CIRCLY 5.

0
New Features Guide 5.0.013

Printed on 13 January, 2004

Contents
What's New in Version 5.0 3

Overview ........................................................................................................................................3 Support of Austroads 2004 Pavement Design Guide ....................................................................3 New "built-in" Graphics Engine ......................................................................................................4 Cost Calculation .............................................................................................................................6 Automatic Parametric Analysis ......................................................................................................7

How to Use Advanced Features

Cost Calculation .............................................................................................................................9 Calculation of Total Cost......................................................................................................9 Material Costs ....................................................................................................................10 Automatic Parametric Analysis ....................................................................................................11 ExampleCost Optimization .......................................................................................................13

Overview of Austroads 2004 Features

19

Model of Standard Axle................................................................................................................20 Project Reliability..........................................................................................................................21 Material Properties .......................................................................................................................22 Sub-layering .......................................................................................................................22 Performance Models..........................................................................................................23

How to Use New Austroads 2004 Features

25

Modelling the Standard Axle ........................................................................................................25 How to Use Project Reliability ......................................................................................................26 Changes to Materials ...................................................................................................................27 Austroads 2004 Examples ...........................................................................................................28

References

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CHAPTER 1

What's New in Version 5.0

Overview
You will find many improvements in CIRCLY 5.0 if you have used earlier versions such as CIRCLY 4.0 or 4.1. Latest improvements include new features to make designing pavements easier, more transparent and more efficient. This section gives a quick overview of the new and improved features in CIRCLY 5.0. Crossreferences to the rest of the manual show you where to look for information on these topics.

Support of Austroads 2004 Pavement Design Guide

The Austroads Pavement Design Guide (the full title is Pavement Design - A Guide to the Structural Design of Road Pavements) was first published in 1992 (Austroads 1992). The Guide has undergone a major re-write over the last few years. The 2001 Draft (Austroads 2001) was the most recent published version at the time of writing this manual. The technical content of the new Guide was finalized in June 2003 and that the Guide is expected to be published in the first quarter of 2004. In what follows, the new Guide will be referred to as the 2004 Guide. Briefly, CIRCLY 5.0 implements the following changed features in the Guide: Standard Axle modelled in full (Austroads 1992 uses only one side or half the axle) Project Reliability as chosen by the designer; Changed methodology for sub-layering of unbound granular material; Introduction of Select Fill as a particular type of unbound granular material; Changed Subgrade Performance model for subgrade materials. These changes are outlined in more detail in Overview of Austroads 2004 Features (on page 19). Detailed instructions on how to use the new features are given in How to Use New Austroads 2004 Features (on page 25).

CIRCLY 5.0 User's Guide

New "built-in" Graphics Engine

CIRCLY now uses its own "built-in" Graphics Engine to create on-screen graphics almost instantaneously. The graphics can be customized, exported and printed. In most cases, results for different layers or Z-depths in a layered system can be created without reanalysing the system. Here is a sample Cumulative Damage graph:

You can choose a graph for a different layer (without re-analysing the system):

Chapter 1 What's New in Version 5.0

Here is a sample "Three-dimensional" graph of vertical displacement:

Click on Customization Dialog to customize the graph:

CIRCLY 5.0 User's Guide

This lets you customize many of the graph parameters such as Minimum and Maximum axis values, etc.

Cost Calculation
The unit costs for the materials laid and constructed in the layers can be specified using a combination of both a volumetric (or weight) component and an areal component. The areal component lets you take account of costs that are primarily a function of area, such as surface treatments, subgrade stabilization and the like. The areal component can also be used in circumstances where the relationship between total layer cost and thickness has a non-zero component for zero thickness.

Chapter 1 What's New in Version 5.0

Automatic Parametric Analysis

Automatic Parametric Analysis lets you automatically loop through a range of thicknesses for one or two nominated layers. For example, you can have Layer 2 vary from 100 mm to 200 mm in steps of 10 mm. Additionally, for each combination of those layer thicknesses, you can automatically design the thickness of another layer. By combining Automatic Parametric Analysis with the Cost Analysis feature you can finetune layer thicknesses to optimise construction cost.

Minimum Total Cost

Automatically generated plot: Total Cost vs. Layer 2 Thickness

CHAPTER 2

How to Use Advanced Features

Cost Calculation
Calculation of Total Cost
CIRCLY 5.0 can automatically calculate Total Cost for a pavement from the unit costs of materials in each layer. Click on the button. This will bring up the following screen:

Total Cost

1 Click on the Calculate Cost checkbox

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CIRCLY 5.0 User's Guide

Material Costs
The unit costs for the layers can be specified using a combination of both a volumetric (or weight) component and an areal component. The areal component lets you take account of costs that are primarily a function of area such as surface treatments, subgrade stabilization, etc. The areal component can also be used in circumstances where the relationship between total layer cost and thickness has a non-zero component for zero thickness.

Unit Material Costs

The Total Cost for a given layer is calculated as follows: Total Cost (layer no. i) ($/m2) = Unit Volumetric Cost (layer no. i) ($/m3) x Thickness (layer no. i) (mm) + Unit Areal Cost (layer no. i) ($/m2) The Unit Volumetric Cost can be defined in terms of: 1 Cost/Volume, or 2 Cost/Weight and the density of the material (Weight/Volume).

Chapter 2 How to Use Advanced Features

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Automatic Parametric Analysis

Automatic Parametric Analysis lets you automatically loop through a range of thicknesses for one or two nominated layers. For example, you can have Layer 2 vary from 100 mm to 200 mm in steps of 10 mm. Additionally, for each combination of those layer thicknesses, you can automatically design the thickness of another layer. Combining this with the Cost Analysis feature lets you fine-tune layer thicknesses to optimize construction cost. Click on the button. This will bring up the following screen:

1 Click to switch on Parametric Analysis. This will bring up the following form:

1 2 3 4

1 This combo box lets you specify the number of Independent Variables (i.e. the number of Layers for which you are varying the thickness):

1. One Independent Variable, or 2. Two Independent Variables.

2 This section gives the details of the first Independent Variable.

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CIRCLY 5.0 User's Guide

3 This lets you choose which layer (thickness) is to be used as the first Independent Variable. 4 Here you specify the range of thicknesses to be used for that layer:

The thickness will range from T1minimum to T1maximum in steps of T1step. To use two Independent Variables, click the combo box ( 1 on the screenshot below).

2 3 4

2 This section gives the additional details for the second Independent Variable 3 Here you specify which layer (thickness) is to be used as the second Independent Variable 4 Here you specify the range of thicknesses to be used for that layer:

The thickness will range from T2minimum to T2maximum in steps of T2step.

Chapter 2 How to Use Advanced Features

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ExampleCost Optimization
In this example you will use the Automatic Parametric Analysis feature to automatically loop through a range of thicknesses for one layer (Layer 2) and to determine which thickness has the minimum Total Cost. For each Layer 2 thickness, you will get CIRCLY to automatically design the thickness of Layer 3.

Thickness T1 = 40 mm
Asphalt: Size 14, Type H Asphalt: Size 20, Type T

Unit Cost $288 / m3

T2 = ?

$288 / m3

T3 = ?

Crushed Rock: 20 mm , Class 4

$50 / m3

Subgrade, CBR = 3

Step 1.
Open the sample file "Economic Analysis - Pavement Option B2".

Step 2.

1 2

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CIRCLY 5.0 User's Guide

1 Make sure the Calculate Cost check-box is ticked. 2 Click the Parametric Analysis check-box. This will bring up the following form:

1 2 3 4

1 This combo box lets you specify the number of Independent Variables (i.e. the number of Layers for which you are varying the thickness).

For this example you will use the default, One Independent Variable.
2 This section gives the details of the Independent Variable, the thickness of Layer 2. 3 This lets you choose which layer (thickness) is to be used as the first Independent Variable.

For this example change this to "2". (as you are varying the thickness of Layer 2).
4 Here you specify the range of thicknesses to be used for Layer 2:

For this example, you will let Layer 2 vary in thickness from 160 mm to 230 mm in steps of 10 mm. Enter the following values: Minimum: 160, Maximum: 230, Step: 10.

Step 3.
Now set the automatic thickness design feature to Layer 3.

Chapter 2 How to Use Advanced Features

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Click on the "Summary" tab (left of the "Variables" tab).

1 Click the check-box labelled 'Design thickness of layer highlighted below'. 2 Click anywhere on the Layer 3 row.

Click in the "Minimum Thickness" cell on this row and enter 100 (mm).

Now click on

to run the analysis.

Step 4- Plot the Total Cost vs Layer 2 thickness.

When the analysis is finished, click on to plot the results.

Minimum Total Cost

This plot shows the Minimum Total Cost condition for Layer 2 thickness is 220 mm (to a resolution of 10 mm).

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CIRCLY 5.0 User's Guide

Step 5- Plot the CDF (for Layer 2) vs. Layer 2 thickness.

Click on the Parameter combo box.

Select CDF (Select Layer =>). Click on the Layer combo box. Select Size 20 Type T - 40km/h (This is Layer No. 2)

Step 6- Plot the Layer 3 thickness (Design Layer) vs. Layer 2 thickness.
Click on the Parameter combo box.

Chapter 2 How to Use Advanced Features

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Select Thickness (Layer used for Thickness Design).

Comments on these results. If the Layer 2 thickness is 160 mm or less, the "designed" thickness of Layer 3 exceeds 5000 mm. Therefore a Layer 2 thickness of less than 160 is not viable if supported by the Layer 3 material. If the Layer 2 thickness is 220 mm, the Layer 3 thickness is 100 mm, because of the Minimum Thickness constraint and because the CDF is 0.91. If there was no Minimum Thickness constraint, the Layer 3 thickness would be 39.6 mm. This would be inconsistent with the Austroads (1992) sub-layering requirement that the minimum thickness of a sub-layer is 50 mm.

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Overview of Austroads 2004 Features

The Austroads Pavement Design Guide (the full title is Pavement Design - A Guide to the Structural Design of Road Pavements) was first published in 1992 (Austroads, 1992). The Guide has undergone a major re-write over the last few years, culminating in the release of the 2001 Draft (Austroads, 2001). The technical content of the new Guide was finalized in June 2003 and that the Guide is expected to be published in the first quarter of 2004. The development of the new features in CIRCLY relating to the Guide was based on the April 2003 Draft. For convenience, we use the convention that Austroads 1992 is the original Guide and that Austroads 2004 is the new Guide. The following notes assume that you are already familiar with the original Guide. These notes should be read in conjunction with Austroads 2004. No attempt is made to comprehensively describe all the features, but the main differences with the original Guide are highlighted.

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CIRCLY 5.0 User's Guide

Model of Standard Axle

The Standard Axle Load consists of a dual-wheeled single axle, applying a load of 80 kN. Austroads 2004 uses a full Standard Axle Loading, whereas Austroads 1992 uses only one half of the Standard Axle. This figure shows the layout of the wheels and their respective positions along the CIRCLY x-axis.

Figure 1: Model of Standard Axle

Chapter 2 Overview of Austroads 2004 Features

21

Project Reliability
The Project Reliability is defined as follows (Austroads 2004): The Project Reliability is the probability that the pavement when constructed to the chosen design will outlast its Design Traffic before major rehabilitation is required. In regard to these reliability procedures, a project is defined as a portion from a uniformly designed and (nominally) uniformly constructed road pavement which is subsequently rehabilitated as an entity. The desired project reliability is chosen by the designer. Typical project reliability levels are given as follows (Austroads 2004):

Road Class Freeway Highway: lane AADT>2,000 Highway: lane AADT<2,000 Main Road: lane AADT>500 Other Roads: lane AADT<500

Project Reliability (%) 95 - 97.5 90 - 97.5 85 - 95 85 - 95 80 - 90

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CIRCLY 5.0 User's Guide

Material Properties
Sub-layering
Unbound Granular Materials
Sub-layering is required for granular materials placed directly on the subgrade. Austroads 2004 always uses 5 equi-thick sub-layers, whereas with Austroads 1992, the number of sub-layers were dependent on the thickness and elastic properties of the layers. The procedure is: a Divide the total depth of unbound granular materials into 5 equi-thick sub-layers. b The vertical Elastic modulus of the top sub-layer is the minimum of the value specified in the CIRCLY input (indicative values are given in Table 6.3 of Austroads 2004) and that determined using:
EV top sublayer = EV subgrade 2(total granular thickness / 125)

c The ratio of Elastic moduli of adjacent sub-layers is given by:

E top granular sublayer 5 R = E subgrade

d The Elastic modulus of each sub-layer may then be calculated from the Elastic modulus of the adjacent underlying sub-layer, beginning with the subgrade or upper sub-layer of selected subgrade material as appropriate, the Elastic modulus of which is known.

Selected Subgrade Materials

Selected subgrade materials are a special case of unbound granular material. The total (i.e. combined) thickness of all selected materials is divided into five sub-layers and each assigned an Elastic modulus value according to the following guidelines: a Divide the total depth of all selected subgrade materials into 5 equi-thick sub-layers. The vertical Elastic modulus of the top sub-layer of selected subgrade is the minimum of 10 times the design CBR of the selected subgrade material and that determined using:

E V top sublayer = E V insitu subgrade 2(total selected subgrade thickness / 150)

b The ratio of Elastic moduli of adjacent sub-layers is given by:

E top selected subgrade sublayer 5 R = E insitu subgrade

Chapter 2 Overview of Austroads 2004 Features

23

c The Elastic modulus of each sub-layer may then be calculated from the Elastic modulus of the adjacent underlying sub-layer, beginning with the insitu subgrade, the Elastic modulus of which is known. d If the pavement includes more than one type of selected subgrade material, a check needs to be made that the vertical Elastic modulus calculated for each sub-layer (step a) does not exceed 10 times the design CBR of each selected subgrade material within the sub-layer. If this condition is not met, an alternative trial selected subgrade configuration needs to be selected.

Performance Models
The main change to the Performance Models is the introduction of a Reliability Factor, RF.

k N = RF

The Performance models for Cemented and Asphalt Materials are the same as for Austroads 1992, apart from the introduction of the Reliability Factor.

Cemented Materials

Suggested Reliability Factors (RF) for Cemented Materials Fatigue (Austroads 2004) Desired Project Reliability Reliability Factor (RF) 80% 4.7 85% 3.3 90% 2.0 95% 1.0 97.5% 0.5

Asphalt
Suggested Reliability Factors (RF) for Asphalt Fatigue (Austroads 2004) Desired Project Reliability Reliability Factor (RF) 80% 2.5 85% 2.0 90% 1.5 95% 1.0 97.5% 0.67

Subgrade
The subgrade Performance Model used in Austroads 2004 is:
9300 N =
7

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CIRCLY 5.0 User's Guide

Note that a Reliability Factor is not used for the subgrade.

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How to Use New Austroads 2004 Features

The previous Section provided an Overview of the new features in the Austroads 2004 Guide. This Section shows how to use the new Austroads features in CIRCLY 5.0. The following notes assume that you are already familiar with using CIRCLY 4.0 or 4.1 in conjunction with the original Guide.

Modelling the Standard Axle

The layout of the four wheels used to model the Standard Axle is shown in the earlier section (see "Model of Standard Axle" on page 20). The design tyre pressure for pavement analysis is taken as 750 kPa (Chapter 7, Austroads 2004). This Standard Axle is provided in the Load Groups database with the ID given by "ESA75Full".

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CIRCLY 5.0 User's Guide

How to Use Project Reliability

Click on the button. This will bring up the following screen:

1 Click the Reliability tab to switch to the Reliability form. This will bring up the following form:

Chapter 2 How to Use New Austroads 2004 Features

27

2 Click on Use Project Reliability Factors.

3 In the Project Reliability list, click the desired Project Reliability.

4 This Table shows the Reliability Factor for each Material Type.

Changes to Materials
The Materials database in CIRCLY is affected by the Austroads 2004 changes in three main areas: 1 Unbound Granular Materials

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CIRCLY 5.0 User's Guide

2 Subgrade Materials 3 Select Subgrade Materials To ensure that pavements can be handled using either the Austroads 1992 or Austroads 2004 methods, separate Material Types are used for variants of these materials: Material Type Design Method: Unbound Granular Material Austroads 1992 Unbound Granular (Austroads 1992 sub-layering) Subgrade (Austroads 1992) n/a Austroads 2004 Unbound Granular (Austroads 2004 sub-layering) Subgrade (Austroads 2004) Subgrade (Selected Material)

Subgrade Select Subgrade Material n/a = not applicable

Austroads 2004 Examples

Appendix 8.3 (Austroads 2004) outlines three worked examples that apply a mechanistic design procedure for flexible road pavements. Copies of these examples are provided in the CIRCLY database:

CIRCLY Job Name Austroads 2004 - Example 1 - Unbound Granular Pavement Austroads 2004 - Example 2- Asphalt Pavement with CT Subbase Austroads 2004 - Example 2- Asphalt Pavement with CT Subbase- Post-Cracked Austroads 2004 - Example 3 - Full Depth Asphalt Pavement CT = Cement Treated

Pavement Description Sprayed Seal Surfaced Unbound Granular Pavement Asphalt Pavement containing a Cemented Material Subbase (pre-cracking phase) Asphalt Pavement containing a Cemented Material Subbase (post-cracking phase) Full Depth Asphalt Pavement

See Appendix 8.3 (Austroads 2004) for full details of the parameters used.

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References
Austroads (1992). Pavement Design A Guide to the Structural Design of Road Pavements. Austroads Publication No. AP-17/92. (Austroads: Sydney). Austroads (2001). 2001 Austroads Pavement Design Guide (Final Draft). Austroads Publication No. AP-T10/01. (Austroads: Sydney). Austroads (2004). 2004 Austroads Pavement Design Guide. Austroads Publication. (Austroads: Sydney). (At the time of writing the publication number and date were not known). Wardle, L.J. (1977). Program CIRCLY Users Manual. CSIRO Australia. Division of Applied Geomechanics, Geomechanics Computer Program. No. 2. Wardle, L.J. (2004). Program CIRCLY Theory and Background Manual. Mincad Systems, Australia.