Steven L. Gillen – Materials Manager, Illinois TollwayAlexander S. Brand – Graduate Student, University of IllinoisJeffery T. Roesler, Ph.D., ‐ Professor, University of IllinoisWilliam R. Vavrik, Ph.D., ‐ Principal Engineer, ARA Inc.
September 19, 2012
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Sustainable Long‐Life Composite Concrete Pavement for the Illinois Tollway
Illinois Tollway ‐ Key Statistics 286‐mile system comprised
of four tollways: Tri‐State (I‐94/I‐294/I‐80) Jane Addams Memorial (I‐90) Reagan Memorial (I‐88) Veterans Memorial (I‐355)
Opened in 1958 as a bypass around Chicago to connect Indiana and Wisconsin
Carries more than 1.4 M vehicles per day
User‐fee system – no state or federal gas tax dollars used
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Congestion‐Relief Program
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90% Complete
> $5B Investedon time, under budget
Congestion‐Relief Program2004‐2016
Job #1 ‐ Take Care of Existing System
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RECONSTRUCT AND WIDEN
Jane Addams Memorial Tollway (I‐90)
RECONSTRUCT Tri‐State Tollway
(I‐94/I‐294)
PRESERVEReagan Memorial Tollway (I‐88)
PRESERVEVeterans Memorial Tollway (I‐355)
REPAIRRoads, Bridges and
Maintenance Facilities
Other Capital Projects Maintenance Site Location
Build a 21st Century Transportation System
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RECONSTRUCTTri‐State Tollway
(I‐94/I‐294) – $1.2 B
PRESERVEReagan Memorial
Tollway (I‐88) – $610 M
PRESERVEVeterans Memorial
Tollway (I‐355) – $400 M
REPAIRRoads, Bridges &
Maintenance Facilities –$1.39 B
Other Capital Projects ‐$600 M
RECONSTRUCT & WIDEN
Jane Addams Memorial Tollway (I‐90) – $1.9 B
(no transit)
TAKE CARE OF EXISTING SYSTEM NEEDS
ILLINOIS ROUTE 53 NORTH EXTENSION
JANE ADDAMS MEMORIAL TOLLWAY
(I‐90)
ELGIN O’HARE WEST BYPASS
I‐294/I‐57 INTERCHANGE
ILLIANA EXPRESSWAY
Tollway Recycling of Concrete and Asphalt Pavements
In Base Aggregates In New Asphalt Mixes
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Innovations Adopted
Fractionated RAP (FRAP)Recycled Asphalt Shingles
(RAS)
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Coarse FRAP for Concrete?
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Answers Needed SHRP R21 Composite Pavement Project
Demonstrations Observed
History of Composites Studied
History of Black Rock Concrete Studied
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Field Trials Initiated in 2010 Asphalt over Concrete Composite Ramps Built
6.5 bag fly ash mix w/ 20% black rock placed
Compressive strengths > 3500 psi in 3 days.
Flexural Strengths >650 psi in 7 days.
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Black Rock Ternary Mixes Researched
Fractionated Reclaimed Asphalt Pavement (FRAP) as a Coarse Aggregate Replacement in a Ternary Blended Concrete Pavement
ict.illinois.edu/publications
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Conclusions of Initial Research Further processing of FRAP to remove agglomerated sand/asphalt particles was not necessary
A ternary concrete design with a cement factor of 6.2 could obtain specified strength properties with up to 50% of the coarse aggregate replaced with FRAP
Durability of concrete will be adequate for composite pavement applications
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Composite Pavement Research Continues Further evaluate black rock concrete mixes for fresh, hardened and durability properties
Develop better predictive models of the field performance for 2 lift composite concrete pavements using recycled materials
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University of Illinois Slab Tests (2012)
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• Two‐lift Slabs:• Virgin over 45% FRAP• Virgin over 45% FRAP (with fibers)
• Virgin over 100% RCA• Virgin over 45‐55 FRAP‐RCA
• Full‐depth Slabs:• 45% FRAP• 100% RCA• 45‐55% FRAP‐RCA• Virgin
Mix Proportions:• 610 lb/yd3 with 35% slag and 10% fly ash• w/cm = 0.37• 41% coarse aggregate (by volume)• 27% fine aggregate (by volume)
All mixes were designed based on a constant volume methodology
Univ. of Illinois Slab Test Results (38 days)
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Slab Peak Load (kN)
Percent Differencefrom Full‐depth
Virgin
Two Lift
Virgin over 45% FRAP 123.2 22.8%
Full Depth45% FRAP 118.2 17.7%
Two Lift
Virgin over 45% FRAP with fibers 109.5 9.1%
Full Depth100% RCA 109.4 9.0%
Two Virgin over
Slab Results (Average of 2 Tests)
MixAverage MOR
(psi)
Fresh Air Content (%)
45% FRAP 584 8.5%
45% FRAP with fibers
451 12%
100% RCA 574 5.5%
45‐55% FRAP‐RCA
593 6.0%
Virgin 786 5.6%
Flexural Strength (3rd point)
Mix Total Fracture Energy (N/m)
45% FRAP 75.7
45% FRAP with fibers 3192.9
100% RCA 84.5
Specifications Established Materials Ternary – 35% to 50% portland cement replaced in bottom Black Rock – 20% to 50% coarse aggregate replaced in bottom RCA – Option given to replace any remaining coarse aggregate with RCA in bottom lift
Two slip form pavers specified unless alternative method for placement is demonstrated
Minimum 5 day cure time before heavy equipment
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Placement Test Strips
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Field Trials Continue in 2012
I‐88 reconstructed and widened with 2 lift PCC composite
Full interchange ramps at I‐90 / Rt. 47 constructed using asphalt over concrete composite
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I‐90 Long Life Pavement Designs
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LCCA’s Determine JPCP to be the Choice
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Major Traffic Inputs for Pavement Design Lane Distribution Traffic Volume Load Spectra
3-Lane 4-Lane
National60%
Tollway70%
National45%
Tollway70%
Design Trucks – Load Distributions
34kip12kip 34kip
Current Load Limits 40kip12kip 40kip
40kip12kip 60kip
Proposed Load Limits
Proposed Load Limits
Tollway Axle Weight Distribution Does Not Follow National Data
0
2
4
6
8
10
12
14
16
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0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 50,000
Percen
t of A
xles
Weight of Tandem Axle Group (lb)
MEPDG
Tollway
Tandem Axle – Class 9
I‐90 Concrete Pavement Design Details 15’ Slab length 1’ Widened slab Doweled Joints (1 ½”)
Topping Concrete
High-recycled Content Concrete
WMA Base
Aggregate Cap
Porous Aggregate
Compacted Subgrade
THANK YOU
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