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Construction Practices and Techniques
Eng. Valmir Bonfim, M.Sc.Grupo ANE
Presentation Topics:
KMA plant characteristics;
Foamed bitumen;
Technology fail criteria;
Jobsite presentation:
Rod. dos Bandeirantes - SP;
Rod. BR-101 – RJ;
Rod. Ayrton Senna – SP;
Av. Sapopemba - SP.
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Mobile plant Cold recycling Emulsion and
foamed bitumen
KMA 220 plant
Characteristics:
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Foamed Bitumen Technology
Foam Bitumen is the result of the asphalt binder at approximately 170°C, which expands when in contact with air and water at room temperature inside
expansion chambers.
Foamed Bitumen Technology
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Finally,What is foamed RAP?
RAP = Reclaimed Asphalt Pavement
Finally,What is foamed RAP?
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Foamed RAP = is the product ofmixing milled pavement with foamedasphalt
Finally,What is foamed RAP?
RAP = Reclaimed Asphalt Pavement
Expansion Chamber
Foamed asphalt process
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Quality control of foamedasphalt
- Expansion rate- Half-life
Half-life is the time measured between themaximum expansion and a half of that expansion.
Quality control of foamedbitumen
- Expansion rate- Half-life
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Foamed bitumen = expanded bitumen binder
WLB10S machine and mini Pug-mill mixer
Design of bitumen binder % in lab
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RAP aggregate gradation
Curva Granulométrica - Esp. = 8 cm - Vel. = 10 m/min
0
10
20
30
40
50
60
70
80
90
100
0,01 0,1 1 10 100
Diâmetr o dos gr ãos (mm)
Mat erial or iginal, ant es da f resagem
Mat erial f resado, sem ext ração de
bet ume
Mat erial f resado, com ext ração de
bet ume
Peneiras
200 100 80 50 40 30 10 8 4 3/8” 1/2” ¾” 1” 1 ½” 2”
Fonte: Livro Fresagem de Pavimentos Asfálticos
Curva Granulométrica - Esp. = 8 cm - Vel. = 10 m/min
0
10
20
30
40
50
60
70
80
90
100
0,01 0,1 1 10 100
Diâmetr o dos gr ãos (mm)
Mat erial or iginal, ant es da f resagem
Mat erial f resado, sem ext ração de
bet ume
Mat erial f resado, com ext ração de
bet ume
Peneiras
200 100 80 50 40 30 10 8 4 3/8” 1/2” ¾” 1” 1 ½” 2”
Fonte: Livro Fresagem de Pavimentos Asfálticos
ISSUES HAPPENING WHENUSING RAP
Undesired Lumps
Not enough fines
RAP aggregate gradation
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Adequate gradation of foamed RAP
Wirtgen Cold Recyclig Manual
Pavement failure criteria
Fatigue cracking
• HMA• Cemented layers
Crack
Rutting
20mm
BSM´s
No crack
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Rutting:
Lower maintenance cost compared with greater depth interventions.
Procedure: Cold milling and overlay.
Pavement failure criteria
Basic steps:
1st step:- Pavement evaluation;
Functional and structural conditions, drainage etc.
2ª step: Design- Choice of the adequate solution (in place, plant);- Economical analysis;- Layers thickness design;- Selection of new materials (crusher dust, bitumen binder etc);- Recycled mix design;- Lab tests.
3ª step: Jobsite execution- Choice of adequate equipment;- Quality control;
Foam quality, mix condition, compaction etc.
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Rodovia dos Bandeirantes
Grupo CCR - AutoBan / Engelog
Cement base recycled in KMA plant
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Plant placed near the road
1st step: Cold milling of HMA
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2nd step:Cold milling of cemented layer
Execution of the 1st cemented base layerNext steps: 2nd cemented base layer and 10cm HMA
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Rodovia BR-101
Section: Rio de Janeiro
Cement base recycling in KMA plant
Milled HMA recycled using polymerized emulsion in KMA plant
Subgrade
Existent cross-section
HMA
Deteriorated cemented layer
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Subgrade
Constructed cross-section
RAP recycled with polymerized emulsion
HMA
Deteriorated base recycled with cement
25/28 cm of the thickness were recycled
Subgrade
Constructed cross-section
HMA
RAP recycled with polymerized emulsion
Deteriorated base recycled with cement
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1st step:Cold milling of the HMA layer
2nd step:Cold milling of thecemented layer
Deflection measure and verification of the reminiscent pavement
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Plant installed near the jobsite
RAP mixing with polymerized emulsion in KMA plant
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Recycled layer open to traffic
Cold recycling in KMA plant with foamed bitumen
STRUCTURAL REHABILITATION
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Deteriorated cemented base High traffic volume Highway without weight control
TEST SECTION
Surface layer exposed to traffic after 10 months
TEST SECTION
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Mix design Mixture in KMA 220 Plant
Crushed RAP. . . . . . . . . . . . 84%Crusher dust . . . . . . . . . . . . 15%Hydrated Lime. . . . . . . . . . . 1%----------------------------------------------Total . . . . . . . . . . . . . . . . . . .100%
CAP 50-70 (bitumen binder): 2,2%
Mix design Mixture in KMA 220 Plant
Crushed RAP. . . . . . . . . . . . 84%Crusher dust . . . . . . . . . . . . 15%Hydrated Lime. . . . . . . . . . . 1%----------------------------------------------Total . . . . . . . . . . . . . . . . . . .100%
CAP 50-70 (bitumen binder): 2,2%
When lime is used as active filler: stockpiling is possible
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Existent cross-section
Deteriorated cemented layer
Deteriorated HMA
Crushed Stone Layer
Milling depth: 30 cm
Deteriorated cemented layer
Existent cross-section
Deteriorated HMA
Subgrade
Crushed Stone Layer
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BGTC deteriorada1st foamed RAP layer: thickness=13,5 cm
Execution steps
Milling depth: 30 cm Subgrade
Crushed Stone Layer
BGTC deteriorada
2nd foamed RAP layer: thickness=13,5 cm
Milling depth: 30 cm
1st foamed RAP layer: thickness=13,5 cm
Subgrade
Crushed Stone Layer
Execution steps
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BGTC deteriorada
2nd foamed RAP layer: thickness=13,5 cm
Milling depth: 30 cm
1st foamed RAP layer: thickness=13,5 cm
Gap Graded: thickness=3 cm
Subgrade
Crushed Stone Layer
Execution steps
Plant installed near the jobsite
Crushed RAP
Crusher dustKMA plant Foamed RAP
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Cold milling step
30 cm thickness in one passCold milling step
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Verification of the reminiscent pavement
thickness = 30 cm
In this section, not all the cracked layer wasmilled
HMA = 20 cm
Cemented Layer = 10 cm
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New milling process to takeaway reminiscent cracked
cemented layer
Deflection measures – Benkelmann beam
Execution of the 1st Foamed RAP and compaction
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Compaction verification test: SAND CONE
Execution of the 2nd Foamed RAP and compaction
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Execution of the gap graded surface layerThickness of 3 cm and compaction
Execution of the gap graded surface layerThickness of 3 cm and compaction
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SUSTAINABLE PAVEMENT
AVENIDA SAPOPEMBASection: Av. dos Sertanistas até Av. Bento Guelfi – São Paulo
Avenida Sapopemba
Crushed CDW layer
Foamed RAP base layer
HMA 5cm
20cm
25cm
Cross-section
Subgrade
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RAP . . . . . . . . . . . . . . . . . . 80%Crusher dust . . . . . . . . . . . 19%Hydrated lime. . . . . . . . . . . 1%----------------------------------------------Total . . . . . . . . . . . . . . . . . . .100%
CAP 50-70 (bitumen binder): 2,5%
Mix design Mixture in KMA 220 Plant
CONSTRUCTION STEPS
Kerb and gutter
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Mill and replace structural layers
CONSTRUCTION STEPS
CDW Sub-base
CONSTRUCTION STEPS
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Sub-base compaction
CONSTRUCTION STEPS
Foamed RAP base
CONSTRUCTION STEPS
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Base compaction
CONSTRUCTION STEPS
HMA surface layer
CONSTRUCTION STEPS
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Compaction
CONSTRUCTION STEPS
CONSTRUCTION STEPS
Compaction
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Construction finished
CONSTRUCTION STEPS
All lab tests the presented projects were conductedat the Laboratório de Tecnologia de Pavimentação da Escola Politécnica da Universidade de São PauloLTP-EPUSP
- Rutting (ornierage);
- Resilient Modulus.
Lab tests:
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Foamed RAP – Rutting80% RAP + 19% crushed dust + 1% cement
+ 2,5% bitumen binder
3,16% 3,78% 4,59% 5,49% 6,67% 7,97%
0%
1%
10%
100%
100 1000 10000 100000
Porcentagem de afundam
ento
na trilha de roda
N. de ciclos
Afund. (A ‐ Esq.‐…
1000
10000
100000
0,1 1 10
MR ‐(kgf/cm2)
Tensão de Confinamento (kgf/cm2)
MR = 10603 * 30,3902
Foamed RAP – Resilient Modulus80% RAP + 19% crushed dust + 1% cement
+ 2,5% bitumen binder
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Foamed CDW – Rutting
0,7%0,8%
1,1%1,3%
1,7%2,1%
0%
1%
10%
100%
100 1000 10000 100000
Po
rcen
tag
em d
e af
un
dam
ento
na
tril
ha
de
rod
a
N. de ciclos
Rutting x # of cycles
CDW + 1% cement + 3,4% foamed asphalt72 h cure in oven at 60ºC and 72 h at room temperature - test temperature = 60ºC
Afund. (A - Esq. - P-2046)
100
1000
10000
100000
0,1 1,0 10,0
MR
-(k
gf/c
m²)
Tensão de Confinamento (kgf/cm²)
CDW + 1% cement + 3,4% foamed bitumenEnergia de Moldagem E.M. - Ensaio realizado na umidade de moldagem = 11,9%
Cura: 72 hs. em estufa 60ºC e 72 hs. ao ar
MR = 10.557* 30,4526
Ensaio realizado conforme o que preconiza a norma DNER-ME 131/94 - Determinação do módulo de resiliência
Foamed CDW – Resilient Modulus
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Foamed crushed stone – Rutting
0,47%0,60%
0,78%0,99%
1,28%1,62%
0%
1%
10%
100%
100 1000 10000 100000
Porcentagem de afundam
ento
na trilha de roda
N. de ciclos
Afund. (A ‐ Esq. ‐ P‐1246)Afund. (B ‐ Dir. ‐ P‐1247)
99% crushed stone + 1% cement + 3% foamed bitumen
1000
10000
100000
0,1 1 10
MR ‐(kgf/cm2)
Tensão Confinamento (kgf/cm2)
MR = 14719 * 30,2509
Crushed Stone
Foamed crushed stone – Resilient Modulus99% crushed stone + 1% cement + 3% foamed bitumen
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Bibliography
Valmir BonfimDiretor TécnicoCel.: (11) [email protected]
FREMIX ENGENHARIA E COMÉRCIO LTDA.Rua Vitorino, 25 - Jardim Mutinga
Fone (11) 4196-5533Barueri/SP- CEP 06463-290
Grato pela atenção!
