Construction Practices and Techniques

Transcription

1 Construction Practices and Techniques Eng. Valmir Bonfim, M.Sc. Grupo ANE Presentation Topics: KMA plant characteristics; Foamed bitumen; Technology fail criteria; Jobsite presentation: Rod. dos Bandeirantes - SP; Rod. BR-101 RJ; Rod. Ayrton Senna SP; Av. Sapopemba - SP. 1

2 KMA 220 plant Characteristics: Mobile plant Cold recycling Emulsion and foamed bitumen 2

3 Foamed Bitumen Technology Foamed Bitumen Technology Foam Bitumen is the result of the asphalt binder at approximately 170 C, which expands when in contact with air and water at room temperature inside expansion chambers. 3

4 Finally, What is foamed RAP? Finally, What is foamed RAP? RAP = Reclaimed Asphalt Pavement 4

5 Finally, What is foamed RAP? RAP = Reclaimed Asphalt Pavement Foamed RAP = is the product of mixing milled pavement with foamed asphalt Expansion Chamber Foamed asphalt process 5

6 Quality control of foamed asphalt - Expansion rate - Half-life Quality control of foamed bitumen - Expansion rate - Half-life Half-life is the time measured between the maximum expansion and a half of that expansion. 6

7 Foamed bitumen = expanded bitumen binder WLB10S machine and mini Pug-mill mixer Design of bitumen binder % in lab 7

8 RAP aggregate gradation 100 Curva Granulométrica - Esp. = 8 cm - Vel. = 10 m/min Peneiras /8 1/2 ¾ 1 1 ½ Mat erial original, ant es da f resagem 70 Mat erial f resado, sem ext ração de betume 60 Mat erial f resado, com ext ração de betume ,01 0, Di âmetr o dos gr ãos (mm) Fonte: Livro Fresagem de Pavimentos Asfálticos RAP aggregate gradation 90 Curva Granulométrica - Esp. = 8 cm - Vel. = 10 m/min Peneiras 100 ISSUES HAPPENING WHEN /8 1/2 ¾ 1 1 ½ 2 USING RAP Undesired Lumps 80 Mat erial original, ant es da f resagem 70 Mat erial f resado, sem ext ração de betume 60 Mat erial f resado, com ext ração de betume Not enough 0 0,01 0, fines Di âmetr o dos gr ãos (mm) Fonte: Livro Fresagem de Pavimentos Asfálticos 8

9 Adequate gradation of foamed RAP Wirtgen Cold Recyclig Manual Pavement failure criteria HMA Cemented layers BSM s 20mm Crack No crack Fatigue cracking Rutting 9

10 Pavement failure criteria Rutting: Lower maintenance cost compared with greater depth interventions. Procedure: Cold milling and overlay. Basic steps: 1 st step: - Pavement evaluation; Functional and structural conditions, drainage etc. 2ª step: Design - Choice of the adequate solution (in place, plant); - Economical analysis; - Layers thickness design; - Selection of new materials (crusher dust, bitumen binder etc); - Recycled mix design; - Lab tests. 3ª step: Jobsite execution - Choice of adequate equipment; - Quality control; Foam quality, mix condition, compaction etc. 10

11 Rodovia dos Bandeirantes Grupo CCR - AutoBan / Engelog Cement base recycled in KMA plant 11

12 Plant placed near the road 1 st step: Cold milling of HMA 12

13 2 nd step: Cold milling of cemented layer Execution of the 1 st cemented base layer Next steps: 2nd cemented base layer and 10cm HMA 13

14 Rodovia BR-101 Section: Rio de Janeiro Cement base recycling in KMA plant Milled HMA recycled using polymerized emulsion in KMA plant Existent cross-section HMA Deteriorated cemented layer Subgrade 14

15 Constructed cross-section HMA RAP recycled with polymerized emulsion Deteriorated base recycled with cement Subgrade Constructed cross-section HMA RAP recycled with polymerized emulsion Deteriorated base recycled with cement Subgrade 25/28 cm of the thickness were recycled 15

16 2 nd step: Cold milling of the cemented layer 1 st step: Cold milling of the HMA layer Deflection measure and verification of the reminiscent pavement 16

17 Plant installed near the jobsite RAP mixing with polymerized emulsion in KMA plant 17

18 Recycled layer open to traffic STRUCTURAL REHABILITATION Cold recycling in KMA plant with foamed bitumen 18

19 TEST SECTION Deteriorated cemented base High traffic volume Highway without weight control TEST SECTION Surface layer exposed to traffic after 10 months 19

20 Mix design Mixture in KMA 220 Plant CrushedRAP... 84% Crusherdust... 15% Hydrated Lime % Total % CAP (bitumen binder): 2,2% Mix design Mixture in KMA 220 Plant CrushedRAP... 84% Crusherdust... 15% Hydrated Lime % Total % When lime is used as active filler: stockpiling is possible CAP (bitumen binder): 2,2% 20

21 Existent cross-section Deteriorated HMA Deteriorated cemented layer Crushed Stone Layer Existent cross-section Deteriorated HMA Deteriorated cemented layer Crushed Stone Layer Milling depth: 30 cm Subgrade 21

22 Execution steps BGTC deteriorada 1 st foamed RAP layer: thickness=13,5 cm Crushed Stone Layer Milling depth: 30 cm Subgrade Execution steps 2 nd foamed RAP layer: thickness=13,5 cm BGTC deteriorada 1 st foamed RAP layer: thickness=13,5 cm Crushed Stone Layer Milling depth: 30 cm Subgrade 22

23 Execution steps Gap Graded: thickness=3 cm 2 nd foamed RAP layer: thickness=13,5 cm BGTC deteriorada 1 st foamed RAP layer: thickness=13,5 cm Crushed Stone Layer Milling depth: 30 cm Subgrade Crushed RAP Crusher dust KMA plant Foamed RAP Plant installed near the jobsite 23

24 Cold milling step Cold milling step 30 cm thickness in one pass 24

25 thickness = 30 cm Verification of the reminiscent pavement HMA = 20 cm Cemented Layer = 10 cm In this section, not all the cracked layer was milled 25

26 Deflection measures Benkelmann beam New milling process to take away reminiscent cracked cemented layer Execution of the 1 st Foamed RAP and compaction 26

27 Compaction verification test: SAND CONE Execution of the 2 nd Foamed RAP and compaction 27

28 1/3/2013 Execution of the gap graded surface layer Thickness of 3 cm and compaction Execution of the gap graded surface layer Thickness of 3 cm and compaction 28

29 SUSTAINABLE PAVEMENT AVENIDA SAPOPEMBA Section: Av. dos Sertanistas até Av. Bento Guelfi São Paulo Avenida Sapopemba Cross-section HMA Foamed RAP base layer 5cm 20cm Crushed CDW layer 25cm Subgrade 29

30 Mix design Mixture in KMA 220 Plant RAP... 80% Crusherdust... 19% Hydrated lime.... 1% Total % CAP (bitumen binder): 2,5% CONSTRUCTION STEPS Kerb and gutter 30

31 CONSTRUCTION STEPS Mill and replace structural layers CONSTRUCTION STEPS CDW Sub-base 31

32 CONSTRUCTION STEPS Sub-base compaction CONSTRUCTION STEPS Foamed RAP base 32

33 CONSTRUCTION STEPS Base compaction CONSTRUCTION STEPS HMA surface layer 33

34 CONSTRUCTION STEPS Compaction CONSTRUCTION STEPS Compaction 34

35 CONSTRUCTION STEPS Construction finished Lab tests: All lab tests the presented projects were conducted at the Laboratório de Tecnologia de Pavimentação da Escola Politécnica da Universidade de São Paulo LTP-EPUSP - Rutting (ornierage); - Resilient Modulus. 35

36 Foamed RAP Rutting 80% RAP + 19% crushed dust + 1% cement + 2,5% bitumen binder 100% Porcentagem de afundamento na trilha de roda 10% 3,16% 1% 3,78% 4,59% 5,49% 6,67% 7,97% Afund. (A Esq. 0% N. de ciclos Foamed RAP Resilient Modulus 80% RAP + 19% crushed dust + 1% cement + 2,5% bitumen binder MR = * 3 0,3902 MR (kgf/cm2) , Tensão de Confinamento (kgf/cm2) 36

37 Foamed CDW Rutting 100% Rutting x # of cycles CDW + 1% cement + 3,4% foamed asphalt 72 h cure in oven at 60ºC and 72 h at room temperature - test temperature = 60ºC Porcentagem de afundamento na trilha de roda 10% 1% 0,7% 0,8% 1,1% 1,3% 1,7% Afund. (A - Esq. - P- 2046) 2,1% 0% N. de ciclos Foamed CDW Resilient Modulus CDW + 1% cement + 3,4% foamed bitumen Energia de Moldagem E.M. - Ensaio realizado na umidade de moldagem = 11,9% Cura: 72 hs. em estufa 60ºC e 72 hs. ao ar MR = * 3 0,4526 MR - (kgf/cm²) Ensaio realizado conforme o que preconiza a norma DNER-ME 131/94 - Determinação do módulo de resiliência 100 0,1 1,0 10,0 Tensão de Confinamento (kgf/cm²) 37

38 Foamed crushed stone Rutting 99% crushed stone + 1% cement + 3% foamed bitumen Porcentagem de afundamento na trilha de roda 100% 10% 1% 0,47% 0,60% 0,78% 0,99% Afund. (A Esq. P 1246) Afund. (B Dir. P 1247) 1,28% 1,62% 0% N. de ciclos Foamed crushed stone Resilient Modulus 99% crushed stone + 1% cement + 3% foamed bitumen MR = * 3 0,2509 MR (kgf/cm2) Crushed Stone , Tensão Confinamento (kgf/cm2) 38

39 Bibliography Grato pela atenção! Valmir Bonfim Diretor Técnico Cel.: (11) FREMIX ENGENHARIA E COMÉRCIO LTDA. Rua Vitorino, 25 - Jardim Mutinga Fone (11) Barueri/SP- CEP