Mindset, Perception and Challenges towards Concrete Roads

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1 Mindset, Perception and Challenges towards Concrete Roads presented by Zack Lim Managing Director of Zacklim Flat Floor Specialist Sdn Bhd Principal of Academy of Concrete Technology

2 New asphalt road (Flexible pavement) Which type of road do you prefer? New concrete road (Rigid pavement) Asphalt road after 10 years Concrete road after 50 years COPYRIGHT ACADEMY OF CONCRETE TECHNOLOGY 2

3 Shifting from constructing asphalt roads to concrete roads can save government / taxpayers billions of Ringgit $$$; BUT first let s look into:- Mindset, Perception and Challenges towards Concrete Roads COPYRIGHT ACADEMY OF CONCRETE TECHNOLOGY 3

4 Mindset Concrete roads are expensive. Concrete roads are not easy to construct. COPYRIGHT ACADEMY OF CONCRETE TECHNOLOGY 4

5 Perception Concrete roads are bumpy. Concrete roads are noisy. Building concrete roads need special machinery and equipment. Concrete roads must have reinforcement. COPYRIGHT ACADEMY OF CONCRETE TECHNOLOGY 5

6 Challenges How to build concrete roads that are smooth to drive? How to build concrete roads that are skid resistance? How to avoid all the cracks and defects? What are the quick methods to repair concrete roads? How to minimize long term maintenance cost? COPYRIGHT ACADEMY OF CONCRETE TECHNOLOGY 6

7 Mindset Concrete roads are expensive Building concrete roads is slightly more expensive initially but cheaper in the long run. 1. Durability Asphalt road average life span 15 years. Concrete roads minimum life span 40 years 2. Maintenance Do it right the first time, long term maintenance of concrete roads will be much lower than Asphalt. Extracted from PCA Perspective July 2009 According to the Portland Cement Association of USA, by 2015 concrete will enjoy a $500, initial bid cost advantage over asphalt for a one mile of standard two-lane roadway, This represent a cost savings of approx. 41%. COPYRIGHT ACADEMY OF CONCRETE TECHNOLOGY 7

8 Mindset Concrete roads are not easy to construct To build concrete roads successfully 1. Pavement structural design CRCP, JRCP, JPCP 2. Special concrete mix design. 3. Specify floor profile flatness & levelness bumpiness & puddling. 4. Roughness index to control noise level and skid resistance. 5. Measure the floor profile after complete. 6. Right machinery, equipment for every stage in building the pavement. 7. Trained workers. 8. Weather control. 9. Do it right the first time with stringent QA/QC to mitigate surface defects, cracks, etc. COPYRIGHT ACADEMY OF CONCRETE TECHNOLOGY 8

9 Perception Concrete roads are bumpy ride quality Consequence: Bumpy, bad finishes and cracks may appear at later stage. COPYRIGHT ACADEMY OF CONCRETE TECHNOLOGY 9

10 Perception Concrete roads are noisy (roughness) Transverse broom lines Longitudinal saw-cuts COPYRIGHT ACADEMY OF CONCRETE TECHNOLOGY 10

11 Perception Require special & costly machinery Truss screed machine Roller screed machine Slipform paver machine COPYRIGHT ACADEMY OF CONCRETE TECHNOLOGY 11

12 Perception Building concrete roads must have reinforcement Micro-fibers Monofilament fibers Road with Fibers Oahu, Hawaii 2009 Courtesy of Hawaii Department of Transport Fibrillated fibers Steel fibers COPYRIGHT ACADEMY OF CONCRETE TECHNOLOGY 12

13 Challenges How to build concrete roads that are smooth to drive Skilled & well-trained workforce QC/QA using the right tools & equipment COPYRIGHT ACADEMY OF CONCRETE TECHNOLOGY 13

14 Challenges How to build concrete roads that are skid resistance Various method of thinning the road surface COPYRIGHT ACADEMY OF CONCRETE TECHNOLOGY 14

15 Challenges How to avoid cracks & common defects Plastic shrinkage cracks Thermal shock cracks Shrinkage cracks Spalling at joints Cracks - curling Water puddle COPYRIGHT ACADEMY OF CONCRETE TECHNOLOGY 15

16 Challenges What are the methods to repair concrete roads? Surface preparation & Know how Analyse the cause of cracks and use the right repair cementitious materials Do not make repair worst than original COPYRIGHT ACADEMY OF CONCRETE TECHNOLOGY 16

17 Challenges How to minimize long term maintenance cost? DO IT RIGHT THE FIRST TIME Concrete designed for roads Sawcuts - when, depth, spacing All types of joint Curing COPYRIGHT ACADEMY OF CONCRETE TECHNOLOGY 17

18 Major advantages of concrete roads 1. Concrete roads are more durable than asphalt roads - concrete >40 yrs, asphalt <20 yrs. 2. Extreme weather conditions are liable to damage asphalt roads more than concrete roads. 3. Concrete roads do not damaged from oil leaks, diesel, etc 4. Concrete is environmentally friendly and sustainable. Asphalt is known to produce polluting gases when it is melted. 5. Lighter colour compared to asphalt, more visible at night. 6. Vehicles save 15 to 20% fuel as wheels of heavy trucks do not deflect under concrete roads. Hence less pollution. COPYRIGHT ACADEMY OF CONCRETE TECHNOLOGY 18

19 Conclusion: Let s go to build more concrete roads Thank You For Your Attention 127 year old concrete road still in service Bellefontaine, Ohio, USA - Built in 1891 COPYRIGHT ACADEMY OF CONCRETE TECHNOLOGY 19