JRI + LOAD TRANSFER DEVICE

1. JRI +LOAD TRANSFER DEVICE Concrete pavementAsphalt surface layer Cheaper and more Durable Pavements F A R O B E L CIVIL WORK TECHNOLOGYjvazquez@farobel.comamlancuentra@farobel.comwww.farobel.com

2. Introduction to JRI+ load transfer device Application fields Highways & Roads Trains Streets Water courses Airport Esplanades Harbour Esplanades …all concrete surfaces resting on the ground Industrial parkings Industrial pavements

3. Concrete pavement Concrete pavement with NEW SYSTEM Other layer Bituminous layer Bituminous layer Bituminous layer Other layer Other layer Other layer Other layer New SYSTEM Introduction to JRI+ load transfer device Object This is a new system based on using the JRI+ load transfer devices in concrete pavementsThere are two JRI load transfer devices, which work with analogous characteristics: JRI+4 JRI+ The final solution is a concrete pavement A proper asphalt layer on top of concrete slabs improves I.R.I and noise levels

4. Introduction to JRI+ load transfer device Basic Concepts Three-dimensional polypropylene surfaces remain embedded in concreteSo, a weak section has been created in concreteShrinkage crack follows the tridimensional surface Shrinkage cracks appear in the surface following the JRI+ shape, which is divided in alternating horizontal surfaces

5. Introduction to JRI+ load transfer device Basic Concepts Concrete slabs with alternate indentation have been createdConcrete teeth end with horizontal surfaces responsible of load transferShrinkage cracks become watertight through a rubber profile at the top

6. Introduction to JRI+ load transfer device Basic Concepts Test-tube manufactured with JRI+ device inside itThe system leads the crack of concrete produced by shrinkage and loads.It is a three-dimensional load transfer systemThe horizontal surface can be noticed observing the crack shape

7. Introduction to JRI+ load transfer device Images Above: JRI+4. Notice the alternate trays and rubber profile on top.The height of the JRI+4 device will be shorter than the thickness of the concrete slab JRI+4

8. Introduction to JRI+ load transfer device Images The picture shows the JRI+ device placed on the esplanade while pouring concrete The height of the JRI+ device is shorter than the thickness of the concrete slab Project with JRI+

9. Introduction to JRI+ load transfer device Detail JRI+

10. Introduction to JRI+ load transfer device Images Both JRI+4 & JRI+ have a rubber profile at the top that makes the shrinkage cracks become watertightThe picture on the right side shows the rubber profile. The upper grey line is the top of the concrete slab.All the rubber gum is embedded inside concrete, protected from the atmosphere and trafficThe zigzag surface at the bottom ensures a watertight crack Top Watertight rubber gum

11. Introduction to JRI+ load transfer device Details The JRI+ devices have alternate trays on either sides of the superficial crack line where the rubber is placed Plan view JRI+4 Plan view JRI+

12. Introduction to JRI+ load transfer device Images JRI+4 device with the rubber to watertight the crack on its top JRI+4

13. Introduction to JRI+ load transfer device Images Once works were finished, the slabs were separated to observe the JRI+In this case the concrete slab thickness is the height of the JRI+Notice the horizontal trays in the concrete alternate teethIt is proved that the shrinkage crack follows the JRI+ surface JRI+

14. Introduction to JRI+ load transfer device Images JRI+ load transfer devices are located on the esplanade and concrete is directly poured on them Project with JRI+

15. Introduction to JRI+ load transfer device Images JRI+4 JRI+4 load transfer devices are inserted automatically into the fresh concrete right after pouring it, using a screed and needle vibrators

16. Index J R I+ LOAD TRANSFER DEVICE • Introduction to JRI+ load transfer device • JRI+ Characteristics • Tests & trials • Projects • Pavement designing • Conclusions

17. JRI+ Characteristics General JRI+ watertights the crack + The load transfer capacity is almost 100% for the whole lifespan. No vertical relative displacement between adjacent slab edges No fine material pumping and ground erosion Layers with high elastic modulus are not required No impact between layers Less stress

18. JRI+ Characteristics General JRI+ system leads the crack through the whole section No cut required The longitudinal compression due to thermal expansion is produced in the whole section so the axial load is centered. There is no buckling because of the compression exerted by the side slabs. As the rubber guarantees a watertight surface , sealing is not needed No maintenance required

19. JRI+ Characteristics Comparison with dowel bars Stresses on the horizontal surface are lower because there is a larger contact area: • The load transfer capacity doesn’t depend on base and sub-base layers Load carrying capacity is improved with base and/or sub-base layers to reduce contact stress in concrete Dowel bar System requires a good base layer

20. JRI+ Characteristics Comparison with dowel bars The durability of the JRI+ System is higher than the dowel bars one because of the lower tensile values achieved in the concrete transfer in the contact surface by the former system. Eventually, dowel bars will break the concrete due to the high strength causing vertical displacement and lower Load Transfer Efficiency. Dowel bars can be oxidized while JRI+ polypropylene devices cannot be oxidized. With JRI+ System load is transferred by the concrete teeth instead of the bars. The rubber profile embedded into the concrete guarantees a watertight system, so water doesn’t reach the esplanade. No seal maintenance required With JRI+, the pavement doesn’t lose the flat surface in case of a breakage. Fast concrete crack repair, with no demolition required. No base layer required JRI+ System: cheaper system with a faster execution

21. JRI+ Characteristics Structural design considerations • Concrete pavements with JRI+ joints don´t need base granulate layers. • Thinner concrete slabs with JRI+ joints thanks to the lower critical stress. The critical stress is centered in the slabs, not on the edges • The concrete pavements with JRI+ and same thickness are more durable. • Shorter slab lengths. This fact also reduces stress. • The road shoulders are built with the same system. This increase of slab width avoids critical stress on slab edges. It also allows future road widening. • JRI+ is a transverse joint system. • External longitudinal joints (pavement machine edges or construction joints) are built with modified JRI+ joints. • Interior longitudinal joints use steel bars. Cutting and sealing with the JRI+ specific rubber

22. JRI+ Characteristics JRI+: Polypropylene tray material Elastic modulus of polypropylene: 500-1000 MPa Elastic modulus of concrete: 25.000- 35.000 MPa It is checked that polypropilene deformation is not an important factor to take into account when calculating deflection JRI+ device thickness = 2 mm stress = 1MPa deformation = 0,002 mm Deflections are 100 times larger Because of the different order of magnitude, the deformation of the polypropylene is a factor that doesn’t have to be considered in deflection with JRI+ system Polypropylene joint allows rotation in one direction (2 degrees maximum) Polypropylene joint allows free rotation in the other one direction

23. JRI+ Characteristics Lower Environmental Impact • Lower land occupation • Lower excavation • Lower transportation • Lower execution time • Higher durability due to lower stress • Lower energy consumption and lower CO2 emission • More convenient repair • Lower maintenance costs

24. JRI+ Characteristics Cost reduction • The JRI+ system pavement is cheaper than current ones, either asphalt either concrete • Aggregate base layers are saved • Building roads with just one concrete layer shorten the execution times • Cut and sealing are saved • Depth drainage is decreased • Excavations are decreased • JRI+ joints are cheaper than bars • Maintenance costs are decreased

25. JRI+ Characteristics JRI+4 Placed after concrete pouring, behind the paving machine Not anchored to the floor Located from the top into fresh concrete through needle vibrators Higher control of execution. Higher Load Transfer Efficiency Rubber profile placed regarding the concrete top surface No Spalling JRI+ Placed before concrete pouring Anchored to the floor, tight to esplanade reference Holes avoid being pushed by concrete Spalling when the rubber profile is below the concrete top surface In pavement executed with asphalt wearing course, spalling doesn´t affect

26. JRI+ Characteristics Asphalt Pavement on concrete base • I.R.I. and noise are improved with a proper asphalt layer on top of concrete slabs. • Shrinkage cracks in concrete slab finally appear in asphalt layer. We have observed in our projects that these cracks don’t do any damage or spalling, even after 13 years of use. • Crack edges don’t erode because there are no relative vertical movements between slabs. • No sealing required. JRI+ joint is already sealed. • Cracks are thin enough they cannot be noticed from the vehicles.

27. Index F A R O B E L CIVIL WORK TECHNOLOGY • Introduction to JRI+ load transfer device • JRI+ Characteristics • Tests & trials • Projects • Pavement designing • Conclusions

28. Tests & trials FWD results M503 Highway Madrid, May 2006 Concrete slab directly executed on top of base course Falling Weight Deflectometer (FWD) tested in 12 JRI+ in both sides The average Load Transfer Efficiency (LTE ) > 98 % The LTE is the ratio between deflections of points which are at the same distance from the applied load (30 cm). The crack is located between both points. Average deflections in the boundaries of the slabs = 0,164 mm.

29. Tests & trials FWD results Barcelona Streetcar 2002 • A 200 meters stretch was tested. After the results, the relevant gouvernmental • agency (Autoridad del TransporteMetropolitano de Barcelona, ATM) decided to • build 30 km of double track. • The FWD tested 31 joints JRI+ of concrete directly placed on top of the base • course with California Bearing Ratio, CBR = 5 . • Results: • The load transfer average was 99.3%. • The deflection average in the center and boundaries of the slabs was 1,13mm and 1,24mm respectively. • The difference between the deflection in the center and in the boundaries of the slabs was lower than 10%.

30. Tests & trials System strength Break strength in boundaries is between 5 and 6 times service strength When real scale test has been done in order to reach the slab break, it always breaks due to bending moments in the center of the slab. Teeth don’t break

31. Tests & trials Real projects JRI+ projects have been carried out since 1998. One of these projects with the higher traffic intensity, more than 4000 trucks per day (Highway A2, Madrid-Barcelona, 1998). It is still in good conditions, no reparations have been required. In the Barcelona Harbour dynamic tests were made with 45 Tonnes axes. There weren’t any damages with slabs of 16 cm of thickness. Another example of how the JRI+ system is suitable for high traffic is road in Gijon Harbour built in 2006. Since then, the road has operated. The pavement is in good conditions, no repairs have been required.

32. Index J R I+ LOAD TRANSFER DEVICE • Introduction to JRI+ load transfer device • JRI+ Characteristics • Tests & trials • Projects • Pavement designing • Conclusions

33. M503 Highway, Madrid, 2006

34. Olean Highway, New York, US, 2006

35. Tortosa Freeway, Spain, 2004

36. Airport esplanade, Barcelona, Spain, 2004

37. Barcelona Streetcar, Spain, 2003

38. Projects

39. Projects

40. Projects

41. Projects

42. Projects Legal issues Catalonia (Spain) Government projects for truck parking slots are designed with JRI+ system. JRI+4 system is approved and legalized in Romania

43. Index J R I+ LOAD TRANSFER DEVICE • Introduction to JRI+ load transfer device • JRI+ Characteristics • Tests & trials • Projects • Pavement designing • Conclusions

44. Concrete pavement Concrete pavement with NEW SYSTEM Other layer Bituminous layer Bituminous layer Bituminous layer Other layer Other layer Other layer Other layer New SYSTEM Pavement design • The pavement is design considering: • Traffic intensity and loads • Soil characteristics • Concrete characteristics • Thermal conditions • Life span (fatigue) • The JRI+ load transfer device transfers perfectly the shear stress • Every project should have its specific design.

45. Pavement design • The optimal solution would be: • Concrete slabs on top of the esplanade using JRI+4, placed behind the paving machine into the fresh concrete • Asphalt layer on top to improve the noise level

46. Pavement design • General design: • Natural esplanade levelled and compacted. • CBR>3 (K>3Kg/cm3), obeying the organic contain and swelling • 4,5MPa flexural strengthen concrete at 28 days • Slab dimensions: 1,32*1,32m2. Ground reaction in 3,96*3,96m2 • Thickness: • 16 cm when over 4000 trucks per day &lane • 16 cm when 2000-4000 trucks per day &lane • 15 cm when 800-2000 trucks per day &lane • 14 cm when 200-800 trucks per day &lane • 13 cm when 100-200 trucks per day &lane • 13 cm when 50-100 trucks per day &lane • (if using bigger slab dimensions and low strength concrete then the slab thickness should be increased) • 3cm asphalt layer with modified bitumen

47. Conclusions J R I+ LOAD TRANSFER DEVICE J R I+ LOAD TRANSFER DEVICE High Load Transfer Efficiency during the whole lifes pan Watertight cracks Lower execution and maintenance costs Faster execution Lower environmental impact Higher durability

48. Thank you for your attention We are at your disposal to design the specific JRI+ solution for your needs F A R O B E L CIVIL WORK TECHNOLOGYjvazquez@farobel.comamlancuentra@farobel.comwww.farobel.com