tools to improve pcc smoothness during construction (r06e) · 2015. 3. 1. · real-time smoothness...
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Tools to Improve PCC Smoothness During
Construction (R06E)
Date: March 10, 2016
Gary Fick
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Real-Time Smoothness
What is it?
An integrated system
of profile data
collection sensors and
processing software
that provides real-time
profile feedback to the
contractor.
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Real-Time SmoothnessSHRP2 Implementation Support
RTS Implementation Support Activities
Objective: Routine use of RTS technology by agencies and
contractors who routinely construct PCC pavement.
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Real-Time SmoothnessSHRP2 Implementation Support
RTS Implementation Support Activities
Task 1: Equipment Loan Program (2015 and 2016)
Full use of an RTS system for two weeks
On-site technical support and training
Budget allows for eleven equipment loans
Projects with a minimum of 10 consecutive mainline paving days
(more is preferable)
Contractor or agency should commit to providing daily QA
profiles during the equipment loan
Contact [email protected] if interested
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Real-Time SmoothnessSHRP2 Implementation Support
RTS Implementation Support Activities
Task 2: Regional Showcase (Open House)
One day classroom presentations with an on-site RTS
demonstration
In conjunction with an equipment loan project
Travel expenses are covered for up to 10 agency participants
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Real-Time SmoothnessSHRP2 Implementation Support
RTS Implementation Support Activities
Task 3: Workshops
Four hour workshops – contact [email protected]
Tentative agenda
1. Importance of Pavement Smoothness
2. Fundamentals of Pavement Smoothness Measurement
3. RTS Measurement Technology and Practices
4. Fundamentals of Ride Quality and Pavement Profile
Analysis
5. Current Practices for Concrete Pavement IRI Specifications
6. Best Practices for Concrete Paving Operations
7. Using RTS Technology to Improve Concrete Pavement
Smoothness
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Real-Time SmoothnessSHRP2 Implementation Support
RTS Implementation Support Activities
Task 4: Documentation of Results/Case Studies
Synthesis of contractors’ experience
Case study – Comparing real-time measurements to QA results
Case study – Long-term performance of RTS
Documentation of equipment loans and lessons learned
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Real-Time SmoothnessSHRP2 Implementation Support
RTS Implementation Support Activities
Task 5: Specification Refinement
QC approach
Process improvement
Task 6: Outreach Materials
Quick field reference guide (pocket reference)
Brochures
Project updates (30 minute briefings)
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Reasons for Using RTS Equipment
• Reduce disincentives
• Increase incentives
• Anticipated change in smoothness acceptance
requirements• PI to IRI
• Change in localized roughness specification limits
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Real-Time Smoothness
Benefits of identifying construction artifacts in real-time
Opportunity to correct objectionable profile features caused by:
Stringline disturbance
Padline variability
Non-uniformity of concrete
…
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Real-Time Smoothness
Benefits of identifying the impact of process changes in real-
time
Validation of adjustments in 1 hour vs. 12 to 24 hours:
Hydraulic sensitivity relative to machine control input (stringline
and stringless)
Vibrator frequencies
Paving speed
Concrete head
Concrete mixture proportions
…
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RTS Systems – Which One is Best?
• They both do the same thing - the correct question is,
“which one is best for me?”
• Factors to consider:
Ease of mounting and switching between multiple pavers
Field ruggedness
Familiarity with Ames lightweight
profiler systems
Laser vs. ultrasonic sensors
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RTS Mounting Locations
• Typically center of each driving lane
• Adjust this for special situations, when tuning the paver:
Tie bar insertion issues
One side of the paver is consistently rougher
Cross-slope changes
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RTS Mounting Locations
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RTS Systems:
Daily Setup and Shutdown
• Start-up - approximately 5 minutes
Install sensors and DMI
Connect cables
Input starting station and direction
Start the system
• Shut-down – approximately 5 minutes
Stop the system
Download data to a USB drive
Disconnect cables
Remove sensors and DMI
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RTS Systems:
Daily Setup and Shutdown
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Ten Commandments of Concrete
Pavement Smoothness (circa 1988)
Source: ACPA Best Practices for Constructing Smooth Concrete Pavements
Credit: Chapin Cipherd, CMI Corp.
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21st Century Approach
The “Sweet Spot”
Mixture Factors
Paving Factors
Human Factors
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Mixture Factors
• Combined gradation
• Between batch uniformity
• Uniform delivery of concrete
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Combined Gradation
Remember the purpose of an optimized gradation:
• Economically combining aggregate particles to achieve the desired
objectives of:
Reduced paste content
Improved workability
Durability
• An optimized mixture must be workable in the field to achieve
durability
• The Tarantula curve was developed concurrently with a lab test that
evaluates a concrete mixture’s response to vibration
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Between Batch Uniformity
Consistent combined gradation and water content
• Scales in tolerance
• Uniform stockpile moistures
• Eliminate stockpile segregation
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Uniform Delivery of Concrete
Translates to minimizing paver stops
• Plant production capacity must be able to feed the paver
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Paving Factors
• Track line
• Stringline/Stringless model
• Paver setup
Draft/Lead
Sensitivities
Vibrator frequency
Vibrator height
Float pan
• Concrete head
• Curing and texturing
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Human Factors
• Training
• Experience
• Communication
• Empowerment
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Using RTS Systems
• Step 1 – Establish a baseline
• Monitor results for 1 to 2 days
• Keep processes static, but make ordinary adjustments
Observe typical responses to the ordinary adjustments
• Mixture
• Vibrators
• Speed
• Head
• Stops
• Etc.
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Using RTS Systems
• The RTS results are higher than the QC hardened profiles –
what’s up with that?
• Don’t panic
• Just focus on making the RTS results better (lower IRI)
• QC profiles will improve as well
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Using RTS Systems
• Step 2 – Pick the low hanging fruit
• Eliminate large events that cause excessive localized
roughness
• Stringline/stringless interference
• Paver stops
• Padline issues
• Etc.
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Localized Roughness Events
• Stringless system interference
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Localized Roughness Events
• Running the paver out of concrete
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Localized Roughness Events
• Stopping the paver
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Using RTS Systems
• Step 3 – Adjust the paving process to improve overall
smoothness
• Maintain a consistent head
• Lead/draft - setup the paver as flat as possible
• Sensitivities
• Vibrators (height and frequency)
• Mixture
• Paver operation
• Paving speed
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Overall Smoothness
• Eliminating big events gave us a new “baseline” to adjust
from
• Systematically make changes in small increments
• Get a minimum of 0.1 mile with consistent paving (no big
events) and then evaluate if the adjustment made things
smoother
• Continue adjusting in small increments and evaluating every
0.1 mile
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Overall Smoothness
• Stay focused and incredible things can happen
• Over a mile per day – average IRI = 28 in/mi
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Using RTS Systems
• Step 4 – Identify repeating features using a PSD plot and
adjust processes when possible
• Joints
• CRCP bar supports
• Dumping/Spreading loads
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Real-Time SmoothnessSHRP2 Implementation Support
Questions and Discussion