Concrete Pavement in Germany Construction, Surface Texture ... · 4.Interlayers, Base Course and Drainage 5.Outlook Content. 1.Introduction 2. Concrete Pavement Construction 3. Concrete

Concrete Pavement in Germany Concrete Pavement in Germany ––Construction, Surface Texture, Construction, Surface Texture,

Interlayer, Drainage and Base Course Interlayer, Drainage and Base Course

by Stefan Hby Stefan Hööller ller

Federal Highway Research InstituteFederal Highway Research Institute(BASt / Germany)(BASt / Germany)

1.Introduction

2. Concrete Pavement Construction

3. Concrete Pavement Surface Texture

4.Interlayers, Base Course and Drainage

5.Outlook

Content

1.Introduction




5.Outlook

Content

Road Network and Traffic in GermanyM

otor

way

Net

wor

k [k

m]

Time 1950 - > 2010

Ice Days [Days max. 0°C/Year]

Precipitation [mm/m²/Year]

Summer Days [Days min. + 25°C/Year

Climate in Germany

Why Concrete Pavement?

and

- National Raw Material

- Light Surface (Traffic Safety)

- High Durability

1.Introduction




5.Outlook

Content

Jointed Plain Concrete Pavement, (unreinforced slabs) JPCP

Concrete Mixing Plant

Important:

- Continuous Delivery of Cement and Aggregates

- Adequate Mixing Capacity

- Adequate Transport Capacity

- Short Distance to Construction Site

- Experienced Operators

Concrete Pavement -- Mix Design -

Examples of Slip Form Paver

Concrete Compaction by Poker Vibrator

Longitudinal

Concentration of Cement Paste and Fines=> Cracks?

Transversal

Construction Site

Concrete – Aluminium - Reaction

Fresh Concrete in Touch with Aluminium

=> Gas Decompression

Transport of Aggregates and Concrete to the Construction Site

Aluminium: NoSteel: Yes

Variable Lane Width

Transportation of Slip Form Paver

„Manual Paving“ for smaller Sites

Positive:- Position of Dowels and Tie Bars fixed by wooden inlays

- no influence of Compaction Energy on Position of Dowels and Tie Bars

Negative:-Delievery of fresh Concrete limited

- Man Power intensive

Dowels and Tie Bars- Expansion Joints -

- Contraction Joints / Baskets -Dowels and Tie Bars

Positive:- Position of Dowels and Tie Bars fixed by Baskets

- no influence of Compaction Energy onPosition of Dowels and Tie Bars

Negative:-Delievery of fresh Concrete limited

- Man Power intensive

Positive:- Less Man Power

-Delievery of fresh Concrete not limited

Negative:-influence of Compaction Energy on Position of Dowels and Tie Bars

- Contraction Joints / Installation by Vibration Devices -Dowels and Tie Bars

Position always correct?

- Dowel Dimension 25mm x 500mm

-Smooth Round Steel

- Plastic Coating 0,3 mm

-Tolerances:

Horizontal Shift : +/- 50 mm

Inclined Position: < 20 mm

Vertical Shift: +/- 20 mm

- Requirements -Dowels and Tie Bars

Damages appear quickly

- Position extremly wrong -Dowels and Tie Bars

Core Samples

Type of Measurement: destructive

effort: high

Quality of Result: high

- Measurement of Position -Dowels and Tie Bars

Output of the Results

Measuring Device

Puls Induction Measurement

Type of Measurement: non destructive

effort: low

Quality of Result: medium

- Measurement of Position -Dowels and Tie Bars

Joint Sealent

Acrylic-based mortarConcrete Pavement

Acrylic-based mortar

Plastic-covered Dowel

Hull

Cut A ‐A

- Retrofit of Dowels -Dowels and Tie Bars

- Retrofit of Tie Bars -Dowels and Tie Bars

- Saw Cutting -Joints (longitudinal and transversal)

after 4 – 12 hours

Bevel Cutting

complete Transversal Joint

- Saw Cutting -Joints (longitudinal and transversal)

The right time?

- Hot Bitumen Joint Sealing -Joints (longitudinal and transversal)

Construction Winter Summer

Primer Application

- Plastic Profile Joint Sealing -Joints (longitudinal and transversal)

Installation at any Weather Condition

„Package Cracking“ in the Early StageJoint 1 Joint 2 Joint 5Joint 4Joint 3 Joint 6

- Plastic Profile Joint Sealing -Joints (longitudinal and transversal)

Choose the right size!

- Sealing of Expansion and Butt Joints -Joints (longitudinal and transversal)

Expansion Joint

Butt JointWooden Inlay

Concrete Pavement

End Areas, to avoid horizontal Movements

Reinforced End Anchoir

Unreinforced „Double Concrete Slab“

1.Introduction




5.Outlook

Content

Concrete Pavement

Surface Texture (1938)

1 cm

Traffic in Germany / Europe

Traffic Volume 1960Traffic Volume 2010

Traffic in Germany / Europe

„Average“ Car in 1950 „Average“ Car in 2010

1 cm

Concrete Pavement

Surface Textures (1972)

-Soft Brush - transversal –

Concrete Pavement

Surface Textures for (1978)

- Steel Brush - transversal -

1 cm

Concrete Pavement


- Hard Plastic Brush - longitudinal -

Concrete Pavement


- Slipform Paver + Super Smoother -

+ Burlap - longitudinal

43

Concrete Pavement

Surface Textures- Analysis of the Tyre – Road - Noise -

Microtexture Macrotexture Megatexture< 0,001 mm 0,5 mm 50 mm 500 mm

high-frequency low frequency

Adhesion

Noise

Negative: polished aggregates

Positive:Fine Structure and high skid resistance

Noise

Amplitude

Positive: roughness 0,4 - 0,8mm,kubic and sharp edge aggregates

Noise

Amplitude

Negative: uneven Surface

Positive: optimisation of construction

10 mm

Concrete Pavement

Surface Textures- Analysis of the Tyre – Road - Noise -

Wavelength

Medium Macrotexture (Gaps) For Water Evacuation and Air Ventilation

Fine Microstructure No Mechanical Stimulation of the Tyre

2. Bewertung der Oberflächentextur

Concrete Pavement

Surface Textures- The Ideal -

Concrete Pavement

Surface Textures for (2000)

-Different Textures in Combinations, -e.g.: Hard Plastic Brush + Tining - longitudinal -

Concrete Pavement

Surface Textures 2002- Artificiale Turf -

Skid Resistance Tester (SRT) Outflow Meter

Concrete Pavement

Surface Textures- Grip and Texture Measurement -

Measurement of Skid Resistance

Sideway Force Measurement

-high-speed measuring system

- skewed test wheel (20°) linear

-continuous data recording

Typical measuring set-up

Concrete Pavement


Sand Patch Method

Volume of Gaps

Concrete Pavement


Microtextur0,5 mm 50 mm 500 mm

Macrotexture Megatexture

Optical Texture Analysis

Streiflicht -GroßesMessfeld

LaserProfilometer

0,001 mm

Laser Measurement Vehicle

Concrete Pavement


+

Concrete Pavement

Surface Textures- Grip Requirements -

Statistical Pass By (SPB), Currently only Indiviual Cars no Trucks

-

Concrete Pavement

Surface Textures- Noise Measurement -

CPX Trailer Measurement, Currently only for Research

Concrete Pavement

Surface Textures- Noise Measurement -

Concrete Pavement

Surface Textures- Noise Requirements -

56

Cement PasteCement Paste and Sand

Cement Paste, Sand and Aggregates

Concrete Pavement

Surface Textures- Three Stages -

Application of Retarder

Cover with Plastic Sheet

Concrete Pavement

Surface Textures- Exposed Aggregate -

Application of Retarder and Curing Compound in Combination

Concrete Pavement


Saw Cutting the Joints

Brushing the Mortar with Water / without Water

Concrete Pavement


22 Peaks (25 cm²)Noise Level (SPB) 84,7 dB(A)inhomogen, noisy

52 Peaks (25cm²)Noise Level (SPB) 82,4 dB(A)homogen, silent

Concrete Pavement


„Manual

for

Concrete Pavement

Surfaces Textures“

Version 2009

by FGSV, Köln

Concrete Pavement

Surface Textures

1.Introduction




5.Outlook

Content

Concrete Pavement

Interlayer , Base Courses and Drainage

Concrete Pavement on

Hydraulically Bound Base Course / Cement Treated Base Course

With

An Interlayer of Non-Woven Geotextile

A2 bei Brandenburg

Before: Concrete Pavement directly on on hydraulically bond base course / cement treated base, Problems at the interface::

Finally: Erosion and Loss of Structural surpport

In the Beginning: Separation and Waterpumping


Hydraulically Bound Base Course / Cement Treated Base with an Interlayer of Non-Woven Geotextile


Hydraulically Bound Base Course / Cement Treated Base Course

With

An Interlayer of Non-Woven Geotextile- History -

Concrete Pavement

Nonwoven Geotextile

Hydraulically Bound Base Course /

Cement Treated Base

1. Separation

2. Elastic Bedding

3. Drainage



- 3 Functions of the Nonwoven Geotextile Interlayer -

Cement Treated Base Course, mixed in place

Hydraulically Bound Base Course, mixed in plant




Hydraulically Bound Base Course /

Cement Treated Base Course

- Requirements -

Grading Curve: only Hydraulically Bound Base Course

Semi-mechanical Installation of Non-woven GeotextileConcrete Pavement Surface on

Non-woven Geotextile Interlayer

Turning Points Outside the installed Non-woven Geotextile

Installation of Non-Woven Geotextile

by washers D=50mm

and nails

Fixing

Fixing of Non-Woven Geotextile

Non-Woven Geotextile manufactured

with multicolor fibers:Completely

Alkali Resistant?

Additives During manufacturing:

100% Polyolefine?

- Production of Non-Woven Geotextile -

for the Non-Woven Geotextile Product for the Installation of the Interlayer

- Requirements for Non-Woven Geotextile -

Test Section 1: Route D in Kansas City, Missouri (2008) -Overlay technique –

(Overlay of a damaged concrete pavement with a concrete overlay)

Before: Asphalt interlayer Now: Geotextile interlayer

Trial applications in the USA

Concrete overlay

Asphalt interlayer

Existing concrete

Base

Concrete overlay

Geotextile Intrlyr.

Existing concrete

Base

Test section 2: Interstate 40 in Warner, Oklahoma (2008)

-New construction (on cement-treated base) –

Concrete placement

Trial applications in the USA

Adhesion to the Concrete Pavement

and the Base Course

Possibilities of using RC-Aggregates

Concrete Pavement

on hydraulically bond base course / cement treated basewith

an interlayer of Non-Woven Geotextile- Recycling -

Concrete Pavement with

Crushed Gravel Base Course

the idea the reality


Crushed Gravel Base Course - Research on the drainage behavior -


Crushed Gravel Base Course - Research on the Drainage Behaviour -

„Double-Ring“ Infiltration


Crushed Gravel Base Course

- Requirements -


Crushed Gravel Base Course- Construction Site -

Grader Finisher


Crushed Gravel Base Course- Traffic on Construction Site -


Crushed Gravel Base Course- Recycling -


Asphalt Base Course


Asphalt Base Course-Construction Site –

Finisher Roller Compaction


Asphalt Base Course-Requirements –

1.Introduction




5.Outlook

Content

Modified Asphalt Paver

Air Void Content 23 % b. vol.

Concrete Pavement Innovations

-Poures Concrete –


-Diamond Grinding –

abstreuen mitChromerzschlacke 1/3 mm


- Epoxy Coating with Chrome-Ore Slag –

Thank You for Your Kind Attention!

Questions?

[email protected]

Documents

Concrete Pavement in Germany Construction, Surface Texture ... · 4.Interlayers, Base Course and Drainage 5.Outlook Content. 1.Introduction 2. Concrete Pavement Construction 3. Concrete