Concrete Airport Pavement Workshop, October 27-28, 2010

Sustainable Pavement Designs for

Runways and Taxiways Runways and Taxiways
Fares Y. Abdo, P.E.
Market Manager, Pavements
Portland Cement Association
TM
Presentation Outline
P t d Pavements and
Sustainability
Cement Treated Cement-Treated
Bases
FAA Requirements FAA Requirements
Standard and Non-
Standard Pavement Standard Pavement
Sections
Case Studies Case Studies
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What is sustainable development?
"Development that meets the needs of the "Development that meets the needs of the
present without compromising the ability
of future generations to meet their own of future generations to meet their own
needs." World Commission on Environment and
Developments Report Our Common Future (Oxford University Press,
198 1987).
Paradigm shift
We have not inherited the world from our
forefathers -- we have borrowed it from our
hild children ancient proverb
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Sustainability
(Thomas Olson-The Pittsburgh Tribune, 10/24/10)
What Exactly is Sustainability?
Sustainability is not an exact science
The concept of sustainability seems to beas the
word implies here to stay word implies here to stay
It's increasingly embedded in business, government
d l h and elsewhere
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Sustainable Strategies
Longe it and Lifec cle Cost Longevity and Lifecycle Cost
Use of In-Situ Materials
Recycling and Waste Reduction
Optimal Material Utilization Optimal Material Utilization
Reduced Energy Use
Reduced Greenhouse Gas Emissions
Water Quality and Stormwater Runoff Water Quality and Stormwater Runoff
Mi i C iti l C t R
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Mission Critical Concrete Runways
Majority of Airports in U.S. were built during j y p g
WWII using concrete
Pittsburgh, Baltimore, Miami, Washington
National, and more are 60+ years old
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Pavement Sustainability Rating systems
Pavement sustainability and USGBC LEED Pavement sustainability and USGBC LEED
rating system
Sustainable sites Sustainable sites
Pavement rating systems
Greenroads 1 0 Greenroads 1.0
GreenLITES
FHWA (under development) FHWA (under development)
ASCE (under development)
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he Future of Pavement Sustainability
Greenroads Greenroads
State DOTs
Rating
System
2
Rating
System
1
FHWA
ASTM
Rating
System
3
2
ASTM
ASCE/APWA/ACEC
3
FAA; Others?
Agency
Specifications
Eventually, the influence of rating systems will diminish as
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Cement-Based Pavement Materials
Roller Compacted Conventional Roller-Compacted
Concrete
Conventional
Concrete
Pervious
Concrete
FAA
FAA
t T t d
Soil-Cement
e
n
t
FAA
Econocrete
P-306
nt-Treated
Subbase
301 &
-304
Flowable Fill
Cement-
Treated
Base
e
n
t

C
o
n
t
e
Flowable Fill
Cement-Modified
Soil
Full-Depth
Reclamation
C
e
m
Soil
TM
efinition
ement-Treated Base an intimate mixture of
ative and/or manufactured aggregates with
easured amounts of portland cement (and
ossibly other cementitious materials) and
ater that hardens after compaction and curing
form a strong durable paving material
TM
at materials can be treated with cement?
Soils (sand, silt, clay)
Gravel Gravel
Shale
C h d t Crushed stone
Slag
Recycled HMA
Recycled concrete
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Why Use CTB?
Economical pavement base Economical pavement base
Decreased base thickness compared to
unbound aggregate base
Structural properties maintained under varying
moisture conditions
High stiffness inhibits fatigue cracking and High stiffness inhibits fatigue cracking and
rutting of asphalt surface
Sustainable paving option Sustainable paving option
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FAA Base/Subbase Approved Materials
P f B /S bb C
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Purpose of Base/Subbase Courses
(FAA AC 150/5320-6E)
Flexible pavements
Principal structural components
Base
Asphalt
Principal structural components
Distribute the loads to the
f d ti
Base
Subbase
(Req. if CBR<20)
foundation
Subgrade
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Improved Performance in Rutting and Fatigue Cracking
P
P
Cement-Treated Base
Unstabilized Granular Base
P f B /S bb C
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Purpose of Base/Subbase Courses
(FAA AC 150/5320-6E)
Flexible pavements
Principal structural component
Base
Asphalt
Principal structural component
Distribute the loads to the
f d ti
Base
Subbase
(Req. if CBR<20)
foundation
Rigid pavements
Subgrade
Provide uniform stable support
Concrete
Subbase
Subgrade
Materials for Base Course
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Materials for Base Course
FAA AC 150/5320-6E Flexible Pavement Design
B C M G L d em Base Course Max. Gross Load,
lbs.
08 Aggregate Base 60 000 08 Aggregate Base 60,000
09 Crushed Aggregate Base 100,000
11 Lime Rock Base N/A /
19 Recycled Concrete Aggregate Base 100,000
04 Cement Treated Base N/A /
06 Econocrete Subbase N/A
01 Plant Mix Bituminous Pavements N/A
03 HMA Base N/A
Materials for Subbase Course
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Materials for Subbase Course
FAA AC 150/5320-6E Flexible Pavement Design
S bb C
1
F P i em Subbase Course
1
Frost Penetrating
Subbase
54 Subbase Course 54 Subbase Course
10 Caliche Base Course
12 Shell Base Course
13 Sand Clay Base Course X
01 Soil Cement Base Course X
aterials acceptable for base course can also be used for subbase course
Materials for Subbase Course
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Materials for Subbase Course
FAA AC 150/5320-6E Rigid Pavement Design
S bb C M G L d tem Subbase Course Max. Gross Load,
lbs.
4 Subbase Course 100,000
Requires quality
,
8 Aggregate Base Course 100,000
9 Crushed Aggregate Base Course 100,000
aggregates or
crushed
concrete
meeting same
1 Lime Rock Base Course 100,000
1 Soil Cement Base Course 100,000
4 Cement Treated Base Course N/A
requirements
4 Cement Treated Base Course N/A
6 Econocrete Subbase Course N/A
1 Plant Mix Bituminous Pavements N/A
3 HMA Base Course N/A
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Engineering Properties of CTB
P
1
FAA P 301 FAA P 304 PCA CTB Property
1
FAA P-301
(Soil Cement)
FAA P-304
(CTB)
PCA CTB
y Compressive N/A
2
Under PCC: 300 min.;
ngth, psi 500 min.; 1000 max.
Under HMA:
750 min.; 1000 max.
800 max.
ic Modulus, ksi 250 500 600-1000
sons Ratio 0.20 0.20 0.15
Refer to FAA AC 150/5320-6E for durability requirements
FAA recommendations for P-301 are based on wet-dry and freeze-thaw tests
and strength should increase with age
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Mi i M th d Mixing Methods
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Mixing Methods
Two methods
Plant Mix
Road Mix (in place) Road Mix (in-place)
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lant Mix
Central
FAA P 301
Central
Concrete
Batch Plant
FAA P-301
FAA P-304
P g ill Pl t
T i t T k Mi
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Road Mix
In-situ or mixed in place materials
Applicable for
FAA P-301 but
not P-304 (unless
variance is
granted)
Road Mix
Spread cement
Add water if Add water if
necessary and mix
G d d t Grade and compact
Cure
Road Mix
FAA P 301 FAA P-301
gineers ordered a number of these large machines and has
ed on the use of Rototillers in the construction of the air field,
Tro Record 1938 Tro P blic Librar Librar So rce
opee, Mass., military airport, Brunswick Maine and airports
ghout the country.
Troy Record, 1938 Troy Public Library, Library Source
Mi fi h 194 31 342
R d Mi
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Road Mix
Then
R d Mi Road Mix
And now
Why cant use this
method to build FAA P method to build FAA P-
304 (CTB)?
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Traffic loading/agency requirements
ant vs. Road Mix Considerations
Traffic loading/agency requirements
FAA P-304 spec includes plant mix only
Q lit f i it t ri l Quality of in-situ materials
Cost
Haul distances: material sources, plant, jobsite
Design thickness (one or multiple lifts)
Sustainable considerations (Reduce, Reuse and
Recycle)
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Applications
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L l r d
ere are stabilized materials used?
Low volume roadways
Residential streets
State routes State routes
Interstate highways
Airport runways and taxiways Airport runways and taxiways
Parking lots
Industrial storage facilities Industrial storage facilities
Port facilities
Truck terminals
In other words
Truck terminals
Commercial sites
any pavement structure!
Washington Dulles
rport Runway 4, 2008 p y ,
18 PCC w/
dowelled transverse
j i t t 20 ft joints at 20 ft
6 CTB, 6% cement
12 Cement-
Stabilized Subgrade,
5% cement
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Washington Dulles
rport Runway 4 p y
Runway 4 completed in 2008
Runway 12 was completed in
2004
dEx Hub at Alliance
rport, Fort Worth,
Taxiway & Ramp
, 1997
14 PCC
Taxiway & Ramp
Truck Terminal &
C t i St g 14 PCC Container Storage
9 CTB
10 JRCP
9 Cement-Treated 6 Cement-Treated
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dEx Hub at Alliance Airport, Fort Worth, TX
50-yr design life
C l t d i 1997 Completed in 1997
330,000 yd
2
Cement-treated subgrade
7 % cement, 250 psi,
reduced PI from 38 to less
than 12
Cement treated base Cement treated base
750 psi at 28 days
FW SE Perimeter
axiway, 2008 y,
First perimeter taxiway in U.S.
Built for safety and to reduce
congestion delays
18 CRCP
congestion delays
18 CRCP
12 CTB
12 Lime-Treated
Subgrade
FW SE Perimeter
xiway
Completed in 2008
225,000 yd
2
Data will be analyzed before Data will be analyzed before
building the remaining 3 loops
i d M i l riedman Memorial
rport, Hailey, Idaho
Single asphalt runway
serving the airport
7,500 ft long runway.
6,900 ft needed rehab 6,900 ft needed rehab
Priority No. 1:
Minimize runway Minimize runway
shutdown time
C t ti ti Construction time
t t 30 d
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riedman Memorial Airport Runway, Hailey, Idaho
Planned replacement Planned replacement
airport in 10 years
Th FAA d Three FAA approved
methods considered but
none could be done within none could be done within
30 days (fastest
construction was estimated
at 48 days)
FAA approved owners FAA approved owner s
petition to use FDR
Courtesy of T-O Engineers
TM
FAA
edman Memorial Airport Runway, Hailey, Idaho
FDR FAA FAA
Standard
HMA
4
Option
HMA
HMA
4
Alternate 1 Alternate 2
Crushed -
Stone Base
6
4
6
4
Crushed-
HMA
14.5
6
FDR
12
Crushed
Stone Base
14
Subbase
15
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edman Memorial Airport Runway, Hailey, Idaho
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riedman Memorial Airport Runway, Hailey, Idaho
Constructed within contract time in 2007
$1 million in construction savings $ o co st uct o sa gs
Reduced use of virgin materials from quarries
Eliminated about 4,000 truck trips
Reduced material disposal p
Reduced fuel use, air emissions, traffic
congestion and damage to nearby roads congestion and damage to nearby roads
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Dauphin Island Airport, Alabama
auphin Island
irport Alabama irport, Alabama
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auphin Island, AL
Distress
Ravelingg
Severe
cracking
Mild base
failure
C t f V lk t
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auphin Island, AL
High water
table
Courtesy of Volkert y
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auphin Island Runway Repair Options
Remove and Replace
Mill existing Asphalt
Full Depth Reclamation
FDR = 7 5 Inches Mill existing Asphalt
Repair base
FDR 7.5 Inches
Cement = 45 Lbs./
S Y
Place 4 asphalt
wearing surface
S.Y.
Place 3.5 asphalt
wearing surface
auphin Island,
LL
Courtesy of Volkert
TM
B fit f FDR O ti
Dauphin Island, AL
Benefits of FDR Option
Reduced construction time
Higher pavement strength
30% cost savings 30% cost savings
Conservations of virgin materials and energy
i savings
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Atlanta Airport Apron Project, 2010
6
8
,
0
0
0
S
Y
1
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FAA
anta Airport Apron Section
As
andard Constructed
CC (P-501)
20 PCC (P-501)
Courtesy of J A Long, Inc.
Econocrete
(P-306)
oil-Cement
P-301)
( )
9 Cement-Treaded
Subgrade; 600 psi
at 7 days
M I f ti
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More Information
www.cement.org/pavements www.cement.org/pavements
fabdo@cement org