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Construction and Testing of Construction Cycle 2 (CC2) Overlay Murphy Flynn FAA Airport Technology R&D Branch, AAR-410 William J. Hughes Technical Center, Atlantic City, NJ 29 th Annual Airport Conference Hershey, Pennsylvania March 1, 2006 Lia Ricalde SRA International 3120 Fire Road, Egg Harbor Twp., NJ 08234 Slide 2 AAR-410 2 Outline Construction Cycle 2 (CC2) Overview CC2 Rubblization CC2 Flexible Overlay Pre-traffic Testing CC2 Overlay Traffic Post-traffic Testing Slide 3 AAR-410 3 NAPTF Construction Cycle Slide 4 AAR-410 4 Outline Construction Cycle 2 Overview CC2 Rubblization CC2 Flexible Overlay Pre-traffic Testing CC2 Overlay Traffic Post-traffic Testing Slide 5 AAR-410 5 Plan View of All CC2 Test Items Slide 6 AAR-410 6 Profile of CC2 Test Items Slide 7 AAR-410 7 CC2 Concrete Mix Cementitious Aggregate: 50% Portland Cement Type I 50% Class C Flyash Mix 50% Natural Sand 50% #57 Crushed Stone Slide 8 AAR-410 8 Traffic Parameters North side 6-wheels (3D) South side 4-wheels (2D) Dual distance 54 inches (1372 mm) Tandem distance 57 inches (1448 mm) 55,000 lbs (25 t) load per wheel 210 psi (1.45 MPa) tire pressure Traffic speed 2.5 mph (855 m/sec) Standard wander pattern, 66 passes per cycle. Slide 9 AAR-410 9 Applied Traffic Wander Pattern Slide 10 AAR-410 10 MRC North MRC South MRC North MRC South First crack on south outer lane at 992 Passes April 29, 2004 First crack on south inner lane at 2,458 passes May 10, 2004 First crack on north outer lane at 3,653 passes May 21, 2004 North side distress at 6,085 passes similar to south side at 4,720 (06/02/04). South side traffic stopped at 4,720 passes (05/20/04). North side traffic 3,331 passes. First crack on north inner lane at 3,273 passes May 19, 2004 Final traffic on MRC north side 12, 675 passes and south side 5,405 passes (06/30/04). CC2 MRC Traffic Slide 11 AAR-410 11 Typical Severity of Cracks Slide 12 AAR-410 12 CC2 Test Items Applied Traffic Full-scale traffic testing began on 4/27/04 and ended 12/10/04. Section Number of Passes MRCMRGMRS North5,40531,02020,262 South12,67531,02031,020 Slide 13 AAR-410 13 Rubblized Section 01/25/05 12/29/04, 5x5x12 cut- out on PCC slab. 01/12/05, P-154 removed, CBR on Subgrade top. 01/17/05, Subgrade removed (1 ft.), CBR test. 01/19/05, Subgrade and P-154 filled back into pit. PCC cut-out put back into pit. 12/29/04, 5x5x12 cut-out on PCC slab. 01/12/05, P-154 removed, CBR on Subgrade top. 03/07/05, Plate Load Test on Subgrade top. Subgrade removed (1 ft.), CBR test, torvane on lateral walls and shelby tubes. N MRC Material Characterization MRC Flexural Strength Sawed Beams: 617 psi Molded Beams: 744 psi North Traffic DT (2D) Abbreviated Wander 12,675 passes (3,336 coverages) South Traffic DT (2D) 5,405 passes (1,138 coverages) 04/21/05, 4x4x12 pit sawed-cut for material gradation. 05/23/05, roofing membrane placement. Slide 14 AAR-410 14 Rubblized Section 01/25/05 03/02/05, 7x4x12 cut-out on PCC slab. CBR on Subgrade top and one foot below, torvane on Subgrade lateral walls. Plate Load Test on Subgrade top. Shelby tubes. PCC cut-out put back into pit. N MRG Material Characterization MRG Flexural Strength Sawed Beams: 675 psi Molded Beams: 833 psi North Traffic TDT (3D) 31,020 passes South Traffic DT (2D) 31,020 passes 04/22/05, 4x4x12 pit sawed-cut for material gradation. 05/23/05, roofing membrane placement. Slide 15 AAR-410 15 Rubblized Section 01/25/05 N MRS Material Characterization 04/22/05, 4x4x12 pit sawed-cut for material gradation. 10/14/04, 7x7x12 cut-out on PCC slab. 01/17/05, Plate Load Test (PLT) on P-306. 5x5x6 cut-out on P-306, PLT on P-154. P-154 removed, PLT on Subgrade top. 01/19/05, P-154 filled back into pit, new 6 P-306 placed. PCC cut-out put back into pit, completed with hand mix concrete. MRS Flexural Strength Sawed Beams: 688 psi Molded Beams: 691 psi 12/30/04, 5x5x18 cut-out on PCC slab. 01/18/05, P-154 removed, CBR on Subgrade top. 01/19/05, P-154 refilled and 6 new P-306 placed, PCC cut-out put back into pit. 03/02/05, 8x4x18 cut-out on PCC slab. P-154 removed, CBR on Subgrade top and one foot below, torvane on Subgrade lateral walls. P-154 refilled and 6 new P-306 placed, slab put back into pit. South Traffic DT (2D) 31,020 passes North Traffic TDT (3D) 20,262 passes 05/23/05, roofing membrane placement. Slide 16 AAR-410 16 Outline Construction Cycle 2 Overview CC2 Rubblization CC2 Flexible Overlay Pre-traffic Testing CC2 Overlay Traffic Post-traffic Testing Slide 17 AAR-410 17 FAA Guidelines for Rubblization Engineering Brief No. 66 (February, 2004) Rubblized Portland Cement Concrete Base Course Interim guidance Based on broad industry experience Full-scale testing is still needed to develop design standards for the use of this technology at airports under heavy aircraft loading Slide 18 AAR-410 18 Rubblization of CC2 Test Items January, 2005 Concrete slabs in the north traffic lane, including those in the transition sections, were rubblized with an RMI RB-500 resonant breaker operating at 44 Hz. Slide 19 AAR-410 19 RMI RB 500 Slide 20 AAR-410 20 Rubblization Video Slide 21 AAR-410 21 CC2 South Side South half of all test items overlaid in the as trafficked condition. Some anti reflective cracking measures applied in key areas. Roofing membrane applied over larger cracks and saw cuts. Slide 22 AAR-410 22 CC2 Before Overlay Rubblized on the Left (North) and As-Trafficked on the Right (South) Slide 23 AAR-410 23 Test Pits in Rubblized Test Items 4-foot (1.22 m) long by 4-foot (1.22 m) wide test pit was saw cut in each test item for visual examination of the rubblized concrete (extent of fractures from rubblization process, particle sizes, etc.). Slide 24 AAR-410 24 Slide 25 AAR-410 25 Slide 26 AAR-410 26 Slide 27 AAR-410 27 Slide 28 AAR-410 28 Slide 29 AAR-410 29 Slide 30 AAR-410 30 Outline Construction Cycle 2 Overview CC2 Rubblization CC2 Flexible Overlay Pre-traffic Testing CC2 Overlay Traffic Post-traffic Testing Slide 31 AAR-410 31 Compacting Rubblized Lane Slide 32 AAR-410 32 Roofing Membrane (South Lane) Slide 33 AAR-410 33 Roofing Membrane Before Overlay Slide 34 AAR-410 34 CC2 Prepared for Overlay Slide 35 AAR-410 35 CC2 Flexible Overlay 5 in. (12.7 cm) of FAA P-401 Hot Mix Asphalt (HMA) applied in two 2.5 in (6.3 cm ) lifts. Tack coat (emulsion) between lifts Slide 36 AAR-410 36 Construction Cycle 2 Overlay (CC2-OL) Slide 37 AAR-410 37 HMA First Lift on Rubblized Lane Slide 38 AAR-410 38 Tack Coat Application Tack coat (emulsion) applied at end of first lift. Allowed to break overnight Slide 39 AAR-410 39 Final Lift Placement Slide 40 AAR-410 40 Outline Construction Cycle 2 Overview CC2 Rubblization CC2 Flexible Overlay Pre-traffic Testing CC2 Overlay Traffic Post-traffic Testing Slide 41 AAR-410 41 Uniformity of Pavement Structures Heavy-weight deflectometer (HWD) tests were performed using the FAAs HWD equipment on a 10-foot (3.05 m) grid to study the uniformity of the pavement structures. 12-inch diameter segmented load plate at three different load levels 12,000, 24,000, and 36,000 lbs (53.4, 106.8, and 160.2 kN). Slide 42 AAR-410 42 Uniformity of Pavement Structures Slide 43 AAR-410 43 Portable Seismic Pavement Analyzer (PSPA) Slide 44 AAR-410 44 Slide 45 AAR-410 45 Slide 46 AAR-410 46 Outline Construction Cycle 2 Overview CC2 Rubblization CC2 Flexible Overlay Pre-traffic Testing CC2 Overlay Traffic Post-traffic Testing Slide 47 AAR-410 47 CC2 Overlay Gear Configurations 4-Wheel Landing Gear Configuration Wheel Load = 55,000 lbs Tire Pressure = 220 psi Slide 48 AAR-410 48 North Wheel Track Wheel Load = 65,000 lbs Tire Pressure = 260 psi South Wheel Track CC2 Overlay Gear Configurations After 5,000 Passes Slide 49 AAR-410 49 Traffic Summary Dates (from-to) Passes (Total)Test Items Load on North Lane Load on South Lane 07/07/05 07/25/05 5,082 (5,082) MRG-N, MRC-N, MRS-N MRG-S, MRC-S, MRS-S 55,000 lbs. (4-Wheels) 55,000 lbs. (4-Wheels) 07/26/05 08/12/05 6,732 (11,814) MRG-N, MRC-N, MRS-N MRG-S, MRC-S, MRS-S 65,000 lbs. (6-Wheels) 65,000 lbs. (4-Wheels) 08/15/05 08/18/05 2,442 (14,256) MRG-N, MRC-NW, MRS-N MRG-S, MRC-S, MRS-S 08/19/05 08/24/05 2,046 (16,302) MRG-N, MRS-N MRG-S, MRC-S, MRS-S 09/13/05 10/06/05 9,306 (25,608) MRG-N, MRS-N MRG-S, MRS-S Slide 50 AAR-410 50 Rut Measurement Slide 51 AAR-410 51 Rubblized Section (North Side) Area of Prior Test Pit Slide 52 AAR-410 52 South Side Area of Prior Test Pit Slide 53 AAR-410 53 Slide 54 AAR-410 54 Longitudinal Joint Failure Slide 55 AAR-410 55 Outline Construction Cycle 2 Overview CC2 Material Characterization CC2 Rubblization Test Pits CC2 Flexible Overlay Surface Preparation CC2 Overlay Pre-traffic Testing Uniformity Test PSPA Test CC2 Overlay Traffic Post-traffic Tests in Trenches Slide 56 AAR-410 56 P-401 Asphalt Concrete Surface Cores. Visual examination for cracks. Lab tests air voids, dynamic modulus. Slide 57 AAR-410 57 Rubblized Concrete Layer (North Lane) Visual examination. Plate load Tests Inside wheel track Outside wheel track Slide 58 AAR-410 58 Plate Load Tests - Rubblized Concrete Slide 59 AAR-410 59 MRC Rubblized Concrete Slide 60 AAR-410 60 MRG Rubblized Concrete Slide 61 AAR-410 61 MRS Rubblized Concrete Slide 62 AAR-410 62 P-306 Econocrete Subbase Plate load tests Inside wheel track Outside wheel track Slide 63 AAR-410 63 P-154 Subbase Plate load tests Inside wheel track Outside wheel track CBRs In-situ density (sand cone) Slide 64 AAR-410 64Subgrade Plate load tests Inside wheel track Outside wheel track CBRs In-situ density (drive cylinders) Shear Strength (vane shear) Slide 65 AAR-410 65 Slide 66 AAR-410 66 MRC-E Slide 67 AAR-410 67 MRC-E: Layer Profiles Slide 68 AAR-410 68 MRC-E Slide 69 AAR-410 69 MRC-W Slide 70 AAR-410 70 MRC-W: Layer Profiles Slide 71 AAR-410 71 MRC-W Slide 72 AAR-410 72 Slide 73 AAR-410 73 MRG Slide 74 AAR-410 74 MRG: Layer Profiles Slide 75 AAR-410 75 Slide 76 AAR-410 76 MRS Slide 77 AAR-410 77 MRS Slide 78 AAR-410 78 MRS: Layer Profiles Slide 79 QUESTIONS? http://www.airtech.tc.faa.gov/