RollerRoller -Compacted Concrete Pavement:

Pavement Thickness Design and RCCRCC -Pave Software

Wouter Gulden, P.E. Dir. of Engineering and Training ACPA-SE Chapter

September 25 25, 2007 Louisville, Kentucky

CementCement -Based Pavement M t i l Materials

Roller-Compacted p Concrete Conventional Concrete

Cement Cont tent

Soil-Cement
CementTreated Base

Flowable Fill
Full-Depth Reclamation

Cement Modified Cement-Modified Soil

Water Content

Pa ement Thickness Design Pavement

Engineering Properties
Compressive strength
4,000 to 10,000 psi

Flexural Fl l strength t th
500 to 1,000 psi fr = C(fc)1/2

Modulus of Elasticity y
3,000,000 to 5,500,000 psi (fc)1/2 E = CE(f

Engineering Properties
RCC can provide higher flexural strength g than conventional concrete

Strength vs. vs Cement Content

6,500

28-Day Co 2 ompressiv ve Streng gth (psi)

6 000 6,000 5,500 5,000 4,500 4,000 10%

12%

14%

16%

18%

Cement Content

Thickness Design of RCC Pavements

Design g methods based on CTL and COE Research in the 1980s Follows rigid pavement design strategies Plain, un-doweled, un-reinforced concrete pavement p

RCC - Unique Loadings

Highway loadings just the start Industrial I d t i l pavements t present t design challenge Container and log sort yard loadings can greatly exceed highway loadings 18,000 18 000 vs 220 220,000+ 000 lb lb. axle l l loads d

Slab Tensile Stress is Critical

Stress is affected by:

load tire pressure and spacing slab thickness subbase support concrete strength

Design for Stress Ratio

Stress Ratio = critical applied tensile stress Modulus of Rupture (flexural strength)
where: critical applied stress is the maximum tensile stress at the bottom of the concrete pavement slab and the Modulus of Rupture p is the tensile strength g of a concrete beam tested using 3-point loading at 28 days Flexural (tensile) strength controls for RCC pavements

Thickness Design Procedure

The desired stress ratio is reached by either increasing the RCC pavement thickness or by increasing the strength of the concrete

Design Assumptions
Interior loading Monolithic slab action for multi multi-layer layer construction Load transfer across joints/cracks Conservatism: Design curve below fatigue tests g gain g with age g Strength

Thi k Thickness Design D i Procedure P d

1. Support strength of subgrade (k value) 2. Vehicle characteristics Wheel loads p g Wheel spacing Tire characteristics p during g design g life Load repetitions 3. Flexural strength 4. Modulus of Elast Elasticity c ty

Thi k Thickness Design D i Procedure P d

Subgrade Support k value Use plate load test, or estimated relationships Vehicle Loads y, heaviest wheel load controls Normally, Contact area: wheel load/tire pressure Wheel spacing: pa ng per p r manufacturer manufa ur r W

S ft Software D Demonstration t ti

Design Example One

Single Axle Single Wheel

Design Example One Passenger Car, Single Axle - Single Wheel Total weight: 4,000 4 000 pounds Axle load: 2,000 pounds Wheel load: 1 1,000 000 pounds Subgrade k value: 210 pci r pressure: pr ssur 35 5 psi ps Tire Tire contact area 1,000/35 = 29 sq in g 600 psi p RCC flexural strength: RCC modulus of elasticity: 3,500,000 psi p y = 35; therefore, Load repetitions/day 20 years: 35 x 365 x 20 = 255,500

Design Example Two

Tandem Axle Dual Wheel

Design Example Two

Truck, Tandem Axle - Dual Wheel Total weight: 40,000 40 000 pounds Subgrade k value: 150 pci RCC compressive strength: 4,000 4 000 psi Load repetitions/day = 50; therefore, , 20 years: 50 x 365 x 20 = 365,000

Design Example 3

Single Wheel

Design Example 3 Straddle S ddl Carrier, C i Single Si l Wh Wheel l Total load: 104k - Wheel load: 26k Subgrade is fine-grained with no subbase Tire pressure: 100 psi Tire contact area 26,000/100 = 260 sq in RCC design strength = 7,000 psi Load repetitions/day = 20; therefore, years: 20 x 365 x 20 = 146,000 20 y

Design Example Four Multiple Loads Equipment + Truck Loads

Top/Side Lifter Equipment Design g period p = 20 years y 100,000 design traffic 5,000 @ 50,000 pounds 50 000 @ 40,000 50,000 40 000 pounds 25,000 @ 30,000 pounds 20,000 @ 20,000 pounds ME = 4,000,000 000 000 psi MR = 700 psi p k = 200 pci Tire pressure = 200 psi Number of wheels = 1

Design Example Four Multiple Loads Equipment + Truck Loads

Load (lbs) 50,000 40,000 30,000 20,000 Total Thickness (in) 12.5 12.5 12.5 12.5 Stress (psi) 394 330 263 189 Stress Applications Number of to Failure Applications Ratio 0.562 0.472 0.376 0.271 9,175 93,874 unlimited unlimited 5,000 50,000 25,000 20,000 Fractional Damage 0.545 0.533 0.000 0.000 1.078

Design Example Four Multiple Loads Equipment + Truck Loads

Load (lbs) 50,000 40,000 30,000 20,000 Total Thickness (in) 13.0 13.0 13.0 13.0 Stress (psi) 369 309 246 177 Stress Applications Number of to Failure Applications Ratio 0.527 0.442 0.351 0.253 22,997 204,418 unlimited unlimited 5,000 50,000 25,000 20,000 Fractional Damage 0.217 0.245 0.000 0.000 0.462

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www cement org/pavements www.cement.org/pavements

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