rubblization of pcc using a resonant breaker january 2018 dot... · rubblization of pcc using a...
TRANSCRIPT
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RUBBLIZATION OF PCC USING
A RESONANT BREAKER
JANUARY 2018
PAVEMENT REHABILITATIONRESONANT RUBBLIZING
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INTRODUCTION
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RMI Worldwide
• RMI Construction Services: BAV Corporation performs subcontractor services for RMI in CIS and Europe:
– Highway and Street surface rehabilitation
– Airport runway reconstruction
– Commercial Parking lot and Warehouse floor reconstruction
• RMI Resonant Machines is a vehicle manufacturer and inventor of the Resonant Beam Technology
• RMI has been in business since 1984
• RMI is headquartered in Tulsa, Oklahoma with satellite offices in:
– Kansas City, Missouri
– Minneapolis Minnesota
– Shanghai, China
– Moscow, Russia
• RMI Construction Services is a specialized subcontractor with expertise in:
– Concrete rubblization
– Concrete demolition
– Concrete breaking – Break and Seat, Crack and Seat, Breaking for Removal
– RMI has successful completed concrete and rubblizing projects throughout North America, China, Eastern Europe and Chili
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Rubblization Technology:
• 40 million m2 in the USA
• 3 million m2 in Russia-Ukraine & Belarus
• 4 million m2 in China
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RUBBLIZATION PROJECTS: 41 States in USA
No ProjectsRubblization
Projects
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Reflecting cracks is an issue
Concrete
«Snips» from
traffic
Close
HMA
Cooling Open
Warming up
«Reflecting crack
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What is Rubblizing?
The Process of Fracturing Pavement of Portland Cement Concrete into Angular “Puzzle-like” Pieces forDirect Overlay
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Structural Design: State Studies
Over 20 Studies from Multiple States support that rubblizing provides:
✓Long life for surfaces – 22+ years✓smooth driving conditions✓Rubblization eliminates reflective cracking and dramatically reduces surface defects
Alabama
Michigan
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Properties of Rubblizing: Comparison
High AmplitudeDamage to Base / Utilities
Low AmplitudeNo Violation of Base / Utilities
“Rubblizing” doesn’t affect the base integrity due to the low amplitude
A A
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Additional Issues with High Impact Rubblizing
Warning
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Application of Recycling
the Concrete Pavement
(Rubblizing)
Environmentally Friendly
Construction
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5
1
4
3
2
PSI
Number of Years
Reflection: Evolution of the Deterioration
Quality of the Road
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5
1
4
3
2
PSI
Number of Years
Quality of the Road
Rehabilitation of Concrete Pavement
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Rubblizing
New HMA layer
Rehabilitation of Concrete Pavement
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≈ 35˚to 40˚
Angular Fracture Pattern for Greater Modulus
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Structural Design: Correlations
Structural FailureReflective Cracking100
0
Pro
ba
bil
ity
of F
ail
ure
Low PCC Modulus High
Small Nominal Fragment Size Large
Target Zone
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DESCRIPTION OF TECHNICAL RUBBLIZING
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Description of Rubblizing Equipment
Pedestal / Shoe
Resonant Beam
Weight
Flotation Tires
MotorComputer Controls
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Description of Rubblizing Equipment:New computer system was installed in 2008
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…. A new generation screen allows to control
and optimize the rubblization process.
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Description of Resonant Beam
Frequency 44 Hz
Amplitude 13-19 mm (3/4”)
Vibration TechnologyWeight
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Vibration TechnologyWeight
Frequency 44 Hz
Amplitude 13-19
mm (3/4”)
Description of Resonant Beam
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Frequency 44 Hz
Amplitude 13-19
mm (3/4”)
Vibration TechnologyWeight
Description of Resonant Beam
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Operational Data of Equipment
• Strikes PCC 44 Times per Second
• 900 kg. of Pressure Per Strike
• Beam Weighs 4080 kg.
• Raises 13-19 mm. Per Strike
• Machine Speed is at
approx. 5-8 km/h
• Breaking Area is 25.4 mm. wide
• Average Rubblized Per Day: 6,000 m2
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STRUCTURAL DESIGN
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Rubblizing Process
• Remove existing overlay
• Install drainage system
• Rubblize concrete pavement
• Remove & replace weak areas
• Roll rubblized concrete
• Place HMA leveling course & overlay
Major Steps
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Structural Design: Methods
• AASHTO – Procedure Design (SN)
• Asphalt Institute – Series Manuals (MS) -17
• NAPA – Series Information (IS) –117
• Airfield Asphalt Pavement Technology Program -AAPTP
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• Pavement after years of use and deterioration.
• Expert analysis is required to insure that the cause of the failure of the pavement.
• If the Damage does Not arise the Subgrade or Sub-Base Problems, Pavement is a Candidate for Rubblization.
• If the Subgrade has Problems, Rubblization willNot Eliminate the Issue.
Structural Design: Evaluation
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Structural Design: Drainage
• Proper Drainage System should be Installed or Repaired Prior to Rubblizing the Pavement.
• Varying Methods of Drainage can be Used Depending on the Site.
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Three Most Damaging Things to a
Highway or Airport
• Water
•Water
•WATER
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Structural Design: Drainage
10 cm open-graded
5 cm dense-graded
# 57 Stone
3 % Slope Outlet
Filter Fabric
Shoulder Area
Rubblized PCC
Base
Course
Subgrade
Permeable Zone
Relief Cut @ 9-12 m.
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Dual outlets at approximately 300 feet
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Dual outlets - 0ne each direction
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The Modulus of the Rubblized Concrete depends on the Thickness, Subbase and
Subgrade. Typically Rubblized Concrete is 2.5 Times Stronger than any
Granular Material.
E1
E3 > E2
E4 > E3
Where E3 = f(E2)
Where E2 = f(E1)E2 > E1Subbase
Subgrade
Structural Design: Scope
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CONSTRUCTION
PROCESS
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Rubblizing Process
•Three Stages of Construction:
• Rubblizing
• Rolling
• Asphalt Overlay
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Prior to Rubblizing Process
• Repair or Replace Drainage System
• Remove any Asphalt Overlay Currently in Place
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Resonant Rubblizing• Capable of Rubblizaing up to 60 cm.
• Ideal Distance Per Run – 1.6 km. / One Lane Wide
• Speed of Resonant Machine 5 – 8 km/h
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Test Pit Confirm Specification and Debonding
Advantages
• Complete debonding of concrete• Removal of mesh reinforcement and rebar
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Fracture Pattern at Memphis International Airport
Cement Stabilized Base
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Wright Patterson Airport, USA
Advantages
• Rubblization of airport concrete up to 60 cm.
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Advantages
• Rubblization doesn’t effect existing slope and level of the surface
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Rubblized Slab Prior to Rolling
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• 10 Ton High Frequency, Low Amplitude Steel Drum Roller (3 Passes)• Only Equipment Necessary After Rubblization• Not Recommended to Drive on Prior to Asphalt Overlay
Rolling
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• Surface after compaction and before overlay
Result
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Asphalt Layer• Leveling Course on First Lift with Ability to Open Traffic• No Primer Required on Rubblized Layer• Minimum of 12 cm. of Asphalt Overlay
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Next Day - Open Traffic
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Recommended State Specification
• High Frequency Low Amplitude Resonant Breaker
• Resonant Breaker shall apply 900 kg. of pressure per strike at 44 Hz
• Removal of any Existing Asphalt Overlay
• Majority of Particle Size of Less than 15 cm.
• Maximum Particle Size of 20 cm.
• 10 Ton High Frequency - Low Amplitude Vibratory Roller
•3 Passes with Maximum Speed of 2 m. per Second
• Minimum of 80% Debonding of Existing Steel Reinforcing
• No Traffic on Rubblized Slab Until First Lift is Placed
• Minimum of 13 cm. of Hot Mix Asphalt Overlay
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The Math (One Lane Mile)Rubblize and Overlay Unbonded Concrete
OverlayRemove & Replace
Concrete
Item Extension Item Extension Item Extension
Edge Drain, Rubblization
4” Unmodified HMA @ 145 lb/ft
4” Modified HMA @ 145 lb/ft
10% Patching existing PCC
2” HMA Bond Breaker,
8” Concrete Overlay
Remove 11” PCC,
Place 11” PCC
Total 100% Total 155% Total 165%
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Results – 22 Year Road
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Rubblization Technology Summary
• Rubblization technology eliminates the source of reflective cracks
• Rubblization technology is a process of fracturing concrete slabs into angular interlocked pieces
• Rubblization technology converts non- flexible structure (PCC pavement) into a flexible structure
• Rubblization technology DOES NOT invade, damage the base. NO displacement into the base!
• Guillotine and other Impactor methods DO invade the base. Integrity of the base is compromised!
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Rubblization Technology Summary Continued
• Rubblization technology:
– Reduces project complexity
– Reduces project cost
– Creates angular fracture pattern for greater modulus
– Creates pieces sand size to 12.5 cm – 17.78 cm at the top to 20cm> towards the bottom
– Microprocessor Impact Adjustment, Consistency in Particle Size
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April 30, 2007
US Federal Aviation Administration Report
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Thank You!