WESTERN CANADA SEMI-FLEXIBLE PAVEMENT FILLS THE GAP BETWEEN ASPHALT AND CONCRETE

Transcription

1 WESTERN CANADA DURATOUGH PAVING SOLUTIONS SEMI-FLEXIBLE PAVEMENT FILLS THE GAP BETWEEN ASPHALT AND CONCRETE

2 DURATOUGH PAVING SOLUTIONS IMAGINE THE POSSIBILITIES

3 Introducing DuraTough DuraTough is a semi flexible surfacing system for pavement areas that are subject to heavy and/or slow moving traffic, or where a hard wearing, impermeable or fuel resistant surface is required. DuraTough is a proprietary grouted composite pavement that offers a durable surface with very high resistance to deformation (i.e. skidding and rutting) and fuel degradation, including aviation fuel, diesel and gasoline. Suitable for both new construction and resurfacing contracts, DuraTough is ideal for use in heavy industrial and commercial applications such as loading bays, distribution centers, aircraft refueling areas, bus stations and dolly pads. Designed using Lafarge's expertise in cement and asphalt technology, as well as our experience in the installation and design of pavements, DuraTough is built to meet the most rigorous conditions in the most demanding of sites. The following document describes how DuraTough is best suited for: Airports Heavy Industrial Paving, Transport and Storage Municipal Roads Gas Stations Buildings and Parking Areas Making DuraTough Work for You DuraTough offers a cost effective alternative to concrete, in addition to providing schedule advantages where construction speed or traffic delays are a factor. In most applications, DuraTough can be trafficked by vehicles within 24 hours and by pedestrian traffic after three hours. DuraTough typically comprises of a 75mm thick porous asphalt support coat, laid by conventional asphalt paving equipment. It is placed over either conventional asphalt or directly over existing asphalt or concrete support structures. The cementitious grout is mixed on site and poured onto the support coat completely filling the voids. The result is a pavement structure that performs similar to a rigid concrete, but offers enough flexibility to reduce cracking and jointing requirements. Asphalt Asphalt Asphalt Base Granular Base Subbase DuraTough DuraTough Asphalt Base Granular Base Concrete Subgrade Subgrade Subgrade Equivalent Structure Comparison (Approximation) Concrete Granular Base RUT RESISTANT COLOUR COMPATIBLE SKID RESISTANT FUEL RESISTANT IMPROVED ILLUMINATION QUICK SETTING HIGH STRENGTH ASPHALT AND CONCRETE COMPATIBLE REDUCED JOINTING

4 AIRPORTS AIRSIDE AND GROUNDSIDE

5 Taking Flight with DuraTough Airports are subject to a wide variety of loading and traffic conditions and already incorporate both concrete and asphalt pavements to match the need, where appropriate. This right pavement for the right application approach is ideally suited for DuraTough, which as a bridge between asphalt and concrete offers unique advantages, particularly where airplanes are turning or making slow, repetitive maneuvers. Some specific examples of where DuraTough might be considered for use at an airport sites include the following: Airside Groundside DuraTough has been used across Western Canada in a number of airport applications, including several examples at the Calgary International Airport. These applications have included apron area repairs to address localized rutting, as well as wheel paths on taxiways and an approach intersection for a major runway. Apron Areas Taxiways Approach intersections Fueling/deicing areas Hangar Bays Entry/exit ways for public parking lots Passenger loading zones Bus stops Loading bays CASE STUDY: PRIVATE AIRCRAFT HANGAR In 2013, Lafarge installed over 18,500 m 2 of DuraTough at a hangar bay in Calgary for a large, private business aircraft operator. DuraTough was proposed as an alternative to concrete for the project, which resulted in significant cost savings as well as a reduced construction schedule. This work was completed over a period of four days by Pro Con Roadworks Ltd., a business trust of Lafarge Canada Inc. AGGREGATES ASPHALT CEMENT CONCRETE PAVE PIPE PRECAST 5

6 HEAVY INDUSTRIAL PAVING TRANSPORT AND STORAGE

7 A Load Off Your Mind With Western Canada s expansive geography and rising population, the transportation industry is supported by an ever-growing network of hightraffic shipping sites. DuraTough is ideally suited to meet the demands of heavy transport and storage operations, including Ports, Inland Terminals, Intermodal Yards, Distribution Centers, and Trailer Storage Sites. Additional industrial uses where DuraTough may be suitable include Saw Mills, Precast Concrete Product Yards, or other heavy production sites. Applications DuraTough allows for busy sites to resume operations quickly, limiting down time and providing maximum site utilization. Whether for site repair or new construction, DuraTough can be installed in strips, pad areas, or over full sites as required for specific project restrictions. Trailer parking Entry/exit ways Loading/unloading areas Storage rack areas Container storage areas CASE STUDY: CN INTERMODAL CN s Calgary Logistics Park operates 24 hours a day, seven days a week. In November 2013, Lafarge installed a series of dolly pad strips using its proprietary DuraTough pavement system to support up to 280 loaded containers on chassis at the site. This design provided an effective alternative to answer CN s needs for minimizing open time and ensuring the surface was installed before winter. Minimizing open time is key to keeping the operation of our Intermodal terminal fluid. Lafarge s DuraTough product was an excellent solution for paving our dolly pad strip for our loaded container storage. The job was done in record time, very late in the season, with great results! Marc Sherwood CN Manager of Operations AGGREGATES ASPHALT CEMENT CONCRETE PAVE PIPE PRECAST 7

8 MUNICIPAL ROADS BUS STOPS, TURNING LANES AND INTERSECTIONS

9 Long Term Performance for Long Term Growth Municipalities across Western Canada are faced with the challenge of increasing operations and maintenance costs as the result of existing infrastructure facing traffic levels beyond their original design. With life cycle representing just as an important consideration as first cost, pavement selection becomes all the more critical when designing public infrastructure. As an alternative to asphalt and concrete, DuraTough carries the best of both pavement systems, often at a reduced cost when compared to concrete. A number of potentially suitable locations for DuraTough selection include: Applications The quick-curing properties of DuraTough are of great value when road closures present major traffic delay concerns for users. Like concrete, DuraTough is highly durable and provides long-lasting performance and reduced maintenance costs compared to asphalt. Bus stops and transit stations Turning lanes Interchanges Traffic circles Entry and exit ways to public buildings Public parking areas Landfill traffic areas and scalehouse Snow melt sites PRODUCT OPPORTUNITY: BUS STOPS Bus stops can present challenges for asphalt pavement as a result of the high levels of stress imposed by frequent, slowmoving wheel loads. Concrete, meanwhile, can be a costly solution to these concerns and may also result in lengthy curing periods that put the bus stops out of operation for days or weeks. With its compressive strength and early trafficability, DuraTough offers a cost-effective alternative to bus stop applications, which can be incorporated into new communities or busy downtown streets. AGGREGATES ASPHALT CEMENT CONCRETE PAVE PIPE PRECAST 9

10 Fueling Your Site Gas stations are generally small project sites that service high levels of traffic every day, continuously at times. This traffic includes passenger vehicles, service vehicles, buses, fueling trucks and delivery trailers. Combined with the potential for fuel spills, service stations present a dynamic challenge for pavement systems. Designed to provide the flexibility of asphalt, with the strength and imperviousness of concrete, DuraTough can be applied across the entire service station, meeting the needs of every corner. Applications Fueling areas Loading areas Entry and exit ways Waste storage areas Resistance to Fuel Ingress 100 GAS STATIONS RETAINED MASS (%) IMMERSION TIME (HRS) Duratough in Kerosene Duratough in Diesel Asphalt (Fuel Resistant Binder) in Kerosene Asphalt (Pen Grade Binder) in Kerosene

11 Building Around Your Needs A building site is subject to a diverse range of traffic, which can vary depending on its primary use, whether industrial, commercial or institutional. From loading bays, to drop-off zones, to site ingress and egress locations, DuraTough presents a pavement alternative designed to perform where asphalt may not be suitable. As DuraTough is installed using standard asphalt equipment, it can easily be incorporated alongside other pavements and provide seamless performance as part of an integrated design. Areas where DuraTough may be particularly suitable for a building site include those listed below: Applications Building apron Waste storage areas Entry and exit ways Industrial floors Waste storage creates localized stress on pavement areas as collection vehicles are constantly lifting and placing heavy storage containers in the same spot. Using DuraTough in these areas can increase pavement performance and reduce long term maintenance costs. BUILDINGS 5 11

12 TECHNICAL DATA SPECIFICATIONS AND TESTING INFORMATION

13 DuraTough Summary DuraTough consists of a porous asphalt support coat designed to provide approximately 20% void content, which is filled with a high strength proprietary grout. The low viscosity of the DuraTough grout ensures the voids are effectively filled throughout the porous layer and the resulting product provides exceptional load spreading ability, resistance to fuel spillage and permanent deformation. Properties of the Support Coat DuraTough utilizes a 12.5 mm or 16.0 mm nominal size asphalt support coat, which provides a better void structure compared with larger nominal size variants, leading to better flexural strength in the finished product. The support coat is manufactured in an asphalt plant using a computerized control system to ensure consistency at a temperature between 140 C and 160 C. Particle Size Distribution Sieve Size (mm) Typical Percentage Passing mm 3 Components Coarse Aggregate 93% High quality, 100% crushed Asphalt Cement 4% Conventional or PMA Fibres Cellulose or MSM (3%) Mixing Temperature o C Laying temperature o C Properties of the Grout Strength typically in excess of 35 MPa at 28 days Rapid strength gain (typically in excess of 15 MPa at 7 days), allowing for early trafficking of the finished material. Low viscosity at time of application, resulting in effective penetration of voids in the porous asphalt structure. A high strength grout is also available for high point load applications, with typical strengths in excess of 30 MPa and 50 MPa at 7 and 28 days, respectively. Strength (MPa) Standard Strength Days Properties of the Composite Typical 28-Day properties of DuraTough: Strength (MPa) High Strength NAT Indirect Tensile Stiffness Modulus: 6,000 MPa Flexural Strength: 2.5 to 3.0 MPa Freeze/Thaw: No impact after 20 cycles Skid Friction (British Pendulum Test): 80 (dry), 65 (wet) DuraTough has a suggested AASHTO 93 structural number of 0.47, This compares to an SN of 0.5 for concrete and 0.44 for asphalt Days AGGREGATES ASPHALT CEMENT CONCRETE PAVE PIPE PRECAST 13

14 Quality Control Testing Samples of the hot applied support coat should be tested for compliance to the Job Mix Formula. Quality Control Testing would include asphalt cement content and gradation analysis. No compaction requirements are required. Coring may be done after completion of the placement of the support course to determine the in-situ air voids content. A minimum air voids content of 18% is recommended. Samples of the grout should be obtained during placement to determine the grout compressive strength. For typical applications, the grout strength should be approximately 15 MPa (7 day compressive strength) and 35 MPa (28 day compressive strength). For high point load applications, a higher strength grout is available, with strength values of 30 MPa (7 day compressive strength) and 50 MPa (28 day compressive strength), respectively. Grout testing may include flow testing measurements to monitor the grout viscosity. APPLICATION INFORMATION PROCEDURES AND QUALITY CONTROLS

15 Support Coat Application The support coat mix shall be transported to the job site using haul trucks that have been thoroughly cleaned of any debris to avoid contamination. The support coat must be placed using a conventional asphalt paver. Any irregular shapes will require the necessary handwork for placement. Generally, any hand work must be kept to a minimum to avoid segregation of the support coat mix. Rolling and compaction of the support coat shall utilize a dual steel drum roller in static mode and rolled to seat the support coat (usually 2 3 passes). No further compaction is required. Under no circumstances is the use of a combination roller or rubber tired rollers permitted. No vehicular traffic is allowed on the support coat prior to the grout placement. In the event of inclement weather, the surface is to be protected from the ingress of surface water. After any rainfall, the support coat must be free of any entrapped water. A vacuum truck and/or compressed air using an air lance shall be used to eliminate any entrapped water. Typical DuraTough Construction DuraTough provides a tough scuff resistance surface to provide superior performance. To ensure superior performance DuraTough must be placed on a stiff support base to minimize cracking. For new construction, a typical pavement cross section would consist of a thick layer of granular base course over prepared subgrade, overlayed by a layer of asphaltic concrete pavement, overlayed by a layer of DuraTough. A 75 mm thick layer of DuraTough is recommended. A structural pavement design is required to determine pavement layer thicknesses to meet the anticipated loading conditions. DuraTough may be overlayed over existing concrete pavement or replacement of a deteriorated asphalt concrete surface. Minimum thickness of 75 mm of DuraTough is recommended. Grout Application DuraTough grout shall be manufactured using a high shear mixer such as an in-line impeller pump to ensure complete dispersion of the cementitious components within the grout mixture.. Grout discharge from the haul truck should be limited to the amount required to facilitate the spreading, which shall be performed using a squeegee applicator. Some vibration may be necessary in order to ensure adequate void reduction and filling with the grout. Several passes of the grout application may be required to fill any surface air bubbles observed. The grout shall be placed to the top surface of the support coat. Using a standard flow cone, the viscosity of the grout should be measured on a continuous basis throughout grout placement. Grout viscosity is measured by the time measured to allow complete discharge of a full grout flow cone. The viscosity should be 12 seconds +/- 2 seconds. Attention to the air temperature and pavement temperature is critical during grout placement. Ideally the pavement temperature should be cool to the touch. During hot weather, attention to the pavement temperature is critical. In no case should grout placement occur if the pavement temperature of the support coat exceeds 60 C. Ice and or retarder admixture may be required to prevent flash setting of the grout prior to complete infilling of the support coat voids. Jointing To minimize cracking, saw cutting of the DuraTough slab is recommended. Typical panel sections should be a square section measuring 15 meters wide or to match existing concrete panel placement as applicable. Saw cuts should be crackfilled with an elastomeric crack filler. AGGREGATES ASPHALT CEMENT CONCRETE PAVE PIPE PRECAST 15

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