EcoLanes - “Economical and sustainable pavement infrastructure for surface transport”

Professor Kypros Pilakoutas Department of Civil and Structural Engineering The University of Sheffield, United Kingodm http://ecolanes.shef.ac.uk – http://www.shef.ac.uk/civil Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

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Outline • Concrete road pavements and fibres from tyre-steel cord • EcoLanes overview • Benefits from EcoLanes

Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

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Surface transport infrastructure • EU infrastructure: €600bn up to 2010 for maintenance and extension of network - respond needs of enlarged EU - benefit single market

• Road pavements main element of infrastructure - Flexible: Asphalt concrete - Rigid: Portland cement concrete Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

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Road pavements Flexible pavements: • •

Deep foundations / multi layer construction Energy consumption due to transportation of materials • Increasing cost of asphalt due to high oil prices

Rigid pavements • Single layer • Generally last longer • May require asphalt topping due to noise / comfort issues Conventional rigid pavements can be more expensive than Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 flexible Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

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Rigid pavements • Use steel reinforcement to - improve mechanical properties

Plain Concrete SFRC SFRC 2% 2% shredded shredded fibres fibres

- reduce pavement depth

• Steel fibres reduce costs associated with rebar placement • Concrete mixes - wet / slip forming (laborious - require side formwork) - dry / roller compaction (fast – cost effective)

• Difficult to add fibres in roller-compacted concrete Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

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EcoLanes background: • University of Sheffield research on tyre recycling (http://www.shef.ac.uk/tyre-recycling) Tyre shredding: SRSF

Microwave induced pyrolysis of whole tyres: PRSF AMAT LTD™

Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

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EcoLanes background UoS research proved that tyre-fibres (e.g PRSF) can be as effective as industrially-produced fibres (ISF). 70

Bending load [kN]

60 50 40 30 PRSF 6% ISF-1 6% ISF-2 6%

20 10 0 0

1 2 3 Mid-span deflection [mm]

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Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

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EcoLanes background • Aggregate Industries Ltd UK (AI) / Holcim − Precast concrete products − Contractors for all types of pavement surfacing and construction − Major supplier of aggregate / asphalt / cement − But interested in concrete road pavements - future competitiveness (uncertain future of asphalt) - environmental issues (CO2 trading scheme) Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

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EcoLanes background •AI’s interest in road pavements - research collaboration between AI and UoS - funded a year’s Fellowship for further research & preparation of proposals on concrete roads

Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

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EcoLanes Development

Steel-Fibre-Reinforced Roller-Compacted-Concrete Road Pavements

Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 10 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

EcoLanes project consortium No.

Participant organisation name

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The University of Sheffield (concrete)

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Akdeniz University (environmental)

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Technical University “Gheorghe Asachi” Iasi (transportation)

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European Tyre Recycling Association (environmental policy)

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Aggregates Industries UK Ltd (concrete materials & pilot demonstration)

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Antalya Municipality (demonstration)

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Romanian National Road Authority (demonstration)

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Adriatica Riciclaggio e Ambiente s.r.l. (tyre recycler)

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Public Works Department (demonstration)

10 Cyprus University of Technology (LCA) Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 11 11Kypros Pilakoutas Scott–Wilson Ltd (LCA) Overview of EcoLanes Project - Professor University of Sheffield

EcoLanes Outline Call: FP6-2005-Transport-4 Type of instrument: Specific Targeted Research Project (STREP) 9 partners, 9 work packages, 633 man-months total cost ~€2.5m Reference Number: 031530 Submitted: 1 September 2005 Evaluated: October 2005 Contract Negotiations: March – August 2006 Start of contract: 1 October 2006 End of contract: 30 September 2009 Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 12 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

EcoLanes aims & objectives Develop pavement infrastructure using: – RCC techniques based on existing asphalt laying equipment

– Steel fibre reinforced concrete – Concept of long-lasting-rigid-pavements Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 13 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

EcoLanes aims and objectives Reduce: – Construction costs by 10-20% – Construction time by 15% – Energy consumption in road construction by 40%, – Maintenance

and to – Use post-consumer materials – Make tyre recycling more economically attractive Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 14 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

European Commission

EcoLanes work plan Project Project Steering Steering and and Management Management Committee Committee Exploitation Exploitation Manager Manager WP8 WP8

Demonstration Management Group

Dissemination Dissemination & & Exploitation Exploitation

Project Project Coordinator Coordinator

Technical Technical Management Management Group Group WP1 WP1 Fibre Fibre sorting sorting

WP3 WP3 WP2 WP2 FRC FRC

Pavement Pavement Testing, Testing, Analysis, Analysis, Design Design

Coordination Coordination Team Team WP4 WP4

Environ. Environ. Studies Studies & & Site Site Processes Processes

WP9 WP9 Project Project Management Management

WP5 WP5 Demonstration Demonstration in in W. Europe W. Europe

WP6 WP6 Demonstration Demonstration in in E. E. Europe Europe

Tasks

WP7 WP7

Demonstration in Industry Seminar “Economical Demonstration in and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 15 E. Mediterranean E. Mediterranean Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

EcoLanes project meetings Inaugural meeting: UK

2nd meeting: Turkey 3rd meeting: Belgium

1st meeting: Italy Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 16 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

WP 1: Fibre Sorting Leader: AD.RI.A (Italian Tyre Recycler)

Develop techniques and equipment: • Post-processing steel fibres extracted from tyres • Arrive at fibres suitable for incorporation in concrete Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 17 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

WP 2: Fibre-reinforced Concrete Leader: The University of Sheffield (United kingdom)

Develop steel fibre-reinforced concrete mixes: • Suitable for slip forming and roller compaction • Use recycled materials, low energy cements Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 18 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

WP 3: Pavement testing, analysis and design Leader: Technical University of Iasi (Romania) Develop long-lasting-rigid-road-pavement concept: • Accelerated load tests (facility ALT-LIRA)

115kN axle load

1.5 million cycles: 30 years (600 trucks /day) • Durability (climate) tests • Develop design guidelines for LLRRPs Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 19 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

WP 4: Environmental studies & site processes Leader: Cyprus University of Technology (Cyprus) Develop life-cycle cost tool to assess environmental impact: • Site construction processes • Long-last-rigid pavements (LLRRP) Develop optimised processes for constructing LLRRPs: • Industry UseSeminar of “Economical existing asphalt equipment and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 Overview of EcoLanes Project

- Professor Kypros Pilakoutas – University of Sheffield

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WP 5 - 7: Demonstrations Leaders: Aggregate Industries (UK), DRDPIASI (RO), Antalya Municipality (TR) • Construct four concrete roads in rural and urban Freeze/thaw damage European environments • Eliminate the problem of road deterioration due to cold and wet environments • Eliminate the problem of asphalt displacement due to hot weather

Mechanical clearing

Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 21 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

WP 5 - 7: Demonstrations WP5: MoD, UK

WP6: Iasi, Romania

WP7: Antalya, Turkey and Pafos, Cyprus

Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 22 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

WP 8: Dissemination and Exploitation Leaders: European Tyre Recycling Association (France), Sheffield University Entrerprices Ltd (UK) • Focus the project on developing solutions needed for transport infrastructure • Develop technology implementation plan (IPR) • Disseminate research findings: - website (http://ecolanes.shef.ac.uk) - 2 industrial seminars Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 23 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

WP 9: Project Management Leader: The University of Sheffield (United Kingdom) • Optimise application of technical resources • Ensure compliance with the project objectives • Ensure efficient communication within the project • Ensure that all aspects of the EC requirements for communication and reporting are met Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 24 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

EcoLanes expected output Tyre-recycled steel fibres: • Processes & machinery to sort and clean shredded fibres

Steel-fibre-reinforced RCC rigid pavements • Processes and machinery to disperse steel fibres in RCC • Use of waste materials • Analysis and design software for concept of LLRRPs

Surface transport infrastructure • Reduction of construction time and cost • Reduction of energy consumption during construction Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 25 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

Benefits for tyre recyclers • Price of industrial fibres: €650 ~ €14000 per tonne

€150 ~ €300 per tonne • Economic benefits for tyre recycling industry

Metric tonnes (millions)

• Initial market value of RSF:

Potential annual amount of RSF (based on steel content of 15% by weight)

3.0 2.5 2.0 1.5 1.0 0.5 0.0

EU - Total Arisings EU - Material Recovery

Tyres

Steel fibres

Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 26 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

Benefits for tyre recyclers Use of recycled tyre-cord in concrete construction • Provide sustainable market for recycled tyre-cord • Encourage material recovery of large amounts of tyres • Facilitate implementation of EC directives Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 27 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

Benefits for construction industry • Low-cost steel-fibre reinforcement • Economic method for road construction • Reduction of industry’s CO2 emissions • Access to construction innovation

Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 28 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

All presentations will be available online (8 October 2008): http://ecolanes.shef.ac.uk/diss/seminar/se minars.htm

Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 29 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

This research has been financially supported by the 6th FP of the European Community within the framework of specific research and technological development programme “Integrating and strengthening the European Research Area”, under contract number 031530.

Thank You Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 30 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

Background Notes

Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 31 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield

Placing of RCC in truck

Placing of RCC in paver

From mixing to rolling ~ ½ hour

Placing of RCC pavement 100-200mm, up3/10/2008 to 250 Industry Seminar “Economical and sustainable pavement infrastructureLayers: for surface transport”, UTI, Iasi Romania, 32 Rolling of RCC pavement Overview of EcoLanes Project - Professor Kypros Pilakoutas University ofpaver) Sheffield mm (with high –density

Industry Seminar “Economical and sustainable pavement infrastructure for surface transport”, UTI, Iasi Romania, 3/10/2008 33 Overview of EcoLanes Project - Professor Kypros Pilakoutas – University of Sheffield