Roller Compacted Concrete Pavement: Design and Construction
Transcript of Roller Compacted Concrete Pavement: Design and Construction
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Cement Stabilization of SoilsCement Stabilization of Soils
Matthew W. Singel, P.E.Program ManagerSoil Cement/Roller-Compacted Concrete
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CementCement--Based Pavement Based Pavement
MaterialsMaterials
Cast
Rolled
No Wearing Course RequiredWearing Course Required
Roller-CompactedConcrete
ConventionalConcrete
Soil-Cement
Flowable Fill
Cement-ModifiedSoil
Full-DepthReclamation
Cement-Treated
Base
Cem
en
t C
on
ten
t
Water Content
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Hydration Products• all particles not coated• voids not filled• linkages bind soilagglomerations together
Cementitious Gel or Paste• coats all particles• fills voids
ConcreteConcrete SoilSoil--CementCement
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SoilSoil--Cement Materials in a Cement Materials in a
Pavement SectionPavement Section
CementCement--Modified
Modified SoilSoil
CementCement--Treated Base
Treated Base
FullFull--Depth Reclamation
Depth Reclamation
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APPLICATIONSAPPLICATIONS
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Reasons to ModifyReasons to Modify� Improve the properties of the subgrade soil
�Reduce volume change caused by moisture�Improve wet strength�Improve compactibility
� Expedite construction by improving subgrade support in wet weather�Eliminate muddy construction sites�Create an all-weather work platform
It is important to remember thatsoil modification is different than soil stabilization
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Construction ProblemsConstruction Problems
with Silts or Sandy Soilswith Silts or Sandy Soils
� Fine-grained and difficult to compact� Poor gradation� Low bearing capacity� Low cohesiveness and shear strength� Unstable under construction equipment
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Construction ProblemsConstruction Problems
with Clay Soilswith Clay Soils
� High plasticity and cohesiveness� Fine-grained and poorly graded� High shrink and swell potential � Expansive when wet� Low bearing strength when moist
and deform under load� Difficult to dry out� Difficult to compact
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Solutions for poor subgrade soilsSolutions for poor subgrade soils� Excavate/replace
with select fill� Aggregate� Soil
� Increase the base/pavement thickness
� Contain usingfabrics or other geotextiles
� Modify soils witha calcium-based additive such as portland cement
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BENEFITSBENEFITS
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Benefits of CementBenefits of Cement--Modified SoilModified Soil
� Small addition of cement to soils to change properties
� Eliminates need for removal/replacement of inferior soils
� Low cost soil improvement� Improves pavement support� Forms weather-resistant
work platform� Provides permanent non-
leaching modification
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By treating the soil with cement, By treating the soil with cement,
the detrimental properties of clay the detrimental properties of clay
can be improved through the can be improved through the
following three processes:following three processes:
1. ParticleRestructuring
2. CementHydration
3. PozzolanicReaction
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Cement Reactions with ClayCement Reactions with Clay
� Primary�Ion exchange between calcium in cement
and clay which occurs immediately
� Secondary�Normal cement hydration contributes to
strength gain
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Primary ReactionPrimary Reaction
� Cation exchange reactions occur
� Intensifies the grouping of the clay particles by neutralizing the negative surface charges
� Produces Calcium Hydroxide – Ca(OH)2 –(hydrated lime)
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Cation ExchangeCation Exchange
+ + +
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Clay particle
Negativelychargedclay surface
Sodium ions
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Originalspacing
Reducedspacingafter ionexchangeandshrinkageof waterlayer
Dipolar H2O
+_
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Calcium ions
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Particle RestructuringParticle Restructuring
Unmodified clay particles
Clay particles afterflocculation / agglomeration
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Secondary ReactionSecondary Reaction
� Clay participates in the secondary process
� Clay is converted to calcium form
� Calcium ions combine with dissolved silica and alumina in the clay to create additional cementitious materials
� Strength gain occurs
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Cement HydrationCement Hydration
Cement + Water = Calcium Silicate Hydrate(Cementitious Gel)
- plus –
Calcium Hydroxide(Hydrated Lime)
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HydrationHydration
clay particle
unhydratedcement grain
cement hydration products(CSH and CAH)
clay-cementbonds
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Pozzolanic ReactionPozzolanic Reaction
Hydrated Lime + Silica = Calcium Silicate Hydrate
Hydrated Lime + Alumina = Calcium Aluminate Hydrate
Supplied byCement
Hydration
ClayMinerals
CementitiousGel
Note: Without silica or alumina-based clay minerals,this process does not occur (e.g. sandy or silty soils).
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Pozzolanic ReactionPozzolanic Reaction
clay particle (SiO2, Al2O3)
cementitious material from
cement hydration
clay-cementbonds
Ca(OH)2
Ca(OH)2
Ca(OH)2
Ca(OH)2
cementitious material from
pozzolanicreactions
(CSH and CAH) calcium hydroxidefrom cement
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Time of Modification ProcessesTime of Modification Processes
1. Particle Restructuring
2.Cement Hydration
3.Pozzolanic Reaction
Immediateto a fewhours
Largest strengthgain between1 day and 1 month
Slowly, overmonths and years
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DESIGNDESIGN
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Laboratory TestsLaboratory Tests
� Sieve Analysis (ASTM C136)� Atterberg Limits (ASTM D4318)� Moisture-Density (ASTM D558)� Durability Tests
�Wet-Dry (ASTM D559)�Freeze-Thaw (ASTM D560)
� Soluble Sulfates (ASTM D516)� Compressive Strength (ASTM D1633)
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ASTM C136ASTM C136
Standard Test MethodStandard Test Method
for Sieve Analysisfor Sieve Analysis
of Fine and Coarse Aggregatesof Fine and Coarse Aggregates
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Particle SizeParticle Size
DistributionDistribution
GravelSandSiltClay
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HydrometerHydrometer
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ASTM D4318ASTM D4318
Standard Test MethodsStandard Test Methods
for Liquid Limit, Plastic Limit,for Liquid Limit, Plastic Limit,
and Plasticity Indexand Plasticity Index
of Soilsof Soils
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Plasticity Index (PI)Plasticity Index (PI)� The range of moisture through which a soil deforms
under loading
� The measure of a soil’s affinity to retain moisture
� Plasticity Index is the difference between the Liquid Limit and the Plastic Limit of a soil
� PI = LL - PL
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Expansive Soils andExpansive Soils and
PI RelationshipsPI Relationships
DegreePercentSwell
ApproximatePI
Non-Expansive 2 or less 0 to 10
ModeratelyExpansive
2 to 4 10 to 20
HighlyExpansive
More than 4 20 and above
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ASTM D558ASTM D558
Standard Test MethodsStandard Test Methods
for Moisturefor Moisture--Density RelationsDensity Relations
of Soilof Soil--Cement MixturesCement Mixtures
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Standard Proctor MoldStandard Proctor Mold
and Rammersand Rammers
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Moisture/Density RelationshipMoisture/Density Relationship
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Moisture/Density RelationshipMoisture/Density Relationship
100
105
110
115
120
125
5% 7% 9% 11% 13% 15% 17%
Moisture Content
Dry
Den
sity
(lb/
cf)
Maximum Dry Density
Optimum Moisture Content
ASTM D558
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ASTM D559ASTM D559
Standard Test MethodsStandard Test Methods
for Wetting and Dryingfor Wetting and Drying
Compacted SoilCompacted Soil--CementCement
MixturesMixtures
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WetWet--Dry TestsDry Tests
� Three cement contents tested� Separate specimens for W-D and F-T� Standard Proctors used at optimum moisture
and maximum dry density� Moist cured for 7 days
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WetWet--Dry TestsDry Tests
� Wet-Dry� Soaked in water for
5 hours� Dried at
70°C (158°F)for 42 hours
� Brushed� Repeat 12 times
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ASTM D516ASTM D516
Standard Test MethodStandard Test Method
for Sulfate Ion in Waterfor Sulfate Ion in Water
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0.00% to 0.30% 0.00% to 0.30% -- Sulfate Levels Too Low to be of ConcernSulfate Levels Too Low to be of Concern
0.31% to 0.50% 0.31% to 0.50% -- Sulfate Levels of Moderate RiskSulfate Levels of Moderate Risk
0.51% to 0.80% 0.51% to 0.80% -- Sulfate Levels of Moderate to High RiskSulfate Levels of Moderate to High Risk
0.81% and up0.81% and up -- Sulfate Levels of High and Unacceptable RiskSulfate Levels of High and Unacceptable Risk
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ASTM D1633ASTM D1633
Standard Test MethodStandard Test Method
for Compressive Strengthfor Compressive Strength
of Molded Soilof Molded Soil--CementCement
CylindersCylinders
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CMS Strength DeterminationCMS Strength Determination
The objective of CMS is to amend undesirable properties of problem
soils or substandard materials so that they are suitable for use in
construction. The amount of cement added to the soil is less than that
required to produce a hardened mass but is enough to improve the
engineering properties of the soil.
It is important to remember thatsoil modification is different than soil stabilization
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CTB Strength DeterminationCTB Strength Determination
� Unconfined Compressive Strength Testing�Used by most State DOT’s and FAA�Simple and quick procedure�7-day strengths ranging
from 300 psi to 800 psi(2.1 MPa to 5.5 MPa) aregenerally recommended
�Strengths vary accordingto project requirements
�300 to 400 psi (2.1 to 2.8 MPa) mixed-in-place and 600 to 800 psi (4.1 to 5.5 MPa) plant mixed
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FDR Strength DeterminationFDR Strength Determination
� Unconfined Compressive Strength Testing� ASTM D1633� Used by most State DOT’s and the FAA� Simple and quick procedure� 7-day strengths ranging
from 300 psi to 400 psi(2.1 MPa to 2.8 MPa) aregenerally recommended
� Proven strength (support)under heavy traffic conditions
� Proven durability (performance)in both wet/dry and freeze/thawenvironments
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Please keep in mind that Please keep in mind that
strength and durabilitystrength and durability
are NOT the same thing!are NOT the same thing!
The purpose of themix design procedureis to select thecorrect additive thatmost closely balancesboth strength ANDperformance for theroadway materials!
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Early Research InvolvingEarly Research Involving
CementCement--Modified SoilsModified Soils
� “Cement Modification of Clay Soils”� A. P. Christensen� Portland Cement Association� 1969
� Studied the effects of treating clay soils with small amounts of portland cement
� He compared:� Plasticity Index (PI) reduction� shrinkage limits� cohesiveness � unconfined and triaxial compressive strengths
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Study SoilsStudy Soils
� Eight were clays, three were clay and silty-clay loams �Four were classification AASHTO A-6�Seven were classification AASHTO A-7-6
� The predominant soil used in the study was a Texas clay (Montmorillonite)
� Cement percentages used were 3% and 5% by weight of dry soil
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19
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18
27
0
10
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Soil 2 Soil 5 Soil 9 Soil 10
Pla
sti
cit
y In
de
x (
%)
Untreated 3% Cement 5% Cement
Effect of ModificationEffect of Modification
on Plasticity Indexon Plasticity Index
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General Results of General Results of
ChristensenChristensen’’s Studys Study
� Portland cement increased the shrinkage limits of clay soils to values greater than optimum moisture
� Soils with a Plasticity Index (PI) between 18 and 29 were reduced to 10 or less after a 24-hour compaction delay
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Current Research Involving Current Research Involving
CementCement--Modified SoilsModified Soils
•“Tube Suction Test for Stabilized Materials”•Tom Scullion, P.E.•Texas Transportation Institute•2001
•Evaluated the moisture susceptibility of subgrade soils used in roadway pavements
•Recognized an empirical relationship between laboratory electrical conductivity values and expected performance (durability) of subgrade materials in the field
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Tightly Bound
Loosely Bound
Viscous Water
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Tube Suction Test (TST)Tube Suction Test (TST)
for Moisture Susceptibilityfor Moisture Susceptibility
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Using the Dielectric ProbeUsing the Dielectric Probe
dielectric - n. A nonconductor of electricity.
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Interpreting TST ResultsInterpreting TST Results
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Sample Test DataSample Test Data
0
2
4
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12
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16
18
0 2 4 6 8 10 12
Time (days)
Die
lectr
ic V
alu
e
Cement 5.5%
C 3.5% + FA 8%
Cement 7.5%
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Summary of Recommended Summary of Recommended
Laboratory Test ProcedureLaboratory Test Procedure
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General Results of the Texas General Results of the Texas
Transportation InstituteTransportation Institute’’ss
ResearchResearch
� A final dielectric value less than 16 appears to be indicative of a stabilized subgrade material adequately resistant to moisture susceptibility
� Reliable durability predictions can be made in two-thirds the time of the conventional W-D and F-T Tests
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CONSTRUCTIONCONSTRUCTION
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Subgrades before and after CMSSubgrades before and after CMS
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TESTINGTESTING
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Primary Testing RequirementsPrimary Testing Requirements
Gradation Moisture Density
A common moisture requirement is to be
within 2% of the laboratory established
optimum moisture content (ASTM D558).
A common density requirement is to be between 95% and
98% of the established laboratory
standard Proctor density (ASTM D558).
A common gradation requirement is for 100% to pass the 1.5-inch (38 mm)
sieve and a minimum of 60% to pass the No. 4 (4.75 mm)
sieve (ASTM C136).
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Secondary Testing RequirementsSecondary Testing Requirements
Thickness Stiffness Stability
Modified subgrade MUST bestable before next pavement
course is constructed! Proof-rolling is the most
commonly accepted practice.
Requirements for subgrade depths can vary from as little as 6 inches (150 mm) up to 2 feet (0.6 m)
depending on governing agency.
Measures in-place engineering values
using structural layer stiffness, klbf/in
(MN/m) and Young’s Modulus of a material,
kpsi (MPa).
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But what about strength?But what about strength?
The objective of CMS is to amend undesirable properties of problem
soils or substandard materials so that they are suitable for use in
construction. The amount of cement added to the soil is less than that
required to produce a hardened mass but is enough to improve the
engineering properties of the soil.
It is important to remember thatsoil modification is different than soil stabilization
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PERFORMANCEPERFORMANCE
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CMS can be used as a subgradeCMS can be used as a subgrade
for either flexible or rigidfor either flexible or rigid
pavement structurespavement structures
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The final impact of CMSThe final impact of CMS
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Summary:Summary:
CementCement--Modified SoilModified Soil
� Cement factors normally 2% to 5%� Significant and immediate reductions in the
soil’s Plasticity Index� Increases bearing ability of granular or
plastic soils� Produces workable foundation for bases for
both rigid and flexible pavements
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Summary:Summary:
Cement EffectsCement Effects
� Strength improves immediately and increases over years
� No long-term effects from leaching
� Compaction can occur immediately with no “mellowing period” necessary
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FullFullFull---Depth ReclamationDepth ReclamationDepth ReclamationMatthew W. Singel, PE
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FullFull--Depth ReclamationDepth Reclamation
with Cementwith Cement
• Applications
• Design
• Construction
• Testing
• Performance
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Definition of ReclamationDefinition of Reclamation
� Method of flexible pavement reconstruction that utilizes the existing asphalt, base, and subgrade material to produce a new stabilized base course for an asphalt, chip seal, or concrete wearing surface.
� Alternative Terms:�Full-Depth Recycling (FDR)�Cement Stabilized Reclaimed Base (CSRB)�Cement Recycled Asphalt and Base (CRAB)�Cement Recycled Asphalt Pavement (CRA……)
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The New Base
The new cement recycled base will be stronger, more uniform, and more moisture resistant than the original base, resulting in a long, low-maintenance life
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Inside a ReclaimerInside a Reclaimer
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SoilSoil--Cement Materials in a Cement Materials in a
Pavement SectionPavement Section
CementCement--Modified
Modified SoilSoil
CementCement--Treated Base
Treated Base
FullFull--Depth Reclamation
Depth Reclamation
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Diesel
(gal)
Landfill
(cu yd)
Material
(tons)
Trucks
(Number)
New
Recycle
180
12
4500
300
2700
0
3000
500
1 Mile of 24’-wide 2-lane road,
6” base + 2” asphalt surface
Equipment and Materials
Recycling vs. New Base
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Pavement Loadings….An Increasing Trend
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Rural Interstates Rural Interstates -- GrowthGrowth
0
100
200
300
400
500
600
700
1970
1972
1974
1976
1978
1980
1982
1984
1986
1988
1990
1992
1994
1996
1998
2000
LOAD
ADTPerc
ent G
row
th (
%)
650%
150%
Source: Highway Statistics 2000
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Pavement DistressPavement Distress
Alligator Cracking
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Pavement DistressPavement Distress
Rutting
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Pavement DistressPavement Distress
Base Failure
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Pavement DistressPavement Distress
Moisture Infiltration
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Pavement DistressPavement Distress
Potholes
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Texas Pavements
1.0
79.0
138.0
79.0
0
50
100
150
Mil
es (
x 1
000)
'
Feder
alSta
teC
ounty
City
/Loc
al 88.2%
6.5%5.3%
RigidComposite
Flexible
Type of PavementCenterline Miles of RoadBy Jurisdiction (296,000 Miles)
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Pavements in thePavements in the
United StatesUnited States
19.2%
74.1%
6.6% High Flexible
Concrete and Composite
2,450,000 miles of surfaced roads
Low Flexible
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Reclamation: A Logical ChoiceReclamation: A Logical Choice
� Aging road systems
� Most highway systems now in place� Emphasis shifting to
maintenance/rehabilitation� Most roads are local, low-volume,
unpaved or flexible pavements� Possible strategies:
�Thick structural overlays�Removal and replacement�Reclamation with cement & thin overlay
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ApplicationsApplications
� Low volume roadways
� Residential streets
� Medium to high-volume roads
� Highways and interstates
� Airports
� Parking lots
� Industrial storage facilities
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Advantages of ReclamationAdvantages of Reclamation
� Save costs by reusing in-place materials
� Little or no material hauling
� Maintain or improve existing grade
� Conserve virgin materials� Reduce construction time
(quick return to traffic)� Environmentally friendly
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Engineering BenefitsEngineering Benefits• Retards Reflective Cracking
• Increased Rigidity Spreads Loads
• Eliminates Rutting Below Surface
• Reduced Moisture Susceptibility
• Reduced Fatigue Cracking
• Allows Thinner Pavement Section
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Retards Reflective CrackingRetards Reflective Cracking
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Creates Stable BaseCreates Stable Base
� Bonds particles together (increases strength, stiffness)
� Reduces plasticity
� Reduces permeability (fills voids, forms membrane)
� Improves compaction (lubrication, particle restructuring)
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Easy Construction Process!Easy Construction Process!
� Design
� Processing
� Compaction
� Finishing
� Curing
� Surfacing
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DESIGNDESIGN
(Preconstruction(Preconstruction
Evaluation)Evaluation)
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Preconstruction Testing
� The procedure includes the following steps:
�Site Investigation.� The site should be investigated to determine the cause and
depth of failure.
� Cores or test holes should be used to determine layer thicknesses and to obtain material samples to be recycled including the asphalt surface, base course aggregate, and subgrade.
�Lab Evaluation.� Representative samples from the site should be pulverized in
the lab to simulate the aggregate-soil mix anticipated during construction.
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Mix Design
The mix design procedure uses PCA publication:
Soil Cement Laboratory Handbook
Includes the determination of:
- maximum dry density,
- optimum moisture content, and
- compressive strength.
(If unconfined compressive strength is used to determine cement content, a 7-day strength of 300 to 400 psi is recommended)
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Mix Design ProportioningMix Design Proportioning� Obtain representative samples of roadway material� Can use up to 50% Reclaimed Asphalt Pavement (RAP)� Pulverize to anticipated gradation
�100% passing 50 mm (2”)�55% min. passing 6 mm (#4)
� Estimate cement content
�Usually 4 to 8%�By weight of dry material
� Run moisture/density curve
�Standard Proctor� (ASTM D558)
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Moisture/Density RelationshipMoisture/Density Relationship
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Strive for a Balance BetweenStrive for a Balance Between
Strength and PerformanceStrength and Performance
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Test for StrengthTest for Strength
� Unconfined Compressive Strength Test�Used by most State DOT’s
�Simple
�Quick
�7-day requirements range
from 200 psi to 800 psi
�300 psi to 400 psi is
generally recommended
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CONSTRUCTIONCONSTRUCTION
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Aggregate AdjustmentAggregate Adjustment
(if necessary)(if necessary)
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PulverizationPulverization
� Pulverize to required depth and gradation
� 1 to 4 passes
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Material RemovalMaterial Removal
Excess material can be removed from roadway
(rare occasions)
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Cement Spreading (Dry)Cement Spreading (Dry)
� Cement is spread on top of roadway in measured amount
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Cement Spreading (Slurry)Cement Spreading (Slurry)
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Blending of MaterialsBlending of Materials
� Cement is
blended into pulverized,
reclaimed
material
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Moisture AdditionMoisture Addition
� Water is
added to
achieve
optimum
moisture
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GradingGrading
� Material is graded to appropriate grade, and cross-slope
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CompactionCompaction
� Material is compacted
� 96% minimum Standard Proctor density
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CuringCuring
BituminousCompound
Water
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SurfacingSurfacing
� Surface course
is applied last
� Conventional
Concrete
� Roller-
Compacted
Concrete
� Hot-Mix Asphalt
� SurfaceTreatment
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Typical Recycled Base and Surface Thickness
Road Function Typical Thickness
RecommendedSurface
Residential 6 in 0.75 – 1.5 in
Secondary 8 in 1.5 – 2.5 in
Highway 10 in 2 – 3+ in
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Review of Construction Procedure
Asphalt
Granular
base
Sub-base
Existing
road
Sub-base
Pulverized
Pulverization
to desired
depth
Sub-base
Pulverized
Removal of
excess material
(if necessary)
and shaping
Sub-base
Stabilized
Addition of
additives, mixing,
reshaping and
compaction
Sub-base
Stabilized
Asphalt
Final surface
treatment
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Quality Control
Quality Control
The success of a recycling project depends upon the careful attention to the following specified control factors:
�pulverization
�cement content
�moisture content
�density
�curing
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Reflective Cracking
Can it be prevented?
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Micro-crackingIntroduces a network of fine
fractures into the base to mitigate the formation of major cracks
� 10-12 ton vibratory roller applied 1–2 day after placement
� Low Speed
� At High Amplitude
� 2 – 4 passes
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PCA Document LT 299
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TESTINGTESTING
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TestingTesting
Moisture
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TestingTesting
DensityASTM D 2922
AASHTO T 310
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TestingTesting
Thickness
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TestingTesting
Stiffness
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TestingTesting
Stability
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Engineering BenefitsEngineering Benefits• Retards Reflective Cracking
• Increased Rigidity Spreads Loads
• Eliminates Rutting Below Surface
• Reduced Moisture Susceptibility
• Reduced Fatigue Cracking
• Allows Thinner Pavement Section
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Retards Reflective CrackingRetards Reflective Cracking
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Increased Rigidity Spreads Loads
100 psi
Cement-Stabilized Base• Soil-Cement• Cement-Treated Base
100 psi
4 psi
Unstabilized Granular Base
15 psi
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Eliminates Rutting Below Surface
Rutting can occur in surface, base and
subgrade of unstabilized bases due to repeated
wheel loading
Cement-stabilized bases resistconsolidation and movement,thus virtually eliminating rutting in all layers but the asphalt surface.
Unstabilized BaseCement-Stabilized
Base
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Subgrade Stress vs. Base Thickness
0
5
10
15
20
25
4 5 6 7 8 9 10 11 12
Base Thickness (in.)
Su
bg
rad
e S
tre
ss
(p
si)
Stone Base
Cement-Treated
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Reduced Moisture SusceptibilityHigh water table
Moisture infiltrates base• Through high water table• Capillary action• Causing softening, lower strength,
and reduced modulus
Cement stabilization:• Reduces permeability• Helps keep moisture out• Maintains high level of strength
and stiffness even when saturated
Unstabilized Granular Base Cement-Stabilized Base
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Reduced Fatigue CrackingReduced Fatigue Cracking
High deflection due tolow base stiffness
Results in high surface strains and eventual fatigue cracking
Unstabilized Base
AsphaltSurface
Cement-StabilizedBase
Higher stiffness ofcement-stabilizedbase produces lowerdeflections
Resulting in lower surface strains and longer pavement life
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Asphalt Strain vs. Base Thickness
0
0.0001
0.0002
0.0003
0.0004
0.0005
4 5 6 7 8 9 10 11 12
Base Thickness (in.)
As
ph
alt
Str
ain
Stone Base
Cement-Treated
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Projects
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Welcome to Navasota, TX� Population 6,296
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“More Bang for the Buck”� Began recycling
program to get people “out of the mud”
� Has recycled well over 300,000 SY of residential streets
� 2002: 93,000 SY in 20 days.
Ron Akin, Street Superintendent
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� Rents CMI 425 for $14,000 ($20,000 w/maintenanceand operations).
� Mixes 4% cement
� Uses city crew
� Seal coats
� Cost = $1.92/SY
� Plans to overlay recycled streets w/asphalt.
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$22,410 per mile
� 20 Days
� 8-hour days
� City Crews
� City Equipment
� Rented CMI
� Chip seal
� Delaying overlay is working well
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FM 1017 Jim Hogg County (2002)
� Two $6M contracts
� Remove/Replace = roughly 23 miles vs. Recycling = 38 miles.
� Existing = 22’ wide hurricane evac route: 2” ACP/8” base
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New FM 1017
� 44 feet wide
� 12” stabilized subgrade
� 8” stabilized flexible base
� 1.5” ACP
� One course seal coat applied between flexible base and ACP to facilitate traffic control and to protect against moisture.
� Contractors – Ballenger & Foremost –suggested widening road extra 4 feet for easier traffic control.
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City of Fort Worth
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City of Fort Worth FDR
1996: 296 lane-miles or 2.26 million SY
Spending 60% of $10-million budget on reclamation
Averagematerial cost: $1.95 to $2.45 SY
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Replace vs RecycleFull reconstruction =
$278,500 per lane mile replacing curbs, gutters, sidewalks & driveway approaches.
FDR = $200,000, a $78,500 cost-savings.
BUT city keeps 40% to 90% of concrete, cutting cost to $83,050 per lane mile.
FINAL Cost-savings = $116,950 lane mile
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US 79 Jacksonville
� 11-mile stretch
� 8,000 tons of cement = 4%
� 333,864 SY
� 13-in deep
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Tarrant County
� Reclaiming with cement since 2001.
� 4.5% cement six to eight inches deep.
� Two-inches of asphalt or a two-course surface treatment tops the roadways.
� Material costs = $1.25 - $1.50 per sq. yd.
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TxDOT - Amarillo� The Amarillo District recycled a portion of IH-40
pavement with cement
� The existing pavement was 11” asphalt and 19” of flexible base
� 4” of asphalt were removed with a milling machine
� The treated base blended 7” asphalt and 4” of flex base
� A cutback asphalt prime coat was used for curing
� The final asphalt surface consisted of a 75 #/sy level-up layer and a 150 #/sy surface
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TxDOT - Amarillo
� Construction process
�Two recycling trains were used that included:
�Milling machines
�Trailer-mounted screening/crushing units
�Cold mixing units w/ belt scale and liquid additive systems
�Cement was applied by two vane spreading units
The original cement content was specified at 4%
but was lowered to 3-3.5% based on lab tests of
the recycled material
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TxDOT - Amarillo
� Construction process (con’t)
� One lane mile per day paved by each train
�Project utilized excellent pulverization, mixing,
and quality control� A month of construction time was saved
� The method was slightly more expensive than other methodsbut the time saving was critical
� Performance� Highly consistent blended material
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Texas DOT Bryan District� On rural FM system
� Increased oil field and farm traffic
� District recycled 10 inches of base creating a layer
� 300-400 psi, 4%
� Roads were opened to traffic daily
� TTI Pavement evaluations of treated layers include
Stiffness, Cracking, Moisture
Susceptibility and performance
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Successes
� TXDOT – Amarillo – IH-40
� NCTCOG - CMS Specification adopted; 100 cities in 16 counties
� TXDOT-Tyler - US 69 CMS (2,200 tons)
� TXDOT Bryan - Over 500 miles roads (50,000tons)
� TXDOT San Antonio - I-37 S. TX - 18 miles of recycling (17,000 tons)
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Who Is Using It In Texas?Who Is Using It In Texas?(Partial List)(Partial List)
�Bedford
�Bell County
�Dallas
�Grand Prairie
�Fort Worth
�Tarrant County
�Goliad County
�Bexar County
�Lubbock District
�Corpus Christi District
�Bryan District
�San Antonio District
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More AdvantagesMore Advantages
�Minimizes inconvenience for both homes and businesses�Less construction equipment
�Fast operation
�Can apply local
traffic almost
immediately
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-100
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% SAND
% SILT and CLAY
% G
RAVE
L
Base and Subbase MaterialsBase and Subbase Materialspoor zone for cement
stabilization
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TheThe BIGGESTBIGGEST Advantage!Advantage!� Versatility through use of portland cement
� Stabilizes many materials
� old base
� asphalt surface
� granular or plastic subgrade
� blends
“Portland Cement is probably the closest thing we have to a universal stabilizer.”
- From a U.S. Army Corps of Engineers Report dated September 2002
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for additional information, please visit our website at
www.cement.org/pavements
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Web Site:www.RecyclingRoads .org
� New and dramatic
� Tells all about the recycling process
� Describes ongoing and completed work
� Provides contact information about the owner, designer, contractor and specifics of each job
� Provides testimonials by user
� Includes “job reports” from each job written up