QUALITY ISSUE
AIRWORTHY With a new FAA asphalt pavement specification and hundreds of airports in California, aviation work is cleared for takeoff
INSIDE: FAA Airfield Specifications Sully-Miller at Fox Airfield Member profile: Sapphire Gas Solutions
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Publisher’s Letter Conducting ourselves in a legal, ethical and transparent way In business and in life, you only get one reputation. If you have a good reputation, it probably took you a lifetime to build. That reputation opens doors, creates opportunities and engenders trust and goodwill from those around you. However, all it takes is one misstep, and a lifetime of good work can evaporate in an instant, creating a black mark on your reputation that will follow you (thanks to the internet) to the grave. Sadly, our news feeds are filled with daily reminders of too many people who forget, ignore, or failed to learn this important life lesson. For most people, simply “doing the right thing” or following “The Golden Rule” is sufficient, but counting on people to do the right thing at all times only goes so far. That is why there are laws, rules and regulations designed to ensure that everyone plays fair, and steers clear of legal or ethical difficulty. The effectiveness of the California Asphalt Pavement Association is owed largely to its sterling reputation. Founded in 1953, our non-profit trade association has steadily built its membership and its influence over the years on a foundation credibility – of being a trusted resource for valuable information and insight about our industry. To safeguard our reputation, we also place a premium on always conducting the business of the association in a legal, ethical and transparent manner. As you may know, non-profit trade associations are corporations, and granted special tax-exempt status by the Internal Revenue Service because the federal government recognized long ago the important role associations play in setting standards for professional behavior, best practices and competence that ultimately benefit all Americans. At CalAPA, we are bound by the same laws that govern for-profit entities, namely that the affairs of the association must be conducted in a lawful, ethical and transparent way. Our bylaws, on file with the California Secretary of State’s Office, govern how we conduct the business of the association, and our policies govern board and individual member conduct. We are bound by federal anti-trust laws to ensure that CalAPA activities do not inhibit competition in a capitalistic economy. Our tax returns are public documents, further underscoring the transparent nature of what we do. Even our Legislative and political engagement is subject to stringent “sunshine” laws on public reporting. The same requirements govern all corporations and the boards that oversee them. I am pleased to report that CalAPA has taken a number of steps to go above and beyond these standards. The association adopted a set of policies that include important Conflict of Interest provisions to ensure everyone is acting in the best interests of our industry, and we review those policies annually. The association also adopted a Code of Ethics that guide our actions, which is prominently featured on our website and in other communications. We have also brought in an attorney with extensive association experience to train our board on association law, ethics and responsibilities. Our new board member orientations cover this information in great detail. Finally, there is transparency. All of our board meetings are advertised well in advance, with detailed agendas and board packages produced and distributed well ahead of the meetings allowing board members ample time to propose topics for discussion, review the information presented and come to the meeting armed with questions. Our financial reports are prepared by staff, reviewed by a Certified Public Accountant, and then reviewed again by our Board Treasurer and, separately, our Audit Committee. It is a rigid structure, to be sure, but we want you to have confidence that the association takes very seriously the duty to conduct its affairs in a lawful and ethical manner, to do so in a very transparent way, to spend your money prudently and in a manner to elevate our entire industry. It is serious, important work, and our reputations are riding on it. Sincerely,
Scott Fraser R.J. Noble Company 2020 CalAPA Board Chairman
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California Asphalt Magazine • 2020 Quality Issue
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Contents Volume 24, Issue 5
4
Publisher’s Letter
8
Latest FAA P-401 Specification takes off
14
Precision measuring of pavement profile is key to a smooth ride
18
Sully-Miller Contracting Co. in phase II of General William J. Fox Airfield runway pavement rehabilitation project
22
Member profile:
28
CalAPA member, Blue Road Solutions merges with Thigpen Solutions to become Sapphire Gas Solutions — a nationwide leader in the mobile, off-pipe natural gas industry
Page 14
Page 18
Industry News On the Cover:
Cover illustration by Aldo Myftari of Construction Marketing Services.
Page 22
CALIFORNIA ASPHALT PAVEMENT ASSOCIATION www.calapa.net HEADQUARTERS: EXECUTIVE DIRECTOR: TECHNICAL DIRECTOR: REGIONAL DIRECTOR: MEMBER SERVICES MANAGER: GUEST PUBLISHER: PUBLISHED BY: GRAPHIC DESIGN: CONTRIBUTING WRITERS: ADVERTISING SALES:
P.O. Box 981300 • West Sacramento • CA 95798 (Mailing Address) 1550 Harbor Blvd., Suite 211 • West Sacramento • CA 95691 • (916) 791-5044 Russell W. Snyder, CAE, rsnyder@calapa.net Brandon M. Milar, P.E., bmilar@calapa.net Bill Knopf, wknopf@calapa.net • (442) 400-9697 Sophie You, syou@calapa.net Scott Fraser, Operations Manager, R.J. Noble Company Construction Marketing Services, LLC • (909) 772-3121 P.O. Box 892977 • Temecula • CA 92589 Aldo Myftari John Crane, PE., Flexible Pavements of Ohio (FPO), Russell W. Snyder, CAE, CalAPA, Chris Gerber, G3 Quality Inc., Nick Schaefer, PE, Surface Systems & Instruments, Inc. and Brian Hoover, CMS Kerry Hoover, CMS, (909) 772-3121
Copyright © 2020 – All Rights Reserved. No portion of this publication may be reused in any form without prior permission of the California Asphalt Pavement Association. California Asphalt is the official publication of the California Asphalt Pavement Association. This bimonthly magazine distributes to members of the California Asphalt Pavem ent Association; contractors; construction material producers; Federal, State and Local Government Officials; and others interested in asphalt pavements in California and gaining exclusive insight about the issues, trends and people that are shaping the future of the industry.
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California Asphalt Magazine • 2020 Quality Issue
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Latest FAA P-401 Specification takes off By John Crane, PE
E
ntering its second paving season, the Federal Aviation Administration’s (FAA) latest revision (10H) of their Standard Specification for Airport Construction, AC 150/5370, packs quite a punch in the constant battle with change. Those who have worked with the FAA likely know AC 150/5370 and its Item P-401, however for those that do not, Item P-401 is the specification that governs asphaltic surfaces for airfield pavements. The 10H revision updates criteria and adds items that will likely affect producers, designers and contractors in the asphalt industry. This article will outline a few of these changes. APPLICATION OF THE SPECIFICATION Right at the beginning of P-401, the FAA updates the requirements on when to apply the Item. This constraint, based on an aircraft’s gross weight, was increased to 30,000 pounds where previously it was limited to 12,500 pounds. In addition, the FAA also stipulated that nonprimary airports have a 60,000 pound threshold. Below these thresholds, given FAA approval, it may be possible for contractors to utilize state Department of Transportation specifications and mixtures. The use of state DOT mixtures makes 8
The FAA chose to use a Loaded Wheel Tracking test, the Asphalt Pavement Analyzer (APA) in particular, as their standard test to determine this property.
sense since the increase to 30,000 pounds brings axle loads and tire pressures into a similar scenario as a standard tractor trailer; 20,000 pounds and 100 psi respectively. This allows more flexibility when it comes to paving areas within airfields that do not see high loading rates and allows for contractors to better economize their asphalt mixtures. BINDER GRADE SELECTION Grade bumping, the increase in the high-temperature binder grade due to higher traffic loading or slow-moving traffic, has been used for some time and the FAA, along with the majority of state DOTs, have applied this method historically. The FAA has now added new criteria in their binder-bumping procedure, which will now distinguish between pavements being subjected to slow and/or stationary
aircraft and those that will not. Those pavements subjected to slow and/or stationary conditions will have an additional grade bump over the standard areas. This additional grade bump is important because asphalt binders act more like a viscous fluid rather than a solid under extended loading times, and by increasing the binder grade the stiffness is being increased to better carry the extended loading times. In addition to the binder bumping, the FAA revised the selection of the base asphalt binder for a mixture. Previously the specification outlined that the base binder would be what the state DOT used on interstate pavements. This can prove to be intricate as many states have various rules on the selection of binders, including the use of multiple binder grades for interstate pavements based on traffic levels and not strictly on
California Asphalt Magazine • 2020 Quality Issue
Aerial view of DeSilva Gates Construction paving Runway 12-30 at the Oakland International Airport, which serves around 13 million passengers each year.
requirements outlined in the specification as finer mixtures with higher asphalt contents tend to compact easier. PERMANENT DEFORMATION CRITERIA
roadway type. With the current revision, the FAA has simplified the situation by adjusting the base binder to be selected utilizing the environmental conditions within the state in which the work is being performed. AGGREGATE BLENDING P-401 specifies three different gradation bands for surface courses and, while they have retained their original nomenclature, Gradation 1, 2 and 3, adjustments to sieve tolerances suggest finer-graded asphalt mixtures. For those more familiar with the Superpave system,
Gradation 1, 2 and 3 loosely resemble a 19mm, 12.5mm and 9.5mm, respectively. The update mainly adjusts Gradations 1 and 2 with all sieves from the No. 50 to their nominal maximum aggerate size, 19mm and 12.5mm, respectively, having an increase of 5 percent passing on average to the lower and upper limits. The increase to the percent passing brings the bottom of the gradation range near the maximum density line, which forces a fine-graded asphalt mixture. While this may slightly increase material costs, it will potentially aid contractors in achieving the strict density
California Asphalt Magazine • 2020 Quality Issue
Permanent deformation or rutting is an important distress to minimize on any surface, especially runways, to prevent pooling of water in the wheel paths, resulting in hydroplaning. Aircraft place extremely heavy loads on the pavement ,which can cause damage to an unstable pavement structure. To minimize this risk, the FAA has added a requirement to analyze a mixture for its resistance to rutting. The FAA has chosen to use a Loaded Wheel Tracking test, the Asphalt Pavement Analyzer (APA) in particular, as their standard test to determine this property. The APA test utilizes concave wheels that load pressurized rubber hoses laid upon an asphalt sample. The wheels then traverse over the samples for a given number of passes at a given temperature to simulate rutting. The FAA is using an altered version of AASHTO T340, which includes an increase to hose pressure, 250psi, rather than the standard 100psi and a fixed testing temperature, 64°C, in lieu of the pavements environmental temperature. The FAA design 9
criteria for all surfaces is a 10mm maximum deformation at 4,000 passes. If an APA is not capable of achieving the higher contact pressures, a standard APA test may be performed with a 5mm maximum deformation at 8,000 passes or a Hamburg Wheel Tracking device may be utilized following AASHTO T324 at 50 °C with a 10mm deformation at 20,000 passes. DENSITY ANALYSIS Often mat and joint densities are expressed in a percent. This is understood in the asphalt industry as referring to relative density, which means that in-place pavement density is really expressed as the percentage of a laboratory measured density. With the recent revision, the
calculation for in-place density will no longer be based on the average bulk specific gravity of laboratory compacted specimens for the lot. Instead, the calculation is based on the theoretical maximum density (TMD) or Rice value, determined within the corresponding sublot of material. This change aligns the FAA with many state DOTs on how in-place density is calculated. With the updated calculation of relative in-place density based on TMD, the FAA also revised the acceptance criteria for mat and joint density to reflect the change. It is important to note, however, that this revision in criteria is not equivalent to the previous criteria. Working through the math shows an increase in the lower-density limits for mat- and joint-density of roughly 0.4 percent and 0.9 percent, respectively.
SUMMARY While the FAA’s latest revision (10H) to the AC 150/5370 -“Standard Specification for Construction of Airports” and its enclosed item P-401 released on Dec. 21, 2018, has some large changes, the implications of those changes being made will lend to higher quality and longer-lasting asphalt airfields in the end. CA John Crane, PE, is a pavements, materials and field applications engineer for Flexible Pavements of Ohio (FPO), the association that represents the asphalt pavement industry in Ohio. This article originally appeared in Ohio Asphalt, Vol. 17, Issue 2 (Summer 2020), the official magazine of the association, and is reprinted with permission of FPO.
Airfields in California
T
he following are excerpts from a publication, “California Airport Land Use Planning Handbook” (rev. October 2011), produced by the California Department of Transportation, Division of Aeronautics. Caltrans counts 240 public-use airports in California: California has a diverse variety of airport types, ranging from large hub commercial airports to small, privately owned airstrips. Additionally, California supports a large number of facilities in a wide range of categories. Although commercial service airports handle most of the public’s air travel needs, the most common type of airport in California is the 10
general aviation airport. General aviation airports offer a wide variety of services, ranging from flight instruction and recreation, to air cargo, emergency medical transportation, law enforcement and firefighting operations. The economic importance of airports in California aviation is a vital link in the local, national and global transportation system. Air cargo, consisting mainly of high-value, time-sensitive documents and goods, plays a significant role in the vitality of the state’s economy. In today’s international and technologyoriented economy, businesses use the speed and reliability of air service to achieve operating
efficiency. California’s airports are critical for providing services such as business travel, tourism, emergency response, fire suppression and law enforcement. Airports, airlines and businesses that support airports provide direct and indirect jobs and income throughout the state. The vital role that airports play in economic development and as a means of passenger and cargo transportation cannot be understated. CA
California Asphalt Magazine • 2020 Quality Issue
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California Asphalt Magazine • 2020 Quality Issue
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Precision measuring of pavement profile is key to a smooth ride By Chris Gerber and Nick Schaefer
I
nertial profiling systems generate 2D surface profiles under industry standards such as ASTM E950 and AASHTO r57. They record the wheelpath elevation profiles that affect the ride quality most noticed by the traveling public. Inertial profiling systems are known for their accuracy, repeatability and the overall ability to precisely measure features on the pavement surface. New advancements in sensor technology have allowed current inertial profilers to also collect texture, Right of Way (ROW) images, rutting, cross-slope, and 3D survey elevations for machine control systems. All inertial profiler data can be collected at highway speeds and therefore do not require costly traffic control measures that may inconvenience motorists. At G3 Quality, a CalAPA member, we rely on our partners at Surface Systems & Instruments Inc. (SSI), another CalAPA member, to provide us with inertial profiling systems that exceed our project needs. We’ve broken down how the different components of an inertial profiling system are utilized to ensure pavement smoothness:
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LASER HEIGHT SENSOR The purpose of a height sensor is to record the distance between the pavement surface and the host vehicle. The vertical measurements are usually acquired by one or multiple non-contact laser sensors. Typical sensors use a 4-inch wide beam laser to average out pavement texture from high-void Hot Mix Asphalt (HMA) mix designs or concrete tining. Each inertial profiler wheelpath laser must retain accuracy of 0.01-inches to comply with AASHTO r56.
DISTANCE MEASUREMENT INSTRUMENT A Distance Measurement Instrument (DMI) is a transducer used to determine the longitudinal distance that the host vehicle has traveled. An inertial profiler captures an elevation sample from the accelerometer and height sensor for every 1-inch traveled. SSI now offers a GPS-DMI option which uses the accurate real-time position of the inertial profiler to govern data collection intervals. COLLECTION PROCEDURE
ACCELEROMETER An accelerometer is paired with each wheelpath height sensor to cancel out the vertical motion of the host vehicle. The inertial profiler uses the on-board accelerometer to establish the inertial reference value, such as the relative height. SSI provides aerospace-grade accelerometer sensors rated for up to +/-5g or 10g, with a resolution to 0.0001g. The accelerometer is an important component that allows inertial profilers to be mounted and certified on a wide range of vehicles – from Smart cars and Segways to Ford F-350’s.
The data gathered from the laser height sensor, accelerometer, and the DMI is used by the inertial profiler to produce the pavement profile. The International Roughness Index (IRI) is then calculated to summarize the impact of the pavement profile on vehicle response for a passenger car. The IRI is the world standard as the roughness measurement statistic of choice. Pavement smoothness specifications are centered around the wheelpath IRI values. Inertial profilers must collect data above a minimum speed, usually 7 mph. The data collection
California Asphalt Magazine • 2020 Quality Issue
Left and above: Surface Systems & Instruments Inc. (SSI) provides the industry with state-of-the-art inertial profiling system equipment.
The revised Caltrans smoothness specification was a collaborative effort spearheaded by Caltrans and CalAPA members, and participants were recognized with special awards presented Oct. 17, 2019 at Caltrans Headquarters by the department’s executive leadership.
will be started either through GPS coordinates, reflective cones marking the project limits, or manual entries. After the inertial profiler collects data within one project lane, the operator can use the inertial profiler analysis software or ProVal to calculate the IRI values. CALTRANS INERTIAL PROFILER SPECIFICATION Caltrans inertial profiler collections follow CTM 387 and AASHTO r57. All inertial profiler systems and operators are verified on a DOT certification track per AASHTO r56. Operators and inertial profilers must renew their certification each year. Caltrans specifies two metrics for acceptance; IRI Areas of Localized Roughness (IRI ALR) and the Mean Roughness Index
(MRI). MRI is calculated as the average IRI for both wheelpaths over a 0.1-mile segment. In general, IRI ALR reports rapid changes in roughness such as headers, joints, and paver induced roughness. The MRI is the overall score for the lane. The revised Caltrans smoothness specification introduced the pay adjustment spreadsheet along with other requirements. The Contractor and inertial profiler operator add the project information to the spreadsheet header for the Excel macros to determine the target smoothness requirements for the project. The pay adjustment spreadsheet will hold all collected data under each smoothness phase (Exist, Baseline, Pave, Final). It is important for the stationing of all smoothness phase data to match within specified tolerances.
California Asphalt Magazine • 2020 Quality Issue
The revised Caltrans smoothness specification was a collaborative effort spearheaded by Caltrans and CalAPA members, and participants were recognized with special awards presented Oct. 17, 2019 at Caltrans Headquarters by the department’s executive leadership. CA Chris Gerber is founder and president of G3 Quality Inc., which provides quality management, pavement engineering, materials design, construction, inspection and testing services on infrastructure projects throughout the Western United States. G3 Quality, based in Cerritos, is a California Small Business Enterprise (SBE), Metro Qualified SBE, and City of Los Angeles SBE. The company’s website is: www.g3quality.com . Nick Schaefer, PE, is a profiling systems engineer with Surface Systems & Instruments, Inc., a U.S. manufacturer of custom testing equipment with facilities in Auburn and Larkspur in Northern California. The company’s website is: www.smoothroad.com
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California Asphalt Magazine • 2020 Quality Issue
Sully-Miller Contracting Co. In phase II of General William J. Fox Airfield runway pavement rehabilitation project By Brian Hoover, CMS
G
eneral William J. Fox Airfield was constructed in 1959 by the county of Los Angeles and is available to general aviation aircraft 24-hours a day, seven days a week. Home to more than 200 based aircraft, this conveniently located airfield also includes several aviation-related businesses and the quaint and popular Foxy's Landing & Restaurant. Additionally, the airport contains an aviation museum and serves as the home base for the U.S. Department of Forestry's local air tanker units. Located in the City of Lancaster, the airport is still owned and operated by the county of Los Angeles. The full-featured airport boasts an air traffic control tower that supports a wide range of fixed-wing and rotary-wing aircraft ranging from small single-engine propeller planes to larger turboprop and even jet aircraft. General William J. Fox Airfield requires rehabilitation, particularly on Runway 6-24, where the pavement is severely degraded
18
and no longer feasible to maintain. A complete reconstruction of Runway 6-24 was required and scheduled to meet the Federal Aviation Administration (FAA) and the county of Los Angeles Airport Pavement Maintenance Program guidelines and standards. The $15.5 million project was awarded to Sully-Miller Contracting Co. (Sully-Miller), who began the first phase of the project in April 2020. The contract includes all costs for design, inspection, administration, engineering, topographic surveying, material testing, and a change order allowance. Construction costs of $14.5 million were funded with a $12.8 million FAA Airport Improvement Program (AIP) grant, with additional funds provided by a Caltrans CAAP AIP grant and the Public Works' Aviation Enterprise Fund. Sully-Miller's portion of the contract was approximately $10.2 million. As the prime contractor, Sully-Miller Contracting Co. (SullyMiller) will completely reconstruct Runway 6-24 and associated
taxiway connectors. This includes the realignment of three taxiways to meet current FAA design standards, with the Fox Airfield runway being shortened to 3,000 feet to aid in the reconstruction of Runway 6-24. It also includes the installation of reinforced concrete pipe and drainage inlets, striping pavement markings and signing, electrical lighting and other miscellaneous work. Each phase of the construction process was designed to keep the opposite end of the runway available for normal operations. In all, approximately 32 acres of the airport runway and taxiway connectors will be reconstructed and completed by the end of the year. Sully-Miller is currently in the second and final phase of construction, where they are utilizing FAA specified P-401 asphalt concrete along with reclaimed AC pavement on a P-154 subbase course. Vince Bommarito is the area manager for Sully-Miller/Blue Diamond overseeing the Fox Airfield project
California Asphalt Magazine • 2020 Quality Issue
Sully-Miller Contracting’s project at General William J. Fox Airfield in Lancaster where they are completely reconstructing Runway 6-24 and associated taxiway connectors.
in the City of Lancaster. "We started by removing the existing runway and taxiway pavement, followed by the subgrade's reconstruction and recompaction. We imported 18,000 tons of new subbase from Hi-Grade Materials and Granite Materials to create the new runway profile," says Bommarito. "We then began the process of installing approximately 56,000 tons of P-401 asphalt concrete provided by Blue Diamond Materials." According to Bommarito, the general area of reconstruction was more than 1,261,000 square feet. The 7,200 linear foot runway was reconstructed in halves and within two phases. "The major challenge on this particular project was keeping the airport open at existing levels during construction. Our Sully-Miller crew members have done an incredible job of administering the necessary airport safety and security elements and procedures required to keep this airport safely open." Mike Ramos is the quality control manager for Sully-Miller on the Fox
Airfield Runway project. "We are using the typical P-401 FAA mix design, along with a PG 76-22 polymer modified binder for optimum rutting resistance and better performance under higher temperatures," says Ramos. "The P-154 subbase course required 100 percent compaction, which is not always easy to achieve. Airport base material specifications are extremely stringent, and it was necessary to acquire high-end base material to meet these requirements." Ramos says that Sully-Miller had the advantage of using their in-house quality control (QC) personnel, with a vested interest in achieving the highest quality possible. "We have AASHTO trained and certified technicians that develop and test our mix designs to verify that they comply with the appropriate specifications," continues Ramos. "We also used a nuclear densometer to determine and verify the specified compacted material. Finally, we obtained all of the necessary asphalt core
California Asphalt Magazine • 2020 Quality Issue
samples and analyzed them to ensure that they met all applicable specifications." Bommarito points out that the Fox Airfield project is located 90 minutes from the Blue Diamond plant, so transporting the mix and keeping it in spec was a challenge. "Logistically, it was a long haul, but with Blue Diamond doing their multiple tests at the plant and our team testing out in the field, everything has gone smoothly," says Bommarito. "This is an airport runway project, and it requires smoothness testing through the use of a profilograph. Our crews have done an outstanding job, and we have been well under the threshold. We do a lot of these airport jobs, and we pride ourselves on smoothness here at Sully-Miller." The General William J. Fox Airfield Runway Pavement Rehabilitation Project represents the second Envision-awarded project for the county of Los Angeles. This award recognizes leadership in building sustainable 19
Right: Drone shot of Runway 6-24 and associated taxiways. Approximately 32 acres of the airport runway and taxiway connectors will be reconstructed and completed by the end of the year.
Above: All in a day’s work for the Sully-Miller team.
infrastructure to projects that have completed the Envision verification process. Quality and professionalism have long been Sully-Miller's primary goals ever since George W. Sully and Earl B. Miller started the company in 1923 with five highway employees, one asphalt plant and a team of mules. Today, as part of the Colas Group, Sully-Miller maintains its technical and financial strength to build infrastructure ranging from roads and heavy highways to airports and commercial private works and maintenance contracts. Sully-Miller Companies are vertically integrated for maximum efficiency with United Rock providing the aggregate, Blue Diamond Materials the hot 20
mix asphalt and then Sully-Miller Contracting, executing the projects. “For almost 100 years, we have built our reputation through our commitment to quality and professionalism. I wish that I could mention and recognize every team member on this Fox Airfield project by name. They give their all on every project and their hard work is very much appreciated,” concludes Bommarito. “I will take the time and space to recognize our management on this job, starting with Scott Conover, our project and area manager. Then there are our project engineers, Mareia Wasef and Andre Tobar and project superintendents, Jim Williamson (construction
superintendent) and Todd Roper (paving superintendent). The hard working foremen on this project include Brian Yates (construction foreman) and Arnie Velarde (paving foreman). These men and women deserve a lot of recognition and credit for giving their all on important jobs like this airport rehabilitation project. The entire Sully-Miller team is dedicated to proudly serving our customers now and for the next hundred years.” CA Brian Hoover is co-owner of Construction Marketing Services, LLC, and editor of CalContractor Magazine.
California Asphalt Magazine • 2020 Quality Issue
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Above: Sapphire Gas Solutions partnered with sister company, Mesa Natural Gas Solutions, to provide clean, reliable fuel and power to the Arizona hot-mix plant pictured above. Sapphire has many permanent LNG installations located throughout the United States. Inset: Sapphire customizes their systems for each individual customer. Pictured inset above is a mobile asphalt plant in Texas with a mobile LNG fueling system that follows the plant wherever it goes.
Sapphire Gas Solutions CalAPA member, Blue Road Solutions merges with Thigpen Solutions to become Sapphire Gas Solutions — a nationwide leader in the mobile, off-pipe natural gas industry By Brian Hoover, CMS
BP Energy Partners has announced the merger of Dallas, TX-based Blue Roads Solutions and Conroe, TX-based Thigpen Solutions, to become Sapphire Gas Solutions. As an innovative, full-service leader in the virtual pipeline industry, Sapphire Gas Solutions (Sapphire) is led by Thigpen founder and CEO, Sam Thigpen. Blue Road’s own, Justin Cordon, has been named chief integration officer for Sapphire, as the new company leverages Blue Roads' distribution capabilities with Thigpen's service expertise. "This expands the capabilities of the two firms from regional delivery to a nationwide presence, with our promise of 22
best-in-class service," said Sam Thigpen, CEO of Sapphire Gas Solutions. "We will offer a greater set of solutions to our diverse and expanding customer base. Additionally, by combining these two service-oriented companies, we can create opportunities for operational efficiencies as they arise." Thigpen was founded in Oct. 2005 and gained notoriety by fueling drilling rigs and hydraulic fracturing pumps with natural gas. They quickly became known as one of the leading natural gas fueling providers while working in many shale plays throughout North America. They eventually shifted their focus to providing
natural gas via virtual pipeline CNG and LNG solutions. Blue Roads has assisted in numerous industrial applications, increasing their operational industry standards along the way. Their focus in California has been on the asphalt and aggregate industries, and this will continue with even more assets and enthusiasm through this recent merger. Due to ongoing regulatory challenges concerning installing new gas pipelines, many businesses and utilities are seeking off-pipe deliveries of natural gas, known as virtual pipelines. These natural gas solutions typically provide
California Asphalt Magazine • 2020 Quality Issue
Above & Inset: While asphalt is a primary focus for Sapphire, they also provide winter peak shaving and supplemental gas supply for pipelines in the forms of CNG and LNG. Above is a CNG layout and to the side is a LNG layout.
utilities and other distribution companies with mobile natural gas support and peak-shaving capabilities. Blue Roads Solutions became one of the first such companies to fuel an asphalt plant with LNG, displacing highcarbon intensity waste oil and diesel in the process. The new company, Sapphire Gas Solutions, will provide turn-key siting, design, installation, monitoring, and operation of remote and unmanned fueling systems utilizing LNG (liquified natural gas) and CNG (compressed natural gas). The merger to become Sapphire Gas Solutions will strengthen the focus of serving the asphalt and aggregate markets with a broader platform of LNG and now CNG. Sapphire will also continue to serve the oil and gas sector, utilities, industrial companies, and remote power installations across the United States.
The new company will provide turn-key siting, design, installation, monitoring, and remote and unmanned fueling systems utilizing natural gas. Walker Steward is one of Blue Roads Solutions' founders and is the business development director for Sapphire Gas Solutions. "We remain focused and committed to the asphalt and aggregate industry in California and beyond. Our past legacy customers are still a major focus of our new company," says Steward. "This merger only strengthens our capabilities with the addition of CNG to our offerings. It also enhances our ability to deliver turn-key fuel systems to a wider variety of companies seeking to utilize environmentally friendly and operationally efficient natural gas." According to Thigpen, aggregate and asphalt industries have been keen to pursue natural gas alternatives to previous
California Asphalt Magazine • 2020 Quality Issue
solutions like diesel, recycled fuel and waste oil, which has already been outlawed in California. "Historically and when off utilities, alternative power consumers have turned to diesel generator technology. From an emissions perspective, there is a huge benefit to moving over to natural gas," says Thigpen. "This includes the benefit of largely reduced emissions, and depending on current diesel prices, substantial economic savings as well." Blue Roads Solutions has been a member of the California Asphalt Pavement Association (CalAPA) since early 2019. "We had been talking with the folks at CalAPA since our inception in 2016 and then joined as a member early last year. We were looking to keep our finger on the pulse of what was going on in the California construction and paving industry. We also wanted to gain exposure 23
Above: Sapphire has a vast LNG and CNG trucking fleet to meet their customer’s fueling demands. See a small glimpse at their fleet above.
Left: Sapphire’s first asphalt plant installation in Texas that continues to provide clean fuel for the hot-mix plant today.
to the producer members that can benefit most from our preferred natural gas solutions," says Steward. "The Vulcan Materials operation in San Bernardino has been a customer since 2016, and we are talking with several other producer members in California. Our membership in CalAPA was an obvious and intelligent decision that is already paying off in many ways." Steward further explains that Vulcan Materials’ San Bernardino operation is a portable plant, while having many other stationary and portable asphalt plants located throughout the state. "We have successfully provided and maintained a virtual pipeline solution of natural gas for Vulcan that has increased their overall efficiency and uptime while lowering their emissions and environmental impact at their San Bernardino plant," continues Steward. "Our project at Vulcan's San Bernardino plant is winding 24
down right now, but they are looking at some additional work soon for this particular facility. There are a lot of lane miles being paved in California right now, and we forecast that our services will increase exponentially along with this tremendous growth." Both Thigpen and Blue Roads were wholly owned by BP Energy Partners, a middle-market private equity firm focused on the energy industry. Now operating as Sapphire Gas Solutions, the new investment portfolio will continue to benefit from BP Energy Partners growth capital across a wide range of energy-dependent industries. BP Energy Partners brings operating experience, knowledge, relationships and management expertise, in addition to capital, to partner with entrepreneurs, family-run businesses, and management teams to grow investments in the energy space. Along with the merger and introduction of Sapphire Gas
Solutions comes certain additional assets and benefits to bolster former entities' customer bases. This includes the availability of approximately 30 LNG delivery transports that deliver throughout the United States daily. It also consists of a little over 20 active field service technicians from Thigpen's heavy field service legacy business. "We can respond to customer's immediate needs, with our new larger footprint and faster response times," says Thigpen. "We are all very excited about this new merger and look forward to introducing all of the new benefits of the new Sapphire Gas Solutions branding." For more information on Sapphire Gas Solutions, please visit their website at www.sapphiregassolutions.com or call their corporate offices in Conroe, TX at 855-564-3722. CA Brian Hoover is co-owner of Construction Marketing Services, LLC, and editor of CalContractor Magazine.
California Asphalt Magazine • 2020 Quality Issue
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California Asphalt Magazine • 2020 Quality Issue
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California Asphalt Magazine • 2020 Quality Issue
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PEOPLE IN THE NEWS
CalAPA instructor Robinson gets the billboard treatment The following has a tenuous connection to asphalt, at best, but in these COVID-19 times it seemed a fitting respite from all the grim headlines. Mike Robinson, a noted asphalt consultant and CalAPA member, is known to many for his "Essentials
of Asphalt Pavement Smoothness" classes he conducts for our association. He's also a familiar face at various CalAPA events, which he livens up with his Mark Twain-esque wit and cookie-duster mustache that would make Twain envious. Robinson, like many CalAPA members (Skip Brown, we're looking at you!), is also quite the outdoorsman. A couple of years ago he purchased a modest spread in Wyoming and his jaw-dropping nature photography and that of his wife, Donna, have created quite the buzz on LinkedIn and even grace a calendar that is on display at the CalAPA World Headquarters. But then, as they say on Reddit, there's "taking it to the next level." Robinson's likeness (a photo taken by his wife) was recently featured on a Wyoming billboard. Robinson tells us his wife's reputation with a camera is well-known locally, and she has done some photography for a local real estate company, Hake Realty. Robinson picks up the story from here: "The Hake broker asked her for local photos to use in a presentation the broker gave, in a local area marketing publication, and for a billboard. We didn't know which photo was selected for the billboard until it went up. As you can see on the billboard, the Hake tagline is "Real Living," which apparently they thought Henry and I represented." Henry, by the way, is Robinson's loyal pointer that is a regular companion on his various hunting and fishing trips. As we said, this has little to do with asphalt, but it is nonetheless a pleasant break from the daily grind and a reminder to strive to maintain a healthy work-life balance. Take it from that guy up on the billboard. CA
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California Asphalt Magazine • 2020 Quality Issue
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California Asphalt Magazine • 2020 Quality Issue
In July 2020, Sapphire Gas Solutions was formed by joining Blue Roads Solutions and Thigpen Solutions into one company. The newly formed Sapphire Gas Solutions is still committed to focus on serving the road construction industry with the same quality product and service with broader offerings of LNG and CNG fueling capabilities.
NEW NAME, SAME PASSION FOR EXCELLENCE IN ASPHALT Sapphire Gas Solutions is a Texas based LNG and CNG solutions provider targeting the mobile and off-pipe use of natural gas in the utility, industrial, and pipeline industries. Through years of experience provide LNG and CNG to asphalt plants, pipeline integrity projects, supplemental winter gas supplies, and a myriad of other applications, Sapphire is a true, national, virtual pipeline solution.
In addition to our emphasis on Asphalt Plants and Remote Power Generation, we now also help with: • Winter supply
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• Supplemental pipeline supply
• Emergency pipeline outages
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