rcc pavements for commercial and industrial applications · rcc pavements for commercial and...
TRANSCRIPT
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morgan corp.
Groundbreaking Solutions
RCC Pavements for Commercial and Industrial Applications
Fares Abdo, PE Director of Technical Services [email protected] morgan corp.
TN Concrete Pavement & Cement-Based
Pavement Solution Conference
Nashville, TN January 31, 2014
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Brief Overview
Commercial & Industrial Applications
Value Engineered Case Studies
Outline
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Introduction Brief Overview of RCC
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■ Definition: “Roller-Compacted Concrete (RCC) is a no- slump concrete that is compacted by vibratory rollers.”
■ Zero slump (consistency of dense-graded aggregate)
■ No forms needed
■ No reinforcing steel
■ No finishing ■ Consolidated with vibratory rollers
After curing, RCC properties are similar to PCC
What is RCC?
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Shared Characteristics
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■ Capacity and durability: Similar benefits unreinforced conventional concrete offers
■ Fast construction with minimum labor
■ Production: ½ to 1 acres per day per paving train, one lift up to 10-inches thick
■ Economical
■ Can beat HMA on initial cost and cost much less to own over the service life of the pavement
Benefits of RCC Paving
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Introduction Construction
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■ 250 to 600 tons/hr
■ Excellent mixing efficiency
■ Mobile, erected on site
■ Mobilization cost
Mixing: Continuous Mix Pugmill
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■ Local availability
■ Smaller output capacity
■ Longer mix times than conventional concrete
■ Frequent cleaning
■ Dedicated production
Central Concrete Batch Plants
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Transporting
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Paving Equipment
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Paving Equipment Dual-Lift Construction
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■ High density pavers
■ Vibrating screed
■ High initial density,
90-95%
■ High-volume
placement (capable
of placing 1,000 to
2,000 cubic yards
per shift)
Placing Equipment
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■ High density is critical for strength and durability
■ Vibratory rollers to achieve density
■ Smaller Rubber-tire or steel-drum roller to improve surface texture
Compaction
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Introduction Commercial &
Industrial Applications
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Ft. Lewis, WA,1986
Ft. Drum, NY, 1990
Ft. Carson, CO, 2008
Military Facilities
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Honda facility, AL, 2001
134 acre parking facility at Saturn plant, TN, 1988
Trailer Employee
Truck
Ohio Turnpike Service Plaza, 2010
Parking Areas BMW, SC, 2009 45 acres
Plant Vogtle, GA, 2011 75 acres
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Port Facilities
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Intermodal Facilities
South Carolina Inland Port, 2013
38 acres
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Introduction Value Engineered Case Studies
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Value Engineered Options
Goals Equal or better
structural capacity/service life
Faster construction
Cost savings • Initial cost
• Cost to own
Less operational interruptions for maintenance/rehab
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GA Port Authority-Ocean Terminal
Ocean Terminal Typical Pavement Section
Value Engineered Option
Pavement Section Optimization
South Carolina Inland Port
Design Sections: Intermodal Dual and Single Lifts
Value Engineered Sections
Why Soil-Cement Base?
Project Notables
VE Options for Two Recent Projects
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Georgia Port Authority Ocean Terminal, Savannah
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Project site
Aggregate Sources ≈ 165 miles from project
Ocean Terminal, GA
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Ocean Terminal, GA
Phase 1: 48,400 SY Phase 2: 30,000 SY
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■ Typical Ocean
Terminal pavement
Flexible pavement
• 10” aggregate base
• 5” asphalt
■ Purposes of
proposed alternate
Provide equal or
higher structural
capacity using RCC
and CTB layers
No additional cost
Ocean Terminal, GA
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Hot-mixed asphalt and RCC equivalent structural numbers
RCC PAVE software predictions
PCA PAVE Software predictions
Structural Capacity/Predicted Service Life for Assumed Loadings
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Pavement Analysis - Equivalent SN Approach
Material SN Coefficient Notations
HMA 0.44 HMA Hot-Mixed asphalt, Binder or Surface Course
RCC 0.5 RCC Roller-Compacted Concrete1
GABC 0.18 GABC Graded Aggregate Base Course
CTB 0.22 CTB Cement-Treated Base2
SN Structural Number
Design Section, HMA& GABC Alternate Section, RCC & CTB (based on
equivalent SN) Thickness, In. SN/in. SN/layer Thickness, In. SN/in. SN/layer HMA 5 0.44 2.20 RCC 6 0.50 3.00
GABC 10 0.18 1.80 CTB 6 0.20 1.20
Total SN 4.00 Total SN 4.20
Footnotes 1. RCC specified compressive strength = 4,000 psi at 28 days.
2. Assume 50% GABC mixed with 50% in-situ soil to make the blended aggregates/soil for CTB. CTB compressive strength target = 300 -500 psi at 7 days.
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Pavement Analysis - Equivalent SN Approach
Asphalt Pavement Design
Subgrade
5” HMAC
10” Aggregate
Base
Subgrade
6” RCC Concrete
Roller Compacted Concrete Design
6” Cement
Treated base
Structural Number= 4.00 Structural Number= 4.20
0
2.22
1.8
0
3
1.2
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Truck Traffic, RCC with CTB Option, 20 Yr
Axle Type Load, lbs Allowable Repetitions/Day
Single Axle Dual Wheel 18,000 Unlimited
Tandem Axle, Dual Wheel 40,000 Unlimited
Prediction using RCC Pave
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PCA PAVE Predictions Using Semi Trailer Trucks, HMA over GABC, and RCC over CTB Options
Total Truck Weight: 12k+40k+40k = 92k lbs
12 20 each 20 each
■ How to model
undefined traffic?
■ Selected truck traffic
for comparison
purposes
Same traffic to
analyze
• 5” HMA over 10”DGA
• RCC over CTB value-
engineered option
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10 Trucks/day, 5” HMA over 10” GABC, on Sandy Soil
12k+40k+40k = 92k lbs
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50 Trucks/day, 5” HMA over 10” GABC, on Sandy Soil
12k+40k+40k = 92k lbs
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100 Trucks/day, 5” HMA over 10” GABC, on Sandy Soil
12k+40k+40k = 92k lbs
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100 Trucks/day, 6” RCC over 6” CTB, on Sandy Soil
12k+40k+40k = 92k lbs
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1000 Trucks/day, 6” RCC over 6” CTB, on Sandy Soil
12k+40k+40k = 92k lbs
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Reinvesting
pulverized asphalt in
CTB layer
Cost savings allowed
for thicker pavement
RCC Pave analyses
Various RCC and CTB
thicknesses to maximize
strength within available
budget
Pavement Section Optimization
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■ Phase I As-Built
Section
RCC/Cement-Treated
Soil
•9” cement-treated soil
•7” RCC
Case Study – Ocean Terminal, GA
Section Structural Number
Flexible 4.0
RCC/CTS 5.3
Made possible by value engineered design/mix optimization/recycling of in-situ materials
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Straddle Carrier, 20 Yrs
Single wheel loading
RCC Pave Prediction of Improved Section
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Container Handler, 20 Yrs
Dual-wheel loading
RCC Pave Prediction of Improved Section
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Case Study – Ocean Terminal, GA
>33% strength
19% savings on initial cost vs. HMA
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South Carolina Inland Port Greer, SC
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SCIP
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SC Inland Port – Site Conditions
■ Variable soils
Sandy SILT in fill area
Silty SAND in cut areas
0.5% grade
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SC Inland Port – VE Options
GABC: Graded aggregate base CTSB: Cement treated soil base
14”
GAB
Prepared Subgrade
3”
RCC
Design
Dual Lifts: 94,000 yd2
13”
CTSB
Prepared Subgrade
6”
RCC
Value Engineered
10” and 10.5”
GAB
Prepared Subgrade
3”
RCC
Design
Single Lift: 88,000 yd2
9.5”
CTSB
Prepared Subgrade
6”
RCC
Value Engineered
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SC Inland Port – CTS Base Construction
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Why CTS base?
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SC Inland Port – Benefits of CTS Base
■ Structural capacity
■ Load transfer at joints and cracks
■ Limited downtime after rain events
■ Economical
■ Sustainability attributes
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SCIP RCC Dual-Lift Placement
Soil-Cement Base
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SCIP RCC Placement
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SCIP RCC Placement
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SCIP RCC Placement
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Transverse Construction Joint
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SCIP RCC
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■ RCC and CTS base option provided higher structural capacity at no additional cost
■ CTS was key to overcome site conditions during an unusual wet season
■ Variable soils required extensive strength testing and proof rolling
■ One lift production rate as high as one acre/day per each paving train
Notables
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morgan corp.
Questions?
Groundbreaking Solutions
Fares Abdo, PE Director of Technical Services