfoot Compactor is not required, it is highly recommended. A Sheepsfoot/Padfoot Compactor is recommended because it allows for very aggressive compaction which will be very helpful during the application process.A Sheepsfoot/Padfoot Compactor with vibratory functionality is the main recommendation,the size is dependent on preference and local availability. SMOOTH WHEEL ROLLER A smooth wheel drum compactor with vibratory is required for all applications of Perma-Zyme.The vibratory functionality is vital throughout the compaction process as it will aid in the compaction of the rocks and particles, moving them around and allowing them to bind properly. RECLAIMER A reclaimer is not required for all projects but are necessary for certain projects such as Full Depth Reclamation (FDR). Users might elect to use a reclaimer for projects when not required due to the ease. The Reclaimer will pulverize the asphalt and/or soil and mix water at the same time. If you have questions about using Perma-Zyme with a Reclaimer, please contact Substrata. WEATHER REQUIREMENTS Prior to applying Perma-Zyme, be sure to consider weather factors such as precipitation and temperature. When applying Perma-Zyme, Substrata recommends that you apply Perma-Zyme when there is no rain in the forecast for at least 3 consecutive days. If there is an unexpected rainstorm within the 3-day timeframe and the roadway has been compromised, rewet the surface if needed and recompact(see the TROUBLESHOOTING section for re-application directions). In the event there was a very large rainstorm, and the surface has been completely compromised and needs to be redone, please contact Substrata. The temperature is an important factor when applying Perma-Zyme. If the temperature is too cold, Perma-Zyme will not fully cure thus will not harden to the desired strength. Substrata recommends applying Perma-Zyme when temperatures are above 40 degrees Fahrenheit for at least 72 hours after application. There is no limitation how hot the temperature can be during the application. It is common for the curing process to take longer during cooler temperatures. DESIGN PARAMETERS 8 SUBSTRATA Version 1.0 Copyright©2022 Substrata,LLC.All Rights Reserved UNPAVED - • • • ' _ DESIGN PARAMETERS TREATMENT DEPTH The biggest factor to keep in mind when considering the depth for Unpaved Roads is what kind of traffic will be expected on the surface, i.e., weight, and at what frequency. (TUTEUQ 3 6 O INCHES INCHES • i • LIGHT TRAFFIC REGULAR TRAFFIC HEAVY TRAFFIC 3 inch treatment depth 6 inch treatment depth 9-12 inch treatment depth For light duty roadways, such as residential roadways that will see mostly passenger vehicles, the recommended depth is 4-6 inches. For roadways that will see medium to heavy weight vehicles, such farming roads or rural roadways with consistent semi- truck traffic,the recommended depth is 6-9 inches. For scenarios that see extremely heavy weight traffic, such as mining or logging vehicles, the recommended depth is 12+ inches. A WARNING: Please contact Substrata for questions regarding the depth of your application. Failure to treat the proper application can result in a failure in the roadway. *NOTE: It is important to compact the soil properly. See UNPAVED ROAD APPLICATION PROCEDURE for instructions on how to compact the soil. DRAINAGE Prior to the construction of the roadway drainage must be considered. If not, water will sit on the roadway and cause expedited wear of the surface. It is recommended that prior to constructing the roadway,ditches or trenches are formed along both sides of the roadway. It is important to note that these ditches or trenches should be lower than the roadway. Forming ditches on either side of the roadway and properly forming the roadway's surface profile(see SURFACE PROFILE) will force water to shed off the surface and into the ditches. This helps elongate the surface's lifespan. UNPAVED ROAD CONSTRUCTION 9 - SUBSTRATA® Version 1.0 Copyright O 2022 Substrata,LLC.All Rights Reserved SURFACE PROFILE In order to have a roadway that can drain properly the surface must be shaped properly. It is necessary, not only for proper functioning, but also to ensure a long surface life of the road.A slight crown running at the centerline of the road will force water to move towards the ditches. As a standard practice, the crown should be created with an increment of half degree per foot towards the center line. Substrata recommends that the profile not be too steep so as to cause traffic issues. CROWN SLOPE 3in SLOPE DITCH SUBBASE DITCH • • . • • • • SUBGRADE , • •• • For example, if constructing a 24 ft wide road,with a center line at 12ft from the sides,the crown will be 3 inches higher than the edges. In the event of turns for the road, the surface must be higher at the outside edge. This will force the water to drain at the inside of the turn. SURFACE TREATMENT Upon completion of construction with Perma-Zyme the surface will be concrete-like.The user may or may not choose to apply a treatment to the surface. The typical treatment would be gravel. The recommended thickness will depend on different uses and preferences, but would range from 3 inches to 12 inches. If a gravel treatment is to be applied, wait for the soil to fully cure prior to the application of gravel. Applying the gravel too early could result in the soil not properly curing. TYPICAL TIMELINE For the first application, Substrata recommends a length of no more than half of a mile long. Once familiarity has been built with Perma-Zyme length can be added.Traditionally, one half of a mile can be accomplished in one day but this will depend on factors such as the ability of construction crew, availability of water, etc. Below is an example timeline of the construction Unpaved Road process with Perma-Zyme. For detailed instructions of each step see the APPLICATION PROCEDURE section. Day 1 - Rip the soil, pre-wet, and form large windrows, let sit overnight Day 2 - Unfold windrows, apply Perma-Zyme, shape roadway surface, compact Day 3 -Allow soil to dry Day 4- Open roadway to light traffic Day 5 - Open roadway to regular traffic dependent on soil being fully dry UNPAVED ROAD CONSTRUCTION i 10 SUBSTRATA - Version 1.0 Copyright 0 2022 Substrata,LLC.All Rights Reserved APPLICATION PROCEDURE STEP OVERVIEW Below are step by step instructions of how to apply and construct a road with Perma-Zyme.Although all soils, roads, and construction techniques are different, these instructions are meant to give a general overview of how to apply Perma- Zyme. g 1�� • •- O4 o fAIERTRU Scarify soil Begin applying water Apply Perma-Zyme Bring soil to optimum moisture AV a koclemtoi An. Shape roadway Compact surface Allow soil to dry RIPPING The first step in the application process is to rip up the soil. This can be performed by using the ripper attachment on the back of the Grader or a Reclaimer. At this 111111. 11 _Mr =. %' • . point,the goal is to bring up the fresh soil from underneath the surface. The depth at which the soil is ripped will be dependent on the depth at which the soil will be treated, i.e. if the soil depth to be treated with Perma-Zyme is 6 inches, the soil will need to be ripped to a depth of 6 inches. gOo ` * IMPORTANT. Prior to ripping the soil, remove any topsoil and/or vegetation from the surface. APPLY WATER AND PERMA-ZYME Once the soil has been fully pulverized the next step is to begin wetting the soil to bring the soil's moisture level up to optimum moisture and apply Perma-Zyme. This process will most likely differ from job to job, so the process detailed below is for general guidance. Begin saturating the soil with water. Once the top of the soil begins to become thoroughly saturated, use the Grader to form a windrow and push the windrow from one side of the roadway to the other. At the same time, keep applying water to the soil. As the windrow is being formed, slowly increase the depth of the windrow, ensuring the depth does not exceed the desired treated depth. As the water is constantly being applied and the soil's windrows are constantly being moved back and forth, keep constantly checking the soil's moisture content by using the Hand Test to ensure the soil is not becoming too wet. 410 —______ NON-POTABLE WATER WATER TRUCK • Step 1:Fill water truck with water Step 2:Pour Perma-Zyme into the water truck Once the soil is at about 80%towards its optimum moisture, apply Perma-Zyme to the soil. It is recommended to fill the water truck, pour the desired amount of Perma-Zyme into the truck, and mix (this can be done with an on-board pump or by driving the water truck for 15-20 minutes). UNPAVED ROAD CONSTRUCTION — 11 SUBSTRATA Version 1.0 Copyright 0 2022 Substrata,LLC.All Rights Reserved MIXING AND SHAPING Upon applying Perma-Zyme to the soil, the soil's moisture content should now be very close to optimum moisture. At this time, continue forming a windrow and moving it from one side of the road to the other. The purpose is to thoroughly / mix and coat the soil particles in the water and Perma-Zyme mixture as much as possible. Depending on the soil and climate conditions, it is common for the soil to Tr- begin to dry. If that begins to happen, apply more water. • .4 , a , Once the water and Perma-Zyme have been thoroughly mixed into the soil, • • • • a begin shaping the road. As mentioned in the DESIGN PERAMETERS section, it • is recommended to construct the roadway with a crown to ensure the water will properly shed on the surface. * NOTE: If at any point during this time the soil begins to dry, immediately apply more water. COMPACTION Once the soil has been thoroughly mixed with Perma-Zyme and shaped,compaction is the next step. If a Padfoot/Sheepsfoot Compactor is available begin compacting 'i the surface with the vibratory functionality turned on. Slowly operate the Padfoot/ Sheepsfoot Compactor up and down the surface while overlapping each path about ` 444, 25%to ensure optimum compaction. Use the Padfoot/Sheepsfoot Compactor until O O the surface has been approximately 80% compacted. If a Padfoot/Sheepsfoot Compactor is not available, it is recommended to fill a • 4 • • • 'A water truck and slowly drive down the roadway. This is often referred to "Wheel Packing". When performing Wheel Packing it is important to operate the water truck slowly and ensure the tire tracks overlap to ensure the soil reaches optimum compaction. Once the soil has reached approximately 80%compaction, begin using the Smooth 1.0 Wheel Drum Compactor with the vibratory functionality turned on. Operate the Smooth Wheel Drum Compactor slowly along the roadway overlapping the previous path to ensure the soil has been thoroughly compacted. Once the soil has in. been thoroughly compacted,turn off the vibratory functionality and perform some ow final few passes with just the Smooth Wheel Drum Compactor. • • * NOTE: If at any point during this time the soil begins to dry, immediately apply _ • • • more water. POST APPLICATION/CURING TIME ■� Upon completion of the compaction, the construction of the roadway is complete. Substrata recommends no traffic on the roadway for at least 24 hours. In the • event the application cannot allow for that, we recommend ensuring the soil is thoroughly dried prior to allowing traffic on the roadway. When allowing traffic on the roadway, only allow light traffic on the roadway for the first 72 hours. This 111F1-iii I means light duty work trucks (-30,000 pounds and under).After 72 hours and after the soil has thoroughly dried, apply heavy duty vehicles and traffic can be allowed - 0 on the surface. In the event of a rainstorm,or if the surface has become deteriorated somehow,the surface can be repaired by re-applying Perma-Zyme (-1000:1) to the surface. A grader would then be used to reshape the surface as desired. Upon reaching the desired the surface, use a Smooth Wheel Drum Compactor to compact the soil to the appropriate compaction level. UNPAVED ROAD CONSTRUCTION 12 I SUBSTRATA. Version 1.0 Copyright O 2022 Substrata,LLC.All Rights Reserved '# . ' . Ji. 1 '''' r "Irt. ' a jo. 4.„,:l r . . i 1 re..,— 'ki ii 1 4. PP * - -- I�.— - - - •- PAVED ROAD • ► • ► DESIGN PARAMETERS TREATMENT DEPTH The biggest factor to keep in mind when considering the depth for Paved Roads is what kind of traffic will be on the surface, i.e., weight, and at what frequency. WW1 Q 12 6 INCHES 3 INCHES INCHES • • •• . - • LIGHT TRAFFIC REGULAR TRAFFIC HEAVY TRAFFIC 3 inch treatment depth 6 inch treatment depth 9-12 inch treatment depth For light duty roadways, such as residential roadways that will see mostly passenger vehicles, the recommended depth is 4-6 inches. For roadways that will see medium to heavy weight vehicles, such farming roads or rural roadways with constant semi- truck traffic,the recommended depth is 6-9 inches. For scenarios that see extremely heavy weight traffic, such as mining or logging vehicles, the recommended depth is 12+ inches. A WARNING: Please contact Substrata for questions regarding the depth of your application. Failure to treat the proper application can result in a failure in the roadway. •NOTE: It is important to compact the soil properly. See the PAVED ROAD APPLICATION PROCEDURE for instructions on how to compact the soil. DRAINAGE Prior to the construction of the roadway drainage must be considered. If not, water will sit on the roadway and cause expedited wear of the surface. It is recommended that prior to constructing the roadway,ditches or trenches are formed along both sides of the roadway. It is important to note that these ditches or trenches should be lower than the roadway. Forming ditches on either side of the roadway and properly forming the roadway's surface profile(see SURFACE PROFILE) will force water to shed off the surface and into the ditches. This helps elongate the surface's lifespan. PAVED ROAD CONSTRUCTION - 13 SUBSTRATA. Version 1.0 Copyright O 2022 Substrata,LLC.All Rights Reserved SURFACE PROFILE To have a roadway that can drain properly the surface must be shaped accordingly. It is necessary not only for proper functioning but also for long service life of the road.A slight crown running at the centerline of the road will force water to move towards the ditches.As a standard practice,the crown should be created with an increment of one-half degree per foot towards the centerline. It should be taken into consideration that the profile is not too steep as to cause traffic issues. CROWN SLOPE 3in SLOPE DITCH SUBBASE DITCH • , , • • • • • • • • SUBGRADE , • • • - • For example, if we are constructing a 24 ft wide road, with a centerline at 12ft from the sides,the crown will be 3 inches higher than the edges. In the event of turns for the road,the surface must be higher at the outside edge. This will force the water to drain at the inside of the turn. TOPCOAT TREATMENT Chipseal Because Perma-Zyme offers a strong and resilient subbase, often times a few layers of chip seal are able to be applied on top of the Perma-Zyme treated surface.This provides the aesthetic and feel of a paved road at a fraction of the cost. It is important to note that this type of application is not ideal for all scenarios. Traditionally, this application succeeds in lower traffic applications. To apply Chip Seal on top of a Perma-Zyme treated subbase, Substrata recommends waiting at least three (3) days for the soil to dry properly and begin curing. Prior to applying the Chipseal, apply a lightly diluted mixture of Perma-Zyme and water(-10,000:1), and then apply the Chipseal. For application questions please contact Substrata or a professional engineer. CHIPSEAL • • • • - • PAVED ROAD CONSTRUCTION 14 SUBSTRATA Version 1.0 Copyright 0 2022 Substrata,LLC.All Rights Reserved Asphalt Asphalt is a traditional topcoat for paved roads.The depth of the asphalt often varies depending on the traffic, subbase, and native soil. The recommended depth of the asphalt is provided by a professional engineer. To apply asphalt on top of a Perma-Zyme treated subbase, wait at least three (3) days for the soil to dry properly and begin curing. Prior to applying the asphalt apply a lightly diluted mixture of Perma-Zyme and water(-10,000:1),and then apply the asphalt. For application questions please contact Substrata or a professional engineer. ASPHALT • Concrete Concrete is used as an occasional topcoat for paved roads. The depth of the concrete often varies depending on the traffic, subbase, and native soil. The recommended depth of the concrete is provided by a professional engineer. To apply concrete on top of a Perma-Zyme treated subbase, wait at least three (3) days for the soil to dry properly and begin curing. Prior to applying the concrete, apply a lightly diluted mixture of Perma-Zyme and water (-10,000:1), and then apply the asphalt. For application questions please contact Substrata or a professional engineer. CEMENT • • PAVED ROAD CONSTRUCTION 15 SUBSTRATA Version 1.0 Copyright 0 2022 Substrata,LLC.All Rights Reserved Full Depth Reclamation Full Depth Reclamation is a process of revitalizing a paved road. Traditionally, Full Depth Reclamation projects are completed with a specific piece of equipment called a Reclaimer. This equipment grinds up the existing paved surface and subbase and allows the millings to then be used as the new subbase material. Utilizing Perma-Zyme with Full Depth Reclamation projects increases the strength of the subbase and eliminates the need to use other additives. When performing Full Depth Reclamation applications with a reclaimer or other pieces of equipment, ensure the depth of reclamation is deep enough to mix the native soil so that the minimum requirements for Perma-Zyme are met.Another option would be to import clay or a compatible material post reclamation to ensure Perma-Zyme is compatible. When using Perma-Zyme in Full Depth Reclamation applications ensure the following requirements are still met: • Greater than 15% passing #200 sieve in entire soil composition • Subbase material has reached optimum moisture • Subbase material has reached maximum compaction Road Reclaim Grinder r'O<IK�y���"t. 4iik•r�ilj:► �,t�io Aggregate G�e���•�I_4rlh►���if�" �.� �1•IV is I'ik� Asphalt 0 liV1rA' `ti irk(416.41-A-ril Native Soil TYPICAL TIMELINE For the first application, Substrata recommends a length of no more than one-half a mile long. Once familiarity has been built with Perma-Zyme length can be added.Traditionally, one-half of a mile can be accomplished in one day but this will depend on factors such as ability of construction crew, availability of water, etc. Below is an example timeline of the construction Paved Road process with Perma-Zyme. For detailed instructions of each step see the PAVED ROAD APPLICATION PROCEDURE. Day 1 - Rip the soil, pre-wet, and form large windrows, let sit overnight Day 2 - Unfold windrows, apply Perma-Zyme, shape roadway surface, compact Day 3 -Allow soil to dry Day 4- Open roadway to light traffic Day 5 - Open roadway to regular traffic dependent on soil being fully dry Day 8 -Apply topcoat PAVED ROAD CONSTRUCTION - 16 SUBSTRATA Version 1.0 Copyright 0 2022 Substrata,LLC.All Rights Reserved APPLICATION PROCEDURE STEP OVERVIEW Below are step by step instructions of how to apply and construct a road with Perma-Zyme.Although all soils, roads, and construction techniques are different, these instructions are meant to give a general overview on how to apply Perma- Zyme. -'Y 1 .��iO 0 0` WATER TRU Scarify existing soil Begin applying water Apply Perma-Zyme Bring soil to optimum moisture O O O. Shape roadway Compact surface Allow soil to dry RIPPING The first step in the application process is to rip up the soil. This can be performed 4ti `V� by using the ripper attachment on the back of the Grader or a Reclaimer. At this =� ' , point,the goal is to bring up the fresh soil from underneath. illIll -- The depth at which the soil is ripped is dependent on the depth at which the soil 1111,-Ii .I will be treated, i.e., if the soil depth to be treated with Perma-Zyme is 6 inches,the / soil will need to be ripped to a depth of 6 inches. _ lOo MIMEO * IMPORTANT Prior to ripping the soil, remove any topsoil and/or vegetation from the surface. APPLY WATER AND PERMA-ZYME Once the soil has been fully pulverized, the next step is to begin wetting the soil to bring the soil's moisture level up to optimum moisture and apply Perma-Zyme.This process is not the same for every job and will most likely differ from job to job, so the process detailed below is for guidance. Begin saturating the soil with water. Once the top of the soil is beginning to become thoroughly saturated, begin using the Grader to form a windrow and push the windrow from one side of the roadway to the other.At the same time, keep applying water to the soil.As the windrow is being formed,slowly increase the depth of the windrow,ensuring the depth does not exceed the desired treated depth. As the water is constantly being applied and the soil's windrows are constantly being moved back and forth, keep constantly checking the soil's moisture content by using the Hand Test to ensure the soil is not becoming too wet. (0 --.- : `1; _ p..-Pft-ii IL_ 1 NON-POTABLE WATER ( WATER TRUCK • 1 I 1 Step 1:Fill water truck with water Step 2:Pour Perma-Zyme into the water truck Once the soil is at about 80%towards its optimum moisture, apply Perma-Zyme to the soil. It is recommended to fill the water truck, pour the desired amount of Perma-Zyme into the truck, and mix (this can be done with an on-board pump or by driving the water truck for 15-20 minutes). PAVED ROAD CONSTRUCTION 17 SUBSTRATA - Version 1.0 Copyright©2022 Substrata,LLC.All Rights Reserved MIXING AND SHAPING Upon applying Perma-Zyme to the soil, the soil's moisture content should now be very close to optimum moisture. At this time, continue forming a windrow and moving it from one side of the road to the other. The purpose is to thoroughly mix and coat the soil particles in the water and Perma-Zyme mixture as much as 1 possible. Depending on the soil and climate conditions it is common for the soil to O \ begin to dry. If that begins to happen, apply more water. • , . , a . Once the water and Perma-Zyme have been thoroughly mixed into the soil, begin • . • • ♦ shaping the road. As mentioned in DESIGN PARAMETERS, it is recommended to • construct the roadway with a crown to ensure the water will properly shed on the surface. * NOTE: If at any point during this time the soil begins to dry, immediately apply more water. COMPACTION Once the soil has been thoroughly mixed with Perma-Zyme and shaped,compaction is the next step. If a Padfoot/Sheepsfoot Compactor is available begin compacting Iffi the surface with the vibratory functionality turned on. Slowly operate the Padfoot/ Sheepsfoot Compactor up and down the surface while overlapping each path about .1064610 - 25%to ensure optimum compaction. Use the Padfoot/Sheepsfoot Compactor until ,ii CD ® the surface has been approximately 80% compacted. • 4 If a Padfoot/Sheepsfoot Compactor is not available, it is recommended to fill a • _ water truck and slowly drive down the roadway. This is often referred to "Wheel • Packing". When performing Wheel Packing it is important to operate the water truck slowly and ensure the tires tracks are overlapped to ensure the soil reaches optimum compaction. Once the soil has reached approximately 80%compaction, begin using the Smooth Wheel Drum Compactor with the vibratory functionality turned on. Operate ��I the Smooth Wheel Drum Compactor slowly along the roadway overlapping the Virili , previous path to ensure the soil has been thoroughly compacted. Once the soil has been thoroughly compacted,turn off the vibratory functionality and perform a final \, - t , - few passed with just the Smooth Wheel Drum Compactor as the finish pass. • 0 4 * NOTE: If at any point during this time the soil begins to dry, immediately apply more water. POST APPLICATION/CURING TIME Upon completion of the compaction, the construction of the roadway is complete. Substrata recommends no traffic on the roadway for 24 hours. In the event the . application cannot allow for that,ensure the soil is thoroughly dried prior to allowing traffic on the roadway. When allowing traffic on the roadway, only allow light traffic on the roadway for the first 72 hours. This means light duty work trucks (-30,000 I * , pounds and under). After 72 hours and the soil has thoroughly dried apply heavy r , duty vehicles and traffic can be allowed on the surface. In the event of a rainstorm, or the surface has become deteriorated somehow, the surface can be repaired by re-applying Perma-Zyme (-1000:1) to the surface. A grader would then be used to reshape the surface as desired. Upon reaching the desired the surface, use a Smooth Wheel Drum Compactor to compact the soil to the appropriate compaction level. PAVED ROAD CONSTRUCTION - 18 SUBSTRATA. Version 1.0 Copyright O 2022 Substrata,LLC.All Rights Reserved TOPCOAT APPLICATION Once the subbase of the paved road has been treated with Perma-Zyme and allowed to dry and cure greater than 3 days the topcoat can now be applied. It is important to allow the soil at least 3 days so the soil can dry and begin to harden prior applying to the topcoat. A WARNING: Not allowing adequate time for the subbase soil to dry can lead to improper curing and non-performing of Perma-Zyme. If applying the topcoat directly to the Perma-Zyme treated soil,follow the instructions below. s PERMA-ZYME OO O o0 0 / �■ 1 Use a grader to ensure Using a water truck apply a Immediately begin applying there is no loose soil or dilution rate of Perma-Zyme the topcoat per the gravel on the surface of the (approximately 1000:1) to manufacturer's instructions roadway the surface PAVED ROAD CONSTRUCTION - 19 SUBSTRATA - Version 1.0 Copyright 0 2022 Substrata,LLC.All Rights Reserved • ,1111 WASHBOARDING WHY DOES WASHBOARDING HAPPEN? Washboarding typically happens because the soil was not allowed to dry thoroughly prior to traffic being on the roadway, and/or the soil was not compacted adequately. When traffic is on the roadway and the area is subject to a significant speed change, the area is susceptible to washboarding. This is because the layers will move as the traffic is slowing down or speeding up. Common areas that see washboarding are hills or areas that see constant speed change, such as intersections or driveway entrances. QUICK STOP STEEP GRADE • • • • • HOW TO FIX WASHBOARDING Usually,the areas that experience the washboarding effect can be repaired without having to rework the entire road. To repair the washboarding areas follow the steps below: 1. Wet the soil with a Perma-Zyme dilution (750:1) 2. Using a grader, loosen and rework the soil to remove the washboarding 3. Compact the soil with a smooth wheel roller with the vibratory functionality turned on 4. Finish compacting the soil with the smooth wheel roller with the vibratory functionality turned off 5. Allow the soil to thoroughly dry prior to allowing traffic on the roadway. TROUBLESHOOTING 20 SUBSTRATA. Version 1.0 Copyright O 2022 Substrata,LLC.All Rights Reserved EXCESSIVE r WHY DOES EXCESSIVE DUST HAPPEN? Once the soil has cured after application, loose soil may begin to form on the soil, depending on the soil characteristics. This traditionally happens because as the soil cures, the silty and sandy soils have effectively been squeezed and forced to the top of the surface. When this happens the soil particles are not bonded to each other, so they are able to enter the atmosphere and produce dust. • • • • HOW TO FIX EXCESSIVE DUST In most cases the entire roadway is plagued with excessive dust. In the event that specific sections are plagued by dust it is possible to fix just those sections. Follow the steps below. 1. Using a grader, finely blade off the loose soil off the surface of the roadway. 2. Wet the soil with a Perma-Zyme dilution (750:1) 3. Compact the soil with a smooth wheel roller with the vibratory functionality turned on 4. Finish compacting the soil with the smooth wheel roller with the vibratory functionality turned off 5. Allow the soil to thoroughly dry prior to allowing traffic on the roadway. WET SOIL WHY WONT THE SOIL DRY? Traditionally soil won't dry because of two factors, climate, or soil characteristics. In our case, climate means rain or very high humidity. This is very rarely the case and if it is, it is often clear to the end user. Soil characteristics pertains to the soil's plasticity and how the soil maintains its moisture content. It is common for very plastic soils(fatty clays)to maintain their moisture content and not dry.This can often be deceiving because the top layer of the soil looks dry, but a few inches underneath the soil is still wet. This compromises the soils structural integrity. DRY SOIL WET SOIL • • , • • • • • • HOW TO FIX WET SOIL In most cases,the best way to rectify wet soil is to remove as much traffic as possible and allow the soil to fully dry. The wait time is dependent on the climate and the depth at which the soil was treated. The damper the climate, the longer the soil will take to dry. The deeper the soil was treated, the longer it will take to dry. In extreme cases, it might be necessary to rework the application and compact the soil in smaller lifts to allow the soil to dry thoroughly. For example, instead of compacting the soil in one 6-inch lift, compact the soil in one 3-inch lift. Then wait for the soil to dry completely, apply the next 3 inches of soil, and compact the soil on top. TROUBLESHOOTING — 21 i — SUBSTRATA® Version 1.0 Copyright O 2022 Substrata,LLC.All Rights Reserved SOIL WONT HARDEN WHY WONT THE SOIL HARDEN? Traditionally soil won't dry because of two factors: climate, or soil characteristics. In this case, "climate" refers to rain or very high humidity. This is very rarely the case, and if it is, it is often clear to the end user. "Soil characteristics" pertain to the soil's plasticity and how the soil maintains its moisture content. It is common for very plastic soils(fatty clays)to maintain their moisture content and not dry.This can often be deceiving because the top layer of the soil looks dry, but a few inches underneath the soil is still wet. This compromises the soil's structural integrity. HARD SOFT HARD SOFT •• • • • 40 • • • • • • • HOW TO FIX SOIL NOT HARDENING In most cases,the best way to rectify wet soil is to remove as much traffic as possible and allow the soil to fully dry. The wait time is dependent on the climate and the depth at which the soil was treated. The damper the climate, the longer the soil will take to dry. The deeper the soil was treated, the longer it will take to dry. In extreme cases, it might be necessary to rework the application and compact the soil in smaller lifts to allow the soil to dry thoroughly. For example, instead of compacting the soil in one 6-inch lift, compact the soil in one 3-inch lift. Then wait for the soil to dry completely, apply the next 3 inches of soil, and compact the soil on top. TROUBLESHOOTING 22 SUBSTRATA. Version 1.0 Copyright O 2022 Substrata,LLC.All Rights Reserved SUPERFICIAL CRACKING WHY IS SUPERFICIAL CRACKING APPEARING? • • It is common for small, superficial cracks to appear on the roadway surface post application and drying. The superficial cracks form because soil has expanded during the soil's moisture state,then contracted once the soil dries. HOW TO FIX SUPERFICIAL CRACKING Depending on the amount of cracking on the surface, it is common to not fix the cracking. If it is deemed necessary to fix,follow the steps detailed below. 1. Wet the soil with a Perma-Zyme dilution (750:1) 2. Compact the soil with a smooth wheel roller with the vibratory functionality turned on 3. Finish compacting the soil with the smooth wheel roller with the vibratory functionality turned off 4. Allow the soil to thoroughly dry prior to allowing traffic on the roadway. TROUBLESHOOTING 23 SUBSTRATA. Version 1.0 Copyright O 2022 Substrata,LLC.All Rights Reserved A Rr. CRACKING WHY IS LARGE CRACKING APPEARING? Soils that are extremely plastic are usually highly expansive. There are instances in which expansive soils are more subject to large cracking. This includes the soil's moisture reaching above optimum moisture, dry climate, and/or extreme high temperature. HOW TO FIX LARGE CRACKING The scale at which the repair happens is dependent on if the cracks are throughout the roadway or isolated to a specific area on the roadway. To fix the cracking, follow the steps detailed below. 1. Wet the soil lightly 2. Using a grader, loosen and rework the soil to remove the cracking 3. Spray a mixture of water and Perma-Zyme (750:1) 4. Mix the Perma-Zyme into the soil using the grader 5. Shape the roadway using the grader b. Compact the soil with a smooth wheel roller with the vibratory functionality turned on 7. Finish compacting the soil with the smooth wheel roller with the vibratory functionality turned off 8. Allow the soil to thoroughly dry prior to allowing traffic on the roadway. TROUBLESHOOTING 24 SUBSTRATA. Version 1.0 Copyright O 2022 Substrata,LLC.All Rights Reserved This manual and its entire contents (including but not limited to all information, text, displays, images, and the design, selection, and arrangement thereof) are owned by Substrata, its licensors, or other providers of such material and are protected by United States and international copyright, trademark, patent,trade secret, and other intellectual property or proprietary rights laws. You are permitted to use this manual for your personal, non-commercial use only. You must not reproduce, distribute, modify, create derivative works of, publicly display, publicly perform, republish, download, store, or transmit any of the material in this manual, except as follows: • You may print or download one copy of a reasonable number of pages of this manual for your own personal, non- commercial use and not for further reproduction, publication, or distribution. You must not: • Modify copies of any materials from this manual. • Use any illustrations, photographs, video or audio sequences, or any graphics separately from the accompanying text. • Delete or alter any copyright, trademark, or other proprietary rights notices from copies of materials from this manual. You must not use for any commercial purposes any part of this manual. If you print, copy, modify,download, or otherwise use or provide any other person with access to any part of this manual in breach of these terms, your right to use this manual will stop immediately and you must, at our option, return or destroy any copies of the materials you have made. No right, title, or interest in or to this manual or any content on this manual is transferred to you, and all rights not expressly granted are reserved by Substrata. Any use of this manual not expressly permitted by these terms is a breach of these terms and may violate copyright, trademark, and other laws. SUBSTRATA MAKES NO WARRANTY WHATSOEVER WITH RESPECT TO THE GOODS, INCLUDING ANY(A)WARRANTY OF MERCHANTABILITY; (B) WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE; OR (C) WARRANTY AGAINST INFRINGEMENT OF INTELLECTUAL PROPERTY RIGHTS OF A THIRD PARTY; WHETHER EXPRESS OR IMPLIED BY LAW, COURSE OF DEALING, COURSE OF PERFORMANCE, USAGE OF TRADE, OR OTHERWISE. COPYRIGHT AND LEGAL 25 I SUBSTRATA. Version 1.0 Copyright O 2022 Substrata,LLC.All Rights Reserved • A A Atterberg Limits 5 E enzyme 3 G Grader 7, 11 gravel 10 0 optimum moisture 5, 6, 7, 11, 12, 13, 14, 16, 17, 19, 20, 21, 23, 24, 25, 26 P paved road 2, 17 Perma-Zyme 1, 2, 3, 4, 5, 6, 7, 8, 10, 11, 12, 13, 14, 15, 16, 17, 19, 20, 21, 22, 23, 24, 25, 26, 27 Pond Lining 3 Proctor Test 5, 6 R Reclaimer 7, 11 S sieve 5 Sieve Analysis 5 Substrata 6, 7, 8, 9, 10, 12 T temperature 3, 7, 8 traffic 9, 10, 12, 15, 16, 17, 19, 21, 22, 24, 26, 27 W water truck 7 INDEX 26 SUBSTRATA® Version 1.0 Copyright 0 2021 Substrata,LLC.All Rights Reserved SUBSTR TA® SUBSTRATA.US I +1 (702) 825-5200 7330 Eastgate Rd #150 Henderson NV, 89011