TCP® Design Optimized Concrete Pavements

TCP® Design Optimized Concrete Pavements

Juan Pablo Covarrubias V
Route 60 in Chile - Panels cut in
The smaller panels:




Reduced the effect of
warping / curling
Final panel size
dimensions: 6.5 ft. (2 M)
long and 5.66 ft. (1.75 M)
wide.
Performance has improved
dramatically.
2 years old without signs of
distress.
Other considerations of the TCP® Design
Optimized (smaller) panel size - 5ft-8ft long
Base conditions: Granular (fines < 8%), ATB, CTB
Normal or fiber-reinforced concrete
Geotextile between the sub grade and base, if
needed
 Thin saw cut (1/16” thick)
 No joint sealing
 Fewer or no dowel bars
 Curb or widened outer lane (1ft)




Joints
 Some joints don't need dowels, but some do, like those with:
 High Traffic;
 Erodible Base; or
 Bad soil support.
 Specialty dowel basket assemblies to optimize the amount of
steel since load transfer is higher than regular size slabs
 Construction Joints:
 For pavements over 7”, plate or round dowels
 Pavements 7” or less, plate dowels
 Longitudinal joints, tie-bars or specialty basket assembly
Completed TCP® Projects in Chile
 Private:
 CD Wallmart-Puerto Seco
 Planta De Perfiles Metalurgia Arrigoni
 CD Sodimac-Lo Espejo
 CD Bodenor Flexcenter 4
 Inmobiliaria El Noviciado S.A.
 Pavimento Patio Grúa, Etac S.A.
 Bodega Galvarino Constructora RYR
 Pavimentos Edificio San Francisco,
Constructora Armas
 Pavimentos Calle Interior,
Construmetal Chiloé
 Pavimentos Edificio Cerro Colorado,
Constructora Armas
 9 Proyectos constructora EBCO
 Vilicic, Pavimentos Puerto Asmar 5 y 6,
Punta Arenas
 Soprole, Puerto Montt
 Public:









Ruta 5 reemplazo de losas Km. 251
Dirección Norte
Ruta 60 Sector 5
Ruta W-195 Quemchi-TocoihueDalcahue
Ruta 7 mina El Toqui
Cerro Sombrero-Onaissin Sector 1 (15
km)
Ruta Cauquenes-Chanco ( 13 Km)
Polideportivo Punta Arenas
Edifico MOP rancagua
Calles SERVIU Punta Arenas
Private projects in construction
 Chile
 Centro de Distribución Fortaleza
 Imagina – WLP
 Perú:
 Urbanización Los sauces 5
 Bodenor -Flexcenter Enea
 DDC, Curicó

 Dapsa- American Screw

 Kaufmann
 DDC Requinioa

 Volvo
 Movicenter

 Claro

 Indumotora

 Stirp center Patio
 Construmart

etapa, Centenario.
Planta Pucusana Lindley
Planta Grupo Gloria Arequipa
Domus Hogares Vias
Secundarias
Proyecto almacenes Pulmón
Planta Coca Cola Lima
Explanada Pacasmayo
Fundo la Antonia
Public projects in construction
 Chile












Ruta 5Tara Compu ( Licitado) 20 km
Ruta 5 Quellon puerto Yungay ( Licitado)
Quilamuta – La Manga
Codigua- Quiranque
Mejoramiento Ruta G21 Farellones – Valle
Nevado
Ruta G-78 Malloco – Melipilla
Mejoramiento Ruta 26 Las Arañas –
Embalse Rapel
Ruta 5 Chiloé (Sur de Castro)
Ruta 5 Chiloé (Bypass Castro)
Cerro Sombrero – Onaissin Sector 3
Ruta Y-205 Cerro Castillo – Frontera
Mejoramiento Ruta 7 Santa Lucía-Límite
Regional, X Región
 Perú
 Intercambio Vial Trujillo ( Av




Mansiche)
Avenida Sullana
Avenida Chulucanas
Rehabilitación de la Carretera
Huamachuco
Carretera Bellamar
ACI 330x (In development)
 Proprietary Design Software C - OptiPave™ - Mechanistic-based software
specifically developed to design concrete pavements for any set of climate, traffic,
subgrade/subbase layers, and material inputs. Critical tensile stresses have been
calculated using finite element analysis for a variety of mechanical and thermal
loading conditions and load positions. This methodology designs the concrete
pavement thickness by optimizing the slab size to suit a given geometry of truck wheel
and axle spacing. The design is based on an unbonded system with granular, HMA,
Stabilized or Concrete Base. The key principle of the design method is to configure
the slab size so that not more than one set of wheels are on any given slab thereby
minimizing the critical top tensile stress in each slab. ……….. The design method is
also able to efficiently design lower volume concrete roads and industrial pavements
that are not comprehensively covered with existing pavement design methods
(Covarrubias, Roesler and Covarrubias 2010). With this method, thicknesses can be
designed as low as 3” (75 mm) for low traffic volumes (parking lots and subdivision
roads) over granular base layer with typically 6 ft. (1.8 M) x 8 ft. (2.4 M) or 6 ft. (1.8 M)
x 6 ft. (1.8 M) panels depending on traffic configuration. Because of the short slabs,
curling stresses are also reduced and higher load transfer efficiency is maintained
across the joints relative to conventional jointed concrete pavements with larger slab
sizes.
1500 camiones diarios
Route 60, Chile 5.000.000Esals
7 in. (170 mm) plain concrete
5,000,000 ESALS in 3 Years 6 in. (150mm) FRC
12,000,000 ESALS in 3 Years 6.25 in.(16 cm)
14,000,000 ESALS in 3,5 Years 6.25 in.(16
cm)
3 years old, 5 in. (12 cm)
1,000,000 ESALS in 1 Year, 5.5 in.(140mm) FRC
Cauquenes – Chanco
6.6 in. (170mm) plain concrete
Designed for 20,000,000 ESALS
10 mile section
Rute 7 Carretera Austral
4 “ FRC
2011
Access Road from the Port of
Guatemala (Constructed in 2005)
 Design life of 15 years with
120,000,000 ESELS
 8 in. (200 mm)
 Granular base
Same project, 6 years in service, 8” concrete
Antigua Guatemala 2007
Route to Antigua, Guatamalla, 6.6 in. (170 mm) plain concrete,
Constructed in 2006
This picture taken after 5 yesars with over 15Million ESELS
Same project after 6 years in service
JR LINDLEY (Trujillo - Peru) , 6”
Constructed in 2012
Low Volume Roads
Development of Ultra-Thin TCPavements®
 Constructed August





2011
3.25 in. (80 mm)
Thickness
650 psi (4.5 Mpa)
FRC max Aggregate
size of 1.5 in. (40 mm)
Fiber to increase the
residual strength to
150 psi (1 Mpa)
No Base, directly over
natural soil – CBR
15%
35 to 4o trucks per
day – zero cracks
Significance of fiber reinforcement
3.25 in. thick Fiber Reinforced Concrete
35 to 40 trucks per day – zero cracks
How thin can we go?
 Test track to calibrate model U-TCP
210 ft.
30 ft.
30 ft.
2.5”
3.25”
30 ft.
30 ft.
4”
4”
Subgrade compaction 95% maximum density
2.5” (63mm) Fiber Reinforced Concrete
Subgrade CBR 4 to 17% -No subbase
30,000 ESALS - 30% slabs cracked
ge cannot currently be displayed.
2.5” with 30,000 ESALS - 30% slabs cracked
Walmart DC 6”& 7”
Sodimac DC – Santiago, Chile
2,500,000 ESALS with 5” (140mm) plain concret
Arrigoni 4” (360,000 sq. ft.)
•2011
•1.000 m2
•14 cm
JR LINDLEY (Callao Plant) 6” Pavement
Constructed in 2011
Introduction
 OptiPave:
 First Software OptiPave has been used since 2009, in Chile Peru, colombia and
Guatemala.
 It was based an a database of Islab 2000 runs, in Spanish and SI units
 OptiPave 2:
 stresses based on a finite element program (ISLAB 2000) and by neuronal
network training .
 More comprehensive and complete, Its able to calculate more possibilities and
higher precision than the older version
 Multi-language and SI an US units
 3 version: Structure Evaluation, Thickness Design , Web based aplication
 Next additions:
 Energy based faulting model
 Partial Bond Interface
Features Optipave™2
 Traffic Input Data:
 ESALS
 Load Spectra
 Materials Characterization
 Plain Concrete
 Fiber Reinforced Concrete
Residual Strength
 Input Material Properties

 Load Transfer Model ( Dan Zollingher)
 Simplified soil model for up to 6 layers
Features OptiPave™2
 Built in Curling
 2 Seasons (Winter & Summer)



LTE
K-Value
Equivalent Temperature Gradient for different locations
 Software Stress Calculation ( Dr. Lev Khazanovich)
 Incorporates Neuronal Network
 Structural equivalence concept




Reduces de amount of Islab Runs
Faster Calculations
Continues output
Models interactions between stresses
Soil Model
LTE ( Dr. Dan Zollenger)
𝑐𝑐𝑐𝑐 = 𝑀𝑀𝑀𝑀𝑀𝑀(𝐿𝐿 � 𝛽𝛽 � 𝛼𝛼 � 𝑇𝑇𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐. − 𝑇𝑇𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 + 𝜀𝜀ℎ𝑜𝑜𝑜𝑜𝑜𝑜
 cw: Joint opening
 L: Joint Spacing
 β: Pavement-Base Friction coeficient
 α: Coeficient of termal expansion
 Tconstr: Concrete Setting Temperature
 Tpromedio: Mean Temperature
 εhorm: 365-days concrete shrinkage
𝐿𝐿𝐿𝐿𝐿𝐿 𝑎𝑎𝑎𝑎𝑎𝑎/𝑘𝑘𝑘𝑘 = 𝑎𝑎 � 𝑒𝑒 −𝑒𝑒
−
𝑠𝑠 = 𝑎𝑎 � ℎ𝑝𝑝𝑝𝑝𝑝𝑝
𝐽𝐽𝑠𝑠 −𝑏𝑏
𝑐𝑐
𝑏𝑏
+ 𝑑𝑑 � 𝑒𝑒 −𝑒𝑒
� 𝑒𝑒 𝑑𝑑�𝑐𝑐𝑤𝑤
−
𝑠𝑠−𝑒𝑒
𝑓𝑓
+ 𝑔𝑔 � 𝑒𝑒 −𝑒𝑒
−
𝐽𝐽𝑠𝑠−𝑏𝑏
𝑐𝑐
� 𝑒𝑒 −𝑒𝑒
−
𝑠𝑠−𝑒𝑒
𝑓𝑓
Load Characterization
Parameter
S1
31 cm
S2
182 cm
S3
213 cm
Tyre Pressure
8,2
Kg/cm2
Tyre Width
25 cm
Parameter
S1
31 cm
S2
182 cm
S3
213 cm
L1
145 cm
Tyre Pressure
8,2
Kg/cm2
Tyre Width
25 cm
σppc,1
σppc,2
lpcc = leqq,eff
Lpcc = Leqq
Φpcc = Φeqq,eff
IF:
spcc=seqq
Example for BWS (Bottom Wheelpath Stress)
Slab
Dimension
Leng Widt
th
h
(Cm)
Axle
Load
(KG)
Load Transfer
Position
(cm)
x
Edge(
%)
Longitudin
al Joint(%)
Transvers
e Joint
(%)
Y
Fixed Values:
hPCC: 15 cm
heff : 15 cm
µ: 0,15
k: 10 kg/cm3
αPCC: 10-5 °C-1
µPCC:0,15
140
180
230
180
210
0
3.000
6.000
10.000
16.000
25.000
40.000
0
10
25
50
80
L/2
0
25
50
50
10
30
50
80
3
2
7
5
1
3
1
4
Material
Properties
Radius
Φ
of
Korone
relative
v
stifness
(cm)
18,4
-100
23,2
-63
30,5
-31
41,2
-13
51,8
0
61,6
13
73,2
25
92,1
50
109,5
81
9
9
Total Runs: 204.120
NN Prediction Bottom Wheelpath Stresses
Hpcc 2,5”
Hpcc 5,5”
140
45
Stresses from NN
35
30
25
20
15
100
80
60
40
10
20
5
0
0
0
10
20
30
40
Stresses from Islab2000
n=2,880 runs
0
20
40
60
All Thicknesses
R² = 0.9975
120
100
80
60
40
20
0
0
20
40
60
80
80
100
Stresses from Islab2000
n=4,320 runs
140
Stresses from NN
Stresses from NN
R² = 0.9958
120
R² = 0.9987
40
100
Stresses from Islab2000
n=14,387 runs
120
140
120
140
NN Prediction Top Corner Stress
50
45
40
R² = 0.983
NN prediction
35
30
25
20
15
10
5
0
0
10
20
30
Islab 2000
7000 runs
40
50
Location
 EICM evaluation for a given location
 Equivalent temperature gradients are used
DRY-NF
DRY-F
WET-NF
WET-F
Sum
Win
Sum
Win
Sum
Win
Sum
Win
ºC/cm
0%
0%
0%
0%
0%
0%
-0,6
0%
0%
1%
1%
3%
3%
0%
0%
-0,5
5%
5%
6%
6%
11%
11%
0%
0%
-0,4
18%
18%
10%
10%
10%
10%
0%
0%
-0,3
15%
15%
14%
14%
10%
10%
11%
11%
-0,2
12%
12%
21%
21%
20%
20%
32%
32%
-0,1
8%
8%
13%
13%
10%
10%
24%
24%
0
4%
4%
11%
11%
8%
8%
16%
16%
0,1
5%
5%
7%
7%
7%
7%
10%
10%
0,2
5%
5%
4%
4%
5%
5%
5%
5%
0,3
4%
4%
3%
3%
3%
3%
2%
2%
0,4
4%
4%
3%
3%
3%
3%
0%
0%
0,5
4%
4%
3%
3%
3%
3%
0%
0%
0,6
4%
4%
2%
2%
3%
3%
0%
0%
0,7
5%
5%
1%
1%
2%
2%
0%
0%
0,8
4%
4%
0%
0%
1%
1%
0%
0%
0,9
2%
2%
0%
0%
0%
0%
0%
0%
1
1%
1%
0%
0%
0%
0%
0%
0%
1,1
1%
1%
Fatigue Algorithm
1.
2.
Islab 2000 runs for stresses and NCHRP 1-37ª for Fatigue algorithm.
Material and geometry calibration are at this level
Log ( N ) = 2 * (
σ
MOR * C1 * C2
FDk = ∑
i
) −1.22
nijk
N ijk
1
𝐶𝐶𝐶𝐶𝐶𝐶% =
1 + 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 −𝐶𝐶𝐶
C1 Calibration Constant
 This behavior is explained because of concrete fracture
 This is only true for Bottom up cracking, top down has a
different calibration function
 Tensile strength of concrete depends on the size of specimen
and support condition
C1 (Bottom)
2
1.8
Log ( N ) = 2 * (
1.6
1.4
1.2
1
0.8
6
11
16
21
σ
MOR * C1 * C2
) −1.22
C2 Calibration Constant (Fibers)
•ASTM 1609 -07
C2= ( 1 + R3,e)
Log ( N ) = 2 * (
C3 * σ
) −1.22
MOR * C1 * C2
Stress Evaluation
Bottom Stress
Bottom Stress
X=20,40 &
60 cm from
edge
Edge; L/2
Top Stress
40,60 &
80cm
From edge
40,60,80 cm from transv. joint
LTE (Average 10 Projects )
120%
100%
LTE
80%
60%
40%
20%
0%
0
0.5
1
1.5
2
2.5
Joint Opening
3
3.5
4
4.5
5
100%
Cracking
BottomTransversal
Up Longitudinal
Crack
90%
80%
Losas Agrietadas (%)
70%
60%
Model
Chinquihue
50%
Brotec Icafal
Alameda
40%
Illinois
Las Casas
30%
20%
10%
0%
0.0001
0.001
0.01
0.1
FD
1
10
100
Bottom up Transverse Crack
Calibration of Corner Cracking Model
1
0.9
Cracked Slabs (%)
0.8
0.7
AASHTO
Chinquihue
0.6
Las Casas
0.5
Alameda
Brotec Icafal
0.4
Illinois
Sodimac Lo Espejo
0.3
Reemplazo Losas Ruta 5
Ruta 60 CH
0.2
0.1
0
0.00001
0.0001
0.001
0.01
0.1
Fatigue Damage
1
10
100
C1 (Bottom)
2.8
C1 Strength Correction Factor
0.8
6
11
16
Log ( N ) = 2 * (
100.0%
σ
21
MOR * C1 * C2
Longitudinal Cracking
90.0%
80.0%
Losas Agrietadas (%)
70.0%
60.0%
50.0%
With C1
Without C1
40.0%
30.0%
20.0%
10.0%
0.0%
0.001
0.01
0.1
1
FD
10
100
1000
) −1.22
www.tcpavements.com