Concrete Airport Pavement Workshop, Nov 4-5, 09

Cement Stabilized Cement-Stabilized Base Courses

Fares Y. Abdo, P.E. , Market Manager, Pavements Portland Cement Association

Cement-Treated Base Courses

Fundamentals Materials Mix Design Thickness Design g Construction Case Studies

Cement-Based Pavement Materials

Roller-Compacted Roller Compacted Concrete Pervious Concrete Conventional Concrete FAA Econocrete P-306 FAA Cement-Treated C tT t d Base/Subbase P-301 & P-304 Cement Conte ent Soil-Cement
CementTreated Base

Full-Depth Reclamation Cement-Modified Soil

Flowable Fill

Water Content

Definition
Cement-Treated Base a intimate mixture of native and/or manufactured aggregates with measured amounts of portland cement (and possibly other cementitious materials) and water that hardens after compaction and curing to form a strong durable paving material

What materials can be treated with cement?

Soils (sand, silt, clay) Gravel Shale Crushed t C h d stone Slag Recycled HMA Recycled concrete

Are all materials suitable for CTB?

Problem Soils
Organic soils Acid soils Sulfate soils Uniform sands

Why Use CTB?

Economical pavement base Decreased base thickness compared to unbound aggregate base Structural properties maintained under varying moisture conditions High stiffness inhibits fatigue cracking and rutting of asphalt surface Sustainable paving option

FAA Base/Subbase Approved Materials

Purpose of Base/Subbase Courses P f B /S bb C

(FAA AC 150/5320-6E)

Flexible pavements Principal structural components Distribute the loads to the foundation f d ti

Asphalt Base Subbase

(Req. if CBR<20)

Subgrade

Improved Performance in Rutting and Fatigue Cracking

P P

Cement-Treated Base Unstabilized Granular Base

Purpose of Base/Subbase Courses P f B /S bb C

(FAA AC 150/5320-6E)

Flexible pavements Principal structural component Distribute the loads to the foundation f d ti Rigid pavements Provide uniform stable support

Asphalt Base Subbase

(Req. if CBR<20)

Subgrade

Concrete Subbase Subgrade

Materials for Base Course FAA AC 150/5320-6E Flexible Pavement Design

Item I P 208 P-208 P-209 P-211 P-219 P-304 P-306 P-401 P-403 Base C B Course Aggregate Base Crushed Aggregate Base Lime Rock Base Recycled Concrete Aggregate Base Cement Treated Base Econocrete Subbase Plant Mix Bituminous Pavements HMA Base Max. Gross L d M G Load, lbs. 60,000 60 000 100,000 N/A / 100,000 N/A / N/A N/A N/A

Materials for Subbase Course FAA AC 150/5320-6E Flexible Pavement Design

Item I P 154 P-154 P-210 P-212 P-213 P-301 Subbase C S bb Course1 Subbase Course Caliche Base Course Shell Base Course Sand Clay Base Course Soil Cement Base Course X X Frost Penetrating F P i Subbase

1. Materials acceptable for base course can also be used for subbase course

Materials for Sbbase Course FAA AC 150/5320-6E Rigid Pavement Design

Item I
P-154 P-208 P-209 P-211 P-301 P-304 P 304 P-306 P-401 P-403

Subbase C S bb Course
Subbase Course Aggregate Base Course Crushed Aggregate Base Course Lime Rock Base Course Soil Cement Base Course Cement Treated Base Course Econocrete Subbase Course Plant Mix Bituminous Pavements HMA Base Course

Max. Gross L d M G Load, lbs.

100,000 , 100,000 100,000 100,000 100,000 N/A N/A N/A N/A

Engineering Properties of CTB

Property1 P
7-Day Compressive Strength, psi

FAA P 301 P-301

(Soil Cement) N/A2

FAA P 304 P-304

(CTB) Under PCC: 500 min.; 1000 max. Under HMA: 750 min.; 1000 max. 500 0.20

PCA CTB
300 min.; 800 max.

Elastic Modulus, ksi Poissons Ratio

250 0.20

600-1000 0.15

1. Refer to FAA AC 150/5320-6E for durability requirements 2. FAA recommendations for P-301 are based on wet-dry and freeze-thaw tests and strength should increase with age

CTB Mix Design

Strive f St i for a Balance Between B l B t Strength and Performance g

Mixture Design-Step 1
Determine moisture-density relationship Select expected median cement content (e.g. 6% by estimated dry weight) Perform standard or modified Proctor test (ASTM D558 or ASTM D1557) Construct moisture-density curve Determine optimum moisture content and maximum dry density

Moisture-Density Relationship

Mix Design-Step 2
Mold specimens for compressive strength testing Select range of cement contents (e.g. 4% 6% and 8% b d weight of material) ( 4%, d by dry i ht f t i l) Use percent OMC from Step 1 and Mold two specimens per cement content (ASTM D559/560 or ASTM D1632) Perform compressive strength testing (ASTM D1633) Plot cement content versus compressive strength

Strength Testing

Strength vs. Cement Content

1000

7-day Compres y ssive Stren ngth, psi

900 800 700 600 500 400 300 200 3 4 5 6 7 8 9

Cement Content, %

Mix Design-Step 3
Determine moisture-density relationship of target cement content Perform standard or modified Proctor test (ASTM D558 or ASTM D1557) Construct moisture-density curve Determine optimum moisture content and maximum dry density

Durability Testing
Specimens containing various cementitious contents molded per ASTM D558 and tested per: ASTM D559; wet-dry cycles ASTM D560; freeze-thaw cycles freeze thaw Select min. cement content that meets weight loss limits set by agency having jurisdiction

Thickness Design

Thickness Design
FAA: FAARFIELD Computer Program PCA Methods of Thickness Design Experience M h i ti E i i l M th d Mechanistic-Empirical Methods

AASHTO MEPDG (guide accepted) PCA-Pave (near completion)

Thickness Design
Factors

Subgrade Strength Pavement Design Period Traffic T ffi Heavy traffic: 6 to 9 inches Highways and airport runways and g y p y taxiways: 6 to 12 inches

Typical Thickness

Construction

Construction

Two methods

Plant Mix Road Mix (in place) (in-place)

Plant Mix: Puggmill

High production Usually close or on-site Mob/demob cost

Continuous Pugmill Mixing Chamber

Plant Mix: Central Concrete Batch Plant

Highly accurate proportioning Local availability Smaller output capacity Longer mix times than conventional concrete Frequent cleaning Dedicated production

Plant Mix: Dry Concrete Batch Plant

Highest local availability Desirable method for the smaller-sized jobs 2-step process Feed into transit mixers Discharge into dumps Low production Frequent cleaning S Segregation i

Construction - Road Mix

In-situ or mixed in place materials Wider variety of materials Dry or slurry cement application method y o s u y ce e t app cat o et od

Road Mix Method

1. 2. 3. 4. 5. 5 Spread cement Add water if necessary and mix Compact p Grade Cure

Portland Cement Addition

Dry spread

Slurry spread

Addition of Water

Gravity dump and mix Via drum of mixer

Road Mixing

With water Without water

Plant vs. Road Mix Considerations

Traffic loading/agency requirements FAA P-304 spec includes plant mix only Q Quality of in-situ materials y Cost Haul distances: material sources, plant, j p jobsite Design thickness (one or multiple lifts) Sustainable considerations (Reduce, Reuse and Recycling)

Plant vs. Road Mix Considerations

Dust controls/location of project

Tuscaloosa, AL

Palo Verde, AZ

Spreading/Placing

Grading/Compaction

Compaction
High density is critical for strength and durability Steel-drum Rubber-tire roller Sheepsfoot roller

Curing
Required for surface durability and normal strength g gain Needed to retain moisture Three methods:

Moist Cure Concrete Curing Compound Asphalt Emulsion

Moist Cure
Continuous operation P Prevent excessive t i drying

Concrete Curing Compound

White-pigmented concrete curing compounds Provide adequate coverage May form a bond breaker

Bituminous Curing Compound

E ll t Excellent moisture barrier G d for asphalt Good f h lt cap

Applications

Where are stabilized materials used?

Low l L volume roadways r d Residential streets State routes Interstate highways Airport runways and taxiways Parking lots Industrial storage facilities Port facilities Truck terminals Commercial sites

In other words any pavement structure!

Residential Streets

Bells Crossing, Mooresville, NC, 2008

Example: County Road

Upgrade 2-lane to 4-lane route Value Engineered Option Value-Engineered

Original Design
Asphalt Int. & Surface Asphalt Base 8

ValueV l Engineered Option

Asphalt Int. & Surface

$900,000 savings on 238,000 SY ($3.78/SY) Faster construction (5 months 3.5 ( savings) Less mined and processed materials 8 8

Crushed CementC t Stone Base Treated Base

Crushed Stone Base Subgrade Subgrade

SC County Road 5

Parking Areas
Design/Bid Section
4 4
Asphalt

Sustainable Contributions As Constructed Reduced

6-8 6 8 RCC 6 6
Soil-Cement Base Subgrade

12

Crushed Stone Base

Subgrade

export/import/fuel use Less mined and processed materials Reduced excavation Faster construction Cooler pavement Used in situ materials in-situ Less damage to area roads

BMW, SC, 2009

Washington Dulles Airport Runway 4, 2008 p y ,

18 PCC w/ dowelled transverse joints t j i t at 20 ft
6 CTB, 6% cement 12 CementStabilized Subgrade, 5% cement

Washington Dulles Airport Runway 4 p y

Runway 4 completed in 2008 Runway 12 was completed in

2004

FedEx Hub at Alliance Airport Fort Worth, TX, 1997

Taxiway & Ramp Truck Terminal & Container St g C t i Storage

14 PCC

10 JRCP
9 CTB 9 Cement-Treated Subgrade 6 Cement-Treated Subgrade

FedEx Hub at Alliance Airport Fort Worth, TX

50-yr design life Completed in 1997 C l t di 330,000 yd2 Cement-treated subgrade 7 % cement, 250 psi, reduced PI from 38 to less than 12 Cement treated base treated 750 psi at 28 days

DFW SE Perimeter Taxiway, 2008 y,

First perimeter taxiway in U.S. Built for safety and reduce
congestion delays

18 18 CRCP

12 CTB 12 Lime-Treated Subgrade

DFW SE Perimeter Taxiway

Completed in 2008 225,000 yd2 Data will be analyzed before
building the remaining 3 loops

McGhee Tyson Airport Knoxville, TN, 2008

Completed in 2008 9,000 yd2 CTB per FAA P 304 P-304

16 PCC

6 CTB, 5% (C+FA) 8 Lime-Treated Subgrade

Charlotte-Douglas Airport, 2008

Completed in 2008 256,000 yd2 CTB per FAA P 304 P-304

Dover AFB, Delaware, 2008

Old concrete and asphalt
crushed and recycled 50% recycled and 50% i i l d d in-situ soil; sandy clays and clear sand CTB 12 thick 12 42 to 80 lb/SY depending on the in-situ and recycled materials 300,000 SY 58 days

More I f M Information ti

www.cement.org/pavements fabdo@cement.org