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 TM 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 TM 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 TM 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 TM 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 TM 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) TM 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 TM 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 TM 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 TM FAA Base/Subbase Approved Materials P f B /S bb C TM 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 TM Improved Performance in Rutting and Fatigue Cracking P P Cement-Treated Base Unstabilized Granular Base P f B /S bb C TM 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 TM 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 TM 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 TM 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 TM 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 TM Mi i M th d Mixing Methods TM Mixing Methods Two methods Plant Mix Road Mix (in place) Road Mix (in-place) TM 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 TM 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 TM 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)? TM 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) TM Applications TM 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 TM 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 TM 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 TM 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 TM edman Memorial Airport Runway, Hailey, Idaho TM 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 TM Dauphin Island Airport, Alabama auphin Island irport Alabama irport, Alabama TM auphin Island, AL Distress Ravelingg Severe cracking Mild base failure C t f V lk t TM auphin Island, AL High water table Courtesy of Volkert y TM 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 TM Atlanta Airport Apron Project, 2010 6 8 , 0 0 0 S Y 1 TM 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 TM More Information www.cement.org/pavements www.cement.org/pavements fabdo@cement org