WINFLEX 2000 is a mechanistic-based overlay design system for flexible pavement. Program was developed at the Center for Transportation Infrastructure (CTI) it was developed under a series of contracts with the Idaho transportation department.
WINFLEX 2000 is a mechanistic-based overlay design system for flexible pavement. Program was developed at the Center for Transportation Infrastructure (CTI) it was developed under a series of contracts with the Idaho transportation department.
WINFLEX 2000 is a mechanistic-based overlay design system for flexible pavement. Program was developed at the Center for Transportation Infrastructure (CTI) it was developed under a series of contracts with the Idaho transportation department.
for Flexible Pavement User Guide June 2001 UI Budget KLK456 ITD Contract 99-163 NIATT Report N01-13 Prepared for Idaho Transportation Department By Center for Transportation Infrastructure (CTI) National Institute for Advanced Transportation Technology (NIATT) University of Idaho Fouad M. Bayomy Mostafa Abo-Hashema ii WINFLEX 2000 INFLEX is a mechanistic-based overlay design system for flexible pavement. This program was developed at the Center for Transportation Infrastructure (CTI), which is part of the National Institute for Advanced Transportation Technology (NIATT) at the University of Idaho (UI). The program was developed under a series of contracts with the Idaho Transportation Department (ITD). The original program (FLEXOLAY, 1996) is a DOS-based program; it was upgraded to a Windows-based program (WINFLEX) in 1997. The 2000 version of the program is an update of the 1997 version, and includes many modifications. Some of the major improvements over the 1997 version are the complete revision of the mechanistic design process, the addition of a metric module, new quality control checks for all input data, and an online help guide. WINFLEX 2000 UI Research Team Dr. Fouad M. Bayomy, P.E. Professor of Civil Engineering Principal Investigator Center for Transportation Infrastructure (CTI) National Institute for Advanced Transportation Technology University of Idaho Moscow, ID 83844-1022 Dr. Mostafa A. Abo-Hashema Post-Doctoral Research Fellow Center for Transportation Infrastructure (CTI) National Institute for Advanced Transportation Technology (NIATT) University of Idaho ITD Research Coordinator Mr. Robert Smith, P.E. Research Supervisor and Assistant Materials Engineer Idaho Transportation Department Boise, Idaho W iii DISCLAIMER The WINFLEX 2000 software is a design tool that incorporates published research results. While utmost care was taken by the program authors to incorporate accurate information, the authors, the University of Idaho and the Idaho Transportation Department assume no responsibility or liability of any kind that may result from using the software. By using the WINFLEX 2000 software, the user agrees to assume complete responsibility for its use. iv TABLE OF CONTENTS Chapter 1 - INTRODUCTION................................................................................................. 1 1.1 Overview of WINFLEX 2000 ........................................................................................ 1 1.2 Input Files ....................................................................................................................... 1 1.3 Program Output............................................................................................................... 2 1.4 Program Functions .......................................................................................................... 2 1.5 System Requirements...................................................................................................... 3 1.6 Installation....................................................................................................................... 4 Chapter 2 - PROGRAM OPERATION.................................................................................... 5 2.1 Starting WINFLEX 2000................................................................................................ 5 Starting the Program......................................................................................................... 5 2.2 Starting a New Design Case ........................................................................................... 6 2.3 Creating a New Input File............................................................................................... 7 Single-Location Option..................................................................................................... 7 Multiple-Locations Option................................................................................................ 7 Entering The Data............................................................................................................. 8 1. Data Entry Form 1/5 (Pavement Data) ..................................................................... 8 Pavement Section Block ........................................................................................... 9 Overlay Block......................................................................................................... 10 Failure Mode Block ................................................................................................ 11 2. Data Entry Form 2/5 (Material Types) ................................................................... 11 Base Block .............................................................................................................. 12 Subbase Block......................................................................................................... 13 Subgrade Block....................................................................................................... 13 3. Data Entry Form 3/5 (Models)................................................................................ 13 4. Data Entry Form 4/5 (General Data) ...................................................................... 14 Commercial Traffic Block...................................................................................... 15 Fatigue Shift Factor Block...................................................................................... 15 Seasonal Variation Block........................................................................................ 15 5. Data Entry Form 5/5 (Modulus-Temperature Adjustment) .................................... 17 Preparing to Run the Design Case .................................................................................. 17 Save the Data Input File.............................................................................................. 18 Modify Models............................................................................................................ 18 Run Single/Multiple.................................................................................................... 18 2.4 Loading an Existing Input File ..................................................................................... 19 2.5 Modifying Input File Data ............................................................................................ 19 2.6 Creating an ETF File..................................................................................................... 20 ETF File Generator Program...................................................................................... 20 Create EFT File Manually........................................................................................... 20 2.7 Saving an ETF File ....................................................................................................... 23 2.8 Loading an Existing ETF File....................................................................................... 23 2.9 Modifying an ETF File ................................................................................................. 23 v 2.10 Running the Calculations on an Input File ................................................................. 23 Single Location Design Case.......................................................................................... 23 Multiple Locations Design Case..................................................................................... 26 2.11 Saving a Report on the Calculations........................................................................... 28 2.12 Printing a Report on the Calculations ......................................................................... 28 Chapter 3 - TUTORIAL EXAMPLES ................................................................................... 29 3.1 Introduction................................................................................................................... 29 3.2 Example on Single Location Design Case.................................................................... 29 Preparing the Data........................................................................................................... 29 Pavement Data ............................................................................................................ 30 Material Types Data.................................................................................................... 30 Models Data................................................................................................................ 30 General Data ............................................................................................................... 30 Modulus-Temperature Adjustment Data .................................................................... 30 Entering the Data ............................................................................................................ 31 Saving the Data............................................................................................................... 34 Running the Calculations on the Input File .................................................................... 34 3.3 Example on Multiple Location Design Case ................................................................ 39 Preparing the Data........................................................................................................... 39 ETF File ...................................................................................................................... 39 Pavement Data ............................................................................................................ 40 Material Types Data.................................................................................................... 40 Models Data................................................................................................................ 40 General Data ............................................................................................................... 40 Modulus-Temperature Adjustment Data .................................................................... 41 Entering the Data ............................................................................................................ 41 Saving the Data............................................................................................................... 44 Running the Calculations on the Input File .................................................................... 44 Conclusion & Technical Support............................................................................................ 51 vi TABLE OF FIGURES Figure 1. Opening Screen ......................................................................................................... 5 Figure 2. Main Menu Screen .................................................................................................... 6 Figure 3. Options for Selecting the Design Case...................................................................... 7 Figure 4. Pavement Data Screen............................................................................................... 8 Figure 5. Pavement Data Screen for Revert to Gravel.............................................................. 9 Figure 6. Material Types Screen............................................................................................. 12 Figure 7. Models Screen ......................................................................................................... 14 Figure 8. General Data Screen................................................................................................ 14 Figure 9. Modulus-Temperature Adjustment Screen.............................................................. 17 Figure 10. Main menu screen after data entry is completed................................................... 18 Figure 11. Modify Option in Main Menu Screen (Multiple Location)................................... 19 Figure 12. ETF File Editor Screen (Multiple Location) ......................................................... 21 Figure 13. Create a New ETF File (Multiple Location) ......................................................... 21 Figure 14. Excel Data Sheet for ETF File............................................................................... 22 Figure 15. Single Location Results Screen............................................................................. 24 Figure 16. Strains Screen in Single Location.......................................................................... 25 Figure 17. Adjusted E-Values Screen in Single Location ...................................................... 26 Figure 18. Run Commands for Multiple Locations ................................................................ 26 Figure 19. Results Screen for Multiple Locations .................................................................. 27 Figure 20. Strains Screen for Multiple Locations................................................................... 28 Figure 21. Pavement Data for Example1_S............................................................................ 32 Figure 22. Material Types for Example1_S............................................................................ 32 Figure 23. Models for Example1_S........................................................................................ 33 Figure 24. General Data for Example1_S............................................................................... 33 Figure 25. Modulus-Temperature for Example1_S................................................................ 34 Figure 26. Results Screen for Example1_S ............................................................................ 35 Figure 27. Comprehensive Report for Example1_S............................................................... 36 Figure 28. Comprehensive Report for Example1_S (Contd) ................................................ 37 Figure 29. Strain Values for Example1_S .............................................................................. 38 Figure 30. Seasonal Adjusted Moduli Values for Example1_S ............................................. 38 Figure 31. ETF File for Example7_M.................................................................................... 39 Figure 32. Pavement Screen for Example7_M....................................................................... 42 Figure 33. Material Types Screen for Example7_M.............................................................. 42 Figure 34. Models Screen for Example7_M........................................................................... 43 Figure 35. General Screen for Example7_M.......................................................................... 43 Figure 36. Modulus-Temperature Adjustment Screen fro Example7_M............................... 44 Figure 37. Results Screen for Example7_M........................................................................... 45 Figure 38. Comprehensive Report for Example7_M.............................................................. 46 Figure 39. Comprehensive Report for Example7_M (Contd)............................................... 47 Figure 40. Comprehensive Report for Example7_M (Contd)............................................... 48 Figure 41. Comprehensive Report for Example7_M (Contd)............................................... 49 Figure 42. Results Screen for Example7_M........................................................................... 50 WINFLEX 2000 User Guide Page 1 CHAPTER 1 - INTRODUCTION 1.1 Overview of WINFLEX 2000 WINFLEX 2000 is a mechanistic-empirical overlay design system for flexible pavement. The program determines asphalt overlay thickness based on mechanistic analysis of the distress in the existing flexible pavement. The mechanistic analysis also takes into account the prediction of fatigue and rutting distresses in the overlaid pavement. Fatigue and rutting models used in the WINFLEX 2000 system are those published by several agencies, including the Asphalt Institute and the FHWA, and most were developed by empirical analysis. WINFLEX was created to operate under the Windows 95 or higher and NT environments, and can be used for single or multiple-location design cases. The program has two modules - one for designing with the US Customary units (English System) and the other for the use with the System International Units (Metric System). 1.2 Input Files For each design case, the user first enters parameters into an input file. Each input file consists of five data screens: Pavement, Material Types, Models, General and Temperature Adjustment: Pavement: In this screen, the user enters the moduli values of the existing pavement. These moduli values can be obtained from backcalculation of Falling Weight Deflectometer (FWD) deflection testing, which is shown on this screen. Material Types: In this screen, the user selects the material types for base, subbase and subgrade layers Models: In this screen, the user selects the failure criteria and the models used for estimating the pavement damage. The user has the option of choosing an existing model or entering new model parameters. General: In this screen, the user can enter information on traffic and other related design parameters, the seasonal adjustment factors for the climatic zones, and fatigue shift factors. Temperature Adjustment: In this screen, the user enters the modulus-temperature adjustment function. The user can select an existing function, or enter a new one. Control checks of the data are built into all data screens. The program will display a warning message if the input data is outside preset reasonable ranges. This control is designed to minimize errors while inputting data, but if the user wants to bypass the preset ranges or default values, the program will allow that too. WINFLEX 2000 User Guide Page 2 1.3 Program Output The program output displays the calculated overlay thickness for each design location, along with other design parameters, all of which can also be printed in various reports. 1.4 Program Functions WINFLEX 2000 has many functions designed to ease data entry, calculations, and the displaying and printing of results. Table 1 below summarizes the programs main menu components and sub-menu commands. Table 1. Description of WINFLEX Main Menu Components Main Menu Component Sub-Menu Command Description New File This command allows the user to create a new input file (a file with extension .INP) for either single or multiple design cases. Load an Existing File This opens a standard Windows OPEN dialog box to load an existing .INP file Save INP File This opens a standard Windows SAVE dialog box. This allows the user to save the current data file, which is loaded in the computer RAM, with an extension .INP. Print a Report This command is activated only after the Run command (see Results menu) has been launched. It allows printing a comprehensive report for the design case (either single or multiple locations). File Exit This command allows the user to exit the program. It warns for saving the current input data file. Toolbar Status Bar View Background The user can choose to show or hide any of these listed options. The toolbar appears at the top of the main screen. It has a set of buttons that work as shortcuts for some of the sub- menu commands. The status bar appears at the bottom of the main screen. It shows the current date and time. Background allows the user to choose either a blank gray or a colorful WINFLEX 2000 image as a background. Pavement This is the input screen for the pavement data, which includes information on the existing pavement and the overlay material. Modify Data Material Types This data input screen allows the user to select the type of materials used in all pavement layers according to pre- established categories. WINFLEX 2000 User Guide Page 3 Main Menu Component Sub-Menu Command Description Models In this input screen, the user selects the various failure models (fatigue or rutting or both). The user can choose pre-established model parameters or enter new ones. General This is the data input screen where the user enters traffic related data, environmental adjusting factors and fatigue shift factors for the selected fatigue model. ETF File This command launches an ETF screen editor (text type editor) in which the user can either create or modify a pre- loaded ETF file. Since the ETF type file is used only with multiple design cases, this command appears only when a multiple location case is selected. Run single This command executes the program calculations for a single location. Once the calculations end, the program displays the output screen showing the overlay design results. Run Multiple This command executes the program calculations for multiple locations. It also has an option to allow the user to run the pre-loaded Input file with any other compatible ETF file. Results Show Results This command retrieves the Results screen that appears at the end of calculations. This command is inactive until the RUN command(s) have been launched. Excel Summary This option allows the user to export the overlay design data to an Excel spreadsheet. Temperature Adjustment This option allows the user to launch an algorithm to choose the modulus-temperature relationship. The user can select either a default or a pre-loaded relationship. The user can also enter test data to develop and use a new one. Options Go to Metric or Go to English This allows the user to switch from one system of units to another. The program closes all opened files and prompts the user to start from the beginning with the selected system of units. About This is a typical About screen About Help Topics This launches the Help menu 1.5 System Requirements The following are recommended computer system configurations for WINFLEX 2000: PC or workstation with a Pentium 166 or higher processor. A minimum of 16 megabytes (MB) of random-access memory (RAM). Hard disk with 25 MB available space. An 800x600 SVGA graphics monitor. Microsoft Windows 95 or higher or NT 4.0 or higher operating systems. WINFLEX 2000 User Guide Page 4 Microsoft Excel is needed for advanced features in WINFLEX 2000, such as exporting a design summary table to an Excel worksheet. 1.6 Installation To install WINFLEX 2000 from a CD: Insert the CD in your CD-ROM drive From the Start menu, click Run and enter the CD location Type in Setup.exe and press Enter. The program will launch the Setup Wizard. Follow the onscreen instructions. To install WINFLEX 2000 from a web-downloaded Zip file: Open the Zip file and install it in a selected directory Double-click on the Setup.exe file. The program will launch the Setup Wizard. Follow the onscreen instructions. WINFLEX 2000 User Guide Page 5 CHAPTER 2 - PROGRAM OPERATION 2.1 Starting WINFLEX 2000 Note: If you intend to create a multiple-location design case, you will need to prepare an ETF file before opening WINFLEX. An ETF file is a text file in which data of pavement layer moduli and thickness values are entered for all mileposts. The temperature for each set of moduli values is also entered. For instructions on creating or modifying ETF files, see the section of this chapter entitled, Creating an ETF File. Starting the Program Start WINFLEX by clicking on its icon in the Windows Start menu, or by double-clicking the program icon on the desktop, if you created an icon. When you first start the program, you will see the animated opening screen shown in Figure 1. WINFLEX has two independent design systems, one for English Units and the other for Metric Units. You need to choose one or the other in order to start a design case. Once you have selected a system, you will have to stay in that system throughout the design case. If you need to shift to the other system, select Options in the main menu, then the Shift command. The program will prompt you to start a new design case. Figure 1. Opening Screen WINFLEX 2000 User Guide Page 6 2.2 Starting a New Design Case Once you have selected a system of units from the opening screen, the main screen will display, shown in Figure 2. At this point, only three command buttons appear in the toolbar - New, Load, and Exit. You can either create a new data input file or load an existing input file. To create a new input file, click on the New button in the toolbar or select the New command under File. Figure 2. Main Menu Screen After you click the New button, the design condition screen will display, as shown in Figure 3. Select for a single location or multiple-locations design case. Select a single-location design case for situations in which you will design an overlay for one pavement cross-section. Whether this single design is for pavement data at a specified milepost or for a set of representative moduli, the thickness and temperature values for the entire pavement section need to be entered. WINFLEX 2000 User Guide Page 7 Figure 3. Options for Selecting the Design Case Select a multiple-locations design case for situations in which you will design an overlay for each milepost in the pavement section. This option automates the design process and eliminates the need for entering pavement section data at each milepost individually while you are entering data in the Pavement data entry screen. To take advantage of this option, you will need to input pavement cross-section data at all mileposts in one file, called the ETF file, before opening WINFLEX. The ETF file includes data on E (elastic modulus), T (temperature at which the E value was determined) and thickness of layers at all mileposts. To create an ETF file, refer to the section 2.6, entitled Creating an ETF File. 2.3 Creating a New Input File Single-Location Option If you select the single-location design option, the program opens the first of five data input screens. You can immediately begin entering the input data as explained on the next page Entering the Data. Multiple-Locations Option If you select the multiple-location design option, the program first prompts you to load the design cases associated ETF file, which you should have prepared prior to launching WINFLEX. The ETF file contains the test temperature, the layer moduli, and the layer thickness for each location. This file can be loaded by clicking on the Load File command button. After you have loaded the ETF file, the name of the file and its location will appear on the bottom of the screen. WINFLEX 2000 User Guide Page 8 Entering The Data Whether you select the single or multiple-locations option, you will need to go through each of the five data entry screens described below to create the input file. The data entry screens are: 1. Pavement Data 2. Material Types 3. Models 4. General Data 5. Modulus Temperature Adjustment. Throughout the program, you can use either the mouse or the Tab key to move from one cell to another. You cannot save the file while you are in the process of entering the data. You must enter all of the data in each of the five screens before you can save the file. You can exit from any data input screen at any time, by clicking on the Exit button, and the program will terminate without creating the .INP file. Once you have completed entering all data in all five screens, save the data input file with the extension .INP by clicking on the Save command button on the toolbar or selecting Save from the main menu under File. 1. Data Entry Form 1/5 (Pavement Data) This is the first data input form in which data for the existing pavement section and the overlay properties are entered. Figure 4 shows the pavement screen. In this screen, preset ranges were assumed for every cell, to assist in input checks and to minimize data input errors. A warning message will appear that directs the user to revise the input value if it is out of the preset range. You can override the preset range by responding to the warning message that you want to keep your value as it is and out of the preset range. Figure 4. Pavement Data Screen WINFLEX 2000 User Guide Page 9 The pavement screen is divided into three blocks: Pavement Section, Failure Mode and Overlay. A description of each block follows. Pavement Section Block Description: Text to describe the design case. You have the option of entering as many characters as needed. No commas or semi-colons are allowed. Treat Old AC as Gravel: If this box is checked, the program will treat the old asphalt concrete layer as a gravel layer. This is a case in which the existing pavement surface is highly cracked. The E value determined from the FWD data could be high due to the fact that the FWD test is performed on a pavement block. In such cases, the designer may choose to consider the pavement surface as a discontinued layer that has been reverted to gravel with considerably high modulus. If this is the case, check this box, and a new cell will appear in the FAILURE MODE block, as shown in Figure 5. Enter an E value of the reverted to gravel layer. It could be the same E value that was entered in the Old AC Layer cell. A minimum value of 50 ksi (350 MPa) is required. Figure 5. Pavement Data Screen for Revert to Gravel Pave. Temp. (F or C): Pavement temperature at which moduli (E) values of the asphalt layers were determined. Options: BS AND SBS: Existing pavement section includes base and subbase. BS ONLY: Existing pavement section includes base only. FULL AC: Existing pavement section is full-depth asphalt. WINFLEX 2000 User Guide Page 10 Note that the screen changes as the selected option changes. The base layer and the subbase layer disappear when FULL AC is selected. The subbase layer disappears when BS ONLY is selected. E (ksi, or MPa): Moduli values for various pavement layers. The E values can be obtained from lab tests on core samples, or (and most commonly), obtained from field-testing by Falling Weight Deflectometer (FWD). Backcalculation programs such as the Texas Transportation Institute software (MODULUS) can be used for backcalculation of Es from FWD deflections. The entered values for the AC layers must be those determined at the pavement temperature, which appears in the PAVE TEMP cell. For unbound layers, the entered values are assumed to be those of the normal season. Pois. Ratio: Poissons ratio of each layer. Typical values assumed for various material types. For example, for AC layer, a range of 0.2 to .35 can be assumed. A lower value may be selected for a stiff, hardened, and aged mix, and a higher value for a softer and fresh mix. For granular materials, a range of 0.4 to 0.45 may be assumed. For subgrade, a range of 0.45 to 0.5 may be assumed. The Poissons ratio was found to have insignificant effect on the calculated overlay thickness. Thus, a user may assume typical values of Poissons ratios as follows: AC and bound layers (0.3), granular base and subbase layers (.4) and for the subgrade layer (0.45). Thick. (in or mm): The thickness of each layer. The subgrade is considered to have an infinite depth, as assumed in the multi-layer elastic analysis. Layer thicknesses may be obtained from construction documents, core analysis or by a Non Destructive Testing (NDT) method such as the Ground Penetration Radar (GPR). Note that if you are in a multiple-locations design case, you will not be able to input the moduli and the thicknesses of different layers in the data entry screens. The program will show N/A in the respective cells, indicating that they cannot be entered by the user, but will be read from the ETF file. You will not be able to enter the test temperature and number of layers, either. They also will be read from the ETF file. For multiple-locations design cases, you will be prompted to load the associated ETF file while you are starting a new design case, once you have selected the multiple-locations option. Overlay Block E (ksi, MPa): The elastic modulus of the new overlay layer. This value could be determined by laboratory testing of the new overlay mix. The user should consult appropriate testing procedures for the dynamic modulus test for AC mixes, such as the ASTM D3497. Other procedures such as Superpave testing procedures may also be consulted. TEMP. (F or C): The reference temperature at which the overlay elastic modulus value was determined. WINFLEX 2000 User Guide Page 11 Pois. Ratio: Poissons ratio of the overlay layer. For AC layer, a range of 0.2 to .35 can be assumed. The Poissons ratio was found to have insignificant effect on the calculated overlay thickness. Minimum Thickness (in or mm): This is the initial value that the program will consider for designing the overlay. It is controlled to be greater than zero to prevent overflow. If the design case does not require an overlay, the program will display the minimum thickness entered by the user. Therefore, try to use as small a value as possible. A suggested initial value of 0.5 inches or 10 mm is reasonable. Thickness Increment (in or mm): The overlay thickness increment. This is the amount by which the program increases the overlay thickness in the design iteration. A reasonable value would be 0.5 inches or 10 mm. Failure Mode Block This block allows the user to specify whether the fatigue failure mode is to be considered in the new overlay only, the old asphalt layer only, or in both. Check the appropriate box for the selection. After completing the data entry in Data Form 1, click the Next command button in the right bottom corner to move to the second data entry form (Material Types). 2. Data Entry Form 2/5 (Material Types) The second data input form is used to enter information about material types, as shown in Figure 6. This screen is divided into three blocks: Base, Subbase, and Subgrade. The screen layout depends on the option selected in the Pavement Data form. The three blocks will appear only if the BS AND SBS option is selected in the Pavement screen. When BS ONLY option is selected, the Subbase block will disappear. When FULL AC option is selected, the Base and the Subbase blocks will disappear. The Subgrade block will always be displayed. WINFLEX 2000 User Guide Page 12 Figure 6. Material Types Screen A description of each of the three blocks in the form appears below. Base Block The user can select only one type of material for the base layer from the following options: Granular: This option indicates that the base layer is granular material and is stress dependent. When this option is selected, two cells to enter the stress dependency parameters K1 and K2 will appear. Enter the appropriate values for the selected material. The K1 and K2 values must be those for the normal season. The program will adjust the determined normal modulus for other seasons using the Seasonal Adjusting Factors. Refer to 4. Data Entry Form 4/5 (General Data). Gran. (Linear): This means that the layer is granular but considered as stress independent. When this option is selected, the cells for the parameters K1 and K2 will disappear. Modulus of the granular linear base will also be adjusted for each season by the Seasonal Adjusting Factors. Cement T.B.: This is option is for Cement Treated Base type. Selecting this option prompts the program to treat the base as a stress insensitive (linear) layer and will not adjust the modulus of the CTB layer for environmental changes. Bitumen T.B.: This option is for Bituminous Treated Base type. When this option is selected the program will adjust the layer modulus to the seasonal temperatures as entered in the General screen (see Data Form 4/5) and will check on the fatigue in the BTB base layer too. WINFLEX 2000 User Guide Page 13 The user needs to be sure that the E value entered for the BS layer in the Pavement screen was at the test temperature entered in the PAVE TEMP cell in the Pavement Data screen (Data Form 1/5). Subbase Block Granular: Similar to the base layer granular option. When this option is selected, the cells for the parameters K1 and K2 will appear. Enter the appropriate values for the subbase layer. Gran. (Linear): Similar to the base layer granular linear option. No stress sensitivity parameters are needed, and the modulus will be adjusted seasonally. Subgrade Block Fine: This option indicates that the subgrade is fine-grained material and it is stress- dependent. When this option is selected the parameters K1-F and K2-F will appear. These are stress dependency factors for the fine material. Granular: This option indicates that the subgrade is coarse-grained material and it is stress- dependent. When this option is selected the parameters K1-G and K2-G will appear. These are stress dependency factors for the coarse grained material. Linear: Means that the subgrade is considered stress independent. As for the base and subbase layers, the modulus value of the subgrade will be adjusted seasonally using the seasonal adjusting factors of the subgrade layer (see . Figure 8.) After completing the inputs in Data Form 2, click Next to move to Data Form 3 (Models). 3. Data Entry Form 3/5 (Models) In the next data entry form, you select the models to be used for the adopted failure criteria, as shown in Figure 7. The choice could be based on either fatigue or rutting or both. The equations of the models are displayed onscreen. For convenience, the selected model parameters (f1, f2, f3 for fatigue model and f4, f5 for rutting model) are displayed, but they cannot be changed. If you decide to use different models, click on Other and enter the appropriate model parameters. The new parameters will be saved in the current input file, but will not be saved in the program database. Consequently, if you want to use the same parameters in another design case, they will have to be re-entered in that cases input file. WINFLEX 2000 User Guide Page 14 Figure 7. Models Screen After completing the inputs in Data Form 3, click Next to move to Data Form 4 (General Data). 4. Data Entry Form 4/5 (General Data) In this form, information on design traffic, model shift factors, and environmental adjusting factors are entered, as shown in Figure 8. Figure 8. General Data Screen WINFLEX 2000 User Guide Page 15 The form consists of three blocks: Commercial Traffic, Fatigue Shift Factors, and Seasonal Variation. A description of each block appears below. Commercial Traffic Block Information on the tire load, dual tires spacing and tire pressure for the design axle are entered here. The program will display the default values, which are for the 18-kip (80-kN) standard Equivalent Single Axle Load (ESAL). They are 4500 lb (20 kN), 13.5 in. (343 mm), and 80 psi (560 kPa) respectively. You may change these values to the selected single axle load. The assumption is that the tire system is a dual system. Super single is not considered in this version of the program. It is also important to note that since AASHTO standard ESALs are used, the axle configuration needs to be that of the default values given. Estimated Future ESALs: This cell is for the estimated future traffic repetitions in units of the standard 18-kip (80-kN) Equivalent Single-Axle Load (ESAL) for the design period. Fatigue Shift Factor Block The Fatigue Shift Factor (FSF) is a factor that will be multiplied by the parameter f1 in the fatigue model (see Models screen, Figure 7) to account for variation of the model from the lab-based equation to actual field conditions. For example, the original FSF used in the Asphalt Institute model is 18.4. It was found that this is a relatively high factor. You must find out the appropriate shift factors for the selected model based on your agencys experience, and enter them for both new and old AC layer. For instance, the ITD uses FSF values between 10 and 12 for new AC layer, and 4 for old AC layers with AI model. Seasonal Variation Block The effect of seasonal variation on the estimated overlay thickness is considered by employing Seasonal Adjustment Factors (SAF) for pavement layers moduli. In this block, you enter SAF, which are used to adjust the normal moduli values to each season. The SAF is a multiplier that changes the normal E value for a layer to the respective season. The normal values are assumed to be those, which were entered in the Pavement Data screen. The SAF values are only required for the unbound layers. For asphalt layers, the moduli are adjusted using the temperature-adjusting function (refer to Data Form 5). The user can select various SAF values based on the climatic zone. The program includes a database of various climatic zones in the state of Idaho. For other locations, a new set of seasonal factors can be entered and the user will be prompted to save them in a new zone, which can then be added to the environmental database. Idaho Climatic Zones: A map is provided to show the six climatic zones in Idaho. Click on the Show Map button to view the limits of different zones. By clicking on a zone, the SAF values will be loaded to the cells. All factors will be shown dimmed, indicating that the user cannot change them. However, the traffic factors can be changed because they are based on the expected operation rather than the soil and climate conditions. See Traffic below for details on entering the Traffic SAF values. WINFLEX 2000 User Guide Page 16 If a different climatic zone is to be entered, or if you need to change any of the default values provided, click on Other. This will allow you to modify the displayed factors. You can also clear all cells to enter new numbers of your choice. A new button, Save Zone As... will appear. Click on this button to save the new set of factors in a file with extension .ZON, which can be loaded later in future design cases. If you choose to load another zone that was previously created, click on the Load Another Zone button, which opens a loading file dialogue box. Select the zone file and press Open to load it in the SAF cells. Subgrade: Values shown or entered here are the SAFs for the subgrade layer. Note that if you load zone 3 or 6, a subset indicating the subgrade classification will appear. Choose the appropriate soil classification. Based on the soil classification, a corresponding SAF value for the winter and spring seasons will be loaded from the seasonal database. Base/Subbase: Values shown or entered here are the SAFs for the base and the subbase layers. If the pavement section is full depth (no unbound base/subbase layer), the cells will show N/A, indicating not applicable. Traffic: The traffic SAF indicates the traffic variation from one season to another, if any. The program will show the number 1 in all cells by default. Change the number to reflect the relative change in traffic among seasons. For instance, if the traffic in summer is expected to be double that of winter, then you may enter 1 for the winter, and 2 for the summer. Follow the same procedure for other seasons. The traffic SAF numbers could be numbers or fractions. What matters is the relativity among them. Temperature: Numbers loaded or entered here are not factors, but they represent the seasonal mean air temperature. You can change the values if you select the Other option in the climatic zone. In this case, enter the temperature in o F or o C, depending on the system. Period (Months): Numbers loaded or entered here are not factors, but represent the average length of the season in months. You can change the values if you select the Other option in the climatic zone. In this case, enter the period of each season. Entered numbers must add up to 12. Subgrade Classification: This subset block will appear if zones 3 or 6 are selected. It indicates the subgrade classification according to the Unified Soil Classification system. The SAF values for Winter and Spring seasons are further broken down into various types of subgrade soil, which can be selected here. After completing the inputs in Data Form 4, click Next to move to Data Form 5 (Modulus- Temperature Adjustment). WINFLEX 2000 User Guide Page 17 5. Data Entry Form 5/5 (Modulus-Temperature Adjustment) This is the fifth and final data entry form, which is shown in Figure 9. In this screen, you can select the modulus-temperature (E-Temp) adjustment relationship. A default relationship is embedded in the program based on data from SHRP LTPP. The default equation is for conventional unmodified asphalts. Select either Use the Default Equation or User Input Relationship. This button will allow you to either create a new equation from testing data or to use one that has been previously created. Figure 9. Modulus-Temperature Adjustment Screen To create a new equation, click on New Relationship. This opens the E-Temp screen for entering data on the E values at various tested temperatures. A minimum of three points is required and a maximum of eighteen data points is allowed. Click on Calculate to execute the calculation algorithm. Follow the screen commands to save the newly created relationship in a file with the extension .ETR. When you are finished, click the Finish button to exit the E-Temp screen. Note that you can also access the E-Temp screen from the Options menu in the Main menu commands for further modifications. When you have completed data entry in Form 5, click Finish. You may now prepare to run this design case. Preparing to Run the Design Case After you click the Finish button, three additional command buttons will appear in the top toolbar, as shown in Figure 10, that allow you to prepare for running the design case. The WINFLEX 2000 User Guide Page 18 new buttons are Save, Modify Models, and Run Single or Multiple, depending on the type of design case that is in progress. Save the Data I nput File To save the data input file with the extension .INP, click on the Save command button on the toolbar or select Save from the main menu under File. Note that you cannot save or create the input file while you are in the process of entering the data. You must complete data entry on all five screens before you can save an input file. Modify Models To modify your models data (Data Form 3,) click on the Modify Models command button in the toolbar. To modify any of the other forms, refer to section 2.5, entitled Modifying Input File Data. Run Single/Multiple If you are ready to run (execute) the design case, click on Run Single/Multiple in the toolbar. For more details, refer to section 2.10, entitled Running the Calculations on an Input File. Figure 10. Main menu screen after data entry is completed WINFLEX 2000 User Guide Page 19 2.4 Loading an Existing Input File The .INP file contains all the data in the data entry forms. To load data from an existing .INP file, click on the Load button in the toolbar or select the Load an Existing File command from the File sub-menu. This will generate an Open File window that allows you to load the pre-saved input file (any file with extension .INP). Once the data is loaded, you can view and modify it as described above, or you can run (execute) the design case directly. 2.5 Modifying Input Fil e Data After you have created a new data input file or loaded an existing .INP file, you can modify the data by clicking on Modify Data in the main menu commands and selecting the desired form. With this command, you can view and edit the data entered in the Pavement data, Material Types, Models, or General forms. For details on working with each form, refer to section 2.3, Creating a New Input File - Entering The Data. Note that, for multiple location design cases, you can only change the Overlay data and the Failure Mode options in the Pavement Data screen. You will have no control over the number of layers, pavement temperature, moduli values and thickness of layers. These data inputs will be loaded from the ETF file when you launch the command Run Multiple. A fourth option in this command, accessing the ETF File, appears only in the multiple locations design case, and is shown in Figure 11 below. Figure 11. Modify Option in Main Menu Screen (Multiple Location) WINFLEX 2000 User Guide Page 20 As an alternate to using the Modify Data command, you can directly access the Model form (Data Form 3) by clicking the Modify Models command button on the toolbar. 2.6 Creating an ETF Fi le An ETF file is required for all multiple-location design cases. It is a text file in which data of pavement layer moduli and thickness values are entered for all mileposts. The temperature for each set of moduli values is also entered in this file. There are two ways to create a new ETF file by using the ETF File Generator Program or creating the ETF file manually. ETF File Generator Program The first method is to create the file automatically, using a computer program called ETF File Generator. This program was prepared by ITD to create the ETF file directly from the Modulus backcalculation program output. The program converts the .DAT file from the Modulus program into an ETF-type file. The ITD ETF File Generator is located on the WINFLEX 2000 CD. To use this option, you will need to have the .DAT file from the Modulus program. Create ETF File Manually The second method is to create the ETF file manually, using a command within WINFLEX itself or by using any word processor or Excel. Within WINFLEX: To create a new ETF file manually within WINFLEX, first click Modify Data in the main menu, then ETF File as shown in Figure 11. The program will lunch the ETF file Editor Screen, shown in Figure 12. In this screen, under the File command, click Create a New ETF File. The next screen, shown in Figure 13, prompts you to enter the header of the file and the number of layers you want to create the ETF file for. Select a number and click OK. The program will open an Excel data sheet, as shown in Figure 14, where you can enter the E, Temp and Thickness data for each milepost. After entering the data in the sheet, you will need to transfer the data to the ETF File Editor screen using Copy and Paste. Then, save the ETF file by clicking on the Save command in the main menu of the ETF File Editor Screen. Outside WINFLEX: To create the ETF file manually, outside WINFLEX, you can use Notepad, Excel, or any word processor such as MS word. When creating the ETF file outside WINFLEX, you must follow the format below. The first row in the .ETF file includes two columns. In the first column, enter the number of layers for the design case. The number should be the number of layers of the existing WINFLEX 2000 User Guide Page 21 pavement including the subgrade layer. Do not count the overlay layer here. In the second column, enter a header. It should be text that describes the design case. Figure 12. ETF File Editor Screen (Multiple Location) Figure 13. Create a New ETF File (Multiple Location) WINFLEX 2000 User Guide Page 22 Figure 14. Excel Data Sheet for ETF File The next set of rows is for data at each milepost. Each row represents one milepost. Data columns are as follows: Column 1: pavement testing temperature Column 2: milepost Columns 3-6: moduli values for the existing pavement layers, in the case of 4 layers. Use columns 3 to 5 in the case of 3 layers. Columns 3 and 4 only are used in case of full depth AC. Columns 7-9: layer thicknesses for n-1 layers. The subgrade is considered infinite. In the case of 3 layers, use column 6 to 8 and use column 5 only for full depth AC, to represent the thickness of AC. Note that if the existing pavement is full depth (i.e., only one layer over the subgrade), the user needs to enter only two E values (surface and subgrade) in columns 3 and 4, and one thickness value in column 5 (asphalt layer). If two layers exist on top of the subgrade, three E values (surface, base, and subgrade) and two thickness values will be needed, and so on. When you are finished, you must save the file with an .ETF extension. When saving the file, select the file type as text only and put the file name with the extension .etf between double quotes, for example, name.etf. Note that the ETF file MUST be created in the English system, even if you are designing with the Metric system. WINFLEX 2000 User Guide Page 23 2.7 Saving an ETF File If you have created the ETF file automatically, using the ETF File Generator, save the file by using the Save command in the programs main menu, as with any program. If you have created the ETF file manually, using WINFLEX, save the file as an ETF type by clicking on the Save command in the main menu of the ETF File Editor Screen. If you have created the ETF file manually outside WINFLEX, you must save the file with an .ETF extension. When saving the file, select the file type as text only and put the file name with the extension .etf between double quotes, for example, name.etf. 2.8 Loading an Existing ETF File If you are going to start a new design case for multiple locations, you must load an ETF file for the new design case prior to opening the first data entry screen. An ETF file can be loaded by clicking on the Load File command button that appears when you select the multiple-locations case in Figure 3. After you have loaded the ETF file, the name of the file and its location will appear on the bottom of the screen. If you are going to load an existing input file for a multiple-locations design case, the program will ask you to load an ETF file before running the case. Remember, there must be compatibility between the ETF file and the loaded input file regarding the number of layers. If your loaded input file includes three layers, then you must run the input file with an ETF file that contains data for three layers. 2.9 Modifying an ETF File You can modify any ETF file by selecting Modify Data in the main menu, then ETF File, as shown in Figure 11. From the ETF File Editor screen, you can open any ETF file by clicking on Open ETF File, as shown in Figure 12. Make any modifications in the opened file and save it as a new file. 2.10 Running the Calculations on an Input File Single Location Design Case If the loaded file was for a single location design case, the Run Single button will appear in the toolbar. You can begin to run this file in one of two ways: by clicking the Run Single command button in the toolbar or by selecting Results from the main menu, and then the Run Single option. WINFLEX 2000 User Guide Page 24 The program will begin running and a message will appear to inform you when the calculations are successfully completed. Upon completion of calculations, two command buttons, Show Results and Print Results, appear on the toolbar, and the Results screen appears, as shown in Figure 15. Figure 15. Single Location Results Screen You can save a detailed report of the results in a text file with extension .TXT, by clicking the Save Report in Text File command button. You can print a comprehensive report of the design results by clicking on the Print a Report command button. Strain values that were determined during the calculation process can be displayed onscreen and printed by clicking on the Show Strains button. The Strains screen is shown in Figure 16. WINFLEX 2000 User Guide Page 25 Figure 16. Strains Screen in Single Location The seasonal adjusted moduli values for each layer can be shown for all layers in each season by clicking on the hover button (Click here to...) in the Results screen, Figure 15. This will launch another screen showing adjusted E-values, as shown in Figure 17. Note that the adjusted E-values for AC layers are computed based on the mid-depth temperature. The first row in this table is for air temperature, and the mid-depth temperature might be higher than this value, depending on the thickness. WINFLEX 2000 User Guide Page 26 Figure 17. Adjusted E-Values Screen in Single Location Multiple Locations Design Case If the loaded file was for a multiple locations design case, the Run Multiple button will appear in the toolbar. You can begin to run this file in one of two ways: by clicking on the Run Multiple command button, or by selecting Results from the main menu, and then the Run Multiple option, as shown in Figure 18. If the ETF file has been loaded, the program will begin running. If the ETF file has not yet loaded, you will be prompted to load it. Figure 18. Run Commands for Multiple Locations After the program has finished the calculations, a message will appear, asking if you want to save a comprehensive report in a text file. Two command buttons will appear on the toolbar - Show Results and Print Results. When you click Show Results, the Results screen will appear, as shown in Figure 19. WINFLEX 2000 User Guide Page 27 Figure 19. Results Screen for Multiple Locations The Results screen has three buttons, that allow you to print a comprehensive report of the results, to show the strains, and to export results to an Excel worksheet. The Strains screen displays the strain values at the bottom of the asphalt layers and at the top of the subgrade, as well as the fatigue and rutting lives, as shown in Figure 20. WINFLEX 2000 User Guide Page 28 Figure 20. Strains Screen for Multiple Locations 2.11 Saving a Report on the Calculations After running the calculations on an input file, you can save this report as a text file. For Single location cases, click on Save a Report in the results screen. For multiple location cases, the program will prompt you to save the results in a text file. 2.12 Printing a Report on the Calculations You can print a comprehensive report in one of two ways: by clicking on File in the main menu, then Print a Report, or you can print directly from the Results screen. WINFLEX 2000 User Guide Page 29 CHAPTER 3 - TUTORIAL EXAMPLES 3.1 Introduction Several data input files have been included on the WINFLEX 2000 CD that you can use as examples for running the program. The examples include both Metric and English data input files. They also cover both single and multiple-location design cases. The data input files for these examples are denoted by .INP extensions. These files have been run in WINFLEX 2000 and the output files are also included, for your information. The sample data input files that are included on the CD are: 1. Example files 1 to 6 are for single location design cases and the English system. 2. Example files 7 to 10 are for multiple-location design cases and the English system. 3. Example Ex_Metric_S is for the Metric system and single location and Ex_Metric_M is for the Metric system and multiple-location design cases. For single location design cases, an example consists of two files - one for the input data with the extension *.INP and another for output data (comprehensive report) with the extension *.TXT. For multiple location design cases, three files are included - two for input data with the extensions *.INP and *.ETF, and a third for output data with the extension *.TXT. The following pages describe in detail the procedures for determining overlay thickness with two of the examples provided on the CD. Example1_S is for a single location design case, and Example 7_M is for a multiple-location design case. Both examples are for the English system only. 3.2 Example of Single Location Design Case The file Example1_S.inp is provided as one example for a single location design case. To use WINFLEX 2000 for calculating the overlay thickness, you will need to perform four steps: Prepare your data. Enter your data in the program to create your input file with the extension *.INP. Run the calculations on the input file to obtain the overlay thickness. Print your results. Preparing the Data Refer to Table 2 below for a summary of all the data required for the Data Input File. The following paragraphs describe how the input values for this case were determined. WINFLEX 2000 User Guide Page 30 Pavement Data These data relate to the existing pavement section and overlay properties. In this example, the existing pavement section consists of AC layer, Base, Subbase, and Subgrade. The moduli values of the existing pavement can be obtained from lab tests on core samples, or obtained from backcalculation of Falling Weight Deflectometer (FWD) deflection testing. The thickness of the existing layers can be obtained from construction documents, core analysis or by NDT methods such as the Ground Penetration Radar (GPR). The elastic modulus of the overlay layer could be obtained by laboratory testing of the new overlay mix. Poissons ratio of each layer can be assumed with a reasonable value. Refer to Pavement Section Block for details. You have to choose an initial value (minimum thickness) for the overlay layer that the program will consider for designing the overlay. In this example, a suggested initial value of 0.5 inches is reasonable. You also have to select a reasonable value for the overlay thickness increment. This is the amount by which the program increases the overlay thickness in the design iteration. In this example, a suggested value of 0.1 inches is reasonable. In this example, consider the fatigue failure mode is to be in the new overlay or old asphalt. Material Types Data These data depend on the existing pavement section that has been selected in the previous step. In this example you have three layers, for BASE, SUBBASE, and SUBGRADE, and you have to choose the material types for each layer. In this example, each layer is considered as stress independent. Models Data This data helps you select the failure criteria and the models used for estimating the pavement damage. Your design could be based on either fatigue or rutting or both. In this example, consider that the failure is controlled by both fatigue and rutting. The Asphalt Institute model is selected for both fatigue and rutting. General Data In this stage, information on design traffic, fatigue shift factors, and seasonal adjusting factors are obtained. Refer to the section of Chapter Two entitled Data Entry Form 4/5 (General Data). Consider that this pavement section is taken from a pavement in Idaho climatic zone number 1. The calculation is based on the 18-kip standard Equivalent Single Axle Load (ESAL). The wheel load, dual spacing, and tire pressure are 4500 lb, 13.5 in. and 80 psi respectively. The estimated future traffic is considered to be 5 million ESALs. Modulus-Temperature Adjustment Data Use the default SHRP equation in this example. All the above data for Example1_S are summarized in Table 2. WINFLEX 2000 User Guide Page 31 Table 2. Data for Example1_S PAVEMENT DATA DESCRIPTION Modulus, ksi Poissons ration Thickness, in Temperature, F Overlay Layer 350 0.35 Required** 77* Existing AC 235 0.35 3.5 91* Base Layer 25 0.40 8 Normal Season Subbase Layer 10 0.40 16 Normal Season Subgrade Layer 4 0.45 ----- Normal Season *Pavement Temperature at which moduli (E) values of the AC layers were determined **Minimum Thickness for overlay is assumed to be 0.5 in. and thickness increment is 0.1 in. Failure mode is considered to be in the new overlay or old Asphalt MATERIAL TYPES DATA Base Layer Granular and stress independent (linear) Subbase Layer Granular and stress independent (linear) Subgrade Layer Stress independent MODELS DATA Fatigue Model Asphalt Institute model Rutting Model Asphalt Institute Model GENERAL DATA Dual Tire Load, lb 4500 Dual Tire Spacing, in. 13.5 Tire Pressure, psi 80 Future 80-kN (18-kip) ESALs (20 years) 5000000 Fatigue Shift Factors (FSF) 18.4 for new AC and 4 for old AC Climate Zone Idaho Climatic Zone No. 1 MODULUS-TEMPERATURE ADJUSTMENT DATA Use the default SHRP equation Entering the Data You are now ready to enter all of the data into WINFLEX 2000. The text below describes the basic steps for entering data into WINFLEX. For more detailed instructions, refer to Chapter Two. Open the program. Specify that you will run WINFLEX 2000 with the English system. Create a new input file by clicking on New File on the toolbar. Select the single location design case option. The first data entry screen is Pavement Data. Enter all the pavement data, as shown in Figure 21. When you finished, click the Next command button. The second data entry screen is Material Types. Enter all the material types data in this screen as shown in Figure 22. Once again, click the Next command button. The third data entry screen is Model Data, A as shown in Figure 23. When you have finished entering data in this screen, click the Next command button. The fourth screen is General Data, as shown in Figure 24. WINFLEX 2000 User Guide Page 32 The fifth screen is for Modulus-Temperature Adjustment data, which uses the default SHRP equation, as shown in Figure 25. Figure 21. Pavement Data for Example1_S Figure 22. Material Types for Example1_S WINFLEX 2000 User Guide Page 33 Figure 23. Models for Example1_S Figure 24. General Data for Example1_S WINFLEX 2000 User Guide Page 34 Figure 25. Modulus-Temperature for Example1_S Saving the Data You have now entered all the data in WINFLEX 2000 for this example. You can save these data in an input file with extension *.INP or run these data directly. To save the data in an input file, click the Save command button in the toolbar. Running the Calculations on the Input File The following text provides an overview of running calculations in WINFLEX. For more detailed instructions, refer to Chapter Two. By pressing the Run Single command button in the toolbar, you can run the calculations on this example to obtain the overlay thickness that the program recommends for this case. After running this example, the Result screen will appear, showing the overlay thickness for this example, which is 5.70 inches, as shown in Figure 26. On the Result screen you can select to save a detailed report in a text file with the extension *.TXT by clicking on Save Report in Text File. You can also print a comprehensive report for this case by clicking on Print a Report. A comprehensive report is shown in two parts, in Figure 27 and Figure 28. WINFLEX 2000 User Guide Page 35 Strain values that were determined during the calculation process can be displayed and printed by clicking on the Show Strains button in Figure 26. A Strains report is shown in Figure 29. The seasonal adjusted moduli values for each layer can be displayed for all layers in each season by clicking on the hover button in the result screen as shown in Figure 30. Figure 26. Results Screen for Example1_S WINFLEX 2000 User Guide Page 36 Figure 27. Comprehensive Report for Example1_S WINFLEX 2000 User Guide Page 37 Figure 28. Comprehensive Report for Example1_S (Contd) WINFLEX 2000 User Guide Page 38 Figure 29. Strain Values for Example1_S Figure 30. Seasonal Adjusted Moduli Values for Example1_S WINFLEX 2000 User Guide Page 39 3.3 Example of Multipl e Location Design Case The file Example7_M.inp is provided as one example for a multiple locations design case. To use WINFLEX 2000 for calculating the overlay thickness, you will need to perform four steps: Prepare your ETF file. Prepare your data. Run WINFLEX and load your ETF file. Enter your data in the program to create your input file with the extension *.INP. Run the calculations on the input file in conjunction with the ETF file to obtain your overlay thickness at every milepost. Print your results. Preparing the Data ETF File This example requires an ETF file, which is a text file in which the user enters data for existing pavement layer moduli, test temperature, and thickness values, for all mileposts. There are seven mileposts in this example. The existing pavement includes AC layer, Base, Subbase, and Subgrade. The moduli values of existing pavement can be obtained from backcalculation of FWD deflection testing. The thickness of the existing layers can be obtained from construction documents, core analysis or by NDT method such as GPR. To create the ETF file for this example, refer to the section entitled Creating an ETF file, and then save it with extension *.ETF. Figure 31 shows the ETF file for this example. Figure 31. ETF File for Example7_M WINFLEX 2000 User Guide Page 40 Pavement Data These data are related to the existing pavement section and overlay properties. In this example, the existing pavement section consists of AC layer, Base, Subbase, and Subgrade. The moduli values of the existing pavement can be obtained from lab tests on core samples, or obtained from backcalculation of Falling Weight Deflectometer (FWD) deflection testing. The thickness of the existing layers can be obtained from construction documents, core analysis or by NDT methods such as the Ground Penetration Radar (GPR). The elastic modulus of the overlay layer could be obtained by laboratory testing of the new overlay mix. Poissons ratio of each layer can be assumed with a reasonable value, refer to Pavement Section Block for details. You have to choose an initial value (minimum thickness) for the overlay layer that the program will consider for designing the overlay. In this example, a suggested initial value of 0.5 inches is reasonable. You also have to select a reasonable value for the overlay thickness increment. This is the amount by which the program increases the overlay thickness in the design iteration. In this example, a suggested value of 0.1 inches is reasonable. In this example, consider the fatigue failure mode is to be in the new overlay or old asphalt. In this example, you cannot enter the moduli, testing temperature, and thicknesses for the existing layers. These values will be read at every milepost from the ETF file that you have created prior to this step. Material Types Data These data depend on the existing pavement section that has been selected in the previous step. Note that the existing pavement section will be selected automatically after loading the ETF file, according to the number of layers, and you have no ability to change this option in the first data entry screen. In this example you have three layers, for BASE, SUBBASE, and SUBGRADE, and you have to choose the material types for each layer. In this example, each layer is considered as stress independent. Models Data This data helps you to select the failure criteria and to select the models used for estimating the pavement damage. The choice could be based on either fatigue or rutting or both. In this example, you can consider that the failure is controlled by both fatigue and rutting. The Asphalt Institute model is selected for both fatigue and rutting in this example. General Data In this stage, information on design traffic, fatigue shift factors, and seasonal adjusting factors are obtained. Consider that this pavement section is taken from a pavement in Idaho climatic zone number 1. The calculation is based on the 18-kip standard Equivalent Single Axle Load (ESAL). The wheel load, dual spacing, and tire pressure are 4500 lb, 13.5 in. and 80 psi respectively. The estimated future traffic is considered to be 5 million ESALs. WINFLEX 2000 User Guide Page 41 Modulus-Temperature Adjustment Data Use the default SHRP equation in this example. All the above data for Example7_M are summarized in Table 3. Table 3. The Data for Example7_M PAVEMENT DATA DESCRIPTION Modulus, ksi Poissons ration Thickness, in Temperature, F Overlay Layer 350 0.35 Required** 77* Existing AC From ETF File 0.35 From ETF File From ETF File Base Layer From ETF File 0.40 From ETF File Normal Season Subbase Layer From ETF File 0.40 From ETF File Normal Season Subgrade Layer From ETF File 0.45 ----- Normal Season *Pavement Temperature at which moduli (E) values of the AC layers were determined **Minimum Thickness for overlay is assumed to be 0.5 in. and thickness increment is 0.1 in. Failure mode is considered to be in the new overlay only. MATERIAL TYPES DATA Base Layer Granular and stress independent (linear) Subbase Layer Granular and stress independent (linear) Subgrade Layer Stress independent MODELS DATA Fatigue Model Asphalt Institute model Rutting Model Asphalt Institute Model GENERAL DATA Dual Tire Load, lb 4500 Dual Tire Spacing, in. 13.5 Tire Pressure, psi 80 Future 80-kN (18-kip) ESALs (20 years) 5000000 Fatigue Shift Factors (FSF) 18.4 for new AC and 4 for old AC Climate Zone Idaho Climatic Zone No. 1 MODULUS-TEMPERATURE ADJUSTMENT DATA Use the default SHRP equation Entering the Data You are now ready to enter all the data into WINFLEX 2000. You have to run WINFLEX 2000 with the English system. Create a new input file by clicking on New File on the toolbar and select a multiple locations design case. Then, load the ETF file that you created earlier, by clicking on the Load File command button. The first data entry screen is Pavement Data. You will not be able to input the moduli and the thicknesses of different layers in the data entry screens. The program will show N/A in the WINFLEX 2000 User Guide Page 42 respective cells. The moduli, thicknesses, test temperature, and number of layers will be read from the ETF file, Example7_M.ETF. Enter the necessary information in all of the data entry screens, as shown in Figure 32, Figure 33, Figure 34, Figure 35, and Figure 36. Figure 32. Pavement Screen for Example7_M Figure 33. Material Types Screen for Example7_M WINFLEX 2000 User Guide Page 43 Figure 34. Models Screen for Example7_M Figure 35. General Screen for Example7_M WINFLEX 2000 User Guide Page 44 Figure 36. Modulus-Temperature Adjustment Screen fro Example7_M Saving the Data You have now entered all the data in WINFLEX 2000 for this example. Save these data in an input file with extension *.INP. Running the Calculations on the Input File Click on the Run Multiple command button in the toolbar of the main screen to run the calculations on this example. After running this example, the result screen will appear, showing the overlay thickness for every milepost, as shown in Figure 37. In this screen you can print a comprehensive report for this case by clicking on the Print a Report command button. A comprehensive report is shown in four parts in Figure 38, Figure 39, Figure 40, and Figure 41. Strain values that were determined during the calculation process can also be shown and printed by clicking on Show Strains button as shown in Figure 42. You can transfer all the results to an Excel data sheet by clicking on the Export Results to Excel command button. WINFLEX 2000 User Guide Page 45 Figure 37. Results Screen for Example7_M WINFLEX 2000 User Guide Page 46 Figure 38. Comprehensive Report for Example7_M WINFLEX 2000 User Guide Page 47 Figure 39. Comprehensive Report for Example7_M (Contd) WINFLEX 2000 User Guide Page 48 Figure 40. Comprehensive Report for Example7_M (Contd) WINFLEX 2000 User Guide Page 49 Figure 41. Comprehensive Report for Example7_M (Contd) WINFLEX 2000 User Guide Page 50 Figure 42. Results Screen for Example7_M WINFLEX 2000 User Guide Page 51 CONCLUSION & TECHNICAL SUPPORT This completes the User Guide for the WINFLEX 2000 program. If, after reviewing the manual and completing the tutorial examples, you have further questions about using WINFLEX 2000, contact ITD headquarters in Boise, Idaho: Bob Smith (208) 334-8437 or Mike Santi (208) 334-8450