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HVSIA meeting.16-18 July 2008 Gautrans HVS Programme

Gautrans HVS Programme

HVSIA 5th meeting16-18 July 2008

Gauteng Department of Public Transport, Roads and Works


Overall trends in South AfricaIntensified migration to urban areas coupled with sustained economic growth of between 5 and 6%: necessitates greater investment in infrastructure to support SA’s socio-economic developmentLarge capital projects in support of economy and FIFA 2010 Significant capital investment in infrastructure provision (>6% of GDP), particularly in roads, electricity, housing, rail and ports

… but, acute lack of skilled resources


Sectoral trends


Investment in InfrastructureESKOM: $20 billion capital pipelineTRANSNET (Ports): $11 billionGAUTRAIN: $3 billion for deployment of a rapid rail networkSoccer Stadiums for FIFA World Cup and annex infrastructure: $2 billionSANRAL: $4 billion for Gauteng Highway Improvement ProjectHousing (low cost): $4 billionACSA: $2.5 billionDWAF (Water): $2.7 billion (4 dams, water transfer schemes), financed on the capital market

Paved national and provincial roads, passenger vehicles,and commercial vehicles for transport of goods

0

100

200

300

400

500

1940 1950 1960 1970 1980 1990 2000

Inde

x (1

970

= 10

0)

Paved roads Passenger vehicles Goods vehicles


GFIP OBJECTIVE

“To provide a sustainable, safe and reliable strategic road network system in the Gauteng Province to optimize the movement of freight and passengers, focusing on the promotion

public transport, in order to grow the economy and enable development to the

benefit of all in the province.”


GFIP Project ExtentPLANNED LANE ADDITIONS: 180 km (2010) Phase 1

FUTURE UPGRADES:(223 KM)

PLANNED NEW ROUTES:158 km

FINAL SCHEME:561 KM


Project financingGFIP Financing & Implementation

• User pay principlewill be used tofinance project

• Open RoadTolling


GFIP Proposed Road Improvements – Phase 1

In general, freeways will be upgraded to 4 lanes per direction - some sections, up to 6 lanes per directionInterchanges will be improvedAuxiliary lanes at on- and off rampsCross road improvementsMedian lighting is provided


GFIP N1 Allandale Interchange


GFIP N1 Lynnwood Interchange


GFIP Phase 1 Project Programme

Award of construction contracts: May 2008

Construction for 2010 phase commences (2,5 year construction period): May 2008

Construction substantially completed: May 2010

Construction completion date: October 2010

Commencement of toll operations: October 2010


D1 D2 C F A1-A2 B E1 E2Brakfontein to

N1/R21 I/CAtterbury to Proefplaas

Buccleuch to Brakfontein

Geldenhuis to Buccleuch

14th Avenue to Uncle Charlies

14th Avenue to Buccleuch

Old Barn to Geldenhuis

Reading to Elands I/C

Section 2200 Concrete 670.00 m3 195.00 m3 1930.00 m3 180.00 m3 312.00 m3 750.00 m3 336.00 m3 825.00 m3 5198.00 m3Prefabricated Culverts Reinforcing 15.50 t 13.00 t 35.00 t 25.00 t 8.90 t 10.00 t 22.40 t 9.20 t 139.00 tSection 2300 Concrete 2620.00 m3 2510.00 m3 280.00 m3 4495.00 m3 5785.00 m3 11740.00 m3 1540.00 m3 2125.00 m3 31095.00 m3Open Drains Reinforcing 48.40 t 37.00 t 2.50 t 61.60 t 13.50 t 134.00 t 53.00 t 41.50 t 391.50 tSection 4100 Prime Prime 160000.00 l 180000.00 l 424400.00 l 24360.00 l 241840.00 l 147000.00 l 77000.00 l 60000.00 l 1314600.00 l

Tack Coat 30% Stable Grade Emulsion

310000.00 l 93600.00 l 1150000.00 l 562342.00 l 424225.00 l 156000.00 l 840000.00 l 140000.00 l 3676167.00 l

Semi Gap 19mm max AR1 6640.00 t 6640.00 tBase 40/50 pen bit. With 26.5mm 159450.00 t 11986.00 t 17320.50 t 64045.00 t 35200.00 t 4221.67 t 292223.17 tContinuously Graded 30950.00 t 12130.00 t 26488.00 t 9239.00 t 1180.00 t 44000.00 t 89000.00 t 2875.00 t 215862.00 tSemi open grade bitumen rubber 12510.00 t 79000.00 t 16700.00 t 108210.00 tConcrete 20391.00 m3 9724.00 m3 32212.00 m3 12672.00 m3 5856.00 m3 26508.50 m3 15962.30 m3 16329.00 m3 139654.80 m3Reinforcing 2876.50 t 1359.00 t 3874.00 t 1579.10 t 1568.10 t 4514.20 t 1792.35 t 2814.60 t 20377.85 t

Section 7100 Concrete 5750.00 m3 3075.00 m3 29036.00 m3 16978.00 m3 7623.00 m3 30362.00 m3 1138.00 m3 93962.00 m3Concrete Pavement Reinforcing 400.00 t 270.00 t 1504.00 t 50055.00 t 22.10 t 550.00 t 254.00 t 53055.10 tBRASO 20831.00 t 116920.00 t 36020.00 t 173771.00 tUTFC 50000.00 m2 50000.00 m2

Structures

Section 4200 Asphalt

GAUTENG TOLL HIGHWAY PROJECTS Total

Total Concrete 269909.80 m3Total Reinforcing 73963.45 tTotal Prime 1314600.00 lTotal Tack Coat 3676167.00 lTotal Asphalt 796706.17 tTotal UTFC 50000.00 m2

Phase 1: Estimated Key Quantities


Will SA be ready for FIFA 2010?

2010 Soccer Stadium … on track


Gautrans HVS Programme

Latest developments

E Sadzik resigned from Department in June-08Official reps of Dept: I Joubert & D Lourens

Contract has been renewed for period of 10 years (2008-2018)Value of contract: approx $14 million


Gautrans HVS ProgrammeStrategic Plan 2006 - 2009

Focus Areas:Sustainable Development and the EnvironmentLabour-Intensive ConstructionAsphalt PerformanceProvision of Low Volume Roads (including upgrading of unpaved roads)Vehicle Pavement Interaction (including dynamic loads and contact stresses)Concrete pavementsStructural Pavement Design methods


Gautrans HVS ProgrammeCurrent HVS programme projects:

Ultra-Thin highly-reinforced CRCP (sponsors: SANRAL & GDPTRW) –Concrete PavementsUltra-thin lightly-reinforced CRCP (sponsor: GDPTRW) – Concrete Pavements

Guidelines for bitumen stabilization with ETB & FB (sponsors: SABITA & GDPTRW) – Sustainable Development and the EnvironmentValidation of HMA design protocols for permanent deformation (Sponsor: GDPTRW & Sabita) – Asphalt PerformanceGuidelines for design and construction of LIC (Including documentation and training issues) – Labour Intensive ConstructionTechnology transfer and implementation of High-Modulus Asphalt (Sponsor: Sabita & GDPTRW) – Structural Design


Gautrans HVS programmeProject status:Guidelines for bitumen stabilization with ETB & FB

Inception report (Phase 1) finalized in January 2006Phase 2 structural and mix design virtually completedPhase 3, drafting of best practice guideline document for foamed-bitumen and bitumen-emulsion treated materials, will be completed by Aug-2008


Hot Bitumen

TG(X)


Knowledge Based Approach

Gather all available field performance dataDistil best elements of mechanistic analysisValidate and refine for robustnessDevelop clear, strong linkage to field testing and specifications

Data Sets:• More than 20 field sites with construction,

maintenance & performance info

• 7 HVS Sites (22 test sections) with construction & performance


The Design Process

LAB

DCPVisuals

Test Pits

FWD

Design InputsCapacity

Assessment

CBR 7-15%

200 mm BSM 1

130 mm C4

> 200 mm G6

Specifications

Mix Design

Materials Classification


Materials Classification Report- Example

Test or Indicator Samples G4 G5 G6 G7

Test Limits for Material Class

G4 G5 G6 G7

Cumulative Certainty for Material Class

DCP Penetration 12 0.13 0.29 0.06 0.00

FWD Stiffness 67 0.26 0.32 0.11 0.00

Grading Analysis 3 0.37 0.34 0.11 0.00

% Passing 0.075 3 0.43 0.37 0.11 0.00

Plasticity Index 5 0.46 0.47 0.11 0.00

California Bearing Ratio 2 0.49 0.54 0.16 0.03

Relative Moisture Content 4 0.52 0.57 0.19 0.00

Outcome: Material is most likely a G5 design equivalent

Confidence: Confidence of the assessment is medium. For structural rehabilitation, it is recommended that the sample size and number of test indicators be increased.


Suitability of PN-Based Method

Method not applicable to:• Design traffic > 30 msa• Design traffic < 1 msa (catalogue required)• Presence of thin, weak lenses• Subgrade CBR < 3 %


Pavement Performance Information System (PPIS)

• Typical Performance Trends• Asphalt Base


www.ppis.roadrehab.com

• Representation of 50 Captured Sections


Summary: Structural Design

Simplified method for determining structural capacityRobust, Easy to understandWell and explicitly validated with TRH4, LTPP and HVS datasetsValid for design traffic up to 20 mesa (majority of SA roads)Should not use independently for traffic > 30 mesaRequires Material Class as design inputs


Gautrans HVS programmeProject status:Validation of design protocols for HMA rutting

Laboratory studies completed on control mixAPT studies completed on control mix:

• Effects of temperature• Effects of layer thickness• Effects of contract stresses• Effects of channelised versus wandering

APT/lab studies in progress on first “rut-resistant mix”APT/lab studies on second “rut-resistant mix” to be initiated


Main objectives of HMA rutting study

Compare permanent deformation results from APT with a range of laboratory tests with the aim to:• Identify appropriate tests for permanent

deformation prediction• Develop protocols & acceptance criteria for

selected testsAssess to what extent aggregate grading can be improved to prevent premature rutting, particularly at intersections


Road R80

7-day average maximum temperature: 58 ºC Minimum surface temperature: -0.6 ºCTest conducted over 40ºC to 60ºC (70ºC) temperature range


APT site


Basic properties of control mix: Marshall

Binder type: 60/70 pen grade (PG 64)Optimum binder content: 5%

Property Test Results Specifications% voids in mix 4.3% 3 to 6%% VMA 15% > 14%% VFB 72% 65 to 75%Filler-bitumen ratio 1.1 1.0 to 1.5Film thickness 8.2 μm > 7 μm

Dynamic creep modulus ~ 16.4 MPa 15-20 MPa

Marshall Stability ~11 kN 10 to 18 kNMarshall Flow ~3.0 mm 2 to 6 mmITS ~1 187 kPa > 800 kPaStatic creep ~242 MPa > 100 MPaGyratory voids (300N) ~2.4% >2.0%

HVS Tests on control mixTest

Number

Loading Conditions(Dual tyres)

Channelised/ wandering

Required Temperatur

e[°C]

Speed[km/h]

Single /

dual tyres

Uni- / bi-directional

Layer thickness

[mm]

Total Repetitions

441A4 1 x std case (40 kN, 620 kPa) Channelised 60°C Constant

10 km/hr Dual Uni 40 97 500

442A4 1 x std case (40 kN, 620 kPa) Channelised 40, 50, 60°C Constant

10 km/hr Dual Uni 40 368 370


10 km/hr Dual Uni 40 247 441


10 km/hr Dual Uni 25 289 886


10 km/hr Dual Uni 60 472 036

445A4A 1 x std case (40 kN, 620 kPa) Channelised 60°C Constant

10 km/hr Dual Uni 60 163 291

446A4 1 x n-shape (60 kN, 800 kPa) Channelised 60°C Constant

10 km/hr Dual Bi 40 80 300

447A4 1 x n-shape (60 kN, 800 kPa) Channelised 60°C Constant

10 km/hr Dual Uni 40 75 337

448A4 1 x m-shape (60 kN, 420 kPa) Channelised 60°C Constant

10 km/hr Dual Bi 40 212 171

449A4 1 x n-shape (60 kN, 800 kPa) Wandering 60°C Constant

10 km/hr Dual Bi 40 306 888

450A4 1 x m-shape (60 kN, 420 kPa) Wandering 60°C Constant

10 km/hr Dual Uni 40 303 000


Effect of temperatureHamburg Rut Test (Field mix with different Temperatures) @ 40mm

0

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30

0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000

Wheel Passes

Rut

dep

th (m

m) A7c40-5 @40deg

A7c40-6 @40degA7c40-3 @50degA7c40-4 @50degA7c40-1 @60degA7c40-2 @60degA7c40-7 @55degA7c40-8 @55degA7c40-9 @45degA7c40-10 @45deg


Creep slope vs. temperatureRelation between temperature and rut rate for standard mix under Hamburg test

y = 2E-05e0.1152x

R2 = 0.9254

0

0.005

0.01

0.015

0.02

0.025

35 40 45 50 55 60 65

Temperature ºC

Stea

dy s

tate

rut r

ate

mm

/pas

s

Hamburg results (40mm field cores)


Permanent deformation under HVS (60ºC)


APT: effect of temperaturePermanent deformation HVS tests 441A (60ºC) and 442A (40ºC)

0

2

4

6

8

10

12

0 20 000 40 000 60 000 80 000 100 000 120 000 140 000 160 000 180 000 200 000

Wheel Passes

Perm

anen

t def

orm

atio

n [m

m]

Avg CS 60ºC

Avg TS 55ºC

Avg CS 40ºC

Avg TS 40ºC


Density of test sections

2.300

2.350

2.400

2.450

2.500

2.550

2.600

0 10 20 30 40 50 60 70

Design thickness [mm]

BR

D

Density vs thickness Average4.3 % voids 7% voids


Uni- versus bi-directional traffic

0.000

1.000

2.000

3.000

4.000

5.000

6.000

7.000

0 10000 20000 30000 40000 50000 60000 70000 80000 90000

Load repetitions

Perm

anen

t Def

orm

atio

n [m

m]

446A4 Avg CS (3-13) 446A4 Avg TS (3-13) 447A4 Avg CS (3-13) 447A4 Avg TS (3-13)

Bi-directional traffic

Uni-directional traffic

-10

-8

-6

-4

-2

0

2

4

6

8

10

900 1000 1100 1200 1300 1400 1500 1600 1700 1800

Cross Sectional Distance (mm)

Perm

anen

t Def

orm

atio

n (m

m)

446A4 447A4

Caravan side Traffic side


Standard versus n- and M-shape contact stresses

INFLATION PRESSURE = 420 kPa

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 200

200

400

600

800

1000

1200

1400

1600

PIN NUMBER ACROSS VRSPTA

Tyre width: 220 mm

20kN 30kN 40kN 50kNWHEEL LOAD:

CO

NTA

CT

STR

ESS

(kPa

)

INFLATION PRESSURE = 420 kPa

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 200

200

400

600

800

1000

1200

1400

1600


Tyre width: 220 mm

20kN 30kN 40kN 50kNWHEEL LOAD:

CO

NTA

CT

STR

ESS

(kPa

)

1000

1200

1400

1600

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 200

200

400

600

800

720 kPa620 kPa520 kPa420 kPa

Tyre width: 220 mm


INFLATION PRESSURE::

Tyre Load = 18 kN

1000

1200

1400

1600

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 200

200

400

600

800

720 kPa620 kPa520 kPa420 kPa 720 kPa620 kPa520 kPa420 kPa

Tyre width: 220 mm


INFLATION PRESSURE::

Tyre Load = 18 kN


Standard versus n- and M-shape contact stresses

0

1

2

3

4

5

6

7

8

9

0 50000 100000 150000 200000 250000

Load repetitions

Perm

anem

t def

orm

atio

n [m

m]

446A4 Avg CS 446A4 Avg TS 447A4 Avg CS 447A4 Avg TS 448A4 Avg CS 448A4 Avg TS445A4A Avg CS 445A4A Avg TS

Standard load uni

M-shape load bi

N-shape load bi

N-shape load uni

-8

-6

-4

-2

0

2

4

6

8

900 1000 1100 1200 1300 1400 1500 1600 1700 1800

Cross Sectional Distance (mm)

Perm

anen

t Def

orm

atio

n (m

m)

446A4 447A4 448A4 445A4A

Standard load

n-shape load

m-shape load


Assessment of “rut-resistant mixes”

Bailey method:

Fine-graded mixes: <90% of loose unit weightCoarse-graded mixes: 95-105% of loose unit weightStone-mastic asphalt: >100% of rodded unit weight


Aggregate packing

Mix Bailey CA CUW DASR porosity

Reference 74 % (fine) 52 % (fine)

East Rand 99 % (coarse) 48.3 % (coarse)

West Rand 105 % (coarse) 46.9 % (coarse)

CA CUW: Coarse Aggregate Chosen Unit WeightDASR: Dominant Aggregate Size Range


Gradings

0

10

20

30

40

50

60

70

80

90

100

0

Sieve size (raised to power 0.45)

perc

enta

ge p

assi

ng

Reference mix Rut challenge E-Rand Rut challenge W-Rand

PCS

(2.3

6 m

m).

SCS

(0.6

0 m

m).

TCS

(0.1

5 m

m).

Hal

f sie

ve (4

.75

mm

). 0.075 0.300 1.18 2.36 4.75 6.7 9.5 13.2 0.015 0.600


Comparison (channelised)60C vs 70C Rut resistant summary

0.0

0.5

1.0

1.5

2.0

2.5

0 10000 20000 30000 40000 50000 60000 70000 80000 90000 100000

Repetitions

Ave

rage

tota

l sur

face

rut [

mm

]

451A4 TOTAL AVG CS 451A4 AVG TS 452A4 TOTAL AVG CS 452A4 AVG TS


Comparison (channelised)Comparison between STD and RR1 HMA mixes - Temperature

0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

16.0

18.0

0 20000 40000 60000 80000 100000 120000

Repetitions

Tota

l sur

face

rut [

mm

]

441A4 TOTAL CS 441A4 TOTAL TS 451A4 TOTAL CS 451A4 TOTAL TS 452A4 TOTAL CS 452A4 TOTAL TS

60C and 70C

58.5C

60.9C


Comparison (wandering)Comparison between STD and RR1 HMA mixes - WANDER

0.0

5.0

10.0

15.0

20.0

25.0

0 50000 100000 150000 200000 250000 300000 350000

Repetitions (wandering, bi-directional)

Perm

anen

t sur

face

def

orm

atio

n (to

tal)

[mm

]

449A4 TOTAL 453A4 TOTAL


Gautrans HVS programmeProject status:High-Modulus Asphalt (HiMA)

• Technology transfer & implementation of HiMA in South Africa

• Four phases of which Phase 1 is essentially completed

0

20

40

60

80

100

120

140

1970 1980 1990 2000

Gra

de [1

/10

mm

]M

odul

us [1

00 M

Pa]

0

1

2

3

4

5

6

Bin

der c

onte

nt [p

pc]

GradeModulusBinder content


Mechanical characteristics of HiMA


Phase 1: Preliminary assessment of viability

Overseas study tour to Colas, Total, Shell and TRL(June 2008)

Preliminary viability assessment(July 2008)

SAT Seminars(August/September 2008)


Phase 2:Preliminary guidelines on design

Task 1: Finalisation of mix design & benchmarking (Aug-Dec 2008)

• Finalise French mix design• Evaluate performance attributes based on French testing

protocols• Parallel testing in South Africa using SA testing protocols• Compare/correlate results• Draft provisional guidelines on mix design

Task 2: Structural design and cost comparisons(Jul-Oct 2008)

• Evaluation of a series of pavement structures (new construction & rehabilitation), with and without HiMA

• Use results to compare initial and life-cycle costs• Draft provisional guidelines on structural design


Phase 2:Preliminary guidelines on design

Task 3: Experimental Plan for Phase 3(Nov-Dec 2008)

• Drafting of plan for construction of demonstration sections in Gauteng and KwaZulu-Natal

• Drafting of plan for APT programme


Phase 3:Demo sections & validation through APT

Objectives:• Hone in on manufacturing & construction and capture

best practice• Compare response & performance of HiMA vis-à-vis

conventional pavements• Establish base line data for LTPP

Expected duration:• January to September 2009


Phase 4:Guidelines, specifications & T’T

Objectives:• Develop Sabita/AsAc guidelines on the Design

and Use of High-Modulus Asphalt Mixes”• Develop South African specifications• Provide feedback at RPFs• Publish papers at SATC• Articles in Digest & trade press• Integrate HiMA in Asphalt Academy courses• Asphalt Academy national seminars

Expected duration:• October 2009 to March 2010


Gautrans HVS ProgrammeHVS future projects:

HMA performance• Testing of rut resistant mixes including Hi-Modulus

Asphalt (HiMA)• Fatigue and durability evaluation of HMA• Updating of design guidelines

South African Pavement Design Method• Model development• Validation & calibration


SA Pavement Design MethodPhase 1 – Develop Detailed Project Briefs – Nov-2006 Phase 2a - Inception Phase (22 Projects) – Jul-2007

Investigate available solutionsFinalize project methodologyFinalize cost and resource allocation

Inception Report Peer Review – Nov-2007Phase 2b – Completion of Inception Phase:

Finalise the end product framework and inter-dependencies;Adjustments to the current project plan based on:

Inclusion of functional performance simulation (roughness, texture, friction, etc) – Close gap between PMS and DesignInclusion economic analysis of design alternatives and maintenance strategies

Phase 3: Project Delivery (July 2008 ?)


Technology transferMarketing brochureSATC papers – July 2008Other conference papersSAT SeminarsRPF feedbackCoursesReports / Executive Summaries Website


Gautrans HVS reports available onwww. gautrans-hvs.co.za

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