WF2000 UserGuide

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WINFLEX 2000Mechanistic-Empirical Overlay Design Systemfor Flexible Pavement

User GuideJune 2001

UI Budget KLK456

ITD Contract 99-163NIATT Report N01-13

Prepared for

Idaho Transportation Department

By

Center for Transportation Infrastructure (CTI)National Institute for Advanced Transportation Technology (NIATT)

University of Idaho

Fouad M. BayomyMostafa Abo-Hashema



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WINFLEX 2000

INFLEX is a mechanistic-based overlay design system for flexible pavement. This program was developed at the Center for Transportation Infrastructure (CTI), which

is part of the National Institute for Advanced Transportation Technology (NIATT) at

the University of Idaho (UI). The program was developed under a series of contracts with theIdaho Transportation Department (ITD). The original program (FLEXOLAY, 1996) is a

DOS-based program; it was upgraded to a Windows-based program (WINFLEX) in 1997.

The 2000 version of the program is an update of the 1997 version, and includes many

modifications. Some of the major improvements over the 1997 version are the completerevision of the mechanistic design process, the addition of a metric module, new quality

control checks for all input data, and an online help guide.

WINFLEX 2000 UI Research Team

Dr. Fouad M. Bayomy, P.E.

Professor of Civil Engineering

Principal Investigator Center for Transportation Infrastructure (CTI)

National Institute for Advanced Transportation Technology

University of Idaho

Moscow, ID 83844-1022

Dr. Mostafa A. Abo-Hashema

Post-Doctoral Research Fellow

Center for Transportation Infrastructure (CTI)

National Institute for Advanced Transportation Technology (NIATT)

University of Idaho

ITD Research Coordinator

Mr. Robert Smith, P.E.

Research Supervisor and Assistant Materials Engineer

Idaho Transportation Department

Boise, Idaho

W



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DISCLAIMERThe WINFLEX 2000 software is a design tool that incorporates published researchresults. While utmost care was taken by the program authors to incorporate accurate

information, the authors, the University of Idaho and the Idaho TransportationDepartment assume no responsibility or liability of any kind that may result fromusing the software. By using the WINFLEX 2000 software, the user agrees toassume complete responsibility for its use.



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TABLE OF CONTENTS

Chapter 1 - INTRODUCTION ................................................................................................. 11.1 Overview of WINFLEX 2000 ........................................................................................ 1

1.2 Input Files ....................................................................................................................... 1

1.3 Program Output............................................................................................................... 21.4 Program Functions .......................................................................................................... 2

1.5 System Requirements...................................................................................................... 3

1.6 Installation....................................................................................................................... 4

Chapter 2 - PROGRAM OPERATION .................................................................................... 5

2.1 Starting WINFLEX 2000................................................................................................ 5

Starting the Program ......................................................................................................... 52.2 Starting a New Design Case ........................................................................................... 6

2.3 Creating a New Input File............................................................................................... 7

Single-Location Option..................................................................................................... 7Multiple-Locations Option................................................................................................ 7

Entering The Data ............................................................................................................. 8

1. Data Entry Form 1/5 (Pavement Data) ..................................................................... 8Pavement Section Block ........................................................................................... 9

Overlay Block ......................................................................................................... 10

Failure Mode Block ................................................................................................ 112. Data Entry Form 2/5 (Material Types) ................................................................... 11

Base Block .............................................................................................................. 12

Subbase Block ......................................................................................................... 13

Subgrade Block ....................................................................................................... 133. Data Entry Form 3/5 (Models)................................................................................ 13

4. Data Entry Form 4/5 (General Data) ...................................................................... 14

Commercial Traffic Block ...................................................................................... 15Fatigue Shift Factor Block ...................................................................................... 15

Seasonal Variation Block ........................................................................................ 15

5. Data Entry Form 5/5 (Modulus-Temperature Adjustment) .................................... 17Preparing to Run the Design Case .................................................................................. 17

Save the Data Input File.............................................................................................. 18

Modify Models............................................................................................................ 18

Run Single/Multiple.................................................................................................... 18

2.4 Loading an Existing Input File ..................................................................................... 192.5 Modifying Input File Data ............................................................................................ 19

2.6 Creating an ETF File..................................................................................................... 20ETF File Generator Program ...................................................................................... 20

Create EFT File Manually........................................................................................... 20

2.7 Saving an ETF File ....................................................................................................... 232.8 Loading an Existing ETF File....................................................................................... 23

2.9 Modifying an ETF File ................................................................................................. 23



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2.10 Running the Calculations on an Input File ................................................................. 23

Single Location Design Case .......................................................................................... 23

Multiple Locations Design Case..................................................................................... 262.11 Saving a Report on the Calculations ........................................................................... 28

2.12 Printing a Report on the Calculations ......................................................................... 28

Chapter 3 - TUTORIAL EXAMPLES ................................................................................... 29

3.1 Introduction................................................................................................................... 29

3.2 Example on Single Location Design Case.................................................................... 29Preparing the Data........................................................................................................... 29

Pavement Data ............................................................................................................ 30

Material Types Data.................................................................................................... 30

Models Data ................................................................................................................ 30General Data ............................................................................................................... 30

Modulus-Temperature Adjustment Data .................................................................... 30

Entering the Data ............................................................................................................ 31

Saving the Data ............................................................................................................... 34Running the Calculations on the Input File .................................................................... 34

3.3 Example on Multiple Location Design Case ................................................................ 39Preparing the Data........................................................................................................... 39

ETF File ...................................................................................................................... 39

Pavement Data ............................................................................................................ 40

Material Types Data.................................................................................................... 40Models Data ................................................................................................................ 40

General Data ............................................................................................................... 40

Modulus-Temperature Adjustment Data .................................................................... 41Entering the Data ............................................................................................................ 41

Saving the Data ............................................................................................................... 44

Running the Calculations on the Input File .................................................................... 44

Conclusion & Technical Support............................................................................................ 51



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TABLE OF FIGURES

Figure 1. Opening Screen ......................................................................................................... 5Figure 2. Main Menu Screen .................................................................................................... 6

Figure 3. Options for Selecting the Design Case ...................................................................... 7Figure 4. Pavement Data Screen............................................................................................... 8

Figure 5. Pavement Data Screen for Revert to Gravel.............................................................. 9Figure 6. Material Types Screen ............................................................................................. 12

Figure 7. Models Screen ......................................................................................................... 14

Figure 8. General Data Screen ................................................................................................ 14Figure 9. Modulus-Temperature Adjustment Screen.............................................................. 17

Figure 10. Main menu screen after data entry is completed ................................................... 18

Figure 11. Modify Option in Main Menu Screen (Multiple Location)................................... 19Figure 12. ETF File Editor Screen (Multiple Location) ......................................................... 21

Figure 13. Create a New ETF File (Multiple Location) ......................................................... 21

Figure 14. Excel Data Sheet for ETF File............................................................................... 22Figure 15. Single Location Results Screen ............................................................................. 24

Figure 16. Strains Screen in Single Location.......................................................................... 25

Figure 17. Adjusted E-Values Screen in Single Location ...................................................... 26

Figure 18. Run Commands for Multiple Locations ................................................................ 26Figure 19. Results Screen for Multiple Locations .................................................................. 27

Figure 20. Strains Screen for Multiple Locations ................................................................... 28

Figure 21. Pavement Data for Example1_S............................................................................ 32Figure 22. Material Types for Example1_S............................................................................ 32

Figure 23. Models for Example1_S........................................................................................ 33

Figure 24. General Data for Example1_S............................................................................... 33

Figure 25. Modulus-Temperature for Example1_S................................................................ 34Figure 26. Results Screen for Example1_S ............................................................................ 35

Figure 27. Comprehensive Report for Example1_S ............................................................... 36

Figure 28. Comprehensive Report for Example1_S (Cont’d) ................................................ 37Figure 29. Strain Values for Example1_S .............................................................................. 38

Figure 30. Seasonal Adjusted Moduli Values for Example1_S ............................................. 38

Figure 31. ETF File for Example7_M .................................................................................... 39Figure 32. Pavement Screen for Example7_M ....................................................................... 42

Figure 33. Material Types Screen for Example7_M .............................................................. 42

Figure 34. Models Screen for Example7_M........................................................................... 43Figure 35. General Screen for Example7_M .......................................................................... 43

Figure 36. Modulus-Temperature Adjustment Screen fro Example7_M ............................... 44Figure 37. Results Screen for Example7_M ........................................................................... 45Figure 38. Comprehensive Report for Example7_M.............................................................. 46

Figure 39. Comprehensive Report for Example7_M (Cont’d) ............................................... 47

Figure 40. Comprehensive Report for Example7_M (Cont’d) ............................................... 48

Figure 41. Comprehensive Report for Example7_M (Cont’d) ............................................... 49Figure 42. Results Screen for Example7_M ........................................................................... 50



WINFLEX 2000 User Guide – Page 1

CHAPTER 1 - INTRODUCTION

1.1 Overview of WINFLEX 2000

WINFLEX 2000 is a mechanistic-empirical overlay design system for flexible pavement.

The program determines asphalt overlay thickness based on mechanistic analysis of the

distress in the existing flexible pavement. The mechanistic analysis also takes into account

the prediction of fatigue and rutting distresses in the overlaid pavement. Fatigue and ruttingmodels used in the WINFLEX 2000 system are those published by several agencies,

including the Asphalt Institute and the FHWA, and most were developed by empirical

analysis.

WINFLEX was created to operate under the Windows 95 or higher and NT environments,

and can be used for single or multiple-location design cases. The program has two modules -

one for designing with the US Customary units (English System) and the other for the usewith the System International Units (Metric System).

1.2 Input Files

For each design case, the user first enters parameters into an input file. Each input file

consists of five data screens: Pavement, Material Types, Models, General and Temperature

Adjustment:

• Pavement: In this screen, the user enters the moduli values of the existing pavement.

These moduli values can be obtained from backcalculation of Falling WeightDeflectometer (FWD) deflection testing, which is shown on this screen.

• Material Types: In this screen, the user selects the material types for base, subbaseand subgrade layers

• Models: In this screen, the user selects the failure criteria and the models used for estimating the pavement damage. The user has the option of choosing an existingmodel or entering new model parameters.

• General: In this screen, the user can enter information on traffic and other relateddesign parameters, the seasonal adjustment factors for the climatic zones, and fatigue

shift factors.

• Temperature Adjustment: In this screen, the user enters the modulus-temperature

adjustment function. The user can select an existing function, or enter a new one.

Control checks of the data are built into all data screens. The program will display a warningmessage if the input data is outside preset reasonable ranges. This control is designed to

minimize errors while inputting data, but if the user wants to bypass the preset ranges or

default values, the program will allow that too.




1.3 Program Output

The program output displays the calculated overlay thickness for each design location, along

with other design parameters, all of which can also be printed in various reports.

1.4 Program Functions

WINFLEX 2000 has many functions designed to ease data entry, calculations, and the

displaying and printing of results. Table 1 below summarizes the program’s main menucomponents and sub-menu commands.

Table 1. Description of WINFLEX Main Menu Components

Main Menu

Component

Sub-Menu

Command

Description

New File This command allows the user to create a new input file (afile with extension .INP) for either single or multiple design

cases.

Load an

Existing File

This opens a standard Windows OPEN dialog box to load

an existing .INP file

Save INP File This opens a standard Windows SAVE dialog box. Thisallows the user to save the current data file, which is loaded

in the computer RAM, with an extension .INP.

Print a Report This command is activated only after the Run command

(see Results menu) has been launched. It allows printing a

comprehensive report for the design case (either single or

multiple locations).

File

Exit This command allows the user to exit the program. It warnsfor saving the current input data file.

Toolbar

Status Bar

View

Background

The user can choose to show or hide any of these listedoptions.

The toolbar appears at the top of the main screen. It has a

set of buttons that work as shortcuts for some of the sub-menu commands.

The status bar appears at the bottom of the main screen. It

shows the current date and time.

Background allows the user to choose either a blank gray or

a colorful WINFLEX 2000 image as a background.Pavement This is the input screen for the pavement data, which

includes information on the existing pavement and the

overlay material.

Modify Data

Material Types This data input screen allows the user to select the type of

materials used in all pavement layers according to pre-established categories.




Main Menu

Component

Sub-Menu

Command

Description

Models In this input screen, the user selects the various failuremodels (fatigue or rutting or both). The user can choose

pre-established model parameters or enter new ones.

General This is the data input screen where the user enters trafficrelated data, environmental adjusting factors and fatigue

shift factors for the selected fatigue model.

ETF File This command launches an ETF screen editor (text type

editor) in which the user can either create or modify a pre-loaded ETF file. Since the ETF type file is used only with

multiple design cases, this command appears only when a

multiple location case is selected.

Run single This command executes the program calculations for asingle location. Once the calculations end, the programdisplays the output screen showing the overlay design

results.Run Multiple This command executes the program calculations for

multiple locations. It also has an option to allow the user torun the pre-loaded Input file with any other compatible ETF

file.

Results

Show Results This command retrieves the Results screen that appears at

the end of calculations. This command is inactive until the

RUN command(s) have been launched.

Excel Summary This option allows the user to export the overlay design

data to an Excel spreadsheet.

Temperature

Adjustment

This option allows the user to launch an algorithm to

choose the modulus-temperature relationship. The user canselect either a default or a pre-loaded relationship. The user

can also enter test data to develop and use a new one.

Options

Go to Metric or

Go to English

This allows the user to switch from one system of units to

another. The program closes all opened files and prompts

the user to start from the beginning with the selectedsystem of units.

About This is a typical About screenAbout

Help Topics This launches the Help menu

1.5 System Requirements

The following are recommended computer system configurations for WINFLEX 2000:

• PC or workstation with a Pentium 166 or higher processor.

• A minimum of 16 megabytes (MB) of random-access memory (RAM).

• Hard disk with 25 MB available space.

• An 800x600 SVGA graphics monitor.

• Microsoft Windows 95 or higher or NT 4.0 or higher operating systems.




• Microsoft Excel is needed for advanced features in WINFLEX 2000, such asexporting a design summary table to an Excel worksheet.

1.6 Installation

To install WINFLEX 2000 from a CD:

• Insert the CD in your CD-ROM drive

• From the Start menu, click Run and enter the CD location

• Type in Setup.exe and press Enter. The program will launch the Setup Wizard.Follow the onscreen instructions.

To install WINFLEX 2000 from a web-downloaded Zip file:

• Open the Zip file and install it in a selected directoryDouble-click on the Setup.exe file. The program will launch the Setup Wizard.

Follow the onscreen instructions.




CHAPTER 2 - PROGRAM OPERATION

2.1 Starting WINFLEX 2000

Note: If you intend to create a multiple-location design case, you will need to prepare an

ETF file before opening WINFLEX. An ETF file is a text file in which data of pavement layer moduli and thickness values are entered for all mileposts. The temperature for each set of

moduli values is also entered. For instructions on creating or modifying ETF files, see the

section of this chapter entitled, “Creating an ETF File.”

Starting the Program

Start WINFLEX by clicking on its icon in the Windows Start menu, or by double-clickingthe program icon on the desktop, if you created an icon. When you first start the program,you will see the animated opening screen shown in Figure 1.

WINFLEX has two independent design systems, one for English Units and the other for

Metric Units. You need to choose one or the other in order to start a design case. Once youhave selected a system, you will have to stay in that system throughout the design case. If

you need to shift to the other system, select Options in the main menu, then the Shift

command. The program will prompt you to start a new design case.

Figure 1. Opening Screen




2.2 Starting a New Design Case

Once you have selected a system of units from the opening screen, the main screen will

display, shown in Figure 2. At this point, only three command buttons appear in the toolbar -

New, Load, and Exit. You can either create a new data input file or load an existing input

file. To create a new input file, click on the New button in the toolbar or select the Newcommand under File.

Figure 2. Main Menu Screen

After you click the New button, the design condition screen will display, as shown in Figure

3. Select for a single location or multiple-locations design case.

Select a single-location design case for situations in which you will design an overlay for one

pavement cross-section. Whether this single design is for pavement data at a specifiedmilepost or for a set of representative moduli, the thickness and temperature values for the

entire pavement section need to be entered.




Figure 3. Options for Selecting the Design Case

Select a multiple-locations design case for situations in which you will design an overlay for

each milepost in the pavement section. This option automates the design process andeliminates the need for entering pavement section data at each milepost individually while

you are entering data in the Pavement data entry screen. To take advantage of this option,

you will need to input pavement cross-section data at all mileposts in one file, called the ETFfile, before opening WINFLEX. The ETF file includes data on E (elastic modulus), T

(temperature at which the E value was determined) and thickness of layers at all mileposts.

To create an ETF file, refer to the section 2.6, entitled “Creating an ETF File.”

2.3 Creating a New Input File

Single-Location Option

If you select the single-location design option, the program opens the first of five data inputscreens. You can immediately begin entering the input data as explained on the next page

“Entering the Data.”

Multiple-Locations Option

If you select the multiple-location design option, the program first prompts you to load the

design case’s associated ETF file, which you should have prepared prior to launchingWINFLEX. The ETF file contains the test temperature, the layer moduli, and the layer

thickness for each location. This file can be loaded by clicking on the Load File command

button. After you have loaded the ETF file, the name of the file and its location will appear

on the bottom of the screen.






The pavement screen is divided into three blocks: Pavement Section, Failure Mode and

Overlay. A description of each block follows.

Pavement Section Block

Description: Text to describe the design case. You have the option of entering as manycharacters as needed. No commas or semi-colons are allowed.

Treat Old AC as Gravel : If this box is checked, the program will treat the old asphaltconcrete layer as a gravel layer. This is a case in which the existing pavement surface is

highly cracked. The E value determined from the FWD data could be high due to the fact that

the FWD test is performed on a pavement block. In such cases, the designer may choose to

consider the pavement surface as a discontinued layer that has been reverted to gravel withconsiderably high modulus. If this is the case, check this box, and a new cell will appear in

the FAILURE MODE block, as shown in Figure 5. Enter an E value of the reverted to gravel

layer. It could be the same E value that was entered in the Old AC Layer cell. A minimum

value of 50 ksi (350 MPa) is required.

Figure 5. Pavement Data Screen for Revert to Gravel

Pave. Temp. (F or C): Pavement temperature at which moduli (E) values of the asphalt

layers were determined.

Options:

BS AND SBS: Existing pavement section includes base and subbase.

BS ONLY: Existing pavement section includes base only.

FULL AC: Existing pavement section is full-depth asphalt.




Note that the screen changes as the selected option changes. The base layer and the subbase

layer disappear when FULL AC is selected. The subbase layer disappears when BS ONLY

is selected.

E (ksi, or MPa): Moduli values for various pavement layers. The E values can be obtainedfrom lab tests on core samples, or (and most commonly), obtained from field-testing by

Falling Weight Deflectometer (FWD). Backcalculation programs such as the Texas

Transportation Institute software (MODULUS) can be used for backcalculation of E’s fromFWD deflections. The entered values for the AC layers must be those determined at the

pavement temperature, which appears in the PAVE TEMP cell. For unbound layers, the

entered values are assumed to be those of the normal season.

Pois. Ratio: Poisson’s ratio of each layer. Typical values assumed for various material types.

For example, for AC layer, a range of 0.2 to .35 can be assumed. A lower value may be

selected for a stiff, hardened, and aged mix, and a higher value for a softer and fresh mix. For

granular materials, a range of 0.4 to 0.45 may be assumed. For subgrade, a range of 0.45 to0.5 may be assumed. The Poisson’s ratio was found to have insignificant effect on the

calculated overlay thickness. Thus, a user may assume typical values of Poisson’s ratios asfollows: AC and bound layers (0.3), granular base and subbase layers (.4) and for the

subgrade layer (0.45).

Thick. (in or mm): The thickness of each layer. The subgrade is considered to have aninfinite depth, as assumed in the multi-layer elastic analysis. Layer thicknesses may be

obtained from construction documents, core analysis or by a Non Destructive Testing (NDT)

method such as the Ground Penetration Radar (GPR).

Note that if you are in a multiple-locations design case, you will not be able to input the

moduli and the thicknesses of different layers in the data entry screens. The program willshow N/A in the respective cells, indicating that they cannot be entered by the user, but will

be read from the ETF file. You will not be able to enter the test temperature and number of

layers, either. They also will be read from the ETF file. For multiple-locations design cases,

you will be prompted to load the associated ETF file while you are starting a new designcase, once you have selected the multiple-locations option.

Over lay Bl ock

E (ksi, MPa): The elastic modulus of the new overlay layer. This value could be determined

by laboratory testing of the new overlay mix. The user should consult appropriate testing

procedures for the dynamic modulus test for AC mixes, such as the ASTM D3497. Other procedures such as Superpave testing procedures may also be consulted.

TEMP. (F or C): The reference temperature at which the overlay elastic modulus value wasdetermined.




Pois. Ratio: Poisson’s ratio of the overlay layer. For AC layer, a range of 0.2 to .35 can be

assumed. The Poisson’s ratio was found to have insignificant effect on the calculated overlay

thickness.

Minimum Thickness (in or mm): This is the initial value that the program will consider for

designing the overlay. It is controlled to be greater than zero to prevent overflow. If thedesign case does not require an overlay, the program will display the minimum thickness

entered by the user. Therefore, try to use as small a value as possible. A suggested initial

value of 0.5 inches or 10 mm is reasonable.

Thickness Increment (in or mm): The overlay thickness increment. This is the amount by

which the program increases the overlay thickness in the design iteration. A reasonable value

would be 0.5 inches or 10 mm.

Failure Mode Block

This block allows the user to specify whether the fatigue failure mode is to be considered in

the new overlay only, the old asphalt layer only, or in both. Check the appropriate box for theselection.

After completing the data entry in Data Form 1, click the Next command button in the right

bottom corner to move to the second data entry form (Material Types).

2. Data Entry Form 2/5 (Materi al Types)

The second data input form is used to enter information about material types, as shown in

Figure 6.

This screen is divided into three blocks: Base, Subbase, and Subgrade. The screen layout

depends on the option selected in the Pavement Data form. The three blocks will appear onlyif the BS AND SBS option is selected in the Pavement screen. When BS ONLY option is

selected, the Subbase block will disappear. When FULL AC option is selected, the Base and

the Subbase blocks will disappear. The Subgrade block will always be displayed.






The user needs to be sure that the E value entered for the BS layer in the Pavement screen

was at the test temperature entered in the PAVE TEMP cell in the Pavement Data screen

( Data Form 1/5).

Subbase Block

Granular : Similar to the base layer granular option. When this option is selected, the cellsfor the parameters K1 and K2 will appear. Enter the appropriate values for the subbase layer.

Gran. (Linear): Similar to the base layer granular linear option. No stress sensitivity parameters are needed, and the modulus will be adjusted seasonally.

Subgrade Bl ock

Fine: This option indicates that the subgrade is fine-grained material and it is stress-dependent. When this option is selected the parameters K1-F and K2-F will appear. These

are stress dependency factors for the fine material.

Granular: This option indicates that the subgrade is coarse-grained material and it is stress-dependent. When this option is selected the parameters K1-G and K2-G will appear. These

are stress dependency factors for the coarse grained material.

Linear: Means that the subgrade is considered stress independent.

As for the base and subbase layers, the modulus value of the subgrade will be adjustedseasonally using the seasonal adjusting factors of the subgrade layer (see .

Figure 8.)

After completing the inputs in Data Form 2, click Next to move to Data Form 3 (Models).

3. Data Entry Form 3/5 (Models)

In the next data entry form, you select the models to be used for the adopted failure criteria,

as shown in Figure 7. The choice could be based on either fatigue or rutting or both.

The equations of the models are displayed onscreen. For convenience, the selected model parameters (f1, f2, f3 for fatigue model and f4, f5 for rutting model) are displayed, but they

cannot be changed. If you decide to use different models, click on Other and enter the

appropriate model parameters. The new parameters will be saved in the current input file, butwill not be saved in the program database. Consequently, if you want to use the same

parameters in another design case, they will have to be re-entered in that case’s input file.




Figure 7. Models Screen

After completing the inputs in Data Form 3, click Next to move to Data Form 4 (GeneralData).

4. Data Entry Form 4/5 (General Data)

In this form, information on design traffic, model shift factors, and environmental adjusting

factors are entered, as shown in Figure 8.

Figure 8. General Data Screen




The form consists of three blocks: Commercial Traffic, Fatigue Shift Factors, and Seasonal

Variation. A description of each block appears below.

Commercial Traf fi c Block

Information on the tire load, dual tires spacing and tire pressure for the design axle areentered here. The program will display the default values, which are for the 18-kip (80-kN)standard Equivalent Single Axle Load (ESAL). They are 4500 lb (20 kN), 13.5 in. (343 mm),

and 80 psi (560 kPa) respectively. You may change these values to the selected single axle

load. The assumption is that the tire system is a dual system. Super single is not considered inthis version of the program. It is also important to note that since AASHTO standard ESALs

are used, the axle configuration needs to be that of the default values given.

Estimated Future ESALs: This cell is for the estimated future traffic repetitions in units of the

standard 18-kip (80-kN) Equivalent Single-Axle Load (ESAL) for the design period.

Fatigue Shif t Factor Block The Fatigue Shift Factor (FSF) is a factor that will be multiplied by the parameter f1 in the

fatigue model (see Models screen, Figure 7) to account for variation of the model from the

lab-based equation to actual field conditions. For example, the original FSF used in theAsphalt Institute model is 18.4. It was found that this is a relatively high factor. You must

find out the appropriate shift factors for the selected model based on your agency’s

experience, and enter them for both new and old AC layer. For instance, the ITD uses FSFvalues between 10 and 12 for new AC layer, and 4 for old AC layers with AI model.

Seasonal Var iati on Block

The effect of seasonal variation on the estimated overlay thickness is considered by

employing Seasonal Adjustment Factors (SAF) for pavement layers’ moduli. In this block,you enter SAF, which are used to adjust the normal moduli values to each season. The SAF

is a multiplier that changes the normal E value for a layer to the respective season. Thenormal values are assumed to be those, which were entered in the Pavement Data screen.

The SAF values are only required for the unbound layers. For asphalt layers, the moduli are

adjusted using the temperature-adjusting function (refer to Data Form 5). The user can selectvarious SAF values based on the climatic zone. The program includes a database of various

climatic zones in the state of Idaho. For other locations, a new set of seasonal factors can be

entered and the user will be prompted to save them in a new zone, which can then be added

to the environmental database.

Idaho Climatic Zones: A map is provided to show the six climatic zones in Idaho. Click onthe Show Map button to view the limits of different zones. By clicking on a zone, the SAFvalues will be loaded to the cells. All factors will be shown dimmed, indicating that the user

cannot change them. However, the traffic factors can be changed because they are based on

the expected operation rather than the soil and climate conditions. See Traffic below for details on entering the Traffic SAF values.




If a different climatic zone is to be entered, or if you need to change any of the default values

provided, click on Other. This will allow you to modify the displayed factors. You can also

clear all cells to enter new numbers of your choice. A new button, Save Zone As... willappear. Click on this button to save the new set of factors in a file with extension .ZON,

which can be loaded later in future design cases.

If you choose to load another zone that was previously created, click on the Load Another

Zone button, which opens a loading file dialogue box. Select the zone file and press Open to

load it in the SAF cells.

Subgrade: Values shown or entered here are the SAFs for the subgrade layer. Note that if

you load zone 3 or 6, a subset indicating the subgrade classification will appear. Choose the

appropriate soil classification. Based on the soil classification, a corresponding SAF value for the winter and spring seasons will be loaded from the seasonal database.

Base/Subbase: Values shown or entered here are the SAFs for the base and the subbase

layers. If the pavement section is full depth (no unbound base/subbase layer), the cells willshow N/A, indicating not applicable.

Traffic: The traffic SAF indicates the traffic variation from one season to another, if any.

The program will show the number 1 in all cells by default. Change the number to reflect the

relative change in traffic among seasons. For instance, if the traffic in summer is expected to

be double that of winter, then you may enter 1 for the winter, and 2 for the summer. Followthe same procedure for other seasons. The traffic SAF numbers could be numbers or

fractions. What matters is the relativity among them.

Temperature: Numbers loaded or entered here are not factors, but they represent the

seasonal mean air temperature. You can change the values if you select the Other option in

the climatic zone. In this case, enter the temperature in oF or oC, depending on the system.

Period (Months): Numbers loaded or entered here are not factors, but represent the average

length of the season in months. You can change the values if you select the Other option in

the climatic zone. In this case, enter the period of each season. Entered numbers must add upto 12.

Subgrade Classification: This subset block will appear if zones 3 or 6 are selected. Itindicates the subgrade classification according to the Unified Soil Classification system.

The SAF values for Winter and Spring seasons are further broken down into various types

of subgrade soil, which can be selected here.

After completing the inputs in Data Form 4, click Next to move to Data Form 5 (Modulus-

Temperature Adjustment).




5. Data Entry Form 5/5 (Modulus-Temperature Adjustment)

This is the fifth and final data entry form, which is shown in Figure 9. In this screen, you can

select the modulus-temperature (E-Temp) adjustment relationship. A default relationship isembedded in the program based on data from SHRP LTPP. The default equation is for

conventional unmodified asphalts. Select either Use the Default Equation or User Input

Relationship. This button will allow you to either create a new equation from testing data or to use one that has been previously created.

Figure 9. Modulus-Temperature Adjustment Screen

To create a new equation, click on New Relationship. This opens the E-Temp screen for

entering data on the E values at various tested temperatures. A minimum of three points is

required and a maximum of eighteen data points is allowed. Click on Calculate to executethe calculation algorithm. Follow the screen commands to save the newly created

relationship in a file with the extension .ETR. When you are finished, click the Finish button

to exit the E-Temp screen. Note that you can also access the E-Temp screen from the Options

menu in the Main menu commands for further modifications.

When you have completed data entry in Form 5, click Finish. You may now prepare to run

this design case.

Preparing to Run the Design Case

After you click the Finish button, three additional command buttons will appear in the toptoolbar, as shown in Figure 10, that allow you to prepare for running the design case. The




new buttons are Save, Modify Models, and Run Single or Multiple, depending on the type

of design case that is in progress.

Save the Data Input F ile

To save the data input file with the extension .INP, click on the Save command button on the

toolbar or select Save from the main menu under File. Note that you cannot save or createthe input file while you are in the process of entering the data. You must complete data entry

on all five screens before you can save an input file.

Modify Models

To modify your models data (Data Form 3,) click on the Modify Models command button in

the toolbar. To modify any of the other forms, refer to section 2.5, entitled Modifying Input

File Data.

Run Single/Mu ltiple

If you are ready to run (execute) the design case, click on Run Single/Multiple in the

toolbar. For more details, refer to section 2.10, entitled Running the Calculations on an InputFile.

Figure 10. Main menu screen after data entry is completed




2.4 Loading an Existing Input File

The .INP file contains all the data in the data entry forms. To load data from an existing .INP

file, click on the Load button in the toolbar or select the Load an Existing File command

from the File sub-menu. This will generate an Open File window that allows you to load the

pre-saved input file (any file with extension .INP). Once the data is loaded, you can view andmodify it as described above, or you can run (execute) the design case directly.

2.5 Modifying Input File Data

After you have created a new data input file or loaded an existing .INP file, you can modify

the data by clicking on Modify Data in the main menu commands and selecting the desired

form. With this command, you can view and edit the data entered in the Pavement data,Material Types, Models, or General forms. For details on working with each form, refer to

section 2.3, Creating a New Input File - Entering The Data.

Note that, for multiple location design cases, you can only change the Overlay data and the

Failure Mode options in the Pavement Data screen. You will have no control over the

number of layers, pavement temperature, moduli values and thickness of layers. These datainputs will be loaded from the ETF file when you launch the command Run Multiple.

A fourth option in this command, accessing the ETF File, appears only in the multiple

locations design case, and is shown in Figure 11 below.

Figure 11. Modify Option in Main Menu Screen (Multiple Location)




As an alternate to using the Modify Data command, you can directly access the Model form

(Data Form 3) by clicking the Modify Models command button on the toolbar.

2.6 Creating an ETF File

An ETF file is required for all multiple-location design cases. It is a text file in which data of

pavement layer moduli and thickness values are entered for all mileposts. The temperaturefor each set of moduli values is also entered in this file. There are two ways to create a new

ETF file – by using the ETF File Generator Program or creating the ETF file manually.

ETF F il e Generator Program

The first method is to create the file automatically, using a computer program called ETF File

Generator. This program was prepared by ITD to create the ETF file directly from the

Modulus backcalculation program output. The program converts the .DAT file from theModulus program into an ETF-type file. The ITD ETF File Generator is located on the

WINFLEX 2000 CD. To use this option, you will need to have the .DAT file from theModulus program.

Create ETF F ile Manually

The second method is to create the ETF file manually, using a command within WINFLEXitself or by using any word processor or Excel.

Within WINFLEX:To create a new ETF file manually within WINFLEX, first click Modify Data in the main

menu, then ETF File as shown in Figure 11.

The program will lunch the ETF file Editor Screen, shown in Figure 12. In this screen, under the File command, click Create a New ETF File.

The next screen, shown in Figure 13, prompts you to enter the header of the file and thenumber of layers you want to create the ETF file for. Select a number and click OK.

The program will open an Excel data sheet, as shown in Figure 14, where you can enter theE, Temp and Thickness data for each milepost. After entering the data in the sheet, you will

need to transfer the data to the ETF File Editor screen using Copy and Paste. Then, save the

ETF file by clicking on the Save command in the main menu of the ETF File Editor Screen.

Outside WINFLEX:

To create the ETF file manually, outside WINFLEX, you can use Notepad, Excel, or any

word processor such as MS word. When creating the ETF file outside WINFLEX, you mustfollow the format below.

The first row in the .ETF file includes two columns. In the first column, enter the number of layers for the design case. The number should be the number of layers of the existing




pavement including the subgrade layer. Do not count the overlay layer here. In the second

column, enter a header. It should be text that describes the design case.

Figure 12. ETF File Editor Screen (Multiple Location)

Figure 13. Create a New ETF File (Multiple Location)






2.7 Saving an ETF File

If you have created the ETF file automatically, using the ETF File Generator, save the file by

using the Save command in the program’s main menu, as with any program.

If you have created the ETF file manually, using WINFLEX, save the file as an ETF type by

clicking on the Save command in the main menu of the ETF File Editor Screen.

If you have created the ETF file manually outside WINFLEX, you must save the file with an

.ETF extension. When saving the file, select the file type as text only and put the file namewith the extension .etf between double quotes, for example, “name.etf”.

2.8 Loading an Existing ETF File

If you are going to start a new design case for multiple locations, you must load an ETF filefor the new design case prior to opening the first data entry screen. An ETF file can be

loaded by clicking on the Load File command button that appears when you select the

multiple-locations case in Figure 3. After you have loaded the ETF file, the name of the fileand its location will appear on the bottom of the screen.

If you are going to load an existing input file for a multiple-locations design case, the program will ask you to load an ETF file before running the case. Remember, there must be

compatibility between the ETF file and the loaded input file regarding the number of layers.

If your loaded input file includes three layers, then you must run the input file with an ETFfile that contains data for three layers.

2.9 Modifying an ETF File

You can modify any ETF file by selecting Modify Data in the main menu, then ETF File, as

shown in Figure 11. From the ETF File Editor screen, you can open any ETF file by clicking

on Open ETF File, as shown in Figure 12. Make any modifications in the opened file and

save it as a new file.

2.10 Running the Calculations on an Input File

Single Location Design Case

If the loaded file was for a single location design case, the Run Single button will appear in

the toolbar. You can begin to run this file in one of two ways: by clicking the Run Single

command button in the toolbar or by selecting Results from the main menu, and then the

Run Single option.




The program will begin running and a message will appear to inform you when the

calculations are successfully completed. Upon completion of calculations, two command

buttons, Show Results and Print Results, appear on the toolbar, and the Results screenappears, as shown in Figure 15.

Figure 15. Single Location Results Screen

You can save a detailed report of the results in a text file with extension .TXT, by clickingthe Save Report in Text File command button. You can print a comprehensive report of the

design results by clicking on the Print a Report command button.

Strain values that were determined during the calculation process can be displayed onscreen

and printed by clicking on the Show Strains button. The Strains screen is shown in Figure

16.




Figure 16. Strains Screen in Single Location

The seasonal adjusted moduli values for each layer can be shown for all layers in each season

by clicking on the hover button (Click here to...) in the Results screen,

Figure 15.

This will launch another screen showing adjusted E-values, as shown in Figure 17. Note that

the adjusted E-values for AC layers are computed based on the mid-depth temperature. The

first row in this table is for air temperature, and the mid-depth temperature might be higher than this value, depending on the thickness.






Figure 19. Results Screen for Multiple Locations

The Results screen has three buttons, that allow you to print a comprehensive report of the

results, to show the strains, and to export results to an Excel worksheet. The Strains screen

displays the strain values at the bottom of the asphalt layers and at the top of the subgrade, aswell as the fatigue and rutting lives, as shown in Figure 20.




Figure 20. Strains Screen for Multiple Locations

2.11 Saving a Report on the Calculations

After running the calculations on an input file, you can save this report as a text file. For Single location cases, click on Save a Report in the results screen. For multiple location

cases, the program will prompt you to save the results in a text file.

2.12 Printing a Report on the CalculationsYou can print a comprehensive report in one of two ways: by clicking on File in the main

menu, then Print a Report, or you can print directly from the Results screen.




CHAPTER 3 - TUTORIAL EXAMPLES

3.1 Introduction

Several data input files have been included on the WINFLEX 2000 CD that you can use as

examples for running the program. The examples include both Metric and English data input

files. They also cover both single and multiple-location design cases. The data input files for these examples are denoted by .INP extensions. These files have been run in WINFLEX

2000 and the output files are also included, for your information.

The sample data input files that are included on the CD are:

1. Example files 1 to 6 are for single location design cases and the English system.

2. Example files 7 to 10 are for multiple-location design cases and the English system.

3. Example Ex_Metric_S is for the Metric system and single location andEx_Metric_M is for the Metric system and multiple-location design cases.

For single location design cases, an example consists of two files - one for the input data withthe extension *.INP and another for output data (comprehensive report) with the extension

*.TXT. For multiple location design cases, three files are included - two for input data with

the extensions *.INP and *.ETF, and a third for output data with the extension *.TXT.

The following pages describe in detail the procedures for determining overlay thickness with

two of the examples provided on the CD. Example1_S is for a single location design case,and Example 7_M is for a multiple-location design case. Both examples are for the English

system only.

3.2 Example of Single Location Design Case

The file Example1_S.inp is provided as one example for a single location design case. To

use WINFLEX 2000 for calculating the overlay thickness, you will need to perform four steps:

• Prepare your data.

• Enter your data in the program to create your input file withthe extension *.INP.

• Run the calculations on the input file to obtain the overlay thickness.• Print your results.

Preparing the Data

Refer to Table 2 below for a summary of all the data required for the Data Input File. Thefollowing paragraphs describe how the input values for this case were determined.




Pavement Data

These data relate to the existing pavement section and overlay properties. In this example, the

existing pavement section consists of AC layer, Base, Subbase, and Subgrade. The modulivalues of the existing pavement can be obtained from lab tests on core samples, or obtained

from backcalculation of Falling Weight Deflectometer (FWD) deflection testing. The

thickness of the existing layers can be obtained from construction documents, core analysisor by NDT methods such as the Ground Penetration Radar (GPR). The elastic modulus of the

overlay layer could be obtained by laboratory testing of the new overlay mix. Poisson’s ratio

of each layer can be assumed with a reasonable value. Refer to Pavement Section Block for details.

You have to choose an initial value (minimum thickness) for the overlay layer that the

program will consider for designing the overlay. In this example, a suggested initial value of 0.5 inches is reasonable. You also have to select a reasonable value for the overlay thickness

increment. This is the amount by which the program increases the overlay thickness in the

design iteration. In this example, a suggested value of 0.1 inches is reasonable. In this

example, consider the fatigue failure mode is to be in the new overlay or old asphalt.

Mater ial Types Data

These data depend on the existing pavement section that has been selected in the previous

step. In this example you have three layers, for BASE, SUBBASE, and SUBGRADE, and

you have to choose the material types for each layer. In this example, each layer is

considered as stress independent.

Models Data

This data helps you select the failure criteria and the models used for estimating the pavement damage. Your design could be based on either fatigue or rutting or both. In this

example, consider that the failure is controlled by both fatigue and rutting. The Asphalt

Institute model is selected for both fatigue and rutting.

General Data

In this stage, information on design traffic, fatigue shift factors, and seasonal adjusting

factors are obtained. Refer to the section of Chapter Two entitled Data Entry Form 4/5

(General Data). Consider that this pavement section is taken from a pavement in Idaho

climatic zone number 1. The calculation is based on the 18-kip standard Equivalent Single

Axle Load (ESAL). The wheel load, dual spacing, and tire pressure are 4500 lb, 13.5 in. and80 psi respectively. The estimated future traffic is considered to be 5 million ESALs.

Modulus-Temperature Adjustment Data

Use the default SHRP equation in this example.

All the above data for Example1_S are summarized in Table 2.




Table 2. Data for Example1_S

PAVEMENT DATADESCRIPTION

Modulus, ksi Poisson’s ration Thickness, in Temperature, F

Overlay Layer 350 0.35 Required** 77*Existing AC 235 0.35 3.5 91*

Base Layer 25 0.40 8 Normal SeasonSubbase Layer 10 0.40 16 Normal SeasonSubgrade Layer 4 0.45 ----- Normal Season

*Pavement Temperature at which moduli (E) values of the AC layers were determined**Minimum Thickness for overlay is assumed to be 0.5 in. and thickness increment is 0.1 in.

Failure mode is considered to be in the new overlay or old Asphalt

MATERIAL TYPES DATA

Base Layer Granular and stress independent (linear)

Subbase Layer Granular and stress independent (linear)

Subgrade Layer Stress independent

MODELS DATA

Fatigue Model Asphalt Institute model

Rutting Model Asphalt Institute Model

GENERAL DATA

Dual Tire Load, lb 4500

Dual Tire Spacing, in. 13.5

Tire Pressure, psi 80

Future 80-kN (18-kip)

ESALs (20 years)5000000

Fatigue Shift Factors

(FSF)18.4 for new AC and 4 for old AC

Climate Zone Idaho Climatic Zone No. 1

MODULUS-TEMPERATURE ADJUSTMENT DATA

Use the default SHRP equation

Entering the Data

You are now ready to enter all of the data into WINFLEX 2000. The text below describes the

basic steps for entering data into WINFLEX. For more detailed instructions, refer to Chapter Two.

• Open the program.

• Specify that you will run WINFLEX 2000 with the English system.

• Create a new input file by clicking on New File on the toolbar. Select the singlelocation design case option.

• The first data entry screen is Pavement Data. Enter all the pavement data, as shown inFigure 21. When you finished, click the Next command button.

• The second data entry screen is Material Types. Enter all the material types data inthis screen as shown in Figure 22. Once again, click the Next command button.

• The third data entry screen is Model Data, A as shown in Figure 23. When you havefinished entering data in this screen, click the Next command button.

• The fourth screen is General Data, as shown in Figure 24.




• The fifth screen is for Modulus-Temperature Adjustment data, which uses the defaultSHRP equation, as shown in Figure 25.

Figure 21. Pavement Data for Example1_S

Figure 22. Material Types for Example1_S




Figure 23. Models for Example1_S

Figure 24. General Data for Example1_S




Figure 25. Modulus-Temperature for Example1_S

Saving the Data

You have now entered all the data in WINFLEX 2000 for this example. You can save these

data in an input file with extension *.INP or run these data directly. To save the data in an

input file, click the Save command button in the toolbar.

Running the Calculations on the Input File

The following text provides an overview of running calculations in WINFLEX. For moredetailed instructions, refer to Chapter Two.

By pressing the Run Single command button in the toolbar, you can run the calculations onthis example to obtain the overlay thickness that the program recommends for this case. After

running this example, the Result screen will appear, showing the overlay thickness for this

example, which is 5.70 inches, as shown in Figure 26.

On the Result screen you can select to save a detailed report in a text file with the extension*.TXT by clicking on Save Report in Text File. You can also print a comprehensive report

for this case by clicking on Print a Report. A comprehensive report is shown in two parts, in

Figure 27 and Figure 28.




Strain values that were determined during the calculation process can be displayed and printed by clicking on the Show Strains button in Figure 26. A Strains report is shown in

Figure 29.

The seasonal adjusted moduli values for each layer can be displayed for all layers in each

season by clicking on the hover button in the result screen as shown in Figure 30.

Figure 26. Results Screen for Example1_S




Figure 27. Comprehensive Report for Example1_S




Figure 28. Comprehensive Report for Example1_S (Cont’d)




Figure 29. Strain Values for Example1_S

Figure 30. Seasonal Adjusted Moduli Values for Example1_S




3.3 Example of Multiple Location Design Case

The file Example7_M.inp is provided as one example for a multiple locations design case.

To use WINFLEX 2000 for calculating the overlay thickness, you will need to perform four

steps:

•

Prepare your ETF file.• Prepare your data.

• Run WINFLEX and load your ETF file.

• Enter your data in the program to create your input file with the extension*.INP.

• Run the calculations on the input file in conjunction with the ETF file toobtain your overlay thickness at every milepost.

• Print your results.

Preparing the Data

ETF Fi le

This example requires an ETF file, which is a text file in which the user enters data for existing pavement layer moduli, test temperature, and thickness values, for all mileposts.

There are seven mileposts in this example. The existing pavement includes AC layer, Base,

Subbase, and Subgrade. The moduli values of existing pavement can be obtained from backcalculation of FWD deflection testing. The thickness of the existing layers can be

obtained from construction documents, core analysis or by NDT method such as GPR.

To create the ETF file for this example, refer to the section entitled Creating an ETF file, and

then save it with extension *.ETF. Figure 31 shows the ETF file for this example.

Figure 31. ETF File for Example7_M




Pavement Data

These data are related to the existing pavement section and overlay properties. In thisexample, the existing pavement section consists of AC layer, Base, Subbase, and Subgrade.

The moduli values of the existing pavement can be obtained from lab tests on core samples,

or obtained from backcalculation of Falling Weight Deflectometer (FWD) deflection testing.The thickness of the existing layers can be obtained from construction documents, core

analysis or by NDT methods such as the Ground Penetration Radar (GPR). The elastic

modulus of the overlay layer could be obtained by laboratory testing of the new overlay mix.Poisson’s ratio of each layer can be assumed with a reasonable value, refer to Pavement

Section Block for details.

You have to choose an initial value (minimum thickness) for the overlay layer that the program will consider for designing the overlay. In this example, a suggested initial value of

0.5 inches is reasonable. You also have to select a reasonable value for the overlay thickness

increment. This is the amount by which the program increases the overlay thickness in the

design iteration. In this example, a suggested value of 0.1 inches is reasonable. In thisexample, consider the fatigue failure mode is to be in the new overlay or old asphalt.

In this example, you cannot enter the moduli, testing temperature, and thicknesses for the

existing layers. These values will be read at every milepost from the ETF file that you have

created prior to this step.

Mater ial Types Data

These data depend on the existing pavement section that has been selected in the previousstep. Note that the existing pavement section will be selected automatically after loading the

ETF file, according to the number of layers, and you have no ability to change this option in

the first data entry screen. In this example you have three layers, for BASE, SUBBASE, andSUBGRADE, and you have to choose the material types for each layer. In this example, each

layer is considered as stress independent.

Models Data

This data helps you to select the failure criteria and to select the models used for estimating

the pavement damage. The choice could be based on either fatigue or rutting or both. In thisexample, you can consider that the failure is controlled by both fatigue and rutting. The

Asphalt Institute model is selected for both fatigue and rutting in this example.

General Data

In this stage, information on design traffic, fatigue shift factors, and seasonal adjusting

factors are obtained. Consider that this pavement section is taken from a pavement in Idahoclimatic zone number 1. The calculation is based on the 18-kip standard Equivalent Single

Axle Load (ESAL). The wheel load, dual spacing, and tire pressure are 4500 lb, 13.5 in. and

80 psi respectively. The estimated future traffic is considered to be 5 million ESALs.






respective cells. The moduli, thicknesses, test temperature, and number of layers will be read

from the ETF file, Example7_M.ETF.

Enter the necessary information in all of the data entry screens, as shown in Figure 32, Figure

33, Figure 34, Figure 35, and Figure 36.

Figure 32. Pavement Screen for Example7_M

Figure 33. Material Types Screen for Example7_M




Figure 34. Models Screen for Example7_M

Figure 35. General Screen for Example7_M




Figure 36. Modulus-Temperature Adjustment Screen fro Example7_M

Saving the Data

You have now entered all the data in WINFLEX 2000 for this example. Save these data in an

input file with extension *.INP.

Running the Calculations on the Input FileClick on the Run Multiple command button in the toolbar of the main screen to run the

calculations on this example. After running this example, the result screen will appear,

showing the overlay thickness for every milepost, as shown in Figure 37.

In this screen you can print a comprehensive report for this case by clicking on the Print a

Report command button. A comprehensive report is shown in four parts in Figure 38, Figure39, Figure 40, and Figure 41.

Strain values that were determined during the calculation process can also be shown and

printed by clicking on Show Strains button as shown in Figure 42. You can transfer all the

results to an Excel data sheet by clicking on the Export Results to Excel command button.




Figure 37. Results Screen for Example7_M




Figure 38. Comprehensive Report for Example7_M






Figure 40. Comprehensive Report for Example7_M (Cont’d)







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