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MODERN TECHNOLOGY IN FAST

TRACK ROAD CONSTRUCTION


ULTRA THIN WHITE TOPPING

SEMINAR BY-

SHAMKANT D.KUMAVAT
T.E.CIVIL ENGINEERING
G.S.M.C.O.E.PUNE.

BITUMINOUS
PAVEMENTS: Problems
Require repeated maintenance
Distress in early service life

Rutting,
Cracking,
Settlement
Pot holes

Expensive if
service life cost
considered

BITUMINOUS PAVEMENTS :
UPGRADATION
Current Practice

Patch repairs with bitumen


Occasional upgradation
with a Bitumen overlay
Results : deterioration
unabated

Is there an alternative?
Which is

Durable
Cost-effective
Technically superior

What is
Whitetopping?

Plain cement concrete layer constructed


on top of an existing HMA-(hot mix asphalt)pavement)
Well established and proven technique in
the Western countries

Used to combat rutting in truck corridors


Usual Pavement thickness > 200 mm
Asphalt layer acts as a base layer
Studies indicates good to excellent
performance
Contd.

What TWT
and UTW ?
Thin Whitetopping (TWT)

Pavement thickness 100-200mm


In most cases, designed and constructed
without consideration of bond between
HMA and concrete

Ultra-Thin Whitetopping (UTW)

Pavement thickness < 100mm


designed and constructed with
consideration of bond between HMA and
concrete
Contd.
Closer joint spacing

Typical c/s of
UTW

HISTORY OF UTW (USA)

YEAR

ADVANTAGES OF
UTW
Reduced thickness
Fast-Track construction
Reduced maintenance
Cost-Effective compared to asphalt overlays
Improved service life
Little pre-overlay repairs
Improvement in safety in view of the
increased reflection of light
Reduction in operational costs and lower
absorption of solar energy
Improving the environmental benefits

Necessity of
Sound Bond
UTW overlays are designed &
constructed with sound bond
between plan concrete and HMA
material
Ensures composite action between
Asphalt and Concrete
Stresses in the top concrete layer
are low in view of the composite
action

Characterisation
of HMA
Adequate characterization of
HMA highly essential for UTW
Visual Inspection
Lab. and field Tests
- The Hamburg wheel track test
- Dynamic Modulus test
- Falling weight deflectometer

Design of UTW
Thickness of UTW determined by:
Type & Volume of existing and
expected traffic
Strength & Condition of existing
pavement
Material properties of the concrete

Design Method
Developed by the PCA, USA

Concrete mixes for UTW :


Main Parameters
Fast-Track type construction

-One day Flexural strength: 4 MPa


-One day Compressive Strength : 35MPa

Mix requirements

Mineral admixtures

Silica fumes,
Fly-ash
Or a combination of two

Low water/binder ratio


Use of a Superplaticiser
Synthetic fibers, if required

Table 1: Laboratory mixes for Ultra-Thin White Topping


Ingredients
Cement, kg
Microsilica, kg
Flyash, kg

VTMS07

VTMF02

VTOF02

VTMS08P

VTMF03P

VTOF03P

450
35

380
30

420
0

450
35

380
30

420
0

100
510
0
607
405
497
331
143
5.30
1.04%
0.28
80

105
525
0
601
400
491
328
147
5.25
0.7%
0.28
80

0
485
0.900
644
430
486
324
121
9.70
2.25%
0.25
55

100
510
0.900
639
426
463
309
143
6.63
1.30%
0.28
60

105
525
0.900
622
415
470
313
147
6.56
1.25%
0.28
75

19.73
32.18
45.51
69.07

19.87
34.89
47.78
69.56

36.31
54.84
68.71
90.42

24.8
38.44
56.31
72.26

26.8
37.95
48.71
70.44

4.20
4.40
7.80

4.00
4.40
6.00

4.00
7.00
9.00

4.20
5.60
8.00

4.2
4.6 (6D)
6.20

0
Total Binder
485
Polypropelene fibres, kg
0
Aggregate, kg: 20 mm
633
Aggregate, kg: 10 mm
422
Vaitarna sand
497
Curser Dust
332
Water, lit
121
HRWRA, lit
9.70
2.00%
W/B Ratio
0.25
Slump (mm)
65
Comp Strength, MPa
1 Day
35.11
3 Days
51.47
7 Days
69.02
28 Days
94.30
Flexural Strength, MPa
1 Day
3.6
3 Days
7 Days
6.80
28 Days
9.2

Construction
Practice
Pre-overlay repair
Creation of uniform support to concrete
pavement essential
Repair of cracks, shoving, leveling
Milling creates
better bond
HMA
Min. HMA
thickness 75 mm

Construction
Practice
Concrete
production
Proper Placing,
vibrating

Construction
Practice

Adequate Curing

Joints in UTW
Usual spacing : 12 to 15 times
thickness (0.6 to1.8 m)
Shorter spacing reduces curling
stresses
Early Joint cutting essential
Can use early entry saws

Conclusions &
Suggestions
UTW is a well established technique
Sufficient experience in the use of
this technique is already avaialbale
in the West
In India, adoption of UTW may be
considered as an alternate to
upgradation of bituminous
pavements with HMA
Some experimental stretches using
UTW can be laid immediately to gain
experience

Case Study
An experimental stretch was laid at
Mahul road, Chembur on 5th March
07
Length=26m
Width=3.25m
Thickness=0.1m
Joint cutting was done at after every
1.08m
Curing was done for 3 days

Results

Mixes: M60 (per m3)


Cement 450 Kg
Micro Silica 35 Kg
W/B 0.25
3 days 47.24 N/mm2
7 days 66.71 N/mm2
28 days 72.27 N/mm2

Results

Mixes: M60 (per m3)


Cement 450 Kg
Micro Silica 35 Kg
Polypropylene fibers 900 grams.
W/B 0.25
3 days 40 N/mm2
7 days 63.4 N/mm2
28 days 74.24 N/mm2

Concrete mixes for UTW :


Main Parameters
Fast-Track type construction

-One day Flexural strength: 4 MPa


-One day Compressive Strength : 35MPa

Mix requirements

Mineral admixtures

Silica fumes,
Fly-ash
Or a combination of two

Low water/binder ratio


Use of a Superplaticiser
Synthetic fibers, if required

Road Length
in Mumbai
1) MUNICIPAL CORPORATION
OF GREATER MUMBAI (MCGM)
has about 1941 kms of roads ,
2) Infrastructure in Mumbai.
In addition, there are roads
owned by PWD, MHADA, MPT
and roads in private layouts.
3) Approximately 351 kms are
concrete roads.

Road Length
in PUNE
1) Road length covering
Pune City Area 1,252
Kms.
2) Around 300 km are
concrete roads.
3) Puneinfrastructureis
increasinglyacquiring
importanceasoneof
themaininfrastructural
supportof
Maharashtraa

PouringofConcrete

CuringofConcrete

CuttingofJoint

BreakingofExistingCCPavement

FixingofChannels

Ultra-ThinWhiteToppingonRigidPavement

AViewofUltra-ThinWhiteTopping

AViewofUltra-ThinWhiteTopping

THANK
YOU