caltrans caltrans contract no. 65a0151 project videoconference september 15, 2005 slurry/micro mix...

Caltrans Caltrans Contract No. 65A0151Caltrans Caltrans Contract No. 65A0151

MACTEC

Project VideoconferenceProject Videoconference

September 15, 2005September 15, 2005

Slurry/Micro Mix Design ProcedureSlurry/Micro Mix Design Procedure


MACTEC

Videoconference OutlineVideoconference Outline

Roll Call and Introductions-HollandRoll Call and Introductions-HollandProject Goals, Objectives, Project Goals, Objectives,

Timeline- MoulthropTimeline- MoulthropPhase III – Design Validation & Phase III – Design Validation &

Training Training Activities-Moulthrop/SeedsActivities-Moulthrop/Seeds

Phase II - Improved Mix Design Phase II - Improved Mix Design Activities -HolleranActivities -Holleran

Wrap Up including next meeting- Wrap Up including next meeting- HollandHolland

Q/A session-Holland Q/A session-Holland


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Introduction to ProjectIntroduction to Project

GoalsGoalsDevelop, Analyze, and Validate an Develop, Analyze, and Validate an

improved mix design procedure for improved mix design procedure for slurry surfacingsslurry surfacings

Objectives/TasksObjectives/TasksPhase 1-Literature review and work Phase 1-Literature review and work

plan development plan development Phase 2-Laboratory phasePhase 2-Laboratory phasePhase 3-Field validation, Guidelines, Phase 3-Field validation, Guidelines,

and Specifications and Specifications


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Videoconference GoalsVideoconference Goals

GoalsGoalsDiscuss the selection of trial Discuss the selection of trial

projects for 2006 construction projects for 2006 construction seasonseason•Selection guidelinesSelection guidelines

Discuss the current Phase II workDiscuss the current Phase II work


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Phase III ActivitiesPhase III Activities

Project Selection Project Selection GuidelinesGuidelinesCandidate Field Candidate Field SitesSitesConstruction and Construction and monitoring of sitesmonitoring of sitesSpecificationsSpecificationsReference Reference ManualManual


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Need sites NOWNeed sites NOW

Construction Construction isis planned for planned for 20062006

Funding of sites needs to be Funding of sites needs to be secured in advancesecured in advance

Fugro needs to be involved Fugro needs to be involved with site selectionwith site selection


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Project Selection - Step 1Project Selection - Step 1

The States are responsible for the The States are responsible for the following activities:following activities:

Nomination of test sitesNomination of test sitesConstruction of test sectionsConstruction of test sectionsProvision of traffic control for all test Provision of traffic control for all test

site data collectionsite data collectionReporting as-built construction dataReporting as-built construction dataReporting structural information Reporting structural information

(cross section thickness/material)(cross section thickness/material)Reporting maintenance activitiesReporting maintenance activitiesReporting friction resistance if Reporting friction resistance if

availableavailable


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Project Selection - Step 2Project Selection - Step 2

Development of experimental plans and Development of experimental plans and designdesign

Coordination among participating Coordination among participating agenciesagencies

Final acceptance of nominated test sitesFinal acceptance of nominated test sites Development of uniform data collection Development of uniform data collection

guidelines and formsguidelines and forms Coordination of material sampling and Coordination of material sampling and

testingtesting Monitoring pavement performanceMonitoring pavement performance Data analysis and reportingData analysis and reporting Review of material mix designs and Review of material mix designs and

construction plansconstruction plans

The Research Team is responsible for:


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Site Selection GuidelinesSite Selection Guidelines

Variables to considerVariables to considerTrafficTrafficClimateClimatePavement Surface and Pavement Surface and

conditionconditionGeometryGeometryLengthLengthSection LayoutSection Layout


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TrafficTraffic Two levels-high and moderateTwo levels-high and moderateHigh->25,000 ADT (>10 million High->25,000 ADT (>10 million

ESALs)ESALs)Moderate->10,000 <25,000 Moderate->10,000 <25,000

ADT (4-10 million ESALs over ADT (4-10 million ESALs over 20 years w/ 10% trucks20 years w/ 10% trucks


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ClimateClimate

Four LTPP regionsFour LTPP regions•Wet FreezeWet Freeze

•Wet No-FreezeWet No-Freeze

•Dry FreezeDry Freeze

•Dry No-FreezeDry No-Freeze


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ClimateClimate

Goal-Projects in each region


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Pavement SurfacePavement SurfaceBituminous Concrete (HMA)Bituminous Concrete (HMA)Portland Cement Concrete Portland Cement Concrete

(PCC)(PCC)• Provided the agency permits Provided the agency permits

placement of bituminous placement of bituminous products on PCC pavementsproducts on PCC pavements


MACTEC

Example Project Nomination Example Project Nomination FactorialFactorial

Pavement Surface Climatic Region Traffic Level Project Name

Moderate Project 1 Project 2

Region 1

High Project 3 Project 4


Asphalt Concrete

Region 2



Region 1



Portland Cement Concrete

Region 2



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Desired CharacteristicsDesired Characteristics

Adequate LengthAdequate LengthTo accommodate the number To accommodate the number

and length of test sectionsand length of test sections

Uniform TrafficUniform TrafficAs much as possibleAs much as possible

Pavement GeometryPavement GeometryHorizontal curves =/< 3Horizontal curves =/< 3°°Vertical grades =/< 4%Vertical grades =/< 4%


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Pavement ConditionsPavement ConditionsLittle distress, but uniform Little distress, but uniform

(raveling, bleeding, transverse (raveling, bleeding, transverse cracks)cracks)

Rutting > 1” unacceptableRutting > 1” unacceptableRide quality - < 100”/mileRide quality - < 100”/mileNo moisture damageNo moisture damage5 years remaining service life5 years remaining service lifeFWD testing if available-SCI < FWD testing if available-SCI <

20 at 9k lbs. load20 at 9k lbs. load


MACTEC

Recommended Pilot Project LayoutRecommended Pilot Project Layout

152-m (500-ft) section placed using the ISSA (International Slurry Surfacing Association) mix design procedure 152-m (500-ft) control section, with no treatment 152-m (500-ft) section placed using the Slurry Systems Mix Design (SSMD) developed in this project Second 152-m (500-ft) ISSA section Second 152-m (500-ft) control section Second 152-m (500-ft) SSMD section Transition zones of 30 m (100 ft) lengths (minimum) are used before and after each section


MACTEC

Recommended Pilot Project LayoutRecommended Pilot Project Layout

Lane

Widt

h

Trans

ition

ISSA

Trans

ition

Contr

ol

Trans

ition

New

Mix

Desig

n

Trans

ition

ISSA

Trans

ition

CONT

ROL

Trans

ition

New

Mix

Desig

n

Trans

ition

100 ft 500 ft 100 ft 500 ft 100 ft 500 ft 100 ft 500 ft 100 ft 500 ft 100 ft 500 ft 100 ft30 m 152 m 30 m 152 m 30 m 152 m 30 m 152 m 30 m 152 m 30 m 152 m 30 m


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Key Training DeliverablesKey Training Deliverables

1.5-Day Training CourseReference ManualVisual AidsInstructors Guide

Pre-Job Training Module


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Reference ManualReference Manual

ChapterChapter Title/DescriptionTitle/Description DraftDraft

11 IntroductionIntroduction

22 Project Selection CriteriaProject Selection Criteria

33 Pre-Construction RequirementsPre-Construction Requirements

44 SpecificationsSpecifications

55 Mix Design CriteriaMix Design Criteria

66 Test Methods and ProceduresTest Methods and Procedures

77 Construction Considerations and LimitationsConstruction Considerations and Limitations

88 Construction OperationsConstruction Operations

99 QC/QA RequirementsQC/QA Requirements

1010 TroubleshootingTroubleshooting

App AApp A Test MethodsTest Methods

App BApp B SpecificationsSpecifications


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Phase III – Remaining WorkPhase III – Remaining Work

Training – Complete 1.5-day Training Course materials and Pre-Job Module


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Phase II Progress ReportPhase II Progress Report

SubtasksSubtasksDevelop and Evaluate new or Develop and Evaluate new or

improved test proceduresimproved test proceduresAnalyze the results of the test Analyze the results of the test

methodsmethodsPrepare test protocolsPrepare test protocolsConduct ruggedness testing of Conduct ruggedness testing of

equipmentequipment


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Phase II TimelinePhase II Timeline

Revised Phase II Timeline

J F M A M J J A S O N D J F M A M J J A S O N D J F M

Equipment Procurement / Modification

Samples Procurement

Materials Testing

Mix Testing / Test Development

Cohesion Testing / French WTAT Development

Long Term Testing

Finalization of Mix Design

Field Test Development / Constructability

Design for Field TrialsOriginal Phase II Timeline Revised Phase II Timeline

Revised Phase II Timeline, 4/15/05

20062004 2005Activity


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Testing PhilosophyTesting PhilosophyWhat do existing tests tell us?What do existing tests tell us?Proposed New TestsProposed New Tests

Laboratory Phase OutlineLaboratory Phase Outline


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Philosophy Of ApproachPhilosophy Of Approach

Performance Related TestsPerformance Related TestsAddress Failure ModesAddress Failure ModesSimulate Field ConditionsSimulate Field ConditionsMeasures Cohesion, Adhesion and Abrasion Measures Cohesion, Adhesion and Abrasion

ResistanceResistance Stages to be evaluatedStages to be evaluated

• MixingMixing• Setting and CuringSetting and Curing• Long Term PerformanceLong Term Performance

Tests that can be used for all slurry Tests that can be used for all slurry systems and to evaluate mix variablessystems and to evaluate mix variables


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New Mix Design ProcedureNew Mix Design Procedure

Will it Mix?Will it Mix?Will it set?Will it set?Will it Perform?Will it Perform?

Properties through Properties through the stages of the the stages of the mixture’s life are mixture’s life are the key!the key!


MACTEC

Drawbacks of the Current SystemDrawbacks of the Current System

Technology and reproducibility of testsTechnology and reproducibility of testsLimited data set (aggregates and Limited data set (aggregates and

binders)binders) Inability to simulate road conditionsInability to simulate road conditions Inability to address various traffic Inability to address various traffic

conditionsconditions

Law


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New Mix Design Procedure New Mix Design Procedure

Materials SelectionMaterials SelectionCreate Matrix of Mix ProportionsCreate Matrix of Mix Proportions

Measure Short Term Constructability Measure Short Term Constructability Select Optimum binder propertiesSelect Optimum binder properties

Measure Long Term PerformanceMeasure Long Term PerformanceIterative process- feedback Iterative process- feedback

controlledcontrolledEvaluate finished product using Evaluate finished product using

field control testsfield control tests


MACTEC

Aggregate TestsAggregate Tests

Sieve AnalysisSieve AnalysisSand EquivalentSand EquivalentAbrasion Resistance by Los Angeles Abrasion Resistance by Los Angeles

AbrasionAbrasionSulfate SoundnessSulfate SoundnessMicro- Deval test for field abrasion Micro- Deval test for field abrasion

performance performance


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Emulsion and Binder TestsEmulsion and Binder Tests

Tests on original emulsionTests on original emulsionRecovered binder testsRecovered binder tests

Ring and Ball Softening Point, Ring and Ball Softening Point, Penetration Penetration

Potential use of DSR, BBR,DTT –Potential use of DSR, BBR,DTT –beyond the scope of project but beyond the scope of project but AEMA is pursuingAEMA is pursuing


MACTEC

New Mixture TestsNew Mixture Tests

Mixing TestMixing Test developed in developed in

GermanyGermanySetting and Setting and CuringCuring

new new developmentdevelopment

Abrasion/Abrasion/Cohesion TestCohesion Test

developed in developed in FranceFrance


MACTEC

New Mix Test New Mix Test

Allows selection and initial ratios Allows selection and initial ratios of componentsof components

Allows examination of effects of Allows examination of effects of different components and different components and additivesadditives

Relates to initial constructabilityRelates to initial constructabilityMeasures mix stiffness and effect Measures mix stiffness and effect

of mix conditionsof mix conditionsProvides the answer to ”will it Provides the answer to ”will it

mix and will it spread?”mix and will it spread?”


MACTEC

Mix Test SetupMix Test Setup


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Outputs - Mixing and WorkabilityOutputs - Mixing and Workability

Stabilized - quick set Micro - fast set

9.09.0

12.0 12.0

time time

Kg

-cm

Kg

-cm


MACTEC New Setting and Curing TestNew Setting and Curing Test

Measures cohesion build UpMeasures cohesion build UpUsed to estimate traffic timeUsed to estimate traffic timeProvides an estimate of Provides an estimate of

resistance to early trafficresistance to early trafficEvaluates the impact of Evaluates the impact of

environmental conditions environmental conditions and physical effects such as and physical effects such as compactioncompaction


MACTEC

Setting and Curing Test SetupSetting and Curing Test SetupClamping Pressure 200Kpa

PC will display spread sheet to include torque time graph and calculation of peak torque.

Interface of foot with sample—this is rubber. Part of the process will use different surface types on the foot to improve grip and reproducibility.

Torque measurement taken at base close to interface. This will prevent bending in the shaft to influence results. Electronic torque (strain gauge) measurement will transmit

to PC for display.

Motorized gear shifts shaft through 180º. Allows precise application of twisting torque to measure resistance to shear

force.

Clamping Pressure 200Kpa

PC will display spread sheet to include torque time graph and calculation of peak torque.

Interface of foot with sample—this is rubber. Part of the process will use different surface types on the foot to improve grip and reproducibility.

Torque measurement taken at base close to interface. This will prevent bending in the shaft to influence results. Electronic torque (strain gauge) measurement will transmit

to PC for display.

Motorized gear shifts shaft through 180º. Allows precise application of twisting torque to measure resistance to shear

force.


MACTEC Curing Test ResultsCuring Test Results

Cohesion results

0

5

10

15

20

25

30

35

40

0 30 60 90 O/N

time min

Cohes

ion

kg-

cm

15%

13%

17%

Will It Set ? Will it take Early traffic?Will It Set ? Will it take Early traffic?

% Emulsion


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Constructability - Short Term Constructability - Short Term Performance Test (CAT)Performance Test (CAT)

A form of cohesion test (French A form of cohesion test (French WTAT)WTAT)

Can be performed on both curing Can be performed on both curing and cured samplesand cured samples

Allows simulation of field conditions Allows simulation of field conditions and physical effects such as and physical effects such as compactioncompaction

Wheel WTAT at different cure and Wheel WTAT at different cure and soak timessoak times


MACTEC New CAT TestNew CAT Test

Rise in Cohesion Rise in Cohesion measured for different measured for different mixes under different mixes under different curing conditionscuring conditionsUses full mix gradationUses full mix gradationCan be performed under Can be performed under waterwater


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CAT SetupCAT Setup


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CAT OutputCAT Output

FWTAT Mix 1 Effect Of Cure Conditions

0

100

200

300

400

500

0.5 1 1.5 2 2.5

Cure Time

Loss

g

25C

25C Hi H

35C

10C

10C Hi H

25C Compaction

Poor

Moderate

High


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FWTAT Cure Test

0

200

400

600

800

1000

30 60 90 120

time of Cure(Min)

Loss

(g)

Std 10C Hi

Std 25C

Std40CHi

Std 40C

Std10CHi

Std 10C

B25C Hi

B25C

B25C

B40CHi

B40C

B10CHi

B10C

CAT Output- Different MixesCAT Output- Different Mixes


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Non CohesiveNon Cohesive

CAT ProcessCAT Process


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Progress to DateProgress to DateMixes selected have been Mixes selected have been

characterized by existing ISSA characterized by existing ISSA Technical BulletinsTechnical Bulletins

Component materials have been Component materials have been characterized characterized

Preliminary testing on wet Preliminary testing on wet cohesion and sample conditioning cohesion and sample conditioning methods has been donemethods has been done

Equipment has been procured, Equipment has been procured, designed and constructeddesigned and constructed

Preliminary testing and Preliminary testing and modifications have been mademodifications have been made


MACTEC

Progress to Date (cont.)Progress to Date (cont.)

CAT-formerly French WTAT final CAT-formerly French WTAT final procedure establishedprocedure establishedThicker samples are produced with the entire Thicker samples are produced with the entire

aggregate gradation aggregate gradation

Mix test equipment programmed and Mix test equipment programmed and operationaloperationalClassification of mixes based on mixing torque Classification of mixes based on mixing torque

developeddevelopedMixing bowl and stirrer geometry establishedMixing bowl and stirrer geometry established

Micro Deval equipment procuredMicro Deval equipment procured Continuing problems with procuring Continuing problems with procuring

equipment for the setting and curing testequipment for the setting and curing test


MACTEC

Phase II Remaining workPhase II Remaining work

Complete the testing matrix Complete the testing matrix of slurry system mixturesof slurry system mixtures

Finalize mix design Finalize mix design procedureprocedure

Prepare test protocolsPrepare test protocolsConduct ruggedness testingConduct ruggedness testingFinalize field testsFinalize field testsPrepare summary reportPrepare summary report


MACTEC

Catch up planCatch up plan

Issues to accelerate lab workIssues to accelerate lab workIncrease laborIncrease laborPhilosophy used on real Philosophy used on real

projectsprojectsEquipmentEquipment

Work will be accomplished Work will be accomplished by 12-05by 12-05

Mix Designs for field trials to Mix Designs for field trials to be done by 1 March 2006be done by 1 March 2006


MACTEC

Strawman Spec v. 3Strawman Spec v. 3Hi Med Low Hi Med Low Hi Normal

35 C 25 C 10 C 90% 50%

PFS-1 (Mixing)Mixing Torque - maximum kg-cm 9 9 9 9 9 9 9 9Mixing time - minimum sec. 120 120 120 120 120 120 120 120

Spread index - maximum @ 120 sec. kg-cm 12 12 12 12 12 12 12 12

Blot test - 30 sec. -clear water

clear water

N/Aclear water

clear water

clear water

clear water

clear water

Coating - 100% 100% 95% 95% 95% 100% 100% 95%PFS-2 (Wet Cohesion)30 min. cohesion - minimum kg-cm 12 12 12 12 12 12 12 1260 min. cohesion - minimum kg-cm 23 20 20 20 20 20 20 2090 min. cohesion - minimum kg-cm 25 25 25 25 25 25 25 2512 hr. cohesion - minimum kg-cm 28 28 28 28 28 28 28 28PFS-3 (Abrasion Loss)

30 min. loss - maximum g/m2 200 200 400 300 300 300 300 300

1hr. loss - maximum g/m2 100 100 300 100 200 100 100 2003 hr. loss - maximum g/m2 100 100 200 100 100 100 100 100

PFS-1 (Mixing)Mixing Torque - maximum kg-cm 9 9 9 9 9 9 9 9Mixing time - minimum sec. 120 120 120 120 120 120 120 120

Spread index - maximum @ 120 sec. kg-cm 12 12 12 12 12 12 12 12

Blot test - 30 sec. -clear water

clear water

N/Aclear water

clear water

clear water

clear water

clear water

Coating - 100% 100% 95% 95% 95% 100% 100% 95%PFS-2 (Wet Cohesion)30 min. cohesion - minimum kg-cm 12 12 12 12 12 12 12 1260 min. cohesion - minimum kg-cm 23 20 20 20 20 20 20 2090 min. cohesion - minimum kg-cm 25 25 25 25 25 25 25 2512 hr. cohesion - minimum kg-cm 28 28 28 28 28 28 28 28PFS-3 (Abrasion Loss)

30 min. loss - maximum g/m2 200 200 400 300 300 300 300 300

1hr. loss - maximum g/m2 100 100 300 100 200 100 100 2003 hr. loss - maximum g/m2 100 100 200 100 100 100 100 100

Slow

Test or field Condition UnitsSet TimeTraffic Temperature Humidity

Rapid


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Phase II DeliverablesPhase II Deliverables

Improved mix Improved mix design design procedures and procedures and performance performance teststestsField test Field test equipment & equipment & proceduresproceduresField Validation Field Validation of mix design of mix design procedureprocedure


MACTEC

Project SummaryProject Summary

Phase I is completePhase I is completePhase II is behind schedule, but Phase II is behind schedule, but

plans have been made to plans have been made to complete work by Dec 05complete work by Dec 05

Phase III is underway, but we Phase III is underway, but we need candidates for field projectsneed candidates for field projects

Pilot projects are to be Pilot projects are to be constructed in 2006 so they have constructed in 2006 so they have at least one year to be monitored at least one year to be monitored for performancefor performance


MACTEC

Wrap-upWrap-up

Next panel meetingNext panel meetingWhen When Will a teleconference workWill a teleconference workJoint Industry meeting in Palm Springs?Joint Industry meeting in Palm Springs?

Need for improved Need for improved communications – Industry is communications – Industry is concernedconcerned

Other issues?Other issues?


MACTEC

Question/ Answer PeriodQuestion/ Answer Period

Posting of progress reports on Posting of progress reports on FP2 website?FP2 website?

Concern over progress Concern over progress addressed? Plans developed to addressed? Plans developed to accelerate lab workaccelerate lab work

Need for field projectsNeed for field projectsOther issues to be resolvedOther issues to be resolved

caltrans caltrans contract no. 65a0151 project videoconference september 15, 2005 slurry/micro mix...

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