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MODERN TECHNOLOGY IN FAST

TRACK ROAD CONSTRUCTION


“ULTRA THIN WHITE TOPPING”

SEMINAR BY-

SHAMKANT D.KUMAVAT

T.E.CIVIL ENGINEERING

G.S.M.C.O.E.PUNE.
BITUMINOUS
PAVEMENTS: Problems

• Require repeated maintenance


• Distress in early service life
– Rutting,
– Cracking,
– Settlement
– Pot holes
• Expensive if
service life cost
considered
BITUMINOUS PAVEMENTS :
UPGRADATION

• Current Practice
– Patch repairs with bitumen
– Occasional upgradation
with a Bitumen overlay
– Results : deterioration
unabated
• Is there an alternative?
– Which is
• Durable
• Cost-effective
• Technically superior
What is
Whitetopping?
 Plain cement concrete layer constructed
on top of an existing HMA-(hot mix asphalt ) pavement)
 Well established and proven technique in
the Western countries
 Used to combat rutting in truck corridors
 Usual Pavement thickness > 200 mm
• Asphalt layer acts as a base layer
• Studies indicates good to excellent
performance
Contd….
What TWT
and UTW ?
• Thin Whitetopping (TWT)
– Pavement thickness – 100-200mm
– In most cases, designed and constructed
without consideration of bond between
HMA and concrete
• Ultra-Thin Whitetopping (UTW)
– Pavement thickness < 100mm
– designed and constructed with
consideration of bond between HMA and
concrete
– Closer joint spacing Contd….
Typical c/s of
UTW
HISTORY OF UTW (USA)

YEAR
ADVANTAGES OF
UTW
 Reduced thickness
 Fast-Track construction
 Reduced maintenance
 Cost-Effective compared to asphalt overlays
 Improved service life
 Little pre-overlay repairs
 Improvement in safety in view of the
increased reflection of light
 Reduction in operational costs and lower
absorption of solar energy
 Improving the environmental benefits
Necessity of
Sound Bond
• UTW overlays are designed &
constructed with sound bond
between plan concrete and HMA
material
• Ensures composite action between
Asphalt and Concrete
• Stresses in the top concrete layer
are low in view of the composite
action
Characterisation
of HMA
• Adequate characterization of
HMA highly essential for UTW
• Visual Inspection
• Lab. and field Tests
- The Hamburg wheel track test
- Dynamic Modulus test
- Falling weight deflectometer
Design of UTW
• Thickness of UTW determined by:
– Type & Volume of existing and
expected traffic
– Strength & Condition of existing
pavement
– Material properties of the concrete
• Design Method
– Developed by the PCA, USA
Concrete mixes for UTW :
Main Parameters

• Fast-Track type construction


-One day Flexural strength: 4 MPa
-One day Compressive Strength : 35MPa
• Mix requirements
– Mineral admixtures
• Silica fumes,
• Fly-ash
• Or a combination of two
– Low water/binder ratio
– Use of a Superplaticiser
– Synthetic fibers, if required
Table 1: Laboratory mixes for Ultra-Thin White Topping

Ingredients VTMS07 VTMF02 VTOF02 VTMS08P VTMF03P VTOF03P

Cement, kg 450 380 420 450 380 420


Microsilica, kg 35 30 0 35 30 0
Flyash, kg 0 100 105 0 100 105
Total Binder 485 510 525 485 510 525
Polypropelene fibres, kg 0 0 0 0.900 0.900 0.900
Aggregate, kg: 20 mm 633 607 601 644 639 622
Aggregate, kg: 10 mm 422 405 400 430 426 415
Vaitarna sand 497 497 491 486 463 470
Curser Dust 332 331 328 324 309 313
Water, lit 121 143 147 121 143 147
HRWRA, lit 9.70 5.30 5.25 9.70 6.63 6.56
2.00% 1.04% 0.7% 2.25% 1.30% 1.25%
W/B Ratio 0.25 0.28 0.28 0.25 0.28 0.28
Slump (mm) 65 80 80 55 60 75
Comp Strength, MPa
1 Day 35.11 19.73 19.87 36.31 24.8 26.8
3 Days 51.47 32.18 34.89 54.84 38.44 37.95
7 Days 69.02 45.51 47.78 68.71 56.31 48.71
28 Days 94.30 69.07 69.56 90.42 72.26 70.44
Flexural Strength, MPa
1 Day 3.6 - - 4.00 - -
3 Days - 4.20 4.00 - 4.20 4.2
7 Days 6.80 4.40 4.40 7.00 5.60 4.6 (6D)
28 Days 9.2 7.80 6.00 9.00 8.00 6.20
Construction
Practice
• Pre-overlay repair
– Creation of uniform support to concrete
pavement essential
– Repair of cracks, shoving, leveling
– Milling creates
better bond
HMA
– Min. HMA
thickness 75 mm
Construction
Practice
• Concrete
production
• Proper Placing,
vibrating
Construction
Practice

Adequate Curing
Joints in UTW
• Usual spacing : 12 to 15 times
thickness (0.6 to1.8 m)
• Shorter spacing reduces curling
stresses
• Early Joint cutting essential
• Can use “early entry” saws
Conclusions &
Suggestions
• UTW is a well established technique
• Sufficient experience in the use of
this technique is already avaialbale
in the West
• In India, adoption of UTW may be
considered as an alternate to
upgradation of bituminous
pavements with HMA
• Some experimental stretches using
UTW can be laid immediately to gain
experience
Case Study
• An experimental stretch was laid at
Mahul road, Chembur on 5th March
’07
• Length=26m
• Width=3.25m
• Thickness=0.1m
• Joint cutting was done at after every
1.08m
• Curing was done for 3 days
Results
• Mixes: M60 (per m3)
• Cement 450 Kg
• Micro Silica 35 Kg
• W/B 0.25
• 3 days 47.24 N/mm2
• 7 days 66.71 N/mm2
• 28 days 72.27 N/mm2
Results
• Mixes: M60 (per m3)
• Cement 450 Kg
• Micro Silica 35 Kg
• Polypropylene fibers 900 grams.
• W/B 0.25
• 3 days 40 N/mm2
• 7 days 63.4 N/mm2
• 28 days 74.24 N/mm2
Concrete mixes for UTW :
Main Parameters

• Fast-Track type construction


-One day Flexural strength: 4 MPa
-One day Compressive Strength : 35MPa
• Mix requirements
– Mineral admixtures
• Silica fumes,
• Fly-ash
• Or a combination of two
– Low water/binder ratio
– Use of a Superplaticiser
– Synthetic fibers, if required
Road Length
in Mumbai
1) MUNICIPAL CORPORATION
OF GREATER MUMBAI (MCGM)
has about 1941 kms of roads ,

2) Infrastructure in Mumbai. ¾
In addition, there are roads
owned by PWD, MHADA, MPT
and roads in private layouts.

3) Approximately 351 kms are


concrete roads.
Road Length
in PUNE
1) Road length covering
Pune City Area 1,252
Kms.
2) Around 300 km are
concrete roads.
3) Pune infrastructure is
increasingly acquiring
importance as one of
the main infrastructural
support of Maharashtraa
Pouring of Concrete
Curing of Concrete
Cutting of Joint
Breaking of Existing CC Pavement
Fixing of Channels
Ultra-Thin White Topping on Rigid Pavement
A View of Ultra-Thin White Topping
A View of Ultra-Thin White Topping
THANK
YOU