Material and Construction Optimization for Prevention of Premature Pavement Distress in PCC Pavements

Overview
Jim Grove Halil Ceylan
Center for Portland Cement Concrete Pavement Technology
Iowa State University

Material and Construction Optimization

Materials And Mixings
Cloud Cover Humidity

Aggregate

Environmental
Mixing
Concrete Temperature and Moisture Monitoring
Cylinder and Beam Breaks

Cements /mineral Admixtures

Chemical Admixture

60F 30F

90F

120F 150F

25% 0%

50%

75% 100%

Curing Methods

Time

Temperature

Humidity

NDT Testing

Horizontal Cracking

Plastic Shrinkage Cracking

Early Opening Traffic

Transporting/ Placement

Construction

Project Requirements

The Issue

Concrete mixtures: complex chemical and physical systems

Variety of ingredients & sources

Proportioning and mixing procedures Construction procedures

The Problem

Material selection and mix design often are not integrated with construction practices Construction and materials testing have not kept up with technology We dont test the right things Too often tests dont relate to performance

Solutions

Characterize materials, compatibilities, and construction procedures

Key to increasing durability Understand properties and compatibilities Increasing need for quick answers New procedures are needed to optimize

Software can help organize the complexities

Project Objectives

Glean materials testing and construction practices from each state Document local unpublished research on materials testing and construction practices Develop a suite of tests that will effectively control the process and predict PCC paving performance

Project Objectives
Conduct shadow demonstration projects, showcasing materials testing and construction practices, in each state Produce a Practices Manual to document the information gathered and test procedures developed VSA

VSA

Managing Performance
Material Selection and Interactions

+
Construction Practices

+
Environmental Affects

Resulting Performance

+
Project Requirements

Managing Performance

Performance Factors + Prediction Tools + Measurements

Optimization

Managing Performance
Prediction Tools Computer-Based Guidelines for Job-Specific Optimization of Paving Concrete (FHWA Task 64)

Performance Factors
0

Workability Strength Development Air Content Permeability Shrinkage

HIPERPAV

Measurement Workability: Variable Slope Apprentice Air Void Characteristics: Air Void Analyzer Strength: Maturity Meter Compatibility: Heat Signature

Curing: Conductivity Meter

Understanding Performance
Research
Identify Gaps in Knowledge and Measurements
Material Interaction Mixing and Hauling

Environmental Affects
Construction Techniques

Laboratory
Develop correlation tests Simulate and quantify material / mixing criteria Quantify construction criteria

Field
Field Trials on lab correlations
Verify tests and protocol

Practices Manual

3 Stages
Design stage
Laboratory Concrete Winter

Verification
Field Beginning of the project

Quality Control

Stages

Mix Design Stage

Characterize the materials Characterize the concrete Materials are similar but not the same as project materials Utilize Task 64 Computer based design Go/ No Go

Stages

Pre-Construction Verification

Test project materials for similarity to design materials Verify mix design Utilize HIPERPAV Field lab tests

Stages

Quality control

Monitor the concrete Predict performance

HIPERPAV

Related Research
FHWA Task 4 Blended cements Mix Uniformity Task 64 HIPERPAV

FHWA Task 4 - Identifying Combinations of Materials That Lead to Premature Deterioration in Concrete Pavements

Identify

Effects of production and placement methods

Factors that influence segregation, bleeding and cohesiveness relative to finish-ability

Influence of environmental conditions

Deficiencies in existing test methods

Provide

A simple test for evaluating compatibility

ISU Blended Cements Project

Identify

How different blended cement influences concrete setting time and heat development in different weather conditions, especially in cold weather How the heat signature of blended cement relates early strength development of the concrete

Provide

Control of a pavements saw cut and opening time Modification of maturity calculation Prediction of early age cracking of concrete

ISU - Mix Optimization Project (Mix Uniformity)

Identify:

Optimal mixing procedures for combinations of supplementary materials and admixtures Characteristics of a good mix received by:

Slip form paver Haul vehicles

Effects of combinations, mixing times, and mixing methods on fresh concrete properties

Workability, uniformity, air void system

Provide

Input to Material and Construction Optimization and guidelines to simplify mixing with supplementary cementitious materials and admixtures

FHWA Task 64: Software to Identify Rapid Optimization of Available Inputs

Criteria Constituents

Cost
Permeability Strength Stiffness Workability Other Factors Optimum PCC Mix
Models

Coarse Aggregate
Fine Aggregate Cement Water Mineral Admixtures Chemical Admixtures

HIPERPAV
Prediction Tool to Help Achieve Construction Optimization

Predicts Controlling Cracking of Pavements

Predict Optimum Sawing Window Predict Impact of Adverse Weather on Construction of Pavement

HIPERPAV

Overview
Construction QC/QA Process Correlates to Lab Tests
Existing Knowledge and Practices
Literature Search Construction Environment Cost Project Criteria

Final Model
Develop Optimization Software *

(FHWA Task 64)

Mix Design that meets specific project performance requirements

Previous Research

Actual Project Performance Problem

Measurable Criteria
Workability Consistency Shrinkage Strength Air Voids Permeability

Develop Tests
Identification of known or proven Impact elements What works & what does not

Knowledge Base on Subject of Materials that allows selection of materials that satisfy specific project performance requirements

Construction
Use proposed field tests on projects in participating states to verify tests

Research Lab
Correlation Test Development

Field Test
Develop Quick Battery of tests to measure criteria
Select Rock Select Sand

ALL AVAILABLE MATERIALS

Select Cement

Select Mineral Admixtures

Select Chemical Admixtures

Multiple Rock Sources

QC/QA
Multiple Sand Sources

Best Practices Manuals

Construction Quick Field Tests to identify or ensure performance

Multiple Cement Sources

Mineral Admixtures
(fly ashes, silica fumes, natural pozzolans, ground granulated blast furnace slag)

Chemical Admixtures
(retarders, accelerators)

Material and Construction Optimization Tasks

Phase I
Data Collection Literature review Current practice survey Database from past projects Field monitor and review current projects Test Development Identify material and concrete tests that characterize properties of durable concrete Further develop existing tests Research new tests Pilot Project Try tests scheme in Iowa Technology Transfer Initial guidelines of known solutions

Phase II
Continued Development of Testing Procedures Laboratory testing Field Demonstration Projects Demonstrate suite of new tests in each state Investigate property effects of construction procedures with various materials SWAT Teams Provide technical assistance to states if problems arise Utilize proposed test to evaluate problems

Phase III
Technology Transfer Training modules on material and construction optimization for prevention of premature pavement distress Material property integration Best construction practices Material and construction effects on performance (system integration) Implementation Assistance

Phase I

Data Collection

Literature review

Current state testing practice

Unpublished state research

Published Research (Task 64)

Database of past state projects with durability issues

Phase I

Test Development

Identify material and concrete tests that characterize properties of durable concrete Further develop existing tests Research new tests

Phase I

Pilot Project

Try tests scheme in Iowa

Technology Transfer

Practices Manual

Report state practices and unpublished research

Suite of tests

Material and Construction Optimization Tasks

Phase I
Data Collection Literature review Current practice survey Database from past projects Field monitor and review current projects Test Development Identify material and concrete tests that characterize properties of durable concrete Further develop existing tests Research new tests Pilot Project Try tests scheme in Iowa Technology Transfer Initial guidelines of known solutions

Phase II
Continued Development of Testing Procedures Laboratory testing Field Demonstration Projects Demonstrate suite of new tests in each state Investigate property effects of construction procedures with various materials SWAT Teams Provide technical assistance to states if problems arise Utilize proposed test to evaluate problems

Phase III
Technology Transfer Training modules on material and construction optimization for prevention of premature pavement distress Material property integration Best construction practices Material and construction effects on performance (system integration) Implementation Assistance

Phase II

Continued Development of Testing Procedures

Laboratory testing

AVA

Phase II

Field Demonstration Projects

Investigate effects of construction procedures with various materials Demonstrate suite of tests in each state

DSC

Phase II

SWAT Teams

Provide technical assistance to states if problems arise

Utilize proposed tests to evaluate problems

Material and Construction Optimization Tasks

Phase I
Data Collection Literature review Current practice survey Database from past projects Field monitor and review current projects Test Development Identify material and concrete tests that characterize properties of durable concrete Further develop existing tests Research new tests Pilot Project Try tests scheme in Iowa Technology Transfer Initial guidelines of known solutions

Phase II
Continued Development of Testing Procedures Laboratory testing Field Demonstration Projects Demonstrate suite of new tests in each state Investigate property effects of construction procedures with various materials SWAT Teams Provide technical assistance to states if problems arise Utilize proposed test to evaluate problems

Phase III
Technology Transfer Training modules on material and construction optimization for prevention of premature pavement distress Material property integration Best construction practices Material and construction effects on performance (system integration) Implementation Assistance

Phase III

Technology Transfer

Training modules on material and construction optimization for prevention of premature pavement distress

Material property integration Best construction practices Material and construction effects on performance (system integration)

Phase III

Implementation Assistance

Participating States

Georgia Indiana Iowa Kansas

Louisiana Michigan Minnesota Missouri

Nebraska New York North Carolina North Dakota

South Dakota Ohio Texas Wisconsin

Summary of Proposed Funding Sources

$1,200,000 16 Pooled fund participants ($15,000/yr. x 16 x 5yrs.)
$ 314,000 $ 200,000 Iowa DOT and PCC Center ($160,000 IHRB + $154,000 PCC Center) Industry (ACPA / State Paving Assoc. & Others)

$ 500,000

PCC Center Federal Appropriation

$2,214,000

Total

Proposed Schedule
= States = PCC Center = Industry = Other

2003
1

2004

2005

2006

2007

Data Collection

A. State Survey B. On-site consultation w/ each state

2. Test Development
A Develop initial suite of tests to measure concrete properties B Refinements based on demonstration projects C. Development of next generation of tests

3. Demonstration Projects
A. Pilot project in Iowa B. Mobile field laboratory C. Demo project in each participating state

4. Technology Transfer
A. Initial standards/guidelines for testing incorporating state practices and initial test B. Best Practices for concrete paving which will include refined suite of tests plus C. Variety of T2 venues
TBD

Questions ??
http//www.ctre.iastate.edu/pccpoolf und/
Jim Grove Center for Portland Cement Pavement Technology Iowa State University 2901 South Loop Drive, Suite 3100 Ames, Iowa 50010 Phone: 515-294-5988 Fax: 515-294-0467 jimgrove@iastate.edu