Mechanical Concrete for Heavy Duty, Low Volume Roads…and more. · 2016. 4. 28. · PIOGA 2012...
Transcript of Mechanical Concrete for Heavy Duty, Low Volume Roads…and more. · 2016. 4. 28. · PIOGA 2012...
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Mechanical Concrete for Heavy Duty,
Low Volume Roads…and more.
PIOGA
2012 Winter Meeting
John A. Nawn, P.E., PTOE, FNSPE
February 8, 20111
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Mechanical Concrete®
• John A. Nawn, PE, PTOE, FNSPE, FACFEI
– Over 25 years roadway/civil engineering
experience
– Licensed Professional Engineer in 7 states
– Executive Vice President/Chief Engineer with
Czop/Specter, Inc.
– Vice President, Pennsylvania Society of
Professional Engineers
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Mechanical Concrete®
• Czop/Specter, Inc.
– 30 year old, Pennsylvania based, award winning,
Civil Engineering Consulting firm
– Survey, Engineering, Construction Management,
Environmental Permitting.
– 60 employees throughout Pennsylvania
– PIOGA Member
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Mechanical Concrete®
• Patented, licensed product/process
• By the Reinforced Aggregates Company
• Developed by Samuel G. Bonasso, P.E.
– Former Secretary of Transportation for WVDOT
• www.mechanicalconcrete.com
• Engineered Product/Process
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Mechanical Concrete®
• Independent consultant
• No contractual relationship between The
Reinforced Aggregates Company and
Czop/Specter, Inc.
• Likewise, no contractual relationship between
John Nawn and Sam Bonasso.
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Tire-Derived-Cylinder (TDC)-Mechanical Cement®
+
Stone Aggregate Material
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How Mechanical Concrete® works
• Gravity & Loads on Particles ↓ create
• Soil Pressure Reaction ↑ also
• Creates & Transmits Lateral Pressure →
• (TDC) Mechanical Cement® Cylinder Direct Lateral
Support for particles (→ ←)
↓
↑
← →
Gravity & Loads
Lateral Pressure(→ ←)Direct LateralSupport byMechanical Cement®TDC
Soil Pressure = Gravity & Loads
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Holistic Sustainability Criteria
• Economically Viable—Reduces initial costs,
maintenance, & extends useful life
• Technically Feasible—Effective, Simple, Fast
& Rugged (high design factor)
• Environmentally Friendly—Reuses & Uses
Less: Material, Energy & Labor
• Socially Supportive—Preserves scarce
resources & improves worker productivity
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The Tire Problem
• 300 Million scrap tires/year
– About 40% turned to crumb rubber and reused or
stockpiled in monofills
– About 50% burned: Tire Derived Fuels
– The other 10% - 30 million tires
• Can’t land fill, tires float
• Can’t fill completely in current form
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First Wall Section
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Basic Load Research Information
• HS 25 Truck Road Tire Pressures ≤ 100psi
• Contact area: 20,000 lb. wheel load ≥ 200 in2
• Allowable bearing pressure sand 8000-4000
psf ≤ 42psi—21psi
• By what factor will confinement increase this
bearing capacity?
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R & D
WVU CE Laboratory Tests
TDC 50K Column StrengthStone Aggregate Behavior
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Aggregate Materials Tested
• Compacted Course Sand
• Compacted Crusher Run Limestone
• Compacted AASHTO #8 Limestone
• AASHTO #57 Limestone
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Test Results 12” Long 20”φ Tube
SAND AGGREGATE
12” tube w/ 6” ɸ loading plate (28 in2) (6000lb max @ 200psi ) Bearing Failure at 1800 lb. approx. 63psi
loading-deflectionloading-deflectionloading-deflectionloading-deflection
0000
500500500500
1000100010001000
1500150015001500
2000200020002000
2500250025002500
0000 0.50.50.50.5 1111 1.51.51.51.5 2222 2.52.52.52.5 3333
deflection (in)deflection (in)deflection (in)deflection (in)
loa
din
g (
lb)
loa
din
g (
lb)
loa
din
g (
lb)
loa
din
g (
lb)
measured average horizontal pressuremeasured average horizontal pressuremeasured average horizontal pressuremeasured average horizontal pressure
-12-12-12-12
-10-10-10-10
-8-8-8-8
-6-6-6-6
-4-4-4-4
-2-2-2-2
0000
0000 1111 2222 3333 4444 5555
horizontal pressure (psi)horizontal pressure (psi)horizontal pressure (psi)horizontal pressure (psi)
de
pth
(in
)d
ep
th (
in)
de
pth
(in
)d
ep
th (
in) 21psi21psi21psi21psi
42psi42psi42psi42psi
64psi64psi64psi64psi
12”tube w/ 12”ɸ plate (113 in2)sand (200psi)(23,000lb max) (HS 25 Wheel 20,000lbs at 100psi)
loading-deflectionloading-deflectionloading-deflectionloading-deflection
0000
5000500050005000
10000100001000010000
15000150001500015000
20000200002000020000
25000250002500025000
30000300003000030000
0000 0.50.50.50.5 1111 1.51.51.51.5 2222 2.52.52.52.5 3333deflection (in)deflection (in)deflection (in)deflection (in)
loa
din
g (
lb)
loa
din
g (
lb)
loa
din
g (
lb)
loa
din
g (
lb)
measured average horizontal pressuremeasured average horizontal pressuremeasured average horizontal pressuremeasured average horizontal pressure
-12-12-12-12
-10-10-10-10
-8-8-8-8
-6-6-6-6
-4-4-4-4
-2-2-2-2
0000
-20-20-20-20 -10-10-10-10 0000 10101010 20202020 30303030 40404040 50505050 60606060
horizontal pressure (psi)horizontal pressure (psi)horizontal pressure (psi)horizontal pressure (psi)
de
pth
(in
)d
ep
th (
in)
de
pth
(in
)d
ep
th (
in)
71psi71psi71psi71psi
141psi141psi141psi141psi
218psi218psi218psi218psi
12” tube / 18” ɸ plate (255 in2) sand (200psi) (50,000lb max) (HS 25 Wheel 20,000lbs / 100psi)
loading-deflectionloading-deflectionloading-deflectionloading-deflection
0000
10000100001000010000
20000200002000020000
30000300003000030000
40000400004000040000
50000500005000050000
60000600006000060000
0000 0.050.050.050.05 0.10.10.10.1 0.150.150.150.15 0.20.20.20.2 0.250.250.250.25 0.30.30.30.3 0.350.350.350.35
deflection (in)deflection (in)deflection (in)deflection (in)
loa
din
g (
lb)
loa
din
g (
lb)
loa
din
g (
lb)
loa
din
g (
lb)
measured average horizontal pressuremeasured average horizontal pressuremeasured average horizontal pressuremeasured average horizontal pressure
-12-12-12-12
-10-10-10-10
-8-8-8-8
-6-6-6-6
-4-4-4-4
-2-2-2-2
0000
0000 20202020 40404040 60606060 80808080 100100100100
horizontal pressure (psi)horizontal pressure (psi)horizontal pressure (psi)horizontal pressure (psi)
de
pth
(in
)d
ep
th (
in)
de
pth
(in
)d
ep
th (
in) 67psi67psi67psi67psi
134psi134psi134psi134psi
197psi197psi197psi197psi
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More R & D Was Performed• Performance in the field
• Speed of Construction
• Effect of tire sizes
• Worker Learning Curve
• Quality Tolerances
• Applications
• Weather and Climate
• Behavior During Construction & Use
• Economics17
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Standard AggregatesUncompacted
– AASHTO #57 Crushed Stone
– Any Relatively Uniform Size, #3, #1
Structural Aggregate Material
Compacted
– Sands & Graded Aggregates
– Indigenous materials
– Existing roadway base materials
– All Recycled aggregate materials
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Wall Construction Field Trials Laurel
Aggregates Quarry in PA
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Wall Tests
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First
Demonstration
Projects
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West Virginia
Division of Highways
Demo Project Doddridge County
Morgan Run Road Base
350 Mechanical Cement®Tire-Derived-Cylinders (TDC)
September, 2006
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Test Road filled TDC
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Test Road Surfaced
September 27, 200625
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First Israel Run Flood April 1, 200726
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Israel Run, June 2008 Flooding Damage
2 Feet of Water
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Israel Run April, 2009
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Israel Run March, 2010
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Bowie, Inc.
Clarksburg, WV
January 2007 Demo Project
Sorbello Gas Well
20’ x 40’ Service Pad
200 Mechanical Cement® TDC
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TDC Layout
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Dozer
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Bowie/SorbelloGas Well Service Pad —2 Hours
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TRIAD MSE Wall
Demo Project June, 2006
• Larger Structure Demonstration
• 650 Mechanical Cement®Steel Belt Truck TDC
• Mechanically Stabilized Earth, MSE
• Use of Medium Truck Tires
• Impacts of Tire Size Variations
• Interconnections between cylinders
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Retaining Wall Construction35
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TRIAD MSE Retaining Wall650 TDC Medium Truck Tires Total Length 190’x15’ Ma x. Height
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First Demo & R/D Outcomes
• Fast, Strong & Economical
• May be surfaced with any material
• Erosion Resistant
• Climate and Weather Resistant (5+yrs.)
• Engineered Product
• Interfaces well with traditional means and methods
• worked as predicted(+)!
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WV DOH Approval October 9, 2008
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•Patent and Trademark Licensor•U.S. Patent 7,470,092 B2 (12/2008)
•Contractor, Manufacturer, Project, Agency, Et. Al. Licenses
• Mechanical Concrete® & Mechanical Cement®
•Construction Technology R & D
•Basic Designs, Details, Specs & Standards
•Construction Market Developer
Reinforced Aggregates Company
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•Specifier
•Engineer specific applications and uses
•Technical support: Design & Construction
•Design/Build
Czop/Specter, Inc.
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Sundt Construction
Tempe, AZ
2009 USDHS-CBP Productivity Assessment
Gibbons Ranch Road, Douglas, AZ
1400 feet unpaved, one lane
3000 Mechanical Cement®
Tire-Derived-Cylinders
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TDC In Place
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Filling TDC with Stone
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Filled TDC
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Stone Surface
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Site / Roadway Construction Productivity
Rates
• Auto Tire Derived Cylinder (TDC) Placement
– 1 Labor Hour = 150-AutoTDC 27”φ x 8”
– 800 ± sf Placed and Attached
– 80 Labor Hours per 12’ Lane Mile
– 55 Labor Hours per Acre
• Stone Spreading w/ 3 cy Wheel Loader
– ± 2400sf / 88 tons per hour
– 27 Machine Hours per 12’ lane mile
– 18 Machine Hours per acre
• Roadway / Site Coverage
– 12,000 - 27” φ ATD Cylinders per 12’ lane mile
– 8100 27” φ ATD Cylinders Per Acre
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How it supports loads
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Sundt Construction
Tempe, AZ
2010 USDHS-CBP Border Roads Project
2miles— 20’ roadway in 4 sections
Mechanical Concrete® 8” Base
Soil-Tac Resin Wearing Surface (6”ABC)
40,000 Tire-Derived Cylinders
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USDHS CBP
Imperial Dunes, CA Section 1 mile
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USDHS CBP
Imperial Dunes, CA Section
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USCHS CBP
O'Neal Valley, CA Section +/- O.5Mile
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USDHS CBP
O Neal Valley, CA Section
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Dana Prime #1 Mine
Coal Haul Road
Laurita, Inc.
Morgantown, WV
REAGCO N. WV Licensee
Project Features
• 10 inch Reinforced Concrete Surface
• 8 inch Mechanical Concrete® Base
• 2 inch AASHTO #57 Cover
• 1450 Mechanical Cement® Cylinders
• 300 40Ton Coal Trucks per Day
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TDC Placement
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TDC Filling w/
ASHTO # 57
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Concrete Slab Placement
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Finished Coal Haul Road
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Laurita, Inc.
CORESCO Mon River
Barge Loading Facility
Morgantown, WV
• 10” Reinforced Concrete Scale Approaches
• 8” Compacted Limestone Road Surface
• 9” Mechanical Concrete® Base
• 300 Coal Trucks Per Day
Project Features
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CORESCO Tire-Derived-Cylinder Placing
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CORESCO TDC Placing and Filling
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CORESCO Scale Approach
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CORESCO Finished Stone Surface
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Longview Power Plant Haul Road—
Crafts Run Road
N. WV/SW PA Licensee Laurita, Inc. ARTBA Member
July, August 2011Morgantown, WV
• 10 inch Mechanical Concrete® Base w/ 6” topping• 10 inch Reinforced Concrete Surface 500feet• 6 inch Asphalt Wearing Surface 400 feet• 600 Coal and Refuse Trucks Per Day
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Laying the base
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Base w/ Geo-
Grid Mesh
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w/Reinforced
Concrete surface
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Base Course
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Base Course
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First Ohio Project
Liberty Tire Recycling
Monofill Industrial Roadway
Minerva, OH
November, 2011
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Liberty Tire Road Under Construction
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Liberty Road Completed In Use
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Mechanical Concrete®
• Economic and Sustainable
• UTUBE Videos Available under “mechanical
concrete”
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3-D Aggregate Confinement
• Sustainably increases aggregate load carrying
capacity by 3x or more
• Eliminates water-based failure mechanisms in
aggregates
• Less Base Failures & Maintenance for
– Pothole, Ruts, & Aggregate Binder Loss Issues
– Road intersections, Interfaces and Boundaries
– Soft Subgrade Destabilization
– Ditch Line & Shoulder Drainage, Erosion, & Collapse
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12 foot wide, I mile long, Road
Mechanical Concrete Base
• Excavation = $24,000
• 12,000 TDCs = $38,000
(includes licensing cost)
• Crushed Aggregate Base =
$85,000
• TOTAL = $ 147,000
Conventional Base Course
• Excavation = $53,000
• Subbase (6”) = $64,000
• Crushed Aggregate Base =
$114,000
• TOTAL = $ 213,000
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MC is 64% of the cost of conventional construction
• Quicker, less material, less labor, less equipment, no
compaction required.
• Based on current PennDOT Statewide average costs
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Other Potential Uses
• Retaining Walls
• Stream Bank Restoration
• EV Access Roads
• Limited use/reserve/overflow parking
• Bridge Abutments
• Drainage
• Beach stabilization
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Q. A.
A.Q.
Q. A.
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