INDUSTRIAL CONCRETE BLOCK PAVING
A VALID ALTERNATIVE Concrete Segmental Paving offers a good alternative to asphalt or cast-in-place concrete because it provides :
Dr Brian Shackel
1. Excellent Operational Characteristics
Professorial Visiting Fellow
2 Cost Effectiveness 2.
School of Civil & Environmental Engineering University of New South Wales Sydney, Australia
3. Well-Developed Technology based on: Full-scale tests Established mechanistic design procedures
© B Shackel 2009 All Rights reserved
4. Good Precedents over more than 20 years of use
OPERATIONAL CHARACTERISTICS
OPERATIONAL CHARACTERISTICS
Property Durability
PAVERS Good
ASPHALT CONCRETE Moderate
Good
PAVERS
are the only surfacing made under controlled factory conditions
Property Durability Resistance to Heavy Axle Loads
PAVERS
ASPHALT CONCRETE
Good Very Good
Moderate Poor
Good Very Good
SALDANHA STEEL SOUTH AFRICA LADLE CARRIER (Kress RBC-410)
120 TONS/Wheel
OPERATIONAL CHARACTERISTICS Property Durability Resistance to Heavy Axle Loads Resistance to Slewing Loads
PAVERS
ASPHALT CONCRETE
Good Very Good
Moderate Poor
Good Very Good
Very y Good
Poor
Very y Good
OPERATIONAL CHARACTERISTICS Property Durability
PAVERS Good
Resistance to Very Good Heavy Axle Loads Resistance to Very y Good Slewing Loads Resistance to Very Good Concentrated Loads
Container Feet
ASPHALT CONCRETE Moderate Poor
Good Very Good
Poor
Very y Good
Poor
Very Good
Dolly Wheels
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OPERATIONAL CHARACTERISTICS Property Durability
PAVERS Good
Resistance to Very Good Heavy Axle Loads Resistance to Very y Good Slewing Loads Resistance to Very Good Concentrated Loads Resistance to fuel & Very Good oil spillage
FUEL & OIL SPILLAGE
ASPHALT CONCRETE Moderate Poor
Good Very Good
Poor
Very y Good
Poor
Very Good
Poor
Very Good
Hydraulically operated straddle carriers
oil
COSTS COSTS Energy Consumption Initial Costs M i t Maintenance
COSTS
PAVERS ASPHALT CONCRETE LOW
HIGH
LOW
LOW LOW
LOW HIGH
HIGH HIGH
Maintenance cost studies have been made for: More than 500 lane-km of roads
COSTS Energy Consumption Initial Costs M i t Maintenance Salvage Value
PAVERS ASPHALT CONCRETE LOW
HIGH
LOW
LOW LOW HIGH
LOW HIGH MEDIUM
HIGH HIGH LOW
More than 5 million m2 of industrial paving These studies show that pavers have only about 30% of the maintenance costs of asphalt surfaces or concrete rafts
COSTS COSTS Energy Consumption Initial Costs M i t Maintenance Salvage Value Life Cycle Costs
COST EFFECTIVENESS
PAVERS ASPHALT CONCRETE LOW
HIGH
LOW
LOW LOW HIGH LOW
LOW HIGH MEDIUM MEDIUM
HIGH HIGH LOW MEDIUM
Overall, Pavers can provide the best economic solution
PAVERS
are often more cost-effective than asphalt or concrete paving on the basis of both Initial (Construction) Costs Whole-of-Life Costs
PROJECTS need to be assessed on a
case-by-case basis
2
CONSTRUCTION COSTS 90
90
80
80
70
70
60
60
50
50
40
COST COMPARISONS FOR AIRPORTS
Flexible
40
30
30
20
20
10
Pavers
10
0
0
AUSTRALIA
HOLLAND
20
Rigid Concrete
Asphalt
15
Pavers
10
5
0
Concrete
0
50
UNIT COSTS $/m2
100
150
SOUTH AFRICA
B747/400 pavements at Cairns International Airport
COMPARATIVE COSTS FOR INDUSTRIAL PAVEMENTS APPLICATION Europe Container Terminus, Rotterdam Terminal Yard A, Port of New Orleans
Berth 208, Port of Tampa, Florida
PAVERS
Type of Cost Initial Cost Present Worth (4%) Present Worth (6%) Present Worth
Units
Pavers
Asphalt
Concrete
fl/m2
55-58
55-61
80-84
2
44.1
-
54.0
US$/m2
43.6
-
52.9
US$ (total) 150000 m2
3.8 million
4.7 million
6.4- 6.9 million
US$/m
80 mm 25 mm
230 mm
Geogrid 230 mm
45
300 mm compacted
PORT OF TAMPA
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COST- EFFECTIVENESS Cost-Effectiveness of concrete block paving increases with:
Increase in Traffic Loads Increase in Repetitions Reduction in Soil Strength Increase in Design Life
FACTORS NEEDING STUDY
FULL-SCALE TESTS OF BLOCK PAVING Pavement Testing & Evaluation
ACCELERATED TRAFFICKING
LABORATORY TESTS
200+ tests
University of N.S.W. Road Simulator (Test Track)
Trucks
UNSW SIMULATOR
Industrial Vehicles
South African Heavy Vehicle Simulator
HEAVY VEHICLE SIMULATOR (HVS)
4
HEAVY VEHICLE SIMULATOR (HVS)
Accelerated Loading Facility, ALF
Accelerated Loading Facility ARRB Transport Research, Australia
NASA TEST FACILITY LANGLEY, VIRGINIA
NASA TESTS
FAST HEAVY SLEWING LOAD
5
NASA TRIALS, LANGLEY, Va
FRONT AXLE LOAD = 22 TONNES
80 mm PAVERS RESISTED 100 CYCLES OF HEAVY SLEWING LOAD
6
FULL-SCALE HEAVY FULLDUTY PAVING TESTS PORT OF FREMANTLE
FULL-SCALE TESTS PORT OF FREMANTLE
FRONT AXLE LOAD 90 TONNES
LABORATORY TESTS OF BLOCK PAVING Pavers resist punching damage by container feet Pavement Testing & Evaluation
ACCELERATED TRAFFICKING
LABORATORY TESTS
300+ tests
Asphalt exhibits severe punching damage University of New South Wales
University of South Australia
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LABORATORY TESTS
LABORATORY TESTS OF PAVERS
FALLING WEIGHT DEFLECTION (FWD) TESTS
Accelerometers Loading Plate
PAVER MODULI FOR DESIGN Test Condition
Moduli (MPa)
FWD tests of trafficked rectangular pavers
500-700
FWD tests of trafficked pavers
720-9600
FWD tests of trafficked shaped pavers
75-19000
Laboratory tests of rectangular pavers
600-750
Laboratory tests of shaped pavers
400-6000
Known
? Deflection Bowl
Calculated
Recommended E = 3200 MPa - shaped pavers E = 2500 MPa - rectangular pavers
PERFORMANCE FACTORS
DESIGN CONSIDERATIONS
Both full-scale and laboratory tests have established the importance of :
1. Spectrum of load magnitudes not just one "Design Load"
PAVER SHAPE
PAVER THICKNESS LAYING PATTERN BEDDING & JOINTING MATERIALS TYPE & THICKNESS OF BASE TYPE & THICKNESS OF SUB-BASE SUBGRADE
2. Repetitions of each load in spectrum t nott just j t Maximum M i or "Equivalent" repetitions Ideal for computer-based MCHANISTIC DESIGN
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DESIGN SOFTWARE
MECHANISTIC STRUCTURAL DESIGN OF CONCRETE BLOCK PAVEMENTS
• Roads
PAVERS
• Airports • Industrial
SAND COURSE Horizontal Tensile Strains - Predict Fatigue Cracking
+ Cost Analyses + Specifications
BASE COURSE SUB-BASE COURSE (If Needed)
COMPACTED SUBGRADE
Structural Design
Vertical Compressive Strains
Hydraulic Design
- Predict Rutting
DESIGN LOADINGS
Used in Australia, USA, Canada, South Africa etc.
REFERENCES
LOCKPAVE uses: 1. Spectrum of load magnitudes 2. Repetitions of each load in spectrum not just Maximum loads
REFERENCES
www cmaa com au www.cmaa.com.au
CASE HISTORIES S O S Listed in order of increasing loads: - Roads - Airports
www.brianshackel.com
www.sept.org
- Industrial Pavements
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PAVER USAGE IN EUROPE
ROAD
ROADS 36% INDUSTRIAL 29%
65% of all pavers are used in Engineered Pavements
AIRPORTS - TERMINAL APRONS - TAXIWAYS - TURNING CIRCLES - HANGARS - AIR-SIDE ROADS - HELIPADS
> 80 airports now use concrete segmental paving
Howe
CHEK LAP KOK AIRPORT, HONG KONG
CHEK LAP KOK AIRPORT, HONG KONG
> 100 000 m2 of airside paving
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CHEK LAP KOK AIRPORT, HONG KONG
CAIRNS INTERNATIONAL AIRPORT
INDUSTRIAL APPLICATIONS - Factory & warehouse floors - Container yards - Intermodal facilities - Ports Warehouse floor, Holland
Warehouse floor, Queensland
Factory Yard using Permeable Paving, Germany
11
EUROPE CONTAINER TERMINUS Rotterdam 100 mm Category A pavers in herringbone bond over Granular Base & Sub-base
SALDANHA STEEL, SOUTH AFRICA LADLE CARRIER (Kress RBC-410) Axle Load > 240 tonnes
ECT ROTTERDAM 120mm pavers 50mm sand 350mm CTB
Vertical drains @ 2m c/c Hydraulically pumped sand fill
Melbourne
PORTS - CASE HISTORIES
Proc 8th International Conf on Concrete Block Pavements, 2003
Brisbane
12
AUSTRALIAN PORT PAVEMENTS FACILITY
A
Identification No. Operational Mode
C
D
2
3
4
5
6
7
8
9
10
11
FLT
SC + TT
SC + TT
SC + Trucks
SC + Trucks
SC + Trucks
SC
SC
SC
SC
SC
80
80
80
80
80
80
80
80
80
30
25
20
20
20
20
20
30
30
Pavers
80
Bedding Sand
25
Unbound Granular Base
Cement modified granular base
B
1
280
100
200 250 100
260
370
370
490
HOWLAND HOOK MARINE TERMINAL, NY
80 20 140
560
Cement treated base
250
Granular subbase
150
Cement treated subbase
150
280
Granular working platform
100
100
Fill materials
Sand Over Mud
Subgrade CBR (%)
15-20
SC = Straddle Carrier
400
Sand Over Mud
Sand Over Mud
-
15-20
15-20
>25
TT = Transtainer
170
-
Granular
-
-
sand
sand
-
>5
>25
>5
>5
1625
16-25
15
Demonstration Project
Permeable Paving
FLT = Front Lift Truck
5.3 ha of paving including test area of 0.1 ha of PICP.
Laid mechanically by 2 machines installing 1500m2 per day.
HOWLAND HOOK MARINE TERMINAL, N Y
Ecoloc
200 000 passes of Top Pick with wheel loads > 23 000 kg
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Concrete Block Paving
PROVEN STRONG ECONOMIC SUSTAINABLE
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