Batching Effects on Properties of

Recycled Aggregate Concretes for

Airfield Rigid Pavements

Dr. Andres Salas

Prof. David Lange
Prof. Jeff Roesler

2010 FAA Technology Transfer Conference and Exposition

April 22, 2010
 OHare Modernization Program
(OMP)

The purpose is to reconfigure the intersecting runways at

OHare International Airport into a more modern parallel
layout.

Prior to this OHare had not added a new runway since

1971.

Project budget of $6.6 billion.

OHare Modernization Program
(OMP)
 Why Recycle?

Sustainable practices are desirable

Reuse and conserve natural resources
Cost savings over traditional methods
Use of RA in concrete and asphalt
showed comparable performance over
virgin aggregates.
 Challenges for using Recycled
Concrete Aggregates

Resistance to change
Lack of experience
Inadequate codes, specifications
and standards
Inconsistent aggregate grading
Lower and variable quality
 Recycled Concrete Aggregates at
Airports

Commonly used for base and subbase

Not used on airport concrete surface before in
U.S.?
Technical issues for surface applications
Durability, shrinkage, premature cracking
 A new idea about mixing with RCA
Two-Stage Mixing Approach, TSMA (Tam et al. 2005):

Mixing process divided into two parts with required

water proportionally split and added at different timing.
Initial water used for the formation of thin layer of
cement slurry on the surface of RA.
Permeate into old porous cement mortar, filling up
the old cracks and voids.
Do the aggregates have to be dry, partially-saturated, or
saturated+surface moisture?
 Mixture Procedure
(Two-Stage Mixing Approach)

mix mix mix

Recycled coarse + cementing material 1 min 50% water 1 min Virgin coarse + sand+ 50%water 2 min

* Control concrete (VAC)

was mixed following the
commonly used mixing
procedure
 OHare Aggregate Physical
Properties

Absorption
Aggregate BSG
Capacity

Sand 2.57 2.43%

CA-16 2.68 2.73%
CA-7 2.67 1.90%
Recycled Agg. 2.41 5.51%
 Mixture Design

w/cm = 0.42
The recycled aggregates sprayed to approximately fill 80% of the total absorption capacity.
 Fresh Properties

AIR UNIT UNIT

SLUMP
MIX CONTENT WEIGHT WEIGHT
(in)
(%) (lb/ft3) (kg/m3)
VAC 5 3.2 146.4 2345
70-30 BLEND 6.5 3.2 147.2 2358
50-50 BLEND 4.5 3.2 145.8 2335
50-50 BLEND + SF 2.5 2.5 146.2 2342
100% RA 7 3.4 149.2 2390
100% RA+ SF 3 2.5 142.8 2287
100% RA +
FIBERS 2.2 2.5 145 2323

Slump for 100% RA was higher than expected. Nearly saturated aggregates
reduces effects of RA absorption
 Drying Shrinkage Results

Lower microstrain for 100% RA at 14 days age

RA soaked for 24 hrs while virgin aggregate in oven dry condition
 Summary Properties of RAC
(Two Stage Mixing Approach)

Similar or higher compressive strength

compared to VAC
Similar shrinkage to VAC at early ages
Reduced bleeding and segregation
Similar concrete workability
Low dosages of silica fume (2 to 3%) enhances
the behavior of RAC
 Issues to Consider for RAC

Minimize old mortar attached to aggregate

Aggregate grain size distribution and proportions
Aggregate Absorption Capacity
RA should be nearly-saturated conditions to
avoid loss in slump and excessive shrinkage.
Two-Stage Mixing Approach (TSMA) and pre-
soaking treatment method for the production of
RAC are encouraged
Field Testing
 Pouring Gate F7B at OHare

Run #2 of VAC Run #1 of RAC

2 strips of 25ft x 125ft x 17in were placed

Prairie supplied the materials
Rossi Construction was the contractor
SAM Consultants handled material testing
 Sensor Installation
28 Sensors to measure RH and
Temperature
7 LVDT sensors to measure lift-off of
the slab
 Placement and Finishing
After placement of the RAC
No bleeding was observed
Finishing took place almost
immediately after placement
Very little effort required to finish
 Field Visits 10/29

VA RAC (Run
C #1)
 Field Visit 11/12

VAC (Run
#2) VA RAC (Run
C #1)

VA
C
 Field Visit 3/18

VAC

Contraction joints remain unchanged

Some scaling observed in the test strips

RAC
 Compare Lab to Field
Compressive Strength Design 4000psi
30% Class C 40% Class C 50% Class C
Prairie (RAC) Prairie (VAC) U of I (20%FA)
FA FA FA
Water (gal) 28 ~26 ~26 ~26 ~26
Cement (lbs) 490 414 362 310 259
Fly Ash (lbs) 130 103 155 207 259
Air (%) 4.5-7.5 3% 3% 3% 3%
Variable
% WRA No No No No
dosage
Initial Slump (in) 31 4 7.5 8 8
Recycled Coarse (lbs) 1500 1688 1683 1677 1672
Extra Fines (lbs) 400 274 273 272 271
Natural Sand (lbs) 1093 1011 1007 1004 1000
Compressive strength at 3 days
3547 3581 - - - -
(psi)
Compressive strength at 7 days
5190 4855 4700 3978 3830
(psi)
Compressive strength at 28 days
6900/5858 5182 5751 5507 5435 5005
(psi)
Flexural strength at 3 days (psi) 704.5 - - - -
Flexural strength at 7 days (psi) 760 - - - -
Flexural strength at 28 days (psi) 915/1052 826 - - - -
w/cementitious ~0.375 0.42 0.42 0.42 0.42
* Blod and blue represents testing results from SAM Consultants

Mix designs and early age results for the Recycled Aggregate Concrete Mixes. Comparison
between U of I mix designs and Prairie Mix Design

24
 Summary
Lab test program helps us predict behavior of RAC using
recycled material sources at OHare
Lab test program encourages us to use high(er) volume
of fly ash
Lab test encourages lower cement than used in the field
RAC
Testing underscores importance of keeping RA supply
near saturation to control shrinkage
Field testing confirms that RAC slabs were well-
constructed and not experiencing high deformations
So far, so good!
Acknowledgements