Beton Yol Yapımı (Power Point İngilizce Sunu)

NATIONAL MEETING ON CONCRETE ROADS
18th December 2002, Ankara
CONCRETE ROAD CONSTRUCTIONS

State of the Art and new Development
by
Jrgen Halm
HeidelbergCement Technology Center GmbH
Department Concrete and Application
Folie 1
siegfried.riffel@heidelbergcement.com
Table of Contents
- New Regulations in Germany (Requirements to be

met)
- Placement of Concrete / Laying Technology
- Paver Compacted Concrete
- Noise-reduced Traffic / Open porous Concrete
(Draining Concrete)
Folie 2
New Regulations
ZTV Beton StB 01 (StB = Road Construction)

(Supplementary Technical Conditions of Contract, Specifications and
Guidelines for the Construction of Concrete Pavements)
The new Edition 2001

Includes new technical developments in the construction
of concrete pavements
Folie 3
New Regulations
The ZTV Beton - StB 01 includes:
- Modifications of the VOB Part C (12.2000)
(VOB = General Technical Conditions of Contract)
- ZTV Fug-StB 01 (Supplementary Technical Conditions of

Contract,
Specifications and Guidelines for sealants and joint
fillings in traffic areas)
- Description of burlap (Special kind of surface treatment)
- Construction method using geotextil as a layer between
concrete pavement and road base
- Cement requirements
- New construction methods (two layer wet in wet)
Folie 4
New Regulations
Pavement construction:
- The concrete pavement can consist of one or two layers
- Thickness of top layer > 4 cm
- The thickness of total pavement depends on the RStO 01
(RStO = Guidelines for the Standardization for Pavement Structures for Traffic Areas)
3 examples for construction class SV (heavy traffic load)

concrete
pavement
geotextil
cement stabilized
base (HGT) 120
subbase
frost-resistant
material
45
MN/m2
Folie 5
27 cm
concrete
pavement
asphalt stabilized
base
15 cm
26 cm
10 cm
subbase
frost-resistant
material 45
MN/m2
36 cm
30 cm
150
crushed-rock
base
120
42 cm
concrete
pavement
subbase
frost-resistant 45
material MN/m2
30 cm
60cm
New Regulations
Alternative concrete construction method:
2 layer-concrete on
standard-pavement structure
crushed-rock base
27 cm
geotextil
15 cm
42 cm
concrete
pavement
cement stabilized
base (HGT)
frost-resistant
material
30 cm
concrete
pavement
30 cm
crushed-rock base
(unbound base)
60 cm
frost-resistant
material
4 cm = top layer
26 cm = bottom layer
The advantages of thick concrete pavement with a thin upper layer of

concrete are:
- Improved skid resistance
- Reduction of noise
- Guarantee of covered dowels
- Use of recycled broken-up material in the lower concrete layer
Folie 6
New Regulations
Cement
- CEM I 32,5 R (DIN EN 197-1)

- upon coordination with the customer the following
cements can also be used:
- CEM II/A-S oder CEM II/B-S
- CEM II/A-T
oder CEM II/B-T
- CEM II/A-L
- CEM III/A
- for CEM I 32,5 R - < 28 % required water (DIN EN 196-3)
- compressive strength, 2 days < 29 N/mm
(DIN EN 196-1)
- 3.500 cm/g fineness of grinding (DIN EN 196-6)
- requirements for all cements - total alkali content < 1,0 M% (required)
- cement temperature < 80C (if possible)
Folie 7
New Regulations
concrete aggregates
- DIN 4226-1 (German Industrial Standard)

- TL Min StB (Technical Conditions for the Supply
of Minerals for Road Construction)
- Limitation of swelling components

- Increased frost resistance requirements
- A percentage of crushed aggregates is required
- High quality crushed aggregates with resistance
to polishing (PSV = polished stone value)
- The alkali guidelines of DAfStb shall be included
Folie 8
New Regulations
Concrete requirements
Construction
class
Minimum values of 28-day-oldconcrete
ZTV Beton Tab.1

Size of aggregates-groupes
Compressive strength
on
the cube with 20 cm
edge lengths
Beam-tensile
strength
[N/mm]
[N/mm]
[mm]
5,5
0/2, 2/8, > 8

0/4, 4/8, > 8
0/2, < 8*
traffic1
load
SV, I - IV
3
35
40
*for 8 mm maximum aggregate size
V - VI
25
30
4,0
0/4, > 4
- Cement content of construction class SV, I, II, III: > 350 kg/m
- Water-cement ratio in tests for construction classes SV, I, II, III: < 0,45
- Mixing time: > 45 seconds
Folie 9
New Regulations
Air void volume of fresh concrete
Micro air void with air-entraining agent guarantee a high
frost-deicing saltresistance in the concrete.
ZTV Beton Tab. 2
Minimum air void volume of fresh concrete

daily average
[Vol.-%]
individual values
[Vol.-%]
Concrete without plasticizer (BV)

or plasticizing agent (FM)
4,0
3,5
Concrete with plasticizer (BV) and/or

plasticizing agent (FM)
5,0
4,5
Folie 10
New Regulations
Observing minimum strengths (table 1)

Observing the air void volume (table 2)
Tolerance of the pavement thickness (< 5 mm on the test specimen)
Max. 20 (50) mm shifting of the positon of the dowles
< 0,5 % deviation for the crossfall
< 4 mm evenness with 4m-long-measuring rod
Observing values for skid resistance TP Griff-StB (SCRIM) (table 4)
Limiting values SCRIM
Measuring
speeds
[km/h]
40
60
80
Folie 11
Acceptance
Until expiry of term

of limitation
0,60
0,53
0,46
0,56
0,50
0,43
ZTV Beton Tab. 4
New Regulations
Surface treatment and curing
Construction classes SV, I, II, III
Final polishing element = longitudinal polisher
Finishing surface treatment by means of 300 g/m burlap or
45 cm wide steel broom
Wider new methodes for finishing surface are burlap with comp
artificial grass and wash concrete (remove the fine mortar)
When the surface is completed, a curing agent as per
TL NBM-StB shall be applied. Densifying coefficient: S > 75 %
- It is suitable to use curing agents with increased brightness referenz
value
(with colour value) VH-W oder VM-W.
Joint cutting
Transverse joint: cutting depth 25 - 30 % of the thickness
Longitudinal joint: cutting depth 40 - 45 % of the thickness
Folie 12
Laying technology
longitudinal smoother
Folie 13
Laying technology
burlap
Folie 14
Laying technology
transverse steel-broom line
Folie 15
Laying technology
wash-concrete surface (Germany)
Folie 16
Laying technology
application curing-agent
Folie 17
Laying technology
Example of BAB 5 expresshighway:
concrete pavement structure + positions of dowels and tie bars
5,0
0
Longitudinal contraction joints, 3 or 5 tie bars per slab
5,0
0
Transverse contraction joint,

with dowels Spacing
of dowels 25 cm
12 %
4,50
3,75
4,25
12,50 m
internal
lane
Folie 18
central
lane
2,50
2,50 m
external
lane
shoulder
lane
concrete pavement
26 cm (19+7)
cement stabilized
base
frost-resistant gravel
and sand material
Joint technology
dummy joint-cut (to prevent wild cracks)
bituminous joint filler

or joint profile
notch
cement stabilized base (HGT)
Folie 19
Joint technology
dummy joint
- longitudinal
- transverse
for expansion
Folie 20
Joint technology
pressed joint sinus profil wich does not allow expansion
(only in aircraft movement areas)
Folie 21
Mixing plant / supply of cement
Folie 22
Stockpile of aggregates
Folie 23
Laying technology
concrete pavement - two layers slipform paver
Folie 24
Laying technology
dowel setting machine
Folie 25
Reinforced pavements
Reinforced concrete pavements
1921
First continuously reinforced pavements in United
States Virginia (60 m long slabs of different reinforcements)

from 1947 Inter-States network in the United States is partly
produced with reinforcement
until 1994
16.000 km of the Inter-States network are
reinforced
from 1970 Belgium
Brussel-Lttich motorway
further applications in Belgium, Spain, UK

until 1994
Belgium
2.950 km
from 1982 France 10 km of the A 6 motorway near Auxerre

until 1994
Folie 26
3,5 Mio m of reinforced pavement
Reinforced pavements (France)

Reinforcement
- 16 mm-dia. round steel, longitudinal/transverse
- percentage of reinforcement 0,6 - 0,8 %
alternatively:
- flat rolled steel bands
40 - 44 mm wide
2 - 3 mm thick (galvanized, with knobs)
- percentage of reinforcement
0,30 % (higher tensile yield point)
Layout:
1/3
1/2
> 60-70 mm
Folie 27
reinforcement layer in the

compression zone
Laying technology
reinforced concrete pavement (slipform paver)
Folie 28
Laying technology
control of reinforcement (slipform paver)
Folie 29
Concrete pavement Paver Compacted Concrete
Folie 30
Paver Compacted Concrete (PCC)

PCC is laid with conventional road pavers equiped with High-PowerCompaction Screeds (HPCS)
PCC is compacted from the surface with tamping,vibrating and pressing
compacting systems
Construction
- Single-layer or two-layer construction (fresh on fresh)
- For use as base course or combined base and wearing course
- Favorable paving depth (15 20 cm)
Construction material
- PCC 0/16 mm, if required with air entraining agent
- Aggregate > 8 mm double screened chippings, or chippings (eFT)
- Concrete strength C25/30 up to C40/50 are achievable
Cost
- Substantially lower cost compared with conventional concrete
- About 8 - 13 /qm without joints
(depending: concrete strength, paving depth, working width)
Folie 31
Paver Compacted Concrete (PCC)

Applications
- Base for roads and traffic surfaces built in two-layer construction according
to RStO-Class SV, I VI
- Industrial roads; bus lanes; draw-ins
- Farm tracks; footpaths and cycle paths
- Crossings; yards; car parks
- Industrial surfaces; exhibition grounds
Advantages
- High quality achieved with low requirement for equipment and personnel
- Very good surface accuracy (longitudinal and traversal)
- Suitable for two-layer construction (pavers operating in echelon)
- Density of >98% achieved right behind the High-Power-Compaction Screed
- Very good green-stability (90edge)
- High resistance to wear
- High paving performance (60 120 m/h)
- Joints can be produced or cut in the fresh concrete
- Distance between joints 5 7 m
- Easy, efficient, economical
Folie 32
Noise-reduced traffic
Noise-reduced concrete pavement
- draining-concrete
Folie 33
Draining-concrete pavement
Folie 34
Draining-concrete pavement
Folie 35
Concrete pavement draining-concrete
draining-concrete = top layer
concrete or
PCC (Paver Compacted Concrete) or
cement stabilized base = bottom layer
Folie 36
Pavement draining-concrete (special slipform paver)
Folie 37
Surface and structure of draining-concrete
Folie 38
Surface and structure of draining-concrete
Folie 39
Open porous concrete draining concrete
Advantages
-very high noise reduction possible by 7 dB(A)
-high sound absorption (up to 98 % within critical frequency ranges)
-good drainage characteristics, i.e. no splash water jets, no aquaplaning
high level of road safety on dry and wet roads

very good transverse and longitudinal evenness
high skid resistance
good non-skid qualities in respect of dry and wet roadway surfaces
good reflections properties
good brightness of surface
high load-bearing capacity (D,BZ,HZatcavitycontent>20Vol.-%)
high deformation stability, i.e. no tracking grooves, consistently freely accessible pore space
favourable thermal properties, i.e. high driving safety in dark and wet conditions
top concrete layer can be constructed without joints
old, loud pavings can be built over (wearing course, superimposition of top layers)
Folie 40
Draining concrete composition

Concrete strength class: > C 25/30
Aggregates:
double crushed and screend chippings 5/8 mm 1450 1500 kg/m3
Cement:
CEM I 32,5 R
300 350 kg/m 3
Water:
only fresh water
50 55
kg/m 3
Plastic dispersion:
20% of cement weight (10% solids)
60 70
kg/m 3
Water-cement ratio:
0,24 0,26 (effective)
Consistency: (Compacting factor test)
v 1,30 1,34
Cavity content:
P > 20 Vol.-%
Compressive strength:
D > 25 N/mm2
Beam-tensile strength:
BZ > 4,5 N/mm2
Tensile splitting strength:
SZ > 2,7 N/mm2
Adhesive pull strength:
HZ > 3,0 N/mm2
Static modulus of elasticity:
E B 16000 18000 N/mm2
Folie 41
Laying of draining-concrete on test section A5
Folie 42
Noise measurement results

Comparison of the measuring results on draining concrete
and cement concrete with a jute cloth texture for
cars at 120 km/h and lorries at 80 km/h
Draining concrete
Cement concrete, jute cloth
88
80,3
80
83,7
84,7
4,3 dB(A)
82
83,8
3,9 dB(A)
84
3,5 dB(A)
86
79,8
87,9
83,1
88,3
82,5
7,0 dB(A)
89,5
5,8 dB(A)
Sound pressure level in dB(A)
90
4,8 dB(A)
92
82,5
80,4
78
76
74
Dec 94
FIGE
Jun 95
Cars at 120 km/h
Folie 43
Sep 96
Dec 94
Jun 95
Sep 96
Lorries at 80 km/h
Measurement noise spectrum

Average range for lorries at 80 km/h
85
-- Draining concrete
-- Cement concrete / Jute cloth
80
70
65
60
55
50
Difference in sound level -7,0 dB(A) for lorries at 80 km/h

between standard cement concrete with a jute cloth texture
and draining concrete of 5/8 mm [Measurement 9/96]
45
Folie 44
8000
6300
5000
4000
3150
2500
Frequency in third bandwidth [Hz]
2000
1600
1250
1000
800
630
500
400
315
250
200
160
125
100
FIGE
80
63
40
10000
Sound pressure level in dB(A)
75
Measurement absorption spectrum

Degrees of absorption for draining concrete 5/8 mm
A5 federal motorway -tyre track- measurement 9/96
90
Degree of absorption [%]
80
Average value of degree of

absorption: 36,8 %
80
73
78
70
64
60
47
50
40
30
28 27 26
23 24
37
33
30
20
17
20
10
Folie 45
8000
6300
5000
4000
3150
2500
2000
1600
1250
1000
800
630
500
315
250
400
Frequency in third bandwidth [Hz]
10000
FIGE
200
160
125
100
HeidelbergCement AG
Thank you very much!

Folie 46

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NATIONAL MEETING ON CONCRETE ROADS

18th December 2002, Ankara

CONCRETE ROAD CONSTRUCTIONS

- New Regulations in Germany (Requirements to be

ZTV Beton StB 01 (StB = Road Construction)

The new Edition 2001

- ZTV Fug-StB 01 (Supplementary Technical Conditions of

3 examples for construction class SV (heavy traffic load)

The advantages of thick concrete pavement with a thin upper layer of

- CEM I 32,5 R (DIN EN 197-1)

- DIN 4226-1 (German Industrial Standard)

- Limitation of swelling components

Minimum values of 28-day-oldconcrete

ZTV Beton Tab.1

0/2, 2/8, > 8

*for 8 mm maximum aggregate size

ZTV Beton Tab. 2

Minimum air void volume of fresh concrete

Concrete without plasticizer (BV)

Concrete with plasticizer (BV) and/or

Observing minimum strengths (table 1)

Until expiry of term

ZTV Beton Tab. 4

Longitudinal contraction joints, 3 or 5 tie bars per slab

Transverse contraction joint,

bituminous joint filler

Mixing plant / supply of cement

First continuously reinforced pavements in United

States Virginia (60 m long slabs of different reinforcements)

16.000 km of the Inter-States network are

further applications in Belgium, Spain, UK

from 1982 France 10 km of the A 6 motorway near Auxerre

3,5 Mio m of reinforced pavement

Reinforced pavements (France)

reinforcement layer in the

Concrete pavement Paver Compacted Concrete

Paver Compacted Concrete (PCC)

Paver Compacted Concrete (PCC)

Concrete pavement draining-concrete

draining-concrete = top layer

Pavement draining-concrete (special slipform paver)

Surface and structure of draining-concrete

Surface and structure of draining-concrete

Open porous concrete draining concrete

high level of road safety on dry and wet roads

Draining concrete composition

double crushed and screend chippings 5/8 mm 1450 1500 kg/m3

300 350 kg/m 3

only fresh water

20% of cement weight (10% solids)

0,24 0,26 (effective)

Consistency: (Compacting factor test)

BZ > 4,5 N/mm2

Tensile splitting strength:

SZ > 2,7 N/mm2

Adhesive pull strength:

HZ > 3,0 N/mm2

Static modulus of elasticity:

E B 16000 18000 N/mm2

Laying of draining-concrete on test section A5

Noise measurement results

Sound pressure level in dB(A)