8 crist - rcc at nit

Pavement Design for Containerized Cargo Terminals

Pavement Design for Containerized Cargo Terminals

Presented by:Michael T. Crist, P.E.

November 3, 2005

Presented by:Michael T. Crist, P.E.

November 3, 2005

Agenda

Introduction to The Port and its Operations

Dynamic and Static Loads of Typical Port Equipment

Basis for Pavement Design at Norfolk International Terminals South

Construction Observations

Lessons Learned

Introduction to The Port of Virginia

In the Year 2004, VPA Handled 1.81 Million TEUs of Containerized Cargo

9.7% Increase Over 2003

So Far, 2005 Cargo Tonnage is Up 11% Compared to 2004

VPA is Currently Ranked:

7th Largest Container Port in the U.S.

2nd Largest Container Port on the East Coast in Terms of General Tonnage

Newport NewsMarine Terminal (NNMT)

Newport News, VA

Location of VPA Terminals

Virginia Inland Port (VIP)Front Royal, VA

Norfolk International Terminals (NIT) Norfolk, VA

Portsmouth Marine Terminal (PMT)Portsmouth, VA

Norfolk International Terminals

HRSDHRSD

USNFFSUSNFFS

Hampton Blvd

Hampton Blvd

Railroad AveRailroad Ave

Gate ComplexGate Complex

Pier 3Pier 3

Term

inal

Blv

dTe

rmin

al B

lvd

Pier 2Pier 2 Pier 1Pier 1

On-Dock Operations

Container Vessel Arrives at the Marine Terminal

Specialized Cranes Unload Containers from the ShipSTRAD Picks Up Container from Wharf

On-Dock OperationsOn-Dock Operations

Container Yard Operations

Containers are Stored in the Yard Until They ArePicked up By a Trucker or Loaded Onto a Train

Container Yard Operations

Straddle Carriers Remove the Container from Storage and Load it onto Trucks

Loaded Trucks and Trains are Processed at theGate and Depart for Their Final Destinations

Gate OperationsGate Operations

Agenda





Lessons Learned

Top PickTop Pick

Containers Are Moved Throughout the Terminal & Loaded Onto Trucks & Trains Using a Variety of Heavy Equipment

Container OperationsContainer Operations

Yard HustlerYard HustlerStraddle CarrierStraddle CarrierReach StackerReach StackerSide PickSide Pick

Rubber-Tire Gantry Cranes (RTGs) are Used to Load Containers Onto Trucks & To Make Up Trains

Container OperationsContainer Operations

Equipment Characteristics

11.9Side Pick

40.8Reach Stacker

4.5Yard Hustler

Load Per Wheel (kips)Equipment Type

Equipment Characteristics

52.0

Rubber-Tire Gantry-8 Wheels

33.8Straddle Carrier

60.3Top Pick

Load Per Wheel (kips)Equipment Type

Static Loads

Container Stack

4-High Container >600 psf Uniform Contact Pressure

Static Loads

Corner Castings

4-High Container Stack >1,000 psiContact Pressure

Static Loads

Dolly Wheels / Shoes

>5,000 psiContact Pressure

Agenda





Lessons Learned

History of Pavement Problems

Rutting


NIT South - Settlement Problems


Raveling of Surface

Design Parameters

Extensive Subsurface Investigation to: Determine Subgrade Characteristics (Strength and Drainage)Estimate Long-Term Settlement Issues

Improve Site Drainage25-Year LifeTerminal Traffic Determination:

Equipment Loading Repetitions

Static LoadingPavement Material Properties

Pavement Alternatives Considered

Asphaltic Concrete (AC) on Crushed Aggregate Base (CAB)

Interlocking Concrete Paver Blocks (ICPB) on Cement Treated Base (CTB)

Portland Cement Concrete (PCC)

Roller Compacted Concrete (RCC) with 3-inch AC Wearing Surface

Interlocking Concrete Paver Blocks

Pavement Alternatives Considered

Focus on Straddle Carrier Grounded Loads

ConcretePaver

16.5”

4”1”

6”

12”

CTBCTB

ABCABC

CBR20CBR20

PaverPaver

PCC

12”

6”

4”

8”

PCCPCC

ABCABC#78 Stone#78 Stone

CBR20CBR20

GeotextileMaterial

RCC

16.5”

6”

4”

8”

RCCRCC

ABCABC#78 Stone#78 Stone

CBR20CBR20

3” ACAC

GeotextileMaterialAC

14”

6”

8”

ACAC

ABCABC

CBR20CBR20

RCC Specification

Flexural Strength of 450 psi @ 7-daysCompressive Strength 2,500 psi @ 7-daysIn Place Field Density > 98% ASTM D 2922In Place Compressive Strength Check Using 6-inch Diameter CoresNo Layer Greater Than 9 Inches ThickNo More Than 60 Minutes From Mixing to Compaction and No More Than 120 Minutes From Mixing to Compaction of Second Lift

RCC Compressive vs. Flexural Strength

100

200

300

400

500

600

700

800

900

1000

1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

6000

Compressive Strength (psi)

Flex

ural

Str

engt

h (p

si)

PCA Correlation

PCA Correlation

Design/Specification

Lab Data

Norfolk International Terminals

HRSDHRSD

USNFFSUSNFFS

Hampton Blvd

Hampton Blvd

Railroad AveRailroad Ave

Gate ComplexGate Complex

Pier 3Pier 3

Term

inal

Blv

dTe

rmin

al B

lvd

Pier 2Pier 2 Pier 1Pier 1

26 Acres

15 Acres

23 Acres

75 Acres

NIT South - Phase II, Stage 1

Costs from Previous Projects at NIT

$643 North Transfer Zone (2002)

$/SYSize (Acres)Project

RCC

PCC

$4440North Pavement (2002 – 2004)

$752South Wharf (2001 – 2003)

7

25

8

$54South Backlands (2003 – 2005)

$42South Backlands (2003 – 2005)

$61North Pavement (2002 – 2004)

Agenda





Lessons Learned

RCC Batch Plant

Placing 2nd Lift of RCC

Compacting RCC

RCC Edge

AC Overlay

Quality Control

Preparing Sample of RCC Using Vibratory Hammer (ASTM C

1435)

Quality Control

Coring Samples for Thickness and

Compressive Strength Testing

Quality Control

Typical 6-inch Diameter Core

Quality Control

Density Testing with Nuclear

Methods

(ASTM D 2922)

Quality Control

Test Area

Compressive Strength

0

5

10

15

20

25

30

35

40

45

50

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

3200

3400

3600

3800

4000

4200

4400

4600


Freq

uenc

y

NIT South BacklandsTop and Bottom Cores Combined

Specified Strength


0

5

10

15

20

25

30

35

40

45

50

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

3200

3400

3600

3800

4000

4200

4400

4600


Freq

uenc

y

Top

Bottom

Approx 25% Increase From Top to Bottom Cores

NIT South BacklandsTop and Bottom Cores Separate

Specified Strength


500

1000

1500

2000

2500

3000

3500

4000

4500

5000

100

200

300

400

500

600

700

800

Stre

ngth

(psi

)

Schnabel Data

Specified Strength 2500 psi90% Specified Strength80% of Specified Strength

NIT South BacklandsTop and Bottom Cores Combined


5

10

15

20

25

30

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

3200

3400

3600

3800

4000

4200

4400

4600


Freq

uenc

y

NIT South WharfTop and Bottom Cores Combined

Specified Strength


500

1000

1500

2000

2500

3000

3500

4000

50 100

150

200

250

300

350

400

450

Com

pres

sive

Str

engt

h (p

si)

NIT South WharfTop and Bottom Cores Combined

Schnabel Data

Specified Strength 1600 psi90% Specified Strength80% of Specified Strength

Core Thickness

10

20

30

40

50

60

1010

.5 1111

.5 1212

.5 1313

.5 1414

.5 1515

.5 1616

.5 1717

.5 1818

.5 1919

.5 2020

.5 2121

.5 22

Core Thickness (inches)

Freq

uenc

y

NIT South BacklandsTotal Core Length

Specified Core Thickness

Tolerance = 0.25 in.

Production Rates

PCC Pavement SectionNIT North Pavement – 40 AC136 Days of Pouring ConcreteApprox = 300 Working Days7.5 Days / Acre

RCC Pavement NIT SouthBacklands – Stage 1

26 AC58 Working Days2.2 Days / Acre

Agenda





Lessons Learned

Lessons Learned

Pre-qualify RCC ContractorsTime to Place is Critical (On-Site Batch Plant)Proper Equipment is EssentialWearing Surface Increases Rideability and Provides a Sacrificial Surface to Mill and ReplaceConsider Expansion of RCC on Adjacent StructuresDevelop a ProperQC/QA Plan

RCC Test Area

Attempt to Place with Box Spreader

RCC Test Area

Attempt to Correct Grades

Watch the Details

Thank You

Michael T. Crist, P.E.Moffatt & Nichol

440 World Trade CenterNorfolk Virginia

757-628-8222

Thank You

Michael T. Crist, P.E.Moffatt & Nichol

440 World Trade CenterNorfolk Virginia

757-628-8222

8 crist - rcc at nit

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