NATIONAL MEETING ON CONCRETE ROADS - PowerPoint Presentation

Slide1

NATIONAL MEETING ON CONCRETE ROADS

18th December 2002, Ankara

„CONCRETE ROAD CONSTRUCTIONS

State of the Art and new Development“

by

Jürgen Halm

HeidelbergCement Technology Center GmbH

Department Concrete and Application

Slide2

Table of Contents

New Regulations in Germany (Requirements to be met)

Placement of Concrete / Laying Technology

Paver Compacted Concrete

Noise-reduced Traffic / Open porous Concrete

(Draining Concrete)

Slide3

New Regulations

ZTV Beton – StB 01 (StB = Road Construction)

(Supplementary Technical Conditions of Contract, Specifications and

Guidelines for the Construction of Concrete Pavements)

The new Edition 2001

Includes new technical developments in the construction

of concrete pavements

Slide4

New Regulations

The ZTV Beton - StB 01 includes:

Modifications of the VOB Part C (12.2000)

(VOB = General Technical Conditions of Contract)

ZTV Fug-StB 01

(Supplementary Technical Conditions of Contract,

Specifications and Guidelines for sealants and joint fillings in traffic areas)

Description of burlap

(Special kind of surface treatment)

Construction method using geotextil as a layer between

concrete pavement and road base

Cement requirements

New construction methods (two layer – wet in wet)

Skid resistance requirements

Slide5

45

MN/m

2

New Regulations

Pavement construction:

The concrete pavement can consist of one or two layers

Thickness of top layer

>

4 cm

The thickness of total pavement depends on the RStO 01

(RStO = Guidelines for the Standardization for Pavement Structures for Traffic Areas)

3 examples for construction class SV (heavy traffic load)

concrete pavement

geotextil

120

27 cm

15 cm

42 cm

asphalt stabilized base



120

45

MN/m

2

26 cm

10 cm

36 cm

crushed-rock

base



150



45

MN/m

2

30 cm

30 cm

60cm

concrete

pavement

concrete

pavement

cement stabilized base (HGT)

subbase

frost-resistant

material

subbase

frost-resistant

material

subbase

frost-resistant

material

Slide6

New Regulations

Alternative concrete construction method:

2 layer-concrete on

standard-pavement structure crushed-rock base

The advantages of thick concrete pavement with a thin upper layer of

concrete are:

Improved skid resistance

Reduction of noise

Guarantee of covered dowels

Use of recycled broken-up material in the lower concrete layer

concrete

pavement

frost-resistant

material

27 cm

15 cm

42 cm

crushed-rock base

(unbound base)

30 cm

30 cm

60 cm

4 cm = top layer

geotextil

concrete

pavement

cement stabilized base (HGT)

frost-resistant

material

26 cm = bottom layer

Slide7

C

ement

- CEM I 32,5 R (DIN EN 197-1)

- upon coordination with the customer the following

cements can also be used: - CEM II/A-S oder CEM II/B-S - CEM II/A-T oder CEM II/B-T - CEM II/A-L - CEM III/A - for CEM I 32,5 R - < 28 % required water (DIN EN 196-3)

- compressive strength, 2 days

<

29 N/mm²

(DIN EN 196-1)

- 3.500 cm²/g fineness of grinding (DIN EN 196-6)

- requirements for all cements - total alkali content < 1,0 M% (required) - cement temperature < 80°C (if possible)

New Regulations

Slide8

New Regulations

concrete aggregates - DIN 4226-1 (German Industrial Standard)

- TL Min – StB

(Technical Conditions for the Supply

of Minerals for Road Construction)

- Limitation of swelling components

- Increased frost resistance requirements

- A percentage of crushed aggregates is required

- High quality crushed aggregates with resistance

to polishing (PSV = polished stone value)

- The alkali guidelines of DAfStb shall be included

Slide9

New Regulations

Concrete requirements

Construction

class

Minimum values of 28-day-old-concrete

Size of aggregates-groupes

[mm]

Compressive strength on

the cube with 20 cm

edge lengths

[N/mm²]

Beam-tensile strength

[N/mm²]

1

2 3

4

5

SV, I - IV

35 40

5,5

0/2, 2/8, > 8

0/4, 4/8, > 8

0/2,

<

8*

*for 8 mm maximum aggregate size

V - VI

25 30

4,0

0/4, > 4

- Cement content of construction class SV, I, II, III:

>

350 kg/m³

- Water-cement ratio in tests for construction classes SV, I, II, III:

<

0,45

- Mixing time:

>

45 seconds

ZTV Beton Tab.1

traffic load

Slide10

New Regulations

Concrete requirements

Air void volume of fresh concrete

Micro air void with air-entraining agent guarantee a high frost-deicing salt- resistance in the concrete.

Minimum air void volume of fresh concrete

daily average

individual values

[Vol.-%] [Vol.-%]

Concrete

without

plasticizer (BV)

or plasticizing agent (FM)

4,0

3,5

Concrete

with

plasticizer (BV) and/or plasticizing agent (FM)

5,0

4,5

ZTV

Beton

Tab. 2

Slide11

New Regulations

Concrete requirements

Observing minimum strengths (table 1)

Observing the air void volume (table 2)

Tolerance of the pavement thickness (< 5 mm on the test specimen)

Max. 20 (50) mm shifting of the positon of the dowles

<

0,5 % deviation for the crossfall

<

4 mm evenness with 4m-long-measuring rod Observing values for skid resistance TP Griff-StB (SCRIM) (table 4)

Measuring speeds

[km/h]

Limiting values

µ

SCRIM

Acceptance Until expiry

of term

of limitation

40

60

80

0,60 0,56

0,53 0,50 0,46 0,43

ZTV Beton Tab. 4

Slide12

New Regulations

Surface treatment and curing

Construction classes SV, I, II, III

Final polishing element = longitudinal polisher

Finishing surface treatment by means of 300 g/m² burlap or

45 cm wide steel broom

Wider new methodes for finishing surface are burlap with comp

artificial grass and „wash concrete“ (remove the fine mortar)

-

When the surface is completed, a curing agent as per

TL NBM-StB shall be applied. Densifying coefficient:

S

> 75 %

It is suitable to use curing agents with increased brightness referenz value (with colour value) VH-W oder VM-W. Joint cutting

Transverse joint: cutting depth 25 - 30 % of the thickness Longitudinal joint: cutting depth 40 - 45 % of the thickness

Slide13

longitudinal smoother

Laying technology

Slide14

Laying technology

burlap

Slide15

transverse „steel-broom line“

Laying technology

Slide16

Laying technology

„wash-concrete“ surface (Germany)

Slide17

application curing-agent

Laying technology

Slide18

2,50

4,25

3,75

4,50

2,50 m

12,50 m

5,00 m

5,00 m

12 %

frost-resistant gravel

and sand material

Transverse contraction joint,

with dowels Spacing

of dowels 25 cm

shoulder

lane

external

lane

central

lane

internal

lane

Longitudinal contraction joints, 3 or 5 tie bars per slab

Laying technology

Example of BAB 5 expresshighway:

concrete pavement structure + positions of dowels and tie bars

concrete pavement

26 cm (19+7)

cement stabilized base

Slide19

dummy joint-cut

(to prevent wild cracks)

bituminous joint filler

or joint profile

notch

cement stabilized base (HGT)

Joint technology

Slide20

Joint technology

dummy joint

- longitudinal - transverse for expansion

Slide21

pressed joint „sinus profil“

wich does not allow expansion

(only in aircraft movement areas)

Joint technology

Slide22

Mixing plant / supply of cement

Slide23

Stockpile of aggregates

Slide24

Laying technology

concrete pavement - two layers slipform paver

Slide25

dowel setting machine

Laying technology

Slide26

Reinforced concrete pavements

1921 First continuously reinforced pavements in

United States

– Virginia (60 m long slabs of different reinforcements)

from 1947 Inter-States network in the United States is partly produced with reinforcement

until 1994 16.000 km of the Inter-States network are reinforced

from 1970

Belgium

Brussel-Lüttich motorway

further applications in Belgium, Spain, UK

until 1994 Belgium 2.950 km

from 1982

France 10 km of the A 6 motorway near Auxerre until 1994 3,5 Mio m² of reinforced pavement

Reinforced pavements

Slide27

Reinforced pavements (France)

Reinforcement

16 mm-dia. round steel, longitudinal/transverse

percentage of reinforcement 0,6 - 0,8 %

alternatively:

flat rolled steel bands 40 - 44 mm wide

2 - 3 mm thick (galvanized, with knobs)

percentage of reinforcement 0,30 % (higher tensile yield point)

Layout:

1/3

1/2

> 60-70 mm



reinforcement layer in the

compression zone

Slide28

Laying technology

reinforced concrete pavement

(slipform paver)

Slide29

Laying technology

control of reinforcement

(slipform paver)

Slide30

Concrete pavement „Paver Compacted Concrete“

Slide31

Paver Compacted Concrete (PCC)

PCC is laid with conventional road pavers equiped with High-Power- Compaction Screeds (HPCS)

PCC is compacted from the surface with tamping,vibrating and pressing compacting systems

Construction

-

Single-layer or two-layer construction (fresh on fresh)

-

For use as base course or combined base and wearing course

-

Favorable paving depth (15 – 20 cm)

Construction material

- PCC 0/16 mm, if required with air entraining agent- Aggregate > 8 mm double screened chippings, or chippings (eFT)

- Concrete strength C25/30 up to C40/50 are achievableCost

- Substantially lower cost compared with conventional concrete- About 8 - 13 €/qm without joints

(depending: concrete strength, paving depth, working width)

Slide32

Paver

Compacted

Concrete

(PCC)

Applications - Base for roads and traffic surfaces built in two-layer construction according to RStO-Class SV, I – VI

-

Industrial roads; bus lanes; draw-ins

-

Farm tracks; footpaths and cycle paths

-

Crossings; yards; car parks- Industrial surfaces; exhibition grounds

Advantages- High quality achieved with low requirement for equipment and personnel

- Very good surface accuracy (longitudinal and traversal)- Suitable for two-layer construction (pavers operating in echelon)

- Density of >98% achieved right behind the High-Power-Compaction Screed-

Very good „green-stability“ (90°edge)- High resistance to wear- High paving performance (60 – 120 m/h)

- Joints can be produced or cut in the fresh concrete-

Distance between joints 5 – 7 m- Easy, efficient, economical

Slide33

Noise-reduced traffic

Noise-reduced concrete pavement

„

draining-concrete

“

Slide34

„Draining-concrete“ pavement

Slide35

„Draining-concrete“ pavement

Slide36

draining-concrete =

top layer

Concrete pavement „draining-concrete“

concrete or

PCC (

P

aver

C

ompacted

C

oncrete) orcement stabilized base = bottom layer

Slide37

Pavement „draining-concrete“ (special slipform paver)

Slide38

Surface and structure of „draining-concrete“

Slide39

Surface and structure of „draining-concrete“

Slide40

Open porous concrete „draining concrete“

 

Advantages

-

        

very high noise reduction possible by 7 dB(A)

-

       

high sound absorption (up to 98 % within critical frequency ranges)

-

       

good drainage characteristics, i.e. no splash water jets, no aquaplaning

-       

high level of road safety on dry and wet roads-

        very good transverse and longitudinal evenness-       

high skid resistance-

        good non-skid qualities in respect of dry and wet roadway surfaces

-

        good reflections properties

-        good brightness of surface-

        high load-bearing capacity (ßD, ßBZ, ßHZ

at cavity content > 20 Vol.-%)-        high deformation stability, i.e. no tracking grooves, consistently freely accessible pore space

-        favourable thermal properties, i.e. high driving safety in dark and wet conditions-        top concrete layer can be constructed without joints

-        old, loud pavings can be built over (wearing course, superimposition of top layers)

Slide41

Draining concrete composition

Concrete strength class:

>

C 25/30

Aggregates: double crushed and screend chippings 5/8 mm 1450 – 1500

kg/m

3

Cement: CEM I 32,5 R 300 – 350 kg/m

3

Water: only fresh water 50 – 55 kg/m3

Plastic dispersion: 20% of cement weight (10% solids) 60 – 70 kg/m3Water-cement ratio: 0,24 – 0,26 (effective)

Consistency: (Compacting factor test) v 1,30 – 1,34Cavity content: P

> 20 Vol.-%Compressive strength: ß

D > 25 N/mm2

Beam-tensile strength: ßBZ >

4,5 N/mm2

Tensile splitting strength: ßSZ

> 2,7 N/mm2

Adhesive pull strength: ßHZ > 3,0 N/mm

2Static modulus of elasticity: EB 16000 – 18000 N/mm2

Slide42

Laying of „draining-concrete“ on test section A5

Slide43

Noise measurement results

Slide44

Measurement „noise spectrum“

Slide45

Measurement „absorption spectrum“

Slide46

HeidelbergCement AG

Thank you very much!