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Construction and Testing of Construction Cycle 2 (CC2) Overlay

Construction and Testing of Construction Cycle 2 (CC2) Overlay. 29 th Annual Airport Conference Hershey, Pennsylvania – March 1, 2006. Murphy Flynn FAA Airport Technology R&D Branch, AAR-410 William J. Hughes Technical Center, Atlantic City, NJ. Lia Ricalde SRA International

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Construction and Testing of Construction Cycle 2 (CC2) Overlay

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  1. Construction and Testing of Construction Cycle 2 (CC2) Overlay 29th Annual Airport ConferenceHershey, Pennsylvania – March 1, 2006 Murphy FlynnFAA Airport Technology R&D Branch, AAR-410William J. Hughes Technical Center, Atlantic City, NJ Lia Ricalde SRA International 3120 Fire Road, Egg Harbor Twp., NJ 08234

  2. Outline • Construction Cycle 2 (CC2) Overview • CC2 Rubblization • CC2 Flexible Overlay • Pre-traffic Testing • CC2 Overlay Traffic • Post-traffic Testing 2

  3. NAPTF Construction Cycle 3

  4. Outline • Construction Cycle 2 Overview • CC2 Rubblization • CC2 Flexible Overlay • Pre-traffic Testing • CC2 Overlay Traffic • Post-traffic Testing 4

  5. Plan View of All CC2 Test Items 5

  6. Profile of CC2 Test Items 6

  7. CC2 Concrete Mix • Cementitious Aggregate: • 50% Portland Cement Type I • 50% Class “C” Flyash Mix • 50% Natural Sand • 50% #57 Crushed Stone 7

  8. Traffic Parameters • North side 6-wheels (3D) • South side 4-wheels (2D) • Dual distance 54 inches (1372 mm) • Tandem distance 57 inches (1448 mm) • 55,000 lbs (25 t) load per wheel • 210 psi (1.45 MPa) tire pressure • Traffic speed 2.5 mph (855 m/sec) • Standard wander pattern, 66 passes per cycle. 8

  9. Applied Traffic – Wander Pattern 9

  10. CC2 MRC Traffic South side traffic stopped at 4,720 passes (05/20/04). North side traffic 3,331 passes. First crack on north inner lane at 3,273 passes May 19, 2004 First crack on north outer lane at 3,653 passes May 21, 2004 North side distress at 6,085 passes similar to south side at 4,720 (06/02/04). MRC North MRC South First crack on south outer lane at 992 Passes April 29, 2004 First crack on south inner lane at 2,458 passes May 10, 2004 Final traffic on MRC north side 12, 675 passes and south side 5,405 passes (06/30/04). 10

  11. Typical Severity of Cracks 11

  12. CC2 Test Items – Applied Traffic Full-scale traffic testing began on 4/27/04 and ended 12/10/04. 12

  13. N MRC Material Characterization Rubblized Section 01/25/05 MRC Flexural Strength Sawed Beams: 617 psi Molded Beams: 744 psi 05/23/05, roofing membrane placement. 04/21/05, 4’x4’x12” pit sawed-cut for material gradation. • 12/29/04, 5’x5’x12” cut-out on PCC slab. • 01/12/05, P-154 removed, CBR on Subgrade top. • 01/17/05, Subgrade removed (1 ft.), CBR test. • 01/19/05, Subgrade and P-154 filled back into pit. • PCC cut-out put back into pit. • 12/29/04, 5’x5’x12” cut-out on PCC slab. • 01/12/05, P-154 removed, CBR on Subgrade top. • 03/07/05, Plate Load Test on Subgrade top. • Subgrade removed (1 ft.), CBR test, torvane on lateral walls and shelby tubes. North Traffic DT (2D) Abbreviated Wander 12,675 passes (3,336 coverages) South Traffic DT (2D) 5,405 passes (1,138 coverages) 13

  14. N MRG Material Characterization MRG Flexural Strength Sawed Beams: 675 psi Molded Beams: 833 psi 05/23/05, roofing membrane placement. Rubblized Section 01/25/05 North Traffic TDT (3D) 31,020 passes South Traffic DT (2D) 31,020 passes • 03/02/05, 7’x4’x12” cut-out on PCC slab. • CBR on Subgrade top and one foot below, torvane on Subgrade lateral walls. • Plate Load Test on Subgrade top. • Shelby tubes. • PCC cut-out put back into pit. 04/22/05, 4’x4’x12” pit sawed-cut for material gradation. 14

  15. N MRS Material Characterization MRS Flexural Strength Sawed Beams: 688 psi Molded Beams: 691 psi Rubblized Section 01/25/05 05/23/05, roofing membrane placement. 04/22/05, 4’x4’x12” pit sawed-cut for material gradation. • 12/30/04, 5’x5’x18” cut-out on PCC slab. • 01/18/05, P-154 removed, CBR on Subgrade top. • 01/19/05, P-154 refilled and 6” new P-306 placed, PCC cut-out put back into pit. • 10/14/04, 7’x7’x12” cut-out on PCC slab. • 01/17/05, Plate Load Test (PLT) on P-306. • 5’x5’x6” cut-out on P-306, PLT on P-154. • P-154 removed, PLT on Subgrade top. • 01/19/05, P-154 filled back into pit, new 6” P-306 placed. • PCC cut-out put back into pit, completed with hand mix concrete. • 03/02/05, 8’x4’x18” cut-out on PCC slab. • P-154 removed, CBR on Subgrade top and one foot below, torvane on Subgrade lateral walls. • P-154 refilled and 6” new P-306 placed, slab put back into pit. North Traffic TDT (3D) 20,262 passes South Traffic DT (2D) 31,020 passes 15

  16. Outline • Construction Cycle 2 Overview • CC2 Rubblization • CC2 Flexible Overlay • Pre-traffic Testing • CC2 Overlay Traffic • Post-traffic Testing 16

  17. FAA Guidelines for Rubblization • Engineering Brief No. 66 (February, 2004) “Rubblized Portland Cement Concrete Base Course” • Interim guidance • Based on broad industry experience • Full-scale testing is still needed to develop design standards for the use of this technology at airports under heavy aircraft loading 17

  18. Rubblization of CC2 Test Items • January, 2005 – Concrete slabs in the northtraffic lane, including those in the transition sections, were rubblized with an RMI RB-500 resonant breaker operating at 44 Hz. 18

  19. RMI RB 500 19

  20. Rubblization Video 20

  21. CC2 South Side • South half of all test items overlaid in the “as trafficked” condition. • Some anti reflective cracking measures applied in key areas. • Roofing membrane applied over larger cracks and saw cuts. 21

  22. CC2 Before Overlay Rubblized on the Left (North) and As-Trafficked on the Right (South) 22

  23. Test Pits in Rubblized Test Items • 4-foot (1.22 m) long by 4-foot (1.22 m) wide test pit was saw cut in each test item for visual examination of the rubblized concrete (extent of fractures from rubblization process, particle sizes, etc.). 23

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  30. Outline • Construction Cycle 2 Overview • CC2 Rubblization • CC2 Flexible Overlay • Pre-traffic Testing • CC2 Overlay Traffic • Post-traffic Testing 30

  31. Compacting Rubblized Lane 31

  32. Roofing Membrane (South Lane) 32

  33. Roofing Membrane Before Overlay 33

  34. CC2 Prepared for Overlay 34

  35. CC2 Flexible Overlay • 5 in. (12.7 cm) of FAA P-401 Hot Mix Asphalt (HMA) applied in two 2.5 in (6.3 cm ) lifts. • Tack coat (emulsion) between lifts 35

  36. Construction Cycle 2 Overlay (CC2-OL) 36

  37. HMA First Lift on Rubblized Lane 37

  38. Tack Coat Application • Tack coat (emulsion) applied at end of first lift. • Allowed to break overnight 38

  39. Final Lift Placement 39

  40. Outline • Construction Cycle 2 Overview • CC2 Rubblization • CC2 Flexible Overlay • Pre-traffic Testing • CC2 Overlay Traffic • Post-traffic Testing 40

  41. Uniformity of Pavement Structures • Heavy-weight deflectometer (HWD) tests were performed using the FAA’s HWD equipment on a 10-foot (3.05 m) grid to study the uniformity of the pavement structures. • 12-inch diameter segmented load plate at three different load levels – 12,000, 24,000, and 36,000 lbs (53.4, 106.8, and 160.2 kN). 41

  42. Uniformity of Pavement Structures 42

  43. Portable Seismic Pavement Analyzer (PSPA) 43

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  46. Outline • Construction Cycle 2 Overview • CC2 Rubblization • CC2 Flexible Overlay • Pre-traffic Testing • CC2 Overlay Traffic • Post-traffic Testing 46

  47. Wheel Load = 55,000 lbs Tire Pressure = 220 psi 4-Wheel Landing Gear Configuration CC2 Overlay Gear Configurations 47

  48. CC2 Overlay Gear Configurations After 5,000 Passes South Wheel Track North Wheel Track Wheel Load = 65,000 lbs Tire Pressure = 260 psi 48

  49. Traffic Summary 49

  50. Rut Measurement 50

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