J03-Sherry Sullivan - Tecnologias de pavimentos de hormigón aplicadas en Norte America

Concrete Pavement Technologies Applied in North America Sherry Sullivan MASc, PEng, LEED AP

C2009. PNA Construction Technologies, Inc. All rights reserved.

TODAY’S DISCUSSION

• What is new with concrete pavements in North America?

– New ACI Technical Guideline – ACI 330.2R-17 – Optimized Designs using AASHTOWare PavementME and OptiPave design methods.

– Accelerated Paving Techniques with 3D laser screeds and Roller Compacted Concrete.

CHAPTER 4 – PAVEMENT DESIGN • “It is imperative that the designer consider all factors that influence the performance of a concrete pavement. Such factors include truck traffic or other vehicular loads, patterns and frequencies, subgrade/subbase support, concrete strength, pavement panel thickness, joint spacing, joint stability (load transfer), the use of curbs and widened lanes, humidity and ambient effects (humidity and temperature).”

Thickness is directly related to joint spacing, curling / warping and load transfer…and CAN NOT be designed independently!

CHAPTER 4 – PAVEMENT DESIGN • “The analysis of ambient effects on the pavement design adds a level of complexity that this guide does not consider, but there are proprietary design systems available that do if the designer should wish to optimize the design to this level. Four of these design approaches are discussed in Appendix B (B.1) under proprietary design software.

• • • •

B.1.1 ACPA StreetPave™ B.1.2 AASHTOWare Pavement ME B.1.3 TCPavements® OptiPave™ B.1.4 ACPA AIRPave™”

HISTORY OF CONCRETE PAVEMENT DESIGN… AND THE MODERN DESIGNS OF ACI 330.2R-17

AASHTO 1962-1998 10 inputs “Performance” Field Data

THE 40 YEAR DIVIDE

Industrial & Trucking Facilities

Highways, Streets & Roads

ACPA

TCPavements

AASHTO

2005-2016 12 inputs Crack & Fault FEA + Field Data

2009-2016 ≈ 50 inputs Crack, Fault, IRI FEA + Field Data

2009-2016 ≈ 1,000 inputs Crack, Fault, IRI FEA + Field Data

Increasing Complexity = More Accurate Models & More Optimization Options

More $, time, and resources spent than needed!

Photo taken June 2019

Photo taken October 2018

6

7

8

Nov 2019

9

US COLD STORAGE – ATLANTA, GA

SOME OF THE COMPANIES USING TCP IN NORTH AMERICA

BENEFITS OF 3D LASER SCREEDING PAVEMENTS BEST SOLUTION FOR INDUSTRIAL PAVEMENTS

• Cross slopes to drainage inlets • Wide bay construction; reduction in forming costs • Easy installation of PD3 Baskets • Improved pavement texture; reduced fibers at surface • Speed of construction; up to 70,000 sqft/day… depending on concrete supply.

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BROOMING OR TINING WIDE PLACEMENTS

WHAT IS ROLLER COMPACTED CONCRETE?

Think of it as a third type of pavement.

ROLLER COMPACTED CONCRETE (RCC)

A negative-slump concrete that is compacted not consolidated.

• Placed with High Density Asphalt Machine • No forms.

• No reinforcing steel or dowels • No finishing • Compacted with rollers • No internal vibration (consistency of damp gravel) • High production (approx. 2,500 m2/day)

After curing, RCC engineering properties are similar to PCC. It’s concrete pavement placed in a different way!

RCC SURFACE APPEARANCE

SURFACE APPEARANCE AND TEXTURE OF RCC •

•

•

Similar appearance & texture as asphalt only light grey instead of black Diamond ground RCC is similar to diamond ground concrete Surface texture depends on aggregate gradation and paste content

Diamond Ground Conventional Concrete

PCC

Diamond Ground RCC

RCC

HMA

THE FINAL SURFACE TYPE WILL DICTATE THE NECESSARY TECHNIQUES & EQUIPMENT NEEDED TO BE SUCCESSFUL

Applications Factors

Asphalt

Diamond Ground RCC

Natural RCC

• • • • •

Ports Distribution centers Industrial yards Residential roads Parking lots

• • •

Collector / Arterial local roads Highway Shoulders State routes

•

Any pavement type

• •

Lowest Cost Most sensitive to contractor skill level Least smooth “Asphalt” appearance

• • • •

Medium cost increase Increased construction time Improved smoothness, skid resistance Reduced noise

• • • •

Highest cost Increased construction time Least sensitive to contractor skill level Improved smoothness, skid resistance

• •

RCC MIX DESIGN USES SAME MATERIALS AS PCC, BUT IN DIFFERENT COMBINATIONS

RCC MIXING: CONTINUOUS MIX PUGMILL • • • •

250 to 600 tons/hr Excellent mixing efficiency Mobile, erected on site Mobilization cost

Credit: Fares Abdo, Morgan Corp.

IMPORTANT MIX REQUIREMENTS

• Dry enough to support a vibratory roller • Wet enough to permit adequate distribution of paste

BASIC CONSTRUCTION SEQUENCE • • • • •

Normally produced in a pugmill or central batch plant Transported by dump trucks Placed with an asphalt paver Compacted by vibratory and pneumatic-tired rollers Cured with water or curing compound

RCC PAVEMENT DESIGN OPTIONS • Follows rigid pavement design methods: • Heavy Duty Industrial, Ports & Intermodals – PCA RCC-PAVE Program – ACPA AirPave (need to manipulate input and confirm correct load is applied) – OptiPave – iSlab (to model different configurations of loads vs sizes and geometries of slabs)

• Medium and Light Duty – Street Pave by ACPA – ACI design tables – OptiPave

RCC IS PLACED WITH ASPHALT PAVERS ACHIEVING DENSITY & SMOOTHNESS IS CRITICAL

RCC RESOURCES

RCC EXPLORER

USE OF RCC PAVEMENTS IN USA RCC utilization began growing in early 2000’s & is now growing at a faster rate

# of Projects SY

1975 - 1999 71 2,999,771

2000-2010 99 8,933,250

2011-2013 172 4,993,296

PAVEMENT TYPES & OWNERS

29

27

24

5

9

16

13

12 7

5

11

7

5

2

2011 2012 2013

Application Type 48

# of Projects

# of Projects

INDUSTRIAL STILL REMAINS LARGEST APPLICATION TYPE

42 34

2011 17

15

15

2012 2013

Private

Public

Owner Type

Why are we seeing an increased use of RCC at intermodal, port and military facilities?

POTENTIAL PROBLEMS WITH RUTTING

Credit: Chris Carwie, AG Peltz Group

POTENTIAL PROBLEMS WITH RUTTING DUE TO CHANNELIZED LOADINGS

Credit: Chris Carwie, AG Peltz Group

POTENTIAL PROBLEMS WITH PUNCTURES

Credit: Chris Carwie, AG Peltz Group

POTENTIAL FOR BEARING CAPACITY FAILURE

Credit: Chris Carwie, AG Peltz Group

RCC FOR PORT FACILITIES

Credit: PortofHouston.com

PORT EXAMPLES • • • •

Bayport Terminal Complex - 2007 Port of Montreal – 2013 Port of Long Beach – 2016 Port of Houston – several projects over the years

Credit: AG Peltz, Lafarge, CEMEX

RCC FOR INTERMODAL TERMINALS

Credit: Fares Abdo, Morgan Corp.

INTERMODAL EXAMPLES • • • • •

CN Intermodal, Calgary - 1998 Norfolk International Terminal - 2009 Memphis Regional Intermodal Facility – 2012 Charlotte Regional Intermodal Facility – 2013 KCS Wylie Intermodal Facility – 2015

Credit: AG Peltz

RCC FOR MILITARY FACILITIES

Credit: Chris Carwie, AG Peltz Group

FORT BENNING, GA - 1986

Tank Trail and Hardstand

OTHER MILITARY FACILITIES

Ft. Carson, CO, 2008 Ft. Lewis, WA,1986

Ft. Drum, NY, 1990

CITY STREETS & HIGHWAY SHOULDERS HAVE ALSO BEEN SUCCESSFULLY CONSTRUCTED WITH RCC

Solms Road – New Braunfels, TX

Lake View Heroes – San Angelo, TX

Grape Creek Road – San Angelo, TX Wistful Vista Lane – Fairview, OR

Sky Harbor Service Road – Phoenix, AZ

Truck Driving School – Yuma, AZ Truck Driving School – Yuma, AZ I-285 Shoulder – Atlanta, GA

East Wetlands Hike / Bike – Yuma, AZ

US 78 – Aiken, SC

WHY RCC WITH TCP?

• Thinner RCC cross-section could allow for more efficient compaction behind the paver.

• Reduction in costs: – Less material – Faster Schedule – Less rolling • Can be the most competitive concrete pavement offer in the market.

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WHY RCC WITH TCP?

Asphalt Design

Traditional RCC

RCC TCP Design

Pavement

4.5”

8”

6.5”

Granular Base

11”

6”

4”

Designed using OptiPave with the following modifications from PCC: - Higher flexural strength - Reduced shrinkage … all other inputs similar to traditional TCP pavements.

SUMMARY - TCP using either a 3D laser screed or RCC paving equipment is the most competitive, high performing pavement in the North American market.

Thank you for your time.

Sherry Sullivan | ssullivan@pna-inc.com