witold zapasnik "Ülevaade betoonteede ehitamisest poolas viimase 25 aasta jooksul"

D e p a r t a m e n t T e c h n o l o g i i

An overview of the construction of concrete roads in Poland over the past 25 years.

„Introducing foreign experience in the construction of concrete pavements”

Conference in Tallinn, Estonia, 7June 2016

Witold Zapaśnik, GDDKiA, DT- WBiNB,


Plan of presentation1. Organization of GDDKiA - General Directorate for National Roads and

Motorways.

2. Program of Construction of National Roads for the years of 2015 – 2023 according to the Council of Ministers’ Act from 24th August 2015. State-of-art. for the 1st October 2015.

2.1. National road sections (motorways and expressways) planned to be constructed in the years of 2015-2023 (circa 1670 km – including 800km in concrete).

3. Existing road projects executed and under execution in Poland on the network of motorways and expressways with concrete pavements.

3.1. Existing and planned road projects executed in bituminous and concrete technology in Poland on the network of motorways and expressways (2015- 2023).

4. Pavement structures and types of concrete pavements.

2


Plan of presentation continued5. Examples of choosen, existing concrete pavements taking into account their present technical condition (photos).

5.1. By-pass of Młodzieszyn in the route of DK 50 (section Wyszogród-Sochaczew) – an example of too fast pavement deteroriation.

5.2. Sections on motorway A4/A18 (Wrocław-Krzyżowa-Olszyna, Krzyżowa – Zgorzelec) executed in continuous reinforced cement concrete (CRCC).

5.3. The section on DK S8 Wolbórz-Polichno executed in the technology of Whitetopping (WT).

5.4. Concrete pavement section executed in whitetopping technology on municipal road section in the town of Żory.

5.5. Refurbishment of S8 at the section Piotrków Tryb - Rawa Maz. – border of voivodeship of łódz/maz., 2013 road works – laying concrete pavement, section of km 323+700 left carriageway.

5.6. Motorway A-2 at the section of Nowy Tomyśl – Świecko.3


Plan of presentation continued5.6.1. The section with the pavement of exposed aggregate (the so called Washbeton).

5.6.2. The section with the pavement of continuous reinforced cement concrete (CRCC) without transverse joints, executed as whitetopping on existing asphalt pavement DK2 at the section from km 0+000 to km 1+100 (north carriageway).

6. Roads of other categories executed in cement concrete technology – around 700 km of voivodeship and communal roads (the 90ties of XX century and beginning of XXI century).

7. The sections of motorways, other roads and infrastructural objects planned in the nearest future to be constructed in cement concrete technology.

8. Updating of GDDKiA technical documents (OST, STWIORB, WWIORB, WT, Technical Cataloques, 2012).

4


Plan of presentation continued

9. Examples of application of new concrete technologies in construction of road pavements.

9.1. French sliding technology to lay down continuous concrete road curbs along road edges, on Motorists Service Points, (MOP) parkings and other areas and also separating barriers on speed traffic roads.

9.2. Technology of RCC (Roller Compacted Concrete).

10. Conclusions. Why is it worth to construct concrete roads ?

11. Summary of main advantages of concrete pavements.

5


Zachodnio-pomorskie

PomorskieWarmińsko-mazurskie

Podlaskie

Lubelskie

Podkarpackie

Mazowieckie

Łódzkie

Wielkopolskie

Kujawsko-pomorskie

Lubuskie

Dolnośląskie

OpolskieŚląskie

Małopolskie

Świętokrzyskie

1. Organization of GDDKiA - 16 Provincial Regions of GDDKiA and 16 WT-LD

(technological units/road laboratories)

6

GDDKiA Headquarters

in Warsaw


2. Program of construction of national roads in the years of 2015 – 2023. State-of-art for the 1st October, 2015.

7


2.1. National road sections (motorways and expressways) planned (in green colour) to be constructed in the years of 2015-2023 (circa 1670 km – including 800 km in concrete)

8



9

Total length of concrete motorway sections

Total length of concrete expressway sections

TOTAL

D e p a r t a m e n t T e c h n o l o g i i 10

3. Existing road projects executed and under execution in Poland on the network of motorways and expressways with concrete pavements .

1. Modernization of motorway A4 at the section of Golnice-Krzywa, two carriageways with the length of 17,0 km (1995-1996),

2. Toll Collections Stations on motorway A4: Brzęczkowice, Balice, Karwiany (1999-2000),

3. DK50, By-pass of Młodzieszyn, the length of 4,0 km, 2002,

4. DK8, the section Wolbórz-Polichno, (whitetopping) two carriageways, the length of 11,0 km, 2002-2003,

5. Intersection of DK1 at the town of Siewierz, 2003,

6. Modernization of motorway A4 at the section of Krzywa-Wądroże Wlk. – Bielany Wrocławskie, two carriageways, the length of 92 km (2003-2006),



7. Modernization of DK18 (A18), the section of Królów-Golnice, north carriageway, the length of 64 km (2005-2006),

8. Construction of motorway A4, section of Jędrzychowice-Krzyżowa, two carriageways, the length of 51 km (2006-2008),

9. Motorway A4, construction of additional traffic and emergency lane at the section of Wrocław-Legnica 2010,

10. Construction of motorway A2, the section of Nowy Tomyśl-Świecko, two carriageways, the length of 105,9 km, 2010,

11. DK S8, the length of 61 km, the section of Piotrków Trybunalski – Rawa Mazowiecka, 2008-2012,


3.1. Existing and planned road projects executed in bituminous and concrete technology in Poland on the network of motorways and expressways.

LEGENDExisting bituminousExisting concretePlanned concretePlanned bituminous


4. Pavement structures and types of concrete pavements.

13


ASPHALT CONCRETE

FLEXIBLE RIGID

Wearing courseBinder course

Base course (mechanically compacted aggregate)

Asphalt and concrete road structure cross-sections

Cement concrete slabBase course (lean concrete)Subgrade (mechanically compacted aggregate)


Podstawowa konstrukcjaBasic structure of concrete pavement

Concrete slab

Base course

Capping layer (frost-protection)

Cement stabilised soil layer

Natural soil (virgin soil)

Desined thicknessess of layers

Artificial soil layer


Concrete pavement nawierzchni betonowej

16

CONCRETE PAVEMENT CROSS-SECTION

Method of exposing fine aggregate in upper layer

„Sand paper”

Asphalt shoulder

Dowels

Longitudinal joint

Transversal joints

Tie bars

Cement concrete

Base course

Side drainage

Subgrade

From 4 to 6 m


TYPES OF CONCRETE PAVEMENTS

Unreinforced and undowelled pavements

Unreinforced pavements but with dowels and tie bars

Reinforced pavements with dowelled joints Continuously reinforced pavaments

Pavements with scattered fibres

Pavements with rolled concrete

Pavements with porous concrete

Pavements with pre-stressed concrete

Prefabricated pavements

Mixed (composite pavements) – pavements in which on the ccmmmmmm

concrete base course the thin layer of asphalt-mineral mixture is placed


Konstrukcja z płytą betonową niedyblowaną

PAVEMENT STRUCTURE WITH CONCRETE UNDOWELLED SLAB

1 Concrete slab

2 Geosynthetics 3 Lean concrete or crushed aggregate stabilised with cement

4 Subgrade


Konstrukcja z płytą betonową niedyblowanąPAVEMENT STRUCTURE WITH CONCRETE UNDOWELLED SLAB

1 Thick concrete slab

2 Drainage layer of crushed aggregate or geosynthetics3 Subgrade


Konstrukcje z płytami dyblowanymiSTRUCTURES WITH DOWELLED SLABS

1 Concrete slab dowelled and tied2 Lean concrete

3 Subgrade


Konstrukcje z płytami zbrojonymiPAVEMENT STRUCTURES WITH REINFORCED SLABS

1 Concrete slab with continuous reinforcement

2 Lean concrete

3 Subgrade


Zużycie betonu na budowie autostrady

Assuming the average thickness of a concrete slab in the pavement structure to be about 25 cm and a typical cross-section of a dual-carriageway motorway, the estimate usage is about 5000 cubic meters of concrete /1km of a new motorway under construction.

Assuming on average 1 engineering structure /700 m of a motorway (e.g. viaduct, animal crossing) with dimensions of 60 x 15 x 1,2 m (the bigger structure thickness has been assumed to consider intermediate supports and piles under foundation), about 1100 cubic meters of concrete is used in their low-bearing structure. Of course, smaller and bigger objects exist which consume other quantities of concrete (eg. road culverts, retaining walls).

22

AVERAGE CONCRETE CONSUMPTION ON MOTORWAY CONSTRUCTION SITE


5. Examples of chosen, existing concrete pavements taking into account their present technical condition (photos).

23


5.1. By-pass of Młodzieszyn in the route of DK 50 (section Wyszogród – Sochaczew) – an example of too fast pavement deterioriation.

24


Mazowieckie VoivodeshipBy-pass of Młodzieszyn

Length – 3000 mWidth – 7,0 mExecuted – 2002 year


31


5.2. Sections on motorway A4/A18 (Wrocław-Krzyżowa-Olszyna, Krzyżowa –Zgorzelec) executed in technology of dowelled concrete slabs and continuously reinforced concrete slabs (CRCC).

MOTORWAY A4/A18


Motorway A4 - Construction of additional traffic and emergency lane at the section of Wrocław-Legnica 2010

34


4.5. Autostrada A4/a18

35


4.5. Autostrada A4/A18

36


4.5. Autostrada A4/A18

37


Motorway A4 Laying of concrete on the pavement with continuous reinforcement, section of Bielany Wrocławskie – Wądroże Wlk.- north carriageway

38


Motorway A4 contd.

39


5.3. Section on DK S-8 Wolbórz-Polichno executed in Whitetopping technology.

DK S8 , Section of Wolbórz – Polichno, Whitetopping 2002


•grunt stabilizowany cementem grub.15cm,•podłoże z gruntu G1. Technological cross-section of DK8, Wolbórz-

Polichno on soil of G1 type

Cement concrete B-40, thickness 27 cmSeparation membrane (slipping layer) – surface treatmentExisting pavement structure:a)Bituminous layer 13-20 cm thick,b)Lean concrete layer 15 cm thick, Soil of G1 type

Cement concrete B-40 thickness 27 cmSeparation membrane (slipping layer) – surface treatmentNew pavement structure:a)Lean concrete base course, thickness 18 cm,b)Cement stabilised soil, Rm= 2,5 Mpa, Soil of G1 type


Odcinek nawierzchni betonowej zrealizowany w technologii Whitetopping na drodze miejskiej w miejscowości Żory

46

5.4. CONCRETE PAVEMENT SECTION EXECUTED IN WHITETOPPING TECHNOLOGY ON MUNICIPAL ROAD SECTION IN

THE TOWN OF ŻORY

Whitetopping 2007, KR6,Length 7,0 km

Width 2 x 3,5 m

- Concrete slab dowelled and tied,- Upper base course of asphalt mixture,- Lower base course, mechanical stabil.,- Drainage course,- Cement stabilised soil


5.5. REFURBISHMENT OF S8 AT THE SECTION PIOTRKÓW TRYB - RAWA MAZ - GR. WOJ. ŁÓDZ/MAZ., 19.06.2013 ROAD WORKS – LAYING CONCRETE PAVEMENT, SECTION OF A1 KM 323+700 LEFT CARRIAGEWAY

47


5.5. REFURBISHMENT OF S8 AT THE SECTION PIOTRKÓW TRYB - RAWA MAZ - GR. WOJ. ŁÓDZ/MAZ.

48



49



50



51



52



53



54



55



56



57



58



59



60



61



62



63



64



65


5.6 Motorway A-2 at section Nowy Tomyśl – Świecko, 2010 - 106 km.

66

Section of A-2 Nowy Tomyśl - Świecko


5.6.1. Motorway A-2 at section of Nowy Tomyśl – Świecko. Concrete pavement section with exposed aggregate (the so called WASHBETON)

67

Concrete pavement surface executed in the technology of the so called Washbeton.



68

Upper and lower layer of concrete slab



69

Layer structure and concrete pavement construction equipment


5.6.2. The section with the pavement of continuous reinforced cement concrete(CRCC) without transverse joints, executed as whitetopping on existing asphalt pavement DK2 at the section from km 0+000 to km 1+100 (north carriageway).

70

PAVEMENT STRUCTURE-Concrete slab with continuous reinforcement C35/45 – 23 cm-Separation membrane mma AC 11S – 4 cm-Profiling layer mma AC 16W – 11-14 cm-Existing mma layer 18 cm (milled to the depth 0-5 cm)-Existing lean concrete layer - 24 cm-Soil layer of G1 type

WIDENING-Separation membrane mma AC 11S - 4 cm-Profiling layer mma AC 16W – 11-14 cm-Lean concrete - 20 cm-Frost protection layer - 35 cm

CBR > 30, k>3m/day, 0,075 mm particles content<5%

- Soil layer of G1 type

Variablewidth

„stair-like” shaping of pavement structure edge120 MPa

60 MPa

2,5%

2,5%


6. Roads of other categories executed in cement concrete technology – around 800 km of voivodeship and communal roads (the 90ties of XX century and beginning of XXI century)

71


7. The sections of motorways, other roads and infrastructural objects planned in the nearest future to be constructed in cement concrete technology.

1. Motorway A1, section Stryków-Tuszyn, two carriageways 40 km (under construction),2. Motorway A1, odcinek Piotrków Tryb-Pyrzowice, length 140 km,3. Motorway A18, refurbishment and reconstruction of north carriageway, section Golnice-Olszyna, 70km,4. Motorway A4, section to the border with Ukraine at Korczowa, 4,5 km (under construction),5. Exspressway S10 Toruń-Bydgoszcz,67km,6. By-pass of Suwałki S61, 10 km (under construction),part of Via Baltica,7. Other national roads (810 km) to be constructed in the perspective of 2015-2023(2024) planned to be constructed according to the decission of GDDKiA of November 2014 (among the others, sections of S2-POW, S6, S7, S8, S17, S61),5. Extension and modernisation of national airports (W-wa, Gdańsk, Katowice, Kraków, Poznań, Rzeszów, Szczecin, Wrocław, Radom, Lublin),6. Voivodeship, communal and municipal roads.

72


8. Updating of GDDKiA technical documents (OST, STWIORB, WWIORB, WT, Technical Cataloques, 2012).

73

Expert teams called-up by GDDKiA

1.Team for environment protection and road furniture,2.Team for pavement diagnostics (DSN),3.Team for bridge works and engineering structures,4.Team for stabilised and unstabilised base courses,5.Team for concrete and concrete pavements,6.Team for soil subgrade and earthworks,7.Team for reconstruction, renovation and rehabilitation of roads,8.Team for preliminary, land-surveying and drainage works,9.Team for road maintenance,10.Team for asphalt pavements,11.Team for road traffic safety.


8.1. New GDDKiA documents relating to cement concrete pavements.

- Updating of „Cataloque of typical structures for rigid pavements”,

- Updating of OST, STWIORB, WWIORB, WT for structural, pavement concrete and concrete prefabricated elements (curbs, sidewalks slabs, concrete blocks).

74


8.1. Updating of „Cataloque of typical structures for rigid pavements”,


8.1. Updating of „Cataloque of typical structures for rigid pavements”,

76


8.1 Updating of OST (General Technical Specifications) for structural, pavement concrete and prefabricated concrete elements (curbs, sidewalk slabs,

77


9. Examples of application of new concrete technologies in construction of road pavements.

9.1. French sliding technology to lay down continuous concrete road curbs along road edges, on Motorists Service Points, (MOP) parkings and other areas and also separating barriers on speed traffic roads.

78


9.1. Execution of continuous concrete curbs and asphalt rims

79


9.1. Execution of isles at the motorway toll collection station

80


9.1. Execution of isles at the motorway toll collection station

81


9.1. A trial with sliding technology on S8 road near Piotrków Trybunalski on the access to the petrol station.

82


.

83


10.Budownictwo nawierzchni betonowych u naszych sąsiadów.

87


10.Budownictwo nawierzchni betonowych u naszych sąsiadów.

88


Results of laboratory tests of sliding concrete curbs at MOP Guzew (construction of S8, section 8)

89

Crushing strength (formulated samples)

Bending strength of ready curb (piece cut)

Crushing strength of ready curb (core 100 x 100 taken from the curb)

Average

Average


Results of laboratory tests of sliding concrete at MOP Guzew (construction of S8, section 8)

90

Water penetrationAbrasion (Boehme test)

Freeze and thaw resistance with deicing salt in 3% solution of NaCl

Mass loss


9.2. Technology of RCC (Roller Compacted Concrete)

91



92

Concrete with composition of aggregate and moisture content chosen in such a way, that before setting it shows properties close to a soil in a moist condition and is susceptible to compacion by the rolling method.



93

Beginning of RCC technology – water dams (RPA 1990,USA, 2004),

USA and Canada – first road pavements in this technology constructed in the 70 ies of the XXth century,

Since the 80ies of the XXth century the RCC pavements are widely used in America and in Europe,

In Europe – the RCC technology mosty used in Germany and France.



94

Properties of Roller Compacted Concrete

Little batch water content, 90-120 kg/mᵌ,

High content in the aggregate mixture of silty fraction (<0,075 mm), 2 – 8%,

High sand equivalent,

Possibility to use of not washed aggregates,

Typical cement content 240-320 kg/mᶟ,

Water/cement ratio (w/c) in the range of 0,30 – 0,45,

Maximum aggregate particle size 25 mm for crushed aggregate and 19 mm for natural aggregate,

Lack of aeration.



95

Strict relationship of roller compacted concrete strength and durability to proper compacion,

Required compacion index Is = 0,98



96

RCC concrete in spite of lack of aeration shows high durability and

frost resistance

Frost resistance of RCC pavement

Frost resistance of pavement constructed of vibro-pressed

concrete blocks Pavement of a test section after 2 years



97

Aggregate choice on the base of the limit curves of good gradation envelope


9.2. Technology of RCC (Roller Compacted Concrete))

98

Aggregate choice by means of iteration method

K1 – gravel 8/16K2 – gravel 2/8K3 – sand 0/2



99

Choice of cement content, 10-17% of aggregate mass, Choice of water content by means of Proctor method.



100

Workability testing by means of a modified Ve-Be apparatus

Load 9,1 kgLoad 22,7 kg



101

Production of concrete mixture in a way, ensuring its steady and unchangable moisture content,

Maximum transport time 60 min,

Laying concrete mixture with pavers ensuring possibly the highest preliminary compaction,

Thickness of concrete pavement laid, should be from 12 to 25 cm,

Additional compation of concrete mixture by means of heavy rollers, Is = 0,98,

Curing of freshly performed concrete pavement.



102



103

Miastko, Fabryczna st., Pomorskie voivodeship, first roller compacted concrete pavement performed in Poland, 2009



104

Basic parameters of RCC used to construct the pavement in Fabryczna st., in Miastko. Results from cores.

Property RCC 25/30

Density (in natural moisture condition)

Water content

Average compressive strength



105

Miłocice, Pomorskie voivodeship, a pavement in a village street performed of RCC, the length of 800 m, 2012.



106

Chances and possibilities for development of RCC technology in Poland.

RCC Technology is a durable and economical solution for construction of:

Road pavements of KR1 and KR2 traffic categories,Local and access road pavements,Forest roads,Treatment of exploited soil roads,Pavements on squares and parkings,Base course layers for roads of higher technical categories.



107

Chances and possibilities for development of RCC technology in Poland.

Expectations and requirements of Polish market (self-governing territorial state units, road authorities, state forest units) in relation to local roads : construction of durable roads with low cost

RCC technology

Creation of Polish technical guidelines and construction of testing sections


10. Conclusions. Why is it worth to construct concrete roads?

Basic advantages:1. Concrete pavements have a number of advantages such as: high bearing capacity, high ability to carry out loads, resistance to permanent strains, good drainage properties, good visibility at night, high skid resistance, low maintenance costs, long operation period, relative ease of current repairs, possibility of usage in recycling process the material from crushed concrete slabs.2. Cement concrete pavements prevail on motorways in the countries of developped road network such as USA, Germany, France, Denmark, Holland, Belgium, Austria and Czech Republic.3. Real exploatation time of concrete pavements is about twice as long as in the case of pavements performed of mineral-bituminous mixtures.4. Concrete pavements are resistant to strains in the whole range of temperatures, there is no phenomemon of rutting on them and the rain water flows well off the pavement.5. According to the foreign research (German studies), the amount of road traffic accidents on concrete pavements is less by about one third than the one on asphalt pavements.

108


10. Conclusions. Why is it worth to construct concrete roads? cntd

6. Availability of domestic resources, relatively simple and efficient technology to produce concrete and its resistance to temperature conditions during its laying process cause, thatconcrete pavements can be performed on national as well as on local roads.7. Due to the bright colour of the pavements, lighting costs of motorway pavements of cement concrete (according to the research studies e.g. in Germany, Belgium) accout for less than 60% of lighting costs of asphalt pavements.

Basic disadvantages :1. Construction cost higher than for asphalt pavements for lower categories of traffic (KR1, KR2),2. Necessity to strictly obey the construction technological regimee, 3. Long time from construction to start operation (minimum 28 days, after obtaining standard crushing strength of pavement concrete), 4. Increased operational noise (possibility to reduce it by using the so called Washbeton, narrow expansion jints and appropriate pavement texturing), 5. Lower riding comfort (transversal joits).Necessity to maintain joints.

109


The costs

110

11. SUMMARY OF MAIN ADVANTAGES OF CONCRETE PAVEMENTS

LOWER INFLUENCE ON NATURAL ENVIRONMENT (LCA ANALYSES, USA, GERMANY)The research LCAs (Life Cycle Analyses) show that the social costs and the influences on the environment (harmful emissions) during the whole (30-year) operation period is even 5 times less for concrete than for asphalt.

LOWER CONSTRUCTION COSTStarting from KR3 traffic category the cost to construct a concrete pavement is lower that an asphalt one by around 17-20% (data from the Polish Cement Association,The study by the Wrocław Technical Uniwersity 2016 ).

LOWER MAIMTENANCE COSTConcrete road maintenance cost is about 28-30% lower than for asphalt road.Full exchange of concrete road (all layers) is required after 30 years, whereas asphalt road requires replacement of wearing course after 8-10 and 20 years and after 30 years it is necessary ro replace its whole structure.

LACK OF RUTTING PHENOMENONThanks to such properties as resistsnce to atmospheric conditions (temperature changes, freeze/thaw cycles) and to high axle loads. With the usage of moder tecjhnological solutions and good execution and maintenance, the 30 or 40 year - concrete pavement operational life is guaranteed even with axle loads of 130kN/axle.

LOWER CONSUMPTION OF FUELReduction in fuel consumption for truck vehicles due to the beter mechanical-physical properties of concrete pavements (lower rolling resistance). Research in Western Europe (Belgium, Denmark, Germany) specifies this reduction to around 2- 5%, in case of American studies this reduction is specified as even reach 8 – 10%.

HIGHER TRAFFIC SAFETY, LOWER ENERGY CONSUMPTIONHigh gripping power of concrete. German studies show that the traffic accident rate on concrete motorways is less by around 32% than on asphalt ones. In addition, the visibility of other road users is better at night on concrete pavements than on asphalt ones, and the lighting costs of concrete roads is less (up to even 60%).


Thank you for your attention !!!

111

witold zapasnik "Ülevaade betoonteede ehitamisest poolas viimase 25 aasta jooksul"

Engineering