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Constructability and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB. Lee, J. Harvey, CW. Ibbs Pavement Research Center + Construction Engineering & Management University of California, Berkeley
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Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

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Page 1: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Constructability and ProductivityAnalysis for Long Life PavementRehabilitation Strategies (LLPRS)

May 4, 2001

EB. Lee, J. Harvey, CW. Ibbs

Pavement Research Center +Construction Engineering & Management

University of California, Berkeley

Page 2: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Backgroundof

Constructability Research

Page 3: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Motivation: CA Highway Situation• Needs Massive Rehabilitation

� Total 80,000 l-km Highway System� Built 50s-70s with 20 years Design Life� Service 30-40 years: Adverse Effects� 7,000 l-km Needs Immediate Care� Other States: Partnership (CA,WA,TX & MN)

• LLPRS: Caltrans’ Rehabilitation Strategies� SHOPP($10B): Rehab. 3,000 l-km (1998-2007)� Long Life Pavement Rehabilitation Strategies

�Provide 30-40 years of Service Life�6 lane-km Rehab./55-hour Weekend Closure

Page 4: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

UCB LLPRS Constructability Research• Stage 1: Concrete Constructability Analysis

� Caltrans (CAL/APT)

• Stage 2: Concrete Case Study� I-10 Project with IPRF/FHWA

• Stage 3: Asphalt Constructability Analysis� Caltrans (P-PRC)

• Stage 4: Asphalt Case Study� I-710 Project with NAPA

• Stage 5: Analysis Simulation Software� 4 States Fund (CA/WA/MN/TX)

Page 5: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

ConstructabilityInformation

Process

DOT(CALTRANS)

UCBPavementResearch

Center

UCBConstructionEngineeringManagement

ContractorsAssociation

(ACPA & NAPA)

FieldSections

LLPRSConstruction WindowsLane Closure Tactics

Technical AnalysisEconomic Analysis

Developing Innovations

Design CriteriaMaterial Design

Material Test

Provision of InformationVerification of Information

Site ObservationsCase Studies

Joint Research

Page 6: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Typical Failures of Rigid Pavement

(from PRC of UCB)

(a) Typical Faulting Distress

(b) Typical Transverse Fatigue and Corner Cracks

(c) Typical Longitudinal Cracks

Page 7: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Example of Typical Failures (I-10)

Page 8: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Two Types of Pavement Rehabilitation

Shoulder Non-Truck Lanes Truck Lanes Shoulder

Shoulder Non-Truck Lanes Truck Lanes Shoulder

• Remove Existing PCC & Base• Place Full Depth A/C

• Crack and Seat Slabs• Place Overlay (CSOL)

• Replace Broken Slabs

� Concrete Rehabilitation

� Asphalt Rehabilitation

• Remove Existing PCC & Base• PCC Reconstruction

Page 9: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

PavingMaterial

DesignProfile

ConstructabilityAnalysis

ConstructionWindow

Curing orCooling Time

Continuous Closure Weekend Closure

Construction Window

Curing Time

203mm Slab 254 or 305 mm Slab

CONCRETE

Cooling Time

CSOL Full Depth

ASPHALT

LLPRS

Constructability Analysis Structure

Page 10: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Research Approach & Objectives• Define Typical Rehabilitation Strategies• Model Detailed Rehabilitation Process

� Hierarchical Analysis Structure• Prototype Analysis Software

� Estimate Production Capability• Parametric Study

� Constraints & Innovation for Improvement• Case Studies

� Validation / Calibration of Analysis Model• Professional Analysis Simulation Software

Page 11: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Two Analysis Modules• Deterministic Analysis

� Constants Parameters� Most Likely Number as Input� Estimate Average Production Capability

• Stochastic Analysis� Random Variable Analysis� “Mote Carlo Simulation” Technique� Crystal Ball / Excel / VBA Interface� PDF (Probability Distribution Function)� Predicted Production Capability

�Lower Boundary, Mean, Upper Boundary

Page 12: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Input Screen for Analysis Tool

Page 13: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Predicted Production (Deterministic)

Page 14: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Predicted Production (Stochastic)

Frequency Chart

Certainty is 68.00% from 1,266 to 1,581 lane-meters

Mean = 1,401.000

.008

.016

.023

.031

0

7.75

15.5

23.25

31

1,026 1,219 1,412 1,605 1,798

1,000 Trials 10 Outliers

Forecast: Distance (CSOL/Half/Profile "A")

Best ScenarioWorst ScenarioMost Likely

Page 15: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

ConcreteAnalysis

Model

Page 16: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

PavingMaterial

DesignProfile

WorkingMethod

ConstructabilityAnalysis

PavingLane

CuringTime

ConstructionWindow Construction Window

4hour: FSHCC 8 or 12hour: PCC

Curing Time

Single-Lane Double-Lane

Concurrent

Single Double

Sequential

203 mm Slab

4 hour 8 or 12hour

Curing

S D

C

S D

S

254 or 305 mm Slab

CONCRETE

LLPRS

Concrete Analysis Structure

Page 17: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

TypicalConcreteProfiles (a) 203 mm Concrete Slab

(b) 254 mm Concrete Slab

(c) 305 mm Concrete Slab

Existing Profile New Profile

Removed Retained

CONCRETE 203mm (8")

CTB 102mm (4")

AB 305mm (12")

SG

CONCRETE 203mm (8")

CTB 102mm (4")

AB 305mm (12")

SG

CONCRETE 205mm (8")

CTB 102mm (4")

AB 305mm (12")

SG

NewPCC

NewCTB

CONCRETE 203mm (8")

CTB 102mm (4")

AB 305mm (12")

SG

CONCRETE 305mm (12")

CTB 152mm (6")

AB 152mm (6")

SG

CONCRETE 254mm (10")

CTB 152mm (6")

AB 203mm (8")

SGOriginal CaltransObjective:6 ln-kmper 55 hrs

Page 18: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

(d) Linear Scheduling

0

2

4

6

8

0 10 20 30 40 50 60Schedule (hours)

Prog

ress

(lan

e-km

)

Mob. Demol CTBPaving Curing C.W.

(a) Concurrent / Single(T1)

S1 P1 P2 T1 T2 S2

Open PavingAccess

(b) Concurrent / Single(T2)

S1 P1 P2 T1 T2 S2

Open PavingAccess

(c) Concurrent / Double(T1+T2)(Counter-Flow Traffic)

S1 P1 P2 T1 T2 S2

Open PavingAccess

Concurrent Working Method

Page 19: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Sequential Working Method

(a) Sequential / Single(T1)

S1 P1 P2 T1 T2 S2

Open PavingAccess

(b) Sequential / Single(T2)

S1 P1 P2 T1 T2 S2

Open PavingAccess

(c) Sequential / Double(T1+T2)

S1 P1 P2 T1 T2 S2

Open PavingAccess

(d) Linear Scheduling

0

2

4

6

8

0 10 20 30 40 50 60

Schedule (hour)

Prog

ress

(lan

e-km

)

Mob. Demol CTBPaving Curing C.W

Page 20: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Typical CPM (Sequential Method)

Page 21: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Resource Constraint (Concrete)No. of Resource Needed for

Resources Unit Capacity Concurrent Sequential

Batch Plant M3 / hour 1 Each 150-250 150-250

Dump Truck (Demo) per hour 25 Ton 8-12 8-12

End Dump Truck (PCC) per hour 6-9 M3 8-12 8-12

Paver Speed M / min. 1 Each 3-5 3-5

End Dump Truck (CTB) per hour 9 M3 5-8 5-8

� Total Number of Trucks to be Mobilized Trucks per hour x Shift No. x Turn-around time

Page 22: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Results ofConcreteAnalysis

Page 23: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Example of Single lane Production(unit: Lane-km)

Slab Thick. 203mm Concrete 254mm Concrete 305mm Concrete

Curing Time Concurrent Sequential Concurrent Sequential Concurrent Sequential

4 hour 3.8 2.4 1.9 1.5 1.7 1.3

8 hour 3.4 2.2 1.7 1.4 1.5 1.2

12 hour 3.0 2.0 1.5 1.3 1.3 1.1

Constraint Paver Speed Paver Speed Dump Truck Dump Truck Dump Truck Dump Truck

(Demo:Pave) N/A 1 : 1.31 N/A 1 : 0.71 N/A 1 : 0.76

Page 24: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Example of Concrete Analysis ResultsProgress vs. Curingtime

0.0

2.0

4.0

6.0

8.0

4 8 12 16 20 24Curing Time (hour)

Prog

ress

(lan

e-km

)8" 10" 12" Objective

Page 25: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

SensitivityAnalysis

forConcrete

Options Comparison Reduction

Design 203 => 254 40% Profile 203 => 305 47%

254 => 305 12% Curing 4 hr => 8 hr 10% Time 8 hr => 12 hr 11%

4 hr => 12 hr 19% Work Method 203 mm 29%

(Concur. =>Sequen.) 254 or 305mm 21% Paving lane 203 mm 17% (Double=>Single) 254 or 305mm 7%

EDT Capacity 22 => 15 ton 15% Cycle Time 3 => 4 min 24%

Page 26: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Comparison of Construction WindowsC o m pa riso n o f C o nstruc tio n W in do w s

0.0

2.0

4.0

6.0

8.0

10.0

12.0

2 0 3 mm 2 5 4 mm 3 0 5 mmS la b T hick nes s

C-W

indo

w (W

eeks

)

Cont. (3 s hift) Cont. (1 Shift) W e e ke nd

Const. Window 203 mm 254 mm 305 mm DurationCont. (3 shift) 1.4 2.1 2.4 WeeksCont. (1 Shift) 4.0 5.9 6.6 Weeks

Weekend 6.2 10.1 11.4 No. of Weekend

Page 27: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

• Caltrans’ Objectives for LLPRS� Maximum Target= 3.5 Truck lane-km / 55 HR

�Most likely = 2.0 - 3.0 lane-km

• Parametric Study (Critical Parameters)� Concrete Curing Time is Not the Most

Critical Parameter� Design Profile has the Biggest Impact� Delivery Trucks Constrain Production

• Unclear Benefits of FSHCC (vs. PCC)� Needs Production vs Cost Analysis

Preliminary Findings for Concrete

Page 28: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Summary ofConcrete

Case Study (I-10)

Page 29: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Case Study: Concrete on I-10Asphalt (AC) on I-710

Page 30: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

I-10 Project: Work Scope

Eastbound Direction

Traffic Lane (#2) Rehabilitated Lane (#3) Construction Access Lane (#4) Shoulder (access + parking area)

Traffic Lane (#1)

10’12’12’12’12’

MCB

Sound Wall

� 20 lane-km (3 l-km Weekend + Nighttime)� Rebuild Two Truck lanes (No.3 & 4)� 8” Slab Replacement with FSHCC (4 hr curing)� Concurrent Work / Single Lane

Page 31: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

I-10 Project: Traffic Conditions

Traffic before Rehabilitation

Traffic during Rehabilitation

Page 32: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

I-10 Project: Slab Demolition (non-impact)

Non-Impact Demolition

Page 33: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Drilling Holes for Tie-bars

Installation of DowelBars and Tie Bars

I-10 Project: Tie-Bars and Dowel-Bars

Page 34: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Paving, Finish, and Texturing

I-10 Project: Screed for FSHCC Paving

Page 35: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

I-10 Project: Washing / Chipping (FSHCC)

Washing Mixer Truck

Chipping FSHCCBuild-up

Page 36: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

I-10 Project: Breakdown of M-T Cycle-timeBreakdown of a Mixer cycle-time (70 min.)

55

15

1055

5

5

15 waiting for pouring

concrete pouring

washing

move to batch plant

measure weight

waiting for charge

concrete charge

record slip

move to site

Page 37: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

I-10 Project: Nighttimes vs Weekend

Nighttime Closure WeekendClosure

7-hourClosure

10-hourClosure

55-hourClosure

Main Work(hours) 2 hour 5 hours 43 hours

Auxiliary Work(hours) 5 hours 5 hours 8 hours

Slab No.Replaced 15 50 615

Productivity(slabs / hour) 7.5 10 14

MajorResources

7 D-T4 M-T

7 D-T8 M-T

21 D-T12 M-T

Page 38: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

I-10 Project: Prediction from the UCB Model

Frequency Chart

Certainty is 85.00% from 2.4 to 3.4

.000

.006

.012

.018

.023

0

8.75

17.5

26.25

35

2.0 2.4 2.8 3.3 3.7

1,500 Trials 12 Outliers

Forecast: FSHCC-4hr

Estimate = 2.4 ~ 3.4 lane-km / 55 hoursMean = 2.9 lane-km / 55 hours

Page 39: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

I-10 Project: Overall Rehabilitation Progress

Actual Performance = 2.8 lane-km / 55 hours

Progress of Rehabilitation

0

500

1000

1500

2000

2500

3000

0 5 10 15 20 25 30 35 40 45 50 55Time (hour)

Pro

gres

s (la

ne-m

eter

)

demolition paving

B-P Break-down

7 Mixers rejected

Screed break-down

Slow-down due toTraffic Regulation

Page 40: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Concrete Case Study: I-10 Project

Page 41: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

I-10 Project: Traffic Flow Comparison

Mean = 2,000 Cars / hourSpeed = 50 ~ 80 mph

Comparison of Eastbound Traffic Volume

0

1500

3000

4500

6000

7500

90008-9

PM12

-1AM

4-5AM

8-9AM

12-1P

M4-5

PM8-9

PM12

-1AM

4-5AM

8-9AM

12-1P

M4-5

PM8-9

PM12

-1AM

4-5AM

55-hour Time Frame

Tota

l Veh

icle

per

hou

rThrough Volume (55-hour) Through Volume (Historical)Before Diversion (55-hour) Before Diversion (Historical)

c

Page 42: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

AC (Asphalt) Analysis

Model

Page 43: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Cooling Time

FullCompletion

Full Closure

PartialCompletion

Full

Half Closure

Profile "A"

Full

Full

Partial Full

Half

Profile "B"

CSOL

Cooling Time

Single Lane Double Lane

Profile "A"

Single Double

Profile "B"

Full Depth

Asphalt Concrete (AC)

Asphalt (AC) Analysis Structure

complete

laneclosure

designprofile

layerprofile

coolingtime

designprofile

Page 44: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Change of Design Profile(CSOL: Crack Seat and Overlay)

Existing Pavement

PCC 203mm (8")

CTB 102mm (4")

AB 305mm (12")

SG

Layer Profile "A"

PCC 203mm (8")

CTB 102mm (4")

AB 305mm (12")

SG

25 mm

75 mm

75 mm

55 mm

0.5 hour

4 hour

4 hour

2 hour

Final Lift

2nd Lift

3rd Lift

1st Lift

Layer Thick. Cooling

OR

Total thick. = 230 mm (9")

Layer Profile "B"

PCC 203mm (8")

CTB 102mm (4")

AB 305mm (12")

SG

25 mm

75 mm50 mm50 mm

0.5 hour

4 hour2 hour2 hour

1st Lift

2nd Lift3rd Lift

Final Lift

Layer Thick. CoolingTotal thick. = 200 mm (8")

Retained AC(CSOL)Fabric

Page 45: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Work Plan (CSOL)

1. Full Closure + Full Completion

2. Half Closure + Full Completion

3. Half Closure + Partial Completion

(b) Sequence of Paving

(a) Plan View (1'st stage)

S1 P1 P2 T1 T2 S2

Open PavingAccess

SafetyBarrier(MCB)

PCC

1st Lift1st Lift2nd Lift

3rd LiftFinal Lift

2nd Lift3rd Lift

Final Lift

3'rdStage

FinalStage

1'stStage

2'ndStage

Lane P1+P2 Lane T1+T2

Page 46: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Change of Design Profile(Full Depth AC Replacement)

Existing Pavement Layer Profile "B"

Removed Retained AC

PCC 203mm(8")

CTB 102mm (4")

AB 305mm(12")

SG

76 mm

AB 203mm(8")

SG

76 mm76 mm76 mm51 mm51 mm

1 hour1.5 hour6 hour4 hour1.5 hour1 hour

1st Lift2nd Lift3rd Lift4th Lift5th Lift

Final Lift

Layer Thick. Cooling

OR

Total thick.=406 mm (16")Layer Thick. Cooling

Layer Profile "A"

76 mm

AB 279mm(11")

SG

76 mm77 mm76 mm25 mm

1 hour2 hour

6.5 hour1.5 hour

0.5 hour

1st Lift2nd Lift3rd Lift4th LiftFinal Lift

Total thick.=330mm (13")

Page 47: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Work Plan (Full Depth AC)

(a) Single-lane (T1: 1'st weekend)

S1 P1 P2 T1 T2 S2

Open PavingAccess

S1 P1 P2 T1 T2 S2

Open PavingAccess

(c) Double-lane (T1+T2)

S1 P1 P2 T1 T2 S2

Open PavingAccess

(d) Linear Scheduling

0

1

2

3

4

0 10 20 30 40 50 60Schedule (hour)

Prog

ress

(lan

e-km

)

Mobil. Demolition PavingDe-mobil. C.W

Safety Barrier(MCB)

(b) Single-lane (T2: 2'nd weekend)

Page 48: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Resource Constraint for AC Analysis

Resources Unit Capacity Number

AC Mixing Plant M3 / hour 1 Each 150 (100-200)

Dump Truck (Demo/Full Depth) per hour 25 Ton 10

(8-12)

Semi-bottom Truck (AC) per hour 25 Ton 12

(9-20)

Paver Speed Km/hour 1 Each 6.0 (4.5 – 7.5)

Page 49: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

CalCoolAC Cooling Time

Analysis Software

Page 50: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

AC Cooling-time Analysis: CalCool• Cooling-time Impact to Production

� Waiting Time (Next Layer Paving or Traffic Switch)• Parameters Considered

� Design� Sub-base� Environment� Delivery & Stop Temperature

Time

Average Pavement Temperature

Overstressed

Understressed

Optimal CompactionTemperatures

Optimal Compaction TimeFrame

Page 51: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

CalCool Input Window

Page 52: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

CalCool: Tabular and Graphic Output

• Download from the PRC or 4 States WEB• http://www.its.berkeley.edu/pavementresearch/CalCool/CalCool.exe

Page 53: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

CalCool Validation (Multi-lift AC)Lompoc H-Street AC ConstructionPoint 11, 2 Lifts over Rich bottom

0

20

40

60

80

100

120

140

160

0:00 1:12 2:24 3:36 4:48 6:00 7:12 8:24 9:36 10:48

Time (hour)

Tem

pera

ture

(°C

)

In-depth (lift 2) Surface (lift 2)

Edge (lift 2) In-depth (lift 3)

Surface (lift 3) Edge (lift 3)

CalCool Lift 2 CalCool Lift 3

Date: October 8, 1999Time: 8:50, 11:22 AMAvg Air Temp: 23, 32 °CAvg Wind: 5.0, 0 kphExisting Surface: AC, ACExisting Surface Temp: 23, 58°CCloud Cover: Clear and dry, clear and dryMix Specification: DGACLift Thickness: 80, 80 mm

Page 54: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Result ofAC (Asphalt)

Analysis

Page 55: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

AC Analysis:CSOL (Deterministic)CSOL Production Graph

(4 lanes: lane-meter)

2,000

4,000

6,000

8,000

2 3 4 5 6 7 8Cycle time of Semi Bottom Truck (min.)

Prod

uctio

n (la

ne-m

eter

)

full-close full-completeprofile "B" full-close full-completeprofile "A" half-close full-completeprofile "B" half-close full-completeprofile "A" half-close part-complete profile "B"

Page 56: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

CSOL Stochastic Analysis (4 lanes: lane-meter)

3,000

5,000

7,000

full-close full-complete profile "B"

full-close full-complete profile "A"

half-close full-complete profile "B"

half-close full-complete profile "A"

half-close partl-complete profile "B"

Analysis Option (Closure / Completion / Profile)

Prod

uctio

n (la

ne-m

eter

)

Lower bound Mean Deterministic Upper bound

AC Analysis:CSOL (Stochastic)

Frequency Chart

Certainty is 68.00% from 1,266 to 1,581 lane-meters

Mean = 1,401.000

.008

.016

.023

.031

0

7.75

15.5

23.25

31

1,026 1,219 1,412 1,605 1,798

1,000 Trials 10 Outliers

Forecast: Distance (CSOL/Half/Profile "A")

Page 57: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

AC Analysis:CSOL Comparison ClosureOption Full Closure Half Closure

Completion Option

Full Completion

Full Completion

PartialCompletion

ProfileOption

Profile“A”

Profile“B”

Profile“A”

Profile“B”

Profile“B”

AverageProduction 4,808 5,534 3,962 4,511 5,208

Comparison 87 % 100% 72% 82% 94%

Waiting(hours) 0 0 9 8.5 3

Coolingwaiting

Trafficswitch 0 0 0 0 2 7 2 6.5 0 3

Page 58: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

AC Analysis:Full Depth (Stochastic)Full-Depth Stochastic Analysis

1,000

1,500

2,000

2,500

3,000

Single Lane Profile "A"

Single Lane Profile "B"

Double Lane Profile "A"

Double Lane Profile "B"

Analysis Option (Paving Lane / Layer Profile)

Pro

duct

ion

(lane

-met

er)

Lower bound MeanDeterministic Upper bound

Frequency Chart

Certainty is 68.00% from 1,211.45 to 1,784.22 lane-meter

Mean = 1,523.85.000

.007

.015

.022

.029

0

7.25

14.5

21.75

29

850.02 1,193.11 1,536.20 1,879.29 2,222.38

1,000 Trials 2 Outliers

Forecast: Production (Lane-Meter)

Page 59: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Construction Windows (Asphalt)

5.94.83.74.2Weekend406mm(16”)330mm(13”)200mm(8”)230mm(9”)Thickness

1.81.41.11.2Cont. (24H)2.62.11.61.8Cont. (16H)

Profile”B”Profile”A”Profile”B”Profile”A”Layer ProfileFull-Depth ACCSOLDesign

C o n s tr u c t io n W in d o w s C o m p a r is o n

0 .0

1 .0

2 .0

3 .0

4 .0

5 .0

6 .0

C S O L P ro f i le " A "

C S O L P ro fi le " B "

F u ll-D e p thP ro f i le " A "

F u ll-D e p thP ro f i le " B "

D e s ig n P r o f i le

No

of w

eek(

end)

W e e k e n d C o n ti n u o u s (1 6 h r /d a y ) C o n t i n u o u s (2 4 h r /d a y )

Page 60: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Sensitivity of AC Analysis• Sensitivity (AC vs. Concrete)

� AC Paving more Complex than Concrete� Sensitivity Study is Difficult

• Most Critical Parameters� Pavement Thickness (Proportional)� Asphalt Delivery Trucks� Demo. Hauling Trucks (Full Depth only)� Lane Closure Tactics (Cooling Time)� Mixing Plant, Paver

Page 61: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Preliminary Finding for AC Analysis• Production Objectives: 6 km per weekend

� CSOL�Achieve 40 % of target (2.5 lane-km Truck-lanes)�Faster, pave all lanes (30% for shoulders)

� Full depth AC�Achieve 30% of Target (2.0 lane-km Truck-lanes)�Slower, but fewer lanes (Truck Lanes only)

• Lane Closure Tactics� CSOL: Full- Closure is 20 % More Productive� Full Depth: Single-lane is 10 % More Productive

Page 62: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Asphalt ConcreteCase StudyI-710 Project

Page 63: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

I-710 Project (Stage Construction)

Construction is Scheduled in 2001

Page 64: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

I-710 Project Section Profiles

Existing PCCProfile

Removed Retained AC

PCC 203mm(8")

CTB 102mm (4")

AB 305mm(12")

SG

Layer Thick. Cooling

Full Depth AC

OR 76 mm

AB 178mm(7")

SG

76 mm77 mm76 mm25 mm

1 hour2 hour

6.5 hour1.5 hour

0.5 hour

1st Lift2nd Lift3rd Lift4th LiftFinal Lift

Total thick.=330mm (13")Deemolition =431mm(17")

more clearance = 101 m

m (4")

Existing Surface

CSOL

PCC 203mm(8")

CTB 102mm (4")

AB 305mm(12")

SG

25 mm

75 mm

75 mm

55 mm

0.5 hour

4 hour

4 hour

2 hour

Final Lift

2nd Lift

3rd Lift

1st Lift

Layer Thick. CoolingTotal thick. = 230 mm (9")

Fabric

Page 65: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

I-710 Project Stage Construction (I)

CSOL

Full Depth

Page 66: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

I-710 Project Stage Construction (II)

Page 67: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

I-710 Project: UCB Model Prediction

710 (CSOL Stochastic Analysis )

0

1,000

2,000

3,000

4,000

5,000

6,000

Cente rline -me te r 3 lanes(Lane -me te r)Analysis Option

Pro

duct

ion

(met

er)

Low e r bound M e anDe te rm inis tic Uppe r bound

710 (Full-depth Stochastic Analysis )

0

500

1,000

1,500

2,000

Cente rline -me te r 3 lanes(Lane-me te r)Analysis Option

Pro

duct

ion

(met

er)

Low e r bound M e anDe te rm inis tic Uppe r bound

Page 68: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

I-710 Project: UCB Prediction vs. Plan

I-710 (Plan)UCBModel

UnitOptionStage

4,5Stage

3,6

2.002.401.50Lane-km

0.650.800.50Centerline-kmFull

Depth

3.304.804.83Lane-km

1.101.601.55Centerline-km

CSOL

Page 69: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Further Steps(Current and Future)

Page 70: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Current Focus and Further Steps• Constructability Analysis Software

� 4 State Fund: CA, WA, MN, and TX DOTs� Knowledge-based Analysis Simulation Software� MS Access + Visual Basic� Deterministic & Stochastic Analysis Modules

• More Case Studies (Validation)� Validation & Calibration of UCB Model� Concrete Model: PCC vs. FSHCC� AC Model with I-710

• Life Cycle Cost Analysis� Direct Construction & Indirect User Delay Costs� Durability, Maintenance Cost, and Policy Aspects

Page 71: Rehabilitation Strategies (LLPRS) Analysis for Long Life ... and Productivity Analysis for Long Life Pavement Rehabilitation Strategies (LLPRS) May 4, 2001 EB.

Questionsand

Answers

If Need More Information …EB Lee Email:[email protected] Lee URL: http://www.ce.berkeley.edu/~eblee/PRC URL: http://www.its.berkeley.edu/pavementresearch/