HOW TO ACHIEVE HIGH QUALITY

CONCRETE PAVEMENTS

Developed by
Ronald M. Guntert, Jr. President & CEO
Guntert & Zimmerman Const. Div., Inc.
Ripon, CA U.S.A.

Presented by Chetan Kanakia

Country Head Marketing

Slipform Pavers & Plants (India)

CEO Allen Buildwell Pvt.Ltd.

What Are the Characteristics of a “HIGH
QUALITY” Concrete Pavement
• Durable (long lasting)
• Smoothness
• Low Noise
• Skid Resistance (in both dry and wet condition for
safety)
How Do We Achieve “HIGH QUALITY”
Pavement For the Motoring Public
• PERCEPTION IS EVERYTHING !
• If the motoring public perceives it is “smooth” and “low noise”
then the pavement is “High Quality”…The Customer is
Always Right!
• It is our job as engineers and contractors to insure that the
concrete pavement is also durable and has sufficient skid
resistance.
How Do We Achieve “GOOD” Pavement For
the Motoring Public
• The factors that influence smooth and low noise concrete
pavement characteristics are also the same factors that
influence durable and skid resistant concrete pavements.
• Thus the focus of this presentation is on the factors that
influence smooth surface and low noise characteristics
on concrete pavements with road building construction
practices in mind.
Smoothness
Smoothness

• Smooth concrete pavements has been a stated and specified

goal in California for over 50 years for the obvious reasons.
• What is considered “smooth” and how to measure
smoothness rapidly with good repeatability was the
challenge prior to this.
• Smooth concrete pavements are not only pleasing to the
motoring public but from a technical standpoint smooth
pavement reduces dynamic loading which extends
pavement life.
Smoothness

• The break through came in 1956, when the late Jim Cox, a
lab tech with the California Department of Transportation,
developed the “California Profilograph” which provided a
repeatable means of measuring and rapidly collecting
pavement smoothness data.
Smoothness
Prototype California Profilograph - 1956
Smoothness

• Today, all of North America and much of the world have

adopted smoothness specification.
• Many use a the CA profilograph to measure smoothness and
have gradually (over a number of years) tightened up their
null band from 2/10th to 1/10th to “zero” blanking band in order
to “raise the bar” to achieve even smoother concrete
pavements.
• We gradually reduced the blanking band to zero with the goal
of getting rid of the “chop” that can hide within the null band
that causes poor “seat of the pants” ride.
A Modern California Profilograph

The Profilograph as a 25 ft. wheel base

Smoothness

• Many states have gone to a International Roughness Index

(IRI) and use light weight profilers equipped with lasers to
measure surface smoothness.
• The lasers are arranged to simulate the footprint of a tire or
what a motorist would feel. The repeatability on these new
RoLine type lasers is much better.
• Light weight profilers can also rapidly collect digital data
which can be fed into a computer program and quickly and
easily analyzed.
A Typical Light Weight Profiler

• Example of a Light Weight Profiler (IRI filtered) equipped

with laser
Smoothness – How Did We Improve

• We developed a rapid and repeatable means to measure

and analyze smoothness.
• We gave realistic and meaningful incentives to the contractor
to achieve smoothness.
• The contractor uses the incentives to invest in new and
better paving technology, better quality materials and reward
good workmanship
LOW NOISE
Low Noise - Introduction

• This is the next frontier on concrete quality improvement.

• The Transtec Group, Austin, Texas U.S.A. has done an
extensive amount of good research and significant data
collection in the U.S.A. and Europe on the relationship and
correlation of texture and noise on concrete pavements.
Low Noise - Introduction

• The Transtec studies concluded that “conventional”

diamond grinding, drag finishes, longitudinal and even
properly done transverse tining can all be “low noise”
pavements.
• The big question is why on one job a certain texture type will
fall in the “Quality Zone” or low noise range (OBSI Zone 2
(99 – 104 dBA)) and on another or even the same job, this
same texture will result in unacceptable noise levels >104
dBA.
Texture Testing: How is Noise Measured
OBSI (On-Board Sound Intensity) is one way

AASHTO TP 76
 OBSI Noise Catalog Summary - Concrete
0.30 Kansas I-70
Exp. Aggregate Exposed Aggregate Concrete

Diamond Grinding
0.25
Drag
Longitudinal Tining
Probability Density

0.20 Transverse Tining

Porous Concrete
0.15

0.10

0.05

0.00
96 98 100 102 104 106 108 110
A-weighted Overall OBSI Level, 60 mph, SRTT (dB ref 1 pW/m²)
So What Causes the Noise?
In Layman’s Terms…
• The “peaks” or high amplitude texture impacts the tire which
act like little hammers creating tire vibration which results in
noise.
• Some negative texture is necessary to “drain away” air
trapped between the tire tread and the pavement. This
explains why some smooth drag textures are noisy.
• Avoid repeating a pattern as this can create a “whine” or
“chatter”. Uniform transverse tining can cause this.
So What Causes the Noise?
In Layman’s Terms…
Thou shalt have Texture...
be it small and negative!
1
Good

Bad
So What Causes the Noise?
In Layman’s Terms…

Negative Texture
Plateaus & Valleys
Surface Excavation
GOOD!

Peaks & Valley’s

Surface Displacement
Variability
BAD!
So What Causes the Noise?
In Layman’s Terms…
• Joint “Slap” contributes to pavement noise and can increase
it up to 2 to 3 dBA or more.
• Joint “Slap” affected by:
- joint width
- joint condition (spalling)
- faulting
- joint sealant depth and condition
For More Detailed Information

Download from
www.TCPSC.com/LittleBookQuieterPavements.pdf
So Knowing What Causes Noise What is
the Best Texture?
• Understanding what caused noise, Transtec studied many
different texture types and from this catalog wrote up
guidelines on best texturing practices.
• The use of Robotex helped us understand at a microscopic
level why some textures are quiet and others are noisy.
Texture Testing: RoboTex 2.0

• Built around LMI-Selcom RoLine Sensor

• Laser height sensor, inertial referencing
• GPS, DMI encoder, video log
RoboTex Showed Us the Way!

ZONE 2. 102 dBA

RoboTex Showed Us the Way!

ZONE 3. 110 dBA

Transverse Tining
111 dBA

103 dBA
Longitudinal Tining
106 dBA

100 dBA
Texturing Guidelines – For Further Reading
– A “how to” guide for designing
and constructing quieter
concrete pavements
– Addresses all conventional
concrete pavement textures
– Simple and practical guidance

Download from www.CPTechCenter.org

Low Noise - Conclusion

• We understand and have good research on how to achieve

very quiet <100 dBA diamond ground pavements.
• As far as texture in plastic concrete, we have learned a lot
about what causes the plastic texture noise and how to
construct traditional texture to avoid “noisy” harmonics.
• Some say our focus should be on finding some exotic next
generation plastic texture type.
• What we should really be focused on is why the lower 5% of
the texture type bell curves are low noise!
 OBSI Noise Catalog Summary - Concrete
0.30 Kansas I-70
Exp. Aggregate Exposed Aggregate Concrete

Diamond Grinding
0.25
Drag
Longitudinal Tining
Probability Density

0.20 Transverse Tining

Porous Concrete
0.15

0.10

0.05

0.00
96 98 100 102 104 106 108 110
A-weighted Overall OBSI Level, 60 mph, SRTT (dB ref 1 pW/m²)
How Do We Reduce Texture Variability
How Do We Reduce Texture Variability

• I think we can agree that the goal is to make every

square yard of the plastic concrete surface of the same
uniformity so the tines dig in the same depth and do
not displace the finished surface.
• To achieve this we need to eliminate localized wet and
dry spots, excess mortar on the surface and concrete
segregation…all factors which cause texture variability
• These factors also adversely affect pavement
smoothness and concrete durability
We Need to Focus on Mitigating the Factors
That Adversely Affect Concrete Uniformity

1. Eliminate gap graded concrete mixtures.

2. Hold gradations at each sieve size within a narrow
band < +5%.
3. Eliminate poor aggregate and other concrete
constituent material process control and handling
4. Insufficient concrete ingredient pre-blending and mixing
– we are not achieving high enough concrete
uniformity within each batch…and batch to batch.
Iowa Figures It Out!

• Iowa has figured out a way to insure they eliminate the

risk of 1 thru 3 through an incentive based specification
based on using the Coarseness Factor Chart.
• This idea was borrowed from the Army Corp of
Engineers specification but incentives were added.
• The specification insures use of only well graded
aggregate mixtures to achieve cohesive, durable
concrete and to avoid segregation
• The specification requires that aggregate gradations
at each sieve size are held within a narrow
tolerance band.
Iowa Figures It Out!

• The specification forces the contractor to focus on good

process control and stockpile management
• Iowa’s incentive based spec keeps the “uninitiated”
contractor from making fatal mistakes on their mix
design and keeps good and inexperienced contractors
on a more level playing field for bidding.
• This incentive based spec offers good, quality
conscience contractors monetary incentive to use
innovative new technology, better materials and the the
means to reward their workforce for good quality.
A Quick Overview of the Merits of Well
Graded Aggregates
• Why well graded aggregate mixtures important?
Well Graded Aggregate Mixtures

Single-Sized Gap-Graded Well-Graded

Use of Aggregates and Water for Concrete by Rick

Bohan, Portland Cement Association, Skokie, IL
Aggregate Grading - Paste Requirements

Amount of paste required > Aggregates need to be coated by

volume of voids between and become dispersed in the paste
aggregates to provide workability

Use of Aggregates and Water for Concrete by Rick

Bohan, Portland Cement Association, Skokie, IL
Particle Shape & Surface Texture
• Rough-textured, angular, elongated particles
require more paste to produce workable concrete
than smooth, rounded, compact aggregate.
Well Graded Aggregate Mixtures

• Volume of paste (cement + water) to fill voids plus some for workability
• Well graded or Dense graded Aggregates greatly minimizes risk of
concrete segregation
• Minimize voids (combined gradation) to minimize paste and thus
cement content for greater strength and for
– Reduced cost
– Reduced temperature rise
– Reduced shrinkage
– Reduced permeability to avoid sulfide and chloride attack
– Reduced risk of spalled joints
Combined Aggregate Grading - Shilstone

• To achieve these well graded aggregates we must attempt to

achieve a haystack shaped or “Shilstone Curve” on the
combined retained aggregate gradation curve.
• This will yield a well graded, densely packed aggregates
shown in the previous slide that results in cohesive, durable
and workable concrete with lower water demand.
Combined Gradation – Well Graded
“Shilstone Curve”

Design and Control of Concrete Mixtures, Portland

Cement Association, Skokie, IL, 2003
Combined Gradation – Gap Graded
Classic Double Humped Curve
Segregation – A Key Contributor to Poor Concrete
Smoothness and Texture Variability / Noise

“Segregation is caused by poor aggregate grading. Where

there are gaps in the gradation, horrible segregation can
occur at those sieve sizes.”
Jim Shilstone
Iowa’s Spec Forces Aggregates to be Held
Within a Narrow Band
Tracking CF & WF – Iowa Incentives
Coarseness Factor Chart – Well Graded

[2.36mm Sieve]
Why is Segregation Bad? – It is a Key Contributor
to Poor Concrete Smoothness and Texture
Variability / Noise

What does segregation look like!

Segregated Concrete
Segregated Concrete
Segregated Concrete – Passing Through
Slipform
Segregated / Non-Uniform Concrete
Plan View
Slipform Pan
Segregated / Non-Uniform Concrete
Section View – Concrete Pile
Segregated / Non-Uniform Concrete
Section View – Slipform Pan
Non-Segregated Concrete
Poor Aggregate Process Control and
Handling
• Clean and uniform aggregates and sand
• Good stockpile management to avoid
segregation and contamination
• Accurate weighing of individual aggregate
sizes for better control of gradations
Clean & Uniform Crushed Intermediate Size
Aggregate
Clean and Uniform Natural Sand
Stockpiles Separated with Barriers
Non-Conical Stockpiles
Multiple Bins / Accurate Weighing / Avoids Cross
Contamination and Segregation
Number of Aggregates Bins –
Something to Think About??
• Many states in the U.S.A. only require two aggregates….a
sand and one coarse aggregate. Based on experience,
three should be the minimum with max. 1” rock.
• Four or more bins and individual and accurate weighing
capability per bin reduces the influence of stockpile
segregation and allows gradations / coarse factor to be
maintained batch to batch within a narrow target range.
• Most specifications in Europe require 4 - 6 bins
Aggregate Stockpile - Rock Dust Contamination
and Segregation
Aggregate Stockpile - Stockpile Segregation,
Contamination and High Percentage of Flat and
Elongated Stones
Effects of Varying Aggregate Gradations
Lamar & Greeley CF/WF
WF/CF CHART Target

50

IV
45

40
III
II

Workability Factor
35

WF
30

25
V
20
100 90 80 70 60 50 40 30 20

CF
Coarseness Factor
Effects of Varying Coarse Ag Gradations
Aggregate Stockpile Cross Contamination
Aggregate Cross Contamination and
Rock Dust Contaminated Manufactured Sand
Be Careful of Too Much Surface Mortar / Finishing
Devices Can Disturb the Mortar Uniformity
Be Careful of Too Much Surface Mortar / Finishing
Devices Can Disturb the Mortar Uniformity
Resulting Pattern Left In the Hardened
Concrete Surface Adversely Affects Pavement
Smoothness and Texture Quality
Texture Variability Hurts Pavement
Smoothness, Surface Durability & Increases Noise
Texture Variability

• If the concrete is severely gap graded (with a high paste

content) or exhibits other issues of non-uniformity, it will
be more difficult to do a high quality tining job.
• Varying tine depth across the slab usually indicates
non-uniform concrete resulting from dry or wet loads or
inadequately mixed or segregated concrete.
Aggregate Gradation Variations / Water
Demand / Segregation
• Variations in the aggregate gradations on a hour to
hour basis that fall within the ASTM C33
specification (which are quite broad) will affect water
demand / concrete characteristics.
• Gradation variations affect strength because as
water demand varies, and cement content stays
fixed, strength will fluctuate. This will increase your
standard deviation on compressive strength.
• Gradation variations at each sieve size will
adversely affect concrete cohesiveness and can
result in segregation, mortar content all of which
adversely affects smoothness and texture uniformity
Concrete Uniformity – The Next Area of Focus
Concrete Uniformity – Two Types

• UNIFORMITY - within each batch: Pre-blending of all batch

ingredients and aggressive and thorough mixing of all for a
sufficient period of time to achieve a homogeneous mass.
• UNIFORMITY - batch to batch:
Accurate weighing and slump control. Slump control is
achieved by good stockpile management, accurate weighing
of all batch ingredients, using clean uniform sand and
aggregates, moisture sensors in the bins, modern plant
controls and a good plant and loader operator.
Accurately Weighed and Pre-blended Aggregates
Pre-Blended Aggregates – Introduced into
Mixer
Blending Cement and Fly Ash
into Pre-blended Aggregates
Water Sprayed into Entire Mixer Surface
Area
Use the Most Efficient Mixer Available
To Insure High Concrete Uniformity
G&Z TSM13 Twin Shaft Mixer – 12 cyd
Twin Shaft Mixers Are The Most Efficient
Mixers in the World for Large Batch Sizes

Turbulent Mixing
Zone in the Center
High Uniformity Concrete Being Discharged
How To Achieve High Concrete Uniformity

• Do we have a quick and repeatable way of measuring

concrete uniformity other than a ASTM C94 Mixer Uniformity
Test…Yes!
• In conjunction with the Iowa CF Chart spec, introduce an
incentive based, Coefficient of Variation (CV) test on the
compressive strengths. We are already tracking
compressive strength.
• CV = std. dev. / mean (of the compressive strengths)
How To Achieve High Concrete Uniformity

The Lower the CV > concrete uniformity. The greater the

Concrete Uniformity
• Lower the texture variability = lower noise
• Lower the smoothness numbers (at least more low numbers,
lower std. dev.)
• Greater concrete durability
How To Achieve High Concrete Uniformity

What are the other byproducts of these two specs?

• Yield denser concrete with a superior hardened concrete air
void system
• Less joint spalling
• Superior imbedded bar locations
• Better, non-slumping edges
• Less mortar required on the surface for finishing = more
durable surface.
How To Achieve High Concrete Uniformity

What will these incentive based specs do?

• It will keep the “uninitiated” contractor focused on the factors
required to get uniform concrete
• The potential incentive will allow the good, quality conscience
contractor to invest in new technology, pay for premium
materials and good practices and motivate his workforce
The Australian’s Got It Right in 2009!
Australian Paving Experience – Contractor
Theiss Pty Ltd. (Div. of Leighton Holding Group)
Well Graded Mixture Used - “Shilstone Mix”

Design and Control of Concrete Mixtures, Portland

Cement Association, Skokie, IL, 2003
Multiple Bins / Accurate Weighing / Accurate Pre-
Blending
Concrete Mixed in a Twin Shaft Mixer
Concrete Pre-Spread in Front of the Paver
Concrete Uniformly Pre-spread in Front of the
Paver
Crawler Tracks Running on Machine Place Base
Uniform Surface Smoothness – No Hand Finishing
Only a Float Pan and Hessian Drag Used
Resulting Hessian Drag Longitudinal Oriented
Microtexture
Uniform Microtextured Concrete Surface
Ready for Transverse Tining
Texture Cure Machine Applying
Transverse Texture
3m Wide Traverse Tine Rake – One Direction Tining
Close-up Tine Rake – Tines Excavating Grout
Australian Transverse Tining Spec
• Random Tine Spacing – widest 19mm w/ average
12mm pattern - repeats every 250mm.
• Depth of Tine – 1mm
• Width of Tine – 3mm
• Texture in one direction only proved to be quieter
Resulting Transverse Macrotexture and
Longitudinally Oriented Microtexture
Proper Tining
• When you are tining high quality and uniform concrete, the
tines actually excavate without vertically displacing grout.
Look for the little grout “balls”.
• Well graded and Uniformly Well Mixed Concrete provides a
perfectly uniform surface resulting in minimal texture
variability = low noise pavement
Resulting Australian Surface Texture – 3mm wide
Saw Cut
Concrete Quality – Australian Experience
Australia set aside 1.5% of the contract value for incentives.
75% are related to concrete quality and smoothness:
• Smoothness – mean + std. deviation (30% of 75%)
• Concrete Uniformity – CV = std. dev. / mean compressive
strength
• Relative Density – Compressive strength comparing core
vs. in-situ density
• Cracks – No. of unplanned cracked panels / panels
The other incentives are related to
• Site Accidents
• Project Delivery
Concrete Quality – Australian Experience

• Australia has an incentive to encourage concrete uniformity

measured by collecting the coefficient of variation (CV) on
compressive strength (CV=std. dev./mean)
• Their logic is the lower the CV the higher the concrete
uniformity which translates into more uniform concrete =
lower texture variability = lower noise
• They proved on this project that higher concrete uniformity
also translates into better pavement smoothness and lower
noise.
Concrete Quality – Australian Experience

• Smoothness – mean + std. deviation (NAASRA mean) as

measured by an RoLine Laser on light weight profiler using
IRI
> 49 – Must Grind into spec
42 – No bonus / no correction or deduction
< 35 – Full bonus
Jobsite currently running averaging 30.6 (best in Australia)
Best Theiss smoothness in the past – other projects in the
low 40s. Best day ever before was a 33.
Concrete Quality – Australian Experience
• Compressive Strength – CV = std. dev. / mean
M302 Mix (290 kg cement / 60 kg fly ash)
35 MPa Min. Spec. on Compressive Strength (28 Day)
• Using a Shilstone type mix
• Two G&Z SCP6 Plants w/ 6m3 Twin Shaft Mixer (60 s mix
time) mean = 52.2 MPa / std. dev. 2.75 / Min. Strength = 42.3
MPa / CV = 5.3%. Peek plant output (each) 240 m3/hr
• One Plant w/ 6m3 SGME Split Drum Mixer (90 s mix time)
mean = 51.1 MPa / std. dev. 3.70 / Min. Strength = 38.3
MPa / CV = 7.3%. Peek plant output 150 m3/hr
• 146,000 m3 batched to date with 100% bonus earned CV <
6.5%
Concrete Quality – Australian Experience
• Noise - Measure with by a microphone located 7.5m away
from a vehicle travelling 100 km/hr – Did not use OBSI
measurement
• Theiss ran two tests 200 m apart with transverse tining - 1
mm tine depth 80.4 dBA and 82.5 with deeper tine.
• Australia designated Low Noise Pavements
SMA – 77.7 dBA after completion and 82.4 two years after
completion
Diamond Grinding – (only 180 blades / m) 84.6 dBA then
83.9 dBA after knocking down fins
Exposed Aggregate (max. 10mm stone) 81 dBA
Conclusion – How to Achieve Smooth,
Durable and Quiet Pavements
• Set aside attractive and meaningful incentives to do it
right in each contract!
• Suggest 1.5 to 2% of the contract value for maximum
incentive. Make at least 75 to 80% of the incentive
related to concrete quality, uniformity and smoothness.
• The contractor who doesn’t seek quality and maximize his
incentive will need to change / improve quality or they
won’t be able to compete.
Conclusion – How to Achieve Smooth,
Durable and Quiet Pavements
• Add a std deviation factor to your smoothness spec and
keep it incentive based. Mean (lots per day) + Std. Dev.
Goal is to have lower std. dev. on the smoothness.
• Borrow the Iowa specification using the incentive based
Coarseness Factory Chart to insure dense, well graded
concrete.
• Add an incentive based CV specification on compressive
strength to insure concrete uniformity within each batch and
batch to batch to minimize texture variability
Conclusion – How to Achieve Smooth,
Durable and Quiet Pavements
• Audit what your contractors are currently doing, gradually
raise the bar but offer meaningful incentives so the good
quality contractors will buy new technology, better materials
and innovate to maximize their incentive dollars.
• Don’t be afraid to incentivize the contractors. Contracting is
perfectly competitive.
• Seeking maximum incentive dollars will drive quality but
eventually with contractor gained confidence, competition will
force a portion of the incentive to be “put on the table” (by the
contractor) to insure they get the work.
Conclusion – How to Achieve Smooth,
Durable and Quiet Pavements
• Design and specify for success!
• DOT and industry need to work together to eliminate
specified designs that detract from durable, smooth and low
noise pavements. Do this at the design stage.
• Allow innovative new technology that meets your end result
specification. Contractor should be required to reasonably
demonstrate the new technologies ability to meet or exceed
the spec.
Special Thanks!

Rob Rasmussen, PhD, PE

Transtec Group, Inc.
6111 Balcones Drive
Austin, TX 78731 U.S.A.
Office (512) 451-6233
www.thetranstecgroup.com
Special Thanks!

Paul Okamoto, PhD, PE

Construction Technology Labs (CTL)
Group
5420 Old Orchard Road
Skokie, IL 60077 U.S.A.
Office (847) 965-7500
okamoto@ctlgroup.com
Thanks!

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presentation are at the sole discretion of
Guntert & Zimmerman Const. Div., Inc.
For additional information contact the
Administrative Department at:
222 E. Fourth St. Ripon, CA 95366 USA
Phone (209) 599-0066 Fax (209) 599-2021
Email gz@guntert.com
Web www.guntert.com