Ultra Thin Continuously Reinforced Concrete Pavement UTCRCP Research

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Ultra Thin Continuously Reinforced Concrete
Pavement(UTCRCP)Research

• Louw Kannemeyer
• SANRAL

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Primary Network Age Trend
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Primary Network Pavement Condition
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Primary Network Congestion
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Vehicle Operating Cost vs Road Condition (2004R)
Articulated Truck
Passenger Car
Good
Poor
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Reducing Total Transportation Costs
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Primary Network Funding
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Primary Network Problems

• Ageing Network
• Limited Budgets results in primary focus being
  preservation of assets through reseals and
  overlays a strategy that cannot be followed for
  ever on portions of the primary network.
• Strengthening Required on portions
• Legislation Materials Availability
• Traffic Increased Growth, Increased Heavy,
  Increased Tire Pressures

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Primary Network Solutions

• Increased Budgets
• SANRAL along with all the other role players are
  continuously lobbying Treasury for more funding,
  but we have no direct control on the final
  outcome
• Innovative Pavement Repair Strategies
• Strategies need to be developed through research
  that will be more cost effective, a process
  SANRAL has direct control over

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Innovative Pavement Repair Strategy

• Requirements
• Must be able to be applied to an existing road
  surface with minimal preparation works required
  to the existing road surface or structures (in
  other words an Inlay or Thin Overlay)
• Must be able to be constructed with road
  construction equipment generally available in
  South Africa
• Must be able to be opened to traffic within 48
  hours
• Must have structural life expectancy in excess of
  30 years with minimal maintenance requirements
  during this period
• Must be able to successfully withstand increased
  axle loads and tyre pressures of modern heavy
  vehicles
• Must be able to meet all functional requirements
  to ensure a safe road surface under all
  conditions, and
• Must be cost affective.

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Potential Solution

• Ultra Thin Continuously Reinforced Concrete
  Pavement (UTCRCP)
• 20 to 40 mm Layer Thickness
• 50 x 50 mm (Ø5mm to Ø8mm) Welded Mesh
• 4.5 versus 0.6 Steel for Traditional CRCP
• Ultra High Strength Cement (UHSC) Paste (Magic
  Stuff)
• WC Ratio 0.30
• Steel- and polypropylene fibres.

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UTCRCP Potential Solution

• Industrial Floor Solution - Denmark

• Used in Netherlands for Bridge Rehabs

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UTCRCP Testing

• Short Term Pavement Performance (STPP)
• HVS Test Sections at Heidelberg TCC
• Long Term Pavement Performance (LTPP)
• Actual Traffic on Heidelberg TCC Screener Lane

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UTCRCP Construction

• Screener Lane

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UTCRCP Construction

• HVS Test Sections - Layout

• 60 m

Test 1.4
40 mm UTCRCP
20 mm AC
150 mm G7
3.7 m
Test 1.3
Test 1.1
Test 1.2
1.0mm (40 kN) Surface Deflection Before Overlay
40 mm UTCRCP
Test 2.3
20 mm AC
150 mm C4

• 3.7 m

Test 2.1
Test 2.4
150 mm G7
Test 2.2
0.3mm (40 kN)
0.6mm (40 kN)
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UTCRCP Construction

• HVS Test Sections - Construction

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UTCRCP STPP Testing

• HVS Section 1.1 Max Deflection

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UTCRCP STPP Testing

• HVS Section 1.1 Basic Material Properties

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UTCRCP STPP Testing

• HVS Section 1.1 Instrumentation

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UTCRCP STPP Testing

• HVS Section 1.1 140 kN Edge Loading

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UTCRCP STPP Testing

• HVS Section 1.1 140 kN Edge Loading

• Tire Pressure 1400 kPa (Aircraft),
• Speed 9.0 km/h,
• Load Application Canalized bi-directional
• Total Water added 260 litre

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What is 50 Million E80S ?
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UTCRCP STPP Testing

• HVS Section 1.2 80 kN Wheel Path Wet

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UTCRCP STPP Testing

• HVS Section 1.2 80 kN Wheel Path (Wet)

• Tire Pressure 800 kPa (Truck),
• Speed 9.0 km/h,
• Load Application Canalized bi-directional
• Total Water added 2800 litre

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UTCRCP STPP Testing

• HVS Section 1.3 80 kN Joints (Wet)

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UTCRCP STPP Testing

• HVS Section 1.3 80 kN Joints (Wet)

• Tire Pressure 800 kPa (Truck),
• Speed 9.0 km/h,
• Load Application Canalized bi-directional
• Total Water added 380 litre

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UTCRCP STPP Testing

• HVS Section 1.4 80 kN 9.5mm Br Seal (Wet)

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UTCRCP STPP Testing

• HVS Section 1.4 80 kN 9.5mm Br Seal (Wet)

• Tire Pressure 800 kPa (Truck),
• Speed 9.0 km/h,
• Load Application Canalized bi-directional
• Total Water added 800 litre

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UTCRCP LTPP Testing

• Screener Lane

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UTCRCP Future

• Data Analysis
• Complete detailed level-III analysis of all data
• Develop performance models for incorporation into
  CNCPAVE
• Mix Solution Optimisation (Lab)
• Reduce Max Aggregate Size from 9.5mm to 6,7mm or
  4,75mm.
• Quantify Impact of Different CEM1 Cements
• Optimise Reinforcing Mesh and Steel Fibres
  Content
• HVS Test Sections
• Complete Test 2.1, 2.2 and 2.3.
• Rebuild HVS Test Section 1 with 0.6mm Support
• Place New UTCRCP mix solution Jan 2006

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UTCRCP Future

• Long Term Pavement Performance (LTPP)
• Replace UTCRCP with new mix solution Jan 2006
• Test Surface Finishing Options
• Life Cycle Cost
• Initial Construction Cost R 300/m2
• Construction time about 1/3 of current practices
• Quantify Life Cycle Costs
• Standard Specifications
• Complete Standard Specifications
• Complete QA Procedures
• Postulated Alternative
• Introduce as postulated alternative Apr 2006

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Thank You