Construction of Polish PERS test section

Transcription

1 PoroElastic Road SUrface: an innovation to Avoid Damages to the Environment EUROPEAN COMMISSION - DG RESEARCH Directorate 1 - Environment Seventh Framework Programme - Contract No Document type and No. Work Package Author(s) Authors' affiliations (acronyms) Contact data for main author Report (no number) 10 March 2015 WP 4 Construction technology and test sections Krzysztof Mirski, Wojciech Bańkowski IBDiM kmirski@ibdim.edu.pl Document status and date Final Dissemination level File Name Internal PERSUADE-IBDiM-D43d-V00-WP Construction of Polish full scale test track

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3 FOREWORD This report has been produced within Work Package WP 4 in the project PERSUADE, is led by the Belgian Road Research Centre (BRRC). This report documents the process and the experiences gained when constructing the first Polish test section with PERS at the Kryspinów near Kraków. The report has been produced IBDiM. PERSUADE is the acronym for PoroElastic Road SUrface: an innovation to Avoid Damage to the Environment. The PERSUADE project aims is developing of silent poroelastic road surfacing (PERS which will improve the quality of life in the city. It is expected that PERS will reduce noise reductions higher than the conventional porous asphalt. PERSUADE has been scheduled for a duration of six years and an overall budget of 4.5 million. Twelve partners from seven European countries are cooperating in this project, including research institutes, universities and companies representing the sectors of industry involved. See also the PERSUADE website at The authors would like to thank the employees and the management of RDM śródmieście and ADD Asphalt for their work when producing and laying the PERS. Only the authors are responsible for the contents of this document. This work is financed by the European Commission. The authors are grateful for the financial support for this project from the European Commission though its 7 th Framework Programme. 2

4 TABLE OF CONTENTS 1 PREPARATION OF THE TEST SECTION- DAY CONSTRUCTION OF THE PERS LAYER DAY Recipe and mixing process Laying the material at the test site Next days: Inspections and opening for traffic 12 3 RECONSTRUCTION OF THE TEST SECTION DAY

5 1 PREPARATION OF THE TEST SECTION- DAY 1 Day 1 (16/09/14): Milling off top layer, cleaning surface, laying a new asphalt base layer In the morning ( ) of 16 September 2014 the old asphalt surface layer (3,5 cm SMA11, 9 years old) and a part of binder course (AC12,8 2,5 cm 9 years old) were removed. The dimensions of the test section were 3 m * 65 m, The narrow band of old SMA was left (on the right site od road) to create a "mould" for PERS, which will help during compaction. It was found that underlayer (binder course) made of AC 0/12,8 was in good condition no cracks were observed, so the surface was cleaned and between and 12 asphalt emulsion was sprayed on the test section. 4

6 The next step made during the first day was paving new asphalt base layer. An asphalt concrete mixture was chosen for this layer. The maximum aggregate size was 12,8 mm and a standard bitumen type 50/70 was used. The paving was performed with use the normal asphalt paver and the compaction was made with use of steel roller. 5

7 Between and hours polyurethane primer S100 was manually sprayed on the asphalt surface applied by pneumatic backsprayer. The amount of tack coat was around 250 g/m². The base layer was still warm, the temparature of AC was 56 ºC. It was observed that the surface was completely wet, so it can be assumed that base course was coated by the primer precisely. Note: The nitro varnish smell was very intense, but it was a problem for workers. Generally it was a sunny day, the maximum air temperature was 19.2 ºC. At the curing process was finished. 6

8 2 CONSTRUCTION OF THE PERS LAYER DAY 2 Day 2 (17/09/14): PERS preparation, laying a PERS layer 2.1 Recipe and mixing process It was decided to use different mix than in Denmark. Polyurethane binder is very expensive and mixture itself so increasing the cost of aggregates was not justified. Polish aggregate was chosen as the substitute for Jelsa aggregates. For the PERS production the standard asphalt plant was used. One day before mixing, asphalt plant had been cleaned thoroughly by water to remove dust and aggregates coming from the common production. The materials were kept outside under roof. The aggregate was dried at 100 ºC two days before (in production day 44,3 ºC) and were kept under the roof, but without solid walls. Binder and rubber were kept in the warehouse (dosage temperature 9,3 ºC) The composition of the Polish PERS mixture and the material used for 1 batch mixed in the asphalt plant is presented in the table below. The aggregate was dosed by the weighing system of asphalt plant, the other components manually. A larger balance with accuracy 0.1 kg was used to measure Stobiblends, Stobiblast and rubber. 7

9 Rubber, binder Stobiblends were transported in plastic bags, cans and buckets with the loader and the cairn. 8

10 Note: All materials for 1 batch were weighed separately, in order to avoid any mistakes, except Stobiblends which were mixed together at the beginning of production. The mixing procedure was as follows: 1) Adding aggregates and rubber to the mixer, 2) Mixing - 3 min, 3) Adding a mix of stobiblends, 4) Mixing 2 min, 5) Adding of binder, 6) Mixing 3 min. 9

11 The PERS mixture was transported from the asphalt plant to Zabierzow (25 km) in approximately 40 min. 2.2 Laying the material at the test site The trucks arrived around 9 10 at the construction site. In this moment the air temperature was 12 ºC, but there was fog earlier in the morning, so the grass was wet. The surface of base layer was dry. Temperature of PERs mixture was 31,5 ºC. Paving began at According to the conclusion form Belgian small test section, paver was set for 100% of beam block and 20% of vibration. Behind finisher PERS layer was smooth and uniform, only the middle of the lane some unevenness remained due to the paver construction, trace of the paver beams. The PERS layer thickness was about 3 mm greater than the depth to fill. All test section was paved in one pass of asphalt paver. 10

12 Compaction started at 9 45, the steel roller was used. at the beginning of the roller going diagonally, but groove in the middle was large. Finally it passed 2 times each strip straight. It was sufficient to compact the layer, a further passage (a few meters at the beginning of test sections) did not give any visible results. 11

13 Further compaction, on the in the middle of the test section was a longitudinal bulge, it was leveled manually using a shovel by the crew of IBDiM. The site works were finished at around 10 AM on the 17 of September NOTE: The roller, asphalt paver, truck were sprayed by demoulding oil (100%). 2.3 Next days: Inspections and opening for traffic The next morning at 8:00 has been found that someone broke the fence and a few traces of cars and bikes are clearly visible on the surface. The PERS surface was slightly sticky. 12

14 The next day morning on Friday at 6 AM it was detected that someone opened test section for traffic, barriers and traffic lights were moved to the road side. After an investigation it was found out that test section was opened for traffic on 18th of September between 17 and 21. (around hours after construction). Visually the surface was not damaged and sound absorption was very large. It had not rained since 16 of September until 20, when strong rainfall was noticed. 13

15 3 RECONSTRUCTION OF THE TEST SECTION DAY 9 On the 26th of September (Friday), the road administration sent to the IBDiM first information about problems. As an attachment to an have been sent pictures with two holes. It was visible that PERS began to delaminate from base layer. The small hole and front of the big hole wear located in the wheel path. On 29 of September (Monday) IBDiM representatives of arrived at the place. The situation was much worse than last Friday, the surface was devastated, pieces of destroyed PERS layer were lying on the side of the road. It was decided to immediately replace PERS by typical SMA wearing course. Technical Univeristy fo Gdansk made noise measurements and the sections has been closed. 14

16 By each passing of the trucks wheels moved the edge of hole for a few cm. In the front of the track wheels the surface was raised, formed a visible "wave". Laying of the new pavement and additional sampling was planned for Wednesday, but unexpectedly the road contractor has free team workers and without consultation with IBDiM done the reconstruction on Tuesday. According to his information, the old PERS surface was excavated without using of heavy equipment, it has been removed manually. The adhesion to the base course was damaged. Unfortunately also the new the surface is already damaged and will soon be replaced again. NOTE: Investigation of the causes of this situation have been carried out in the framework of WP4. 15