FLEXIBLE PAVEMENT DESIGN WORKSHOP Ljubljana, 2012

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1 FLEXIBLE PAVEMENT DESIGN WORKSHOP Ljubljana, 2012 Current Practice in Flexible Pavement Design - GERMANY Dipl.-Ing. Jan Jähnig 2 1

2 T E A M Prof. Dr.-Ing. habil. Frohmut Wellner Professur für Straßenbau Dipl.-Ing. Jan Jähnig Dipl.-Ing. Alexander Kiehne 3 INDEX PAVEMENT DESIGN TRAFFIC LOAD CALCULATION MATERIAL CHARACTERISTICS NEW CONSTRUCTIONS MATERIAL CHARACTERISTICS RECONSTRUCTIONS REQUIRED LAYER THICKNESS ADVANTAGES/DISADVANTAGES OF USED METHOD PROBLEMS WITH/POSSIBLE IMPROVEMENT OF CURRENT PAVEMENT DESIGN METHOD 2

3 INTRODUCTION Highway Network (2012): 12.5 km 23% of whole road network % of road performance ~ 70% Asphalt ~ 30% Concrete 5 PAVEMENT DESIGN METHOD Pavement Design empirical method analytic method Standardization - layer thickness based on experience - innovative materials are ignored Flexible Procedure - calculation of required layer thickness - based on performance tests - innovative materials can be considered 6 3

4 EMPIRIC PAVEMENT DESIGN METHOD German Design Guide RStO 01 Number of loads (ESAL) Tafel 1: Bauweisen mit Asphaltdecke für Fahrbahnen auf F2- und F3-Untergrund/Unterbau (Bauweisen auf F1-Böden s. Abschnitt 3.1.2) (Dickenangaben in cm; u E v2 -Mindestwerte in MN/m²) Zeile Bauklasse SV I II III IV V VI Äquivalente -t-achsübergänge B > 32 > - 32 > 3 - > 0, - 3 > 0,3-0, > 0,1-0,3 0,1 in Mio. Dicke des frostsich. Oberbaues 1) Asphalttragschicht auf Frostschutzschicht Asphaltdeckschicht 6) Asphaltbinderschicht Asphalttragschicht u 120 u 120 u 120 u 120 u 120 u 0 u Frostschutzschicht u 5 u 5 u 5 u 5 u 5 u 5 u 5 Dicke der Frostschutzschicht ) ) ) ) ) ) Asphalttragschicht und Tragschicht mit hydraulischem Bindemittel auf Frostschutzschicht bzw. Schicht aus frostunempfindlichem Material construction Asphaltdeckschicht Asphaltbinderschicht Asphalttragschicht Hydraulisch gebundene u 120 u 120 u 120 u Tragschicht (HGT) Frostschutzschicht u 5 u 5 u 5 u 5 Dicke der Frostschutzschicht ) - 2 3) 3-302) ) Asphaltdeckschicht Asphaltbinderschicht 1 1 Asphalttragschicht 2.2 Verfestigung 33 Schicht aus 1 37 frostunempfindlichem Material weit- oder intermittierend gestuft u 5 5 u 5 u 5 u 5 gemäß DIN 1196 Dicke der Schicht aus ) 20 ) ) ) ) frostunempfindlichem Material Asphaltdeckschicht Asphaltbinderschicht 1 Asphalttragschicht Verfestigung Schicht aus 3 frostunempfindlichem Material u u 5 2 u 5 u 5 enggestuft gemäß DIN 1196 Dicke der Schicht aus 5 ) ) ) 19) ) ) frostunempfindlichem Material 17) Asphalttragschicht und Schottertragschicht auf Frostschutzschicht u 120 u 0 u u 5 u 5 u ) ) ) u 5 u 5 u 5 16 ) ) 16) ) 16) u 5 u 5 u 5 16 ) ) 16) ) 16) TRAFFIC LOAD CALCULATION Calculation of traffic loads Calculation of ESAL... B-Number - cumulated passages of 0kN standard axle loads in design period - N years - Several factors (number of lanes, lane width,...) B ( SV ) = N DTA q Bm f1 f 2 f 3 f z 365 Traffic growth estimation - DTV SV... number of daily load applications (> 3,5 to) - growth factor [ - highways p = 3% - state roads p = 2% - country roads p = 1%

5 ANALYTIC PAVEMENT DESIGN METHOD BMBF Projekt Nachhaltiger Straßenbau S 26-1 B 35 S 26-2 B 273 BAB A BAB A5 B 26 9 ANALYTIC PAVEMENT DESIGN METHOD loads temperature materials Pavment modell (stresses, strains) assessment Σ MINER fatigue rutting cement stabilized layers unbound base layers sub-grade 5

6 ANALYTIC PAVEMENT DESIGN METHOD Top Layer Binder Course Base Course ugl linear elastic multi-layer-theory 11 ANALYTIC PAVEMENT DESIGN METHOD Compressive stress σ 1 - Top Layer Binder Course Base Course ugl 12 6

7 ANALYTIC PAVEMENT DESIGN METHOD Tensile stresses σ 2/3 - Top Layer Binder Course Base Course + ugl Fatigue Testing 13 TRAFFIC LOAD CALCULATION 0,20 0,1 0,16 0,1 0,12 Anteil [-] 0, 0,0 0,06 0,0 0,02 0,00 load spectrum different classes (weighing) > 0 bis < 1 >= 1 bis < 2 >= 2 bis < 3 >= 3 bis < >= bis < 5 >= 5 bis < 6 >= 6 bis < 7 >= 7 bis < >= bis < 9 >= 9 bis < >= bis < 11 >= 11 bis < 12 Achslastklasse >= 12 bis < 13 >= 13 bis < 1 >= 1 bis < >= bis < 16 >= 16 bis < 17 >= 17 bis < 1 >=1 [RDO Asphalt 09] Special loads 1 7

8 CLIMATIC CONDITIONS Zone 3 relative Häufigkeit [%] 20,0% 1,0% 16,0% 1,0% 12,0%,0%,0% 6,0%,0% 2,0% 0,0% 17,6% 17,% 1,7% 13,% 12,%,1% 5,1% 3,% 2,3% 2,% 0,6% 0,3% 0,3% [RDO Asphalt 09] Oberflächentemperatur [ C] [RDO Asphalt 09] MATERIAL CHARACTERISTICS Performance based material-properties Stiffness (elastic Modulus) Fatigue Testing Layer adhesion high temperture performance (rutting) low temperture performance (low temperature cracking) 16

9 MATERIAL CHARACTERISTICS ITS Test German Instruction AL Sp-Asphalt 09 (modelled after EN / 26) Frequencies 0,1 Hz Temperatures C 17 MATERIAL CHARACTERISTICS Stiffness Elastic Modulus σ ε ITS - Test 1 9

10 MATERIAL CHARACTERISTICS Stiffness absoluter E-Modul [MPa] C 0 C C 20 C 0 0,01 0,1 1 f [Hz] abs. E-Modul [N/mm²] f = Hz Temperatur [ C] 19 MATERIAL CHARACTERISTICS Fatigue Testing 20 C Hz σ O =1,5 N/mm² 20

11 MATERIAL CHARACTERISTICS Fatigue Testing Lastwechselzahl N Makro [-] ,01 0, 1,00 elastische Anfangsdehnung ε el [ ] 21 ANALYTIC PAVEMENT DESIGN METHOD tests tests abs. E-Modul [N/mm²] Lastwechselzahl N Makro [-] Temperatur [ C] 0 0,01 0, 1,00 elastische Anfangsdehnung ε el [ ] 22 11

12 ANALYTIC PAVEMENT DESIGN METHOD Effect of material properties 1. standard asphalts standard-results layer thicknesses on a level with empiric design method Zeile Bauklasse SV I II Äquivalente B > 32 > - 32 > 3 - -t-achsübergänge in Mio. Dicke des frostsich. Oberbaues 1) Asphalttragschicht auf Frostschutzschicht Asphaltdeckschicht Asphaltbinderschicht 1 Asphalttragschicht u 120 u 120 u 120 Frostschutzschicht u 5 u 5 u 5 Dicke der Frostschutzschicht ) ) ) Asphalttragschicht und Tragschicht mit hydraulischem Bindemittel au Schicht aus frostunempfindlichem Material Asphaltdeckschicht Asphaltbinderschicht Asphalttragschicht 2.1 Hydraulisch gebundene u 120 u 120 u Tragschicht (HGT) 120 Frostschutzschicht u 5 u 5 u 5 Dicke der Frostschutzschicht ) - 2 3) 3-302) 0 50 Asphaltdeckschicht Asphaltbinderschicht Asphalttragschicht 2.2 Verfestigung Schicht aus frostunempfindlichem Material weit- oder intermittierend gestuft u 5 u 5 u 5 gemäß DIN 1196 Dicke der Schicht aus ) 20) frostunempfindlichem Material ) 2 3 1) improved asphalts better performance compared with standard-asphalts (based on performance testing) longer lifetime (if layer thickness as RStO) reduced layer thickness (if N = 30 years) 23 EXAMPLE 2 12

13 EXAMPLE 25 EXAMPLE 26 13

14 EXAMPLE ATS 1 ATS 2 ATS 2 H bit H bit PmB H bit PmB 27 ANALYTIC PAVEMENT DESIGN METHOD Advantages of analytic pavement design method consideration of material characteristics calculation of required layer thicknesses (no fatigue in base layer during lifetime) consideration of extreme traffic growth (B > 0 Mio empiric design shouldn't applied) Disadvantages of analytic pavement design method expensive and time-consuming contractual arrangements are revised actual research results have to be integrated (e.g. probabilitistic, non linear elastic material properties, FEM) 2 1

15 EXPERIENCES Testtrack S 26 in Saxony Section 1 Length: 1,3 km build in testfield Section 2 Length: ~ 7 km build in 200 testfields 29 EXPERIENCES 30

16 EXPERIENCES - 6 cm Special Mix Design 31 EXPERIENCES improved asphalt mixtures low air void content continuous grading modified binder Sieblinienbereich für modifizierte ATS binder content:, M.-% air void content:,7 Vol.% 32 16

17 EXPERIENCES special requirements Compaction testing 33 EXPERIENCES comliance testing cores for ITS-testing 3 17

18 EXPERIENCES comliance testing [S 26] [S 26] stiffness fatigue 35 RECONSTRUCTIONS German Design Guide RStO

19 RECONSTRUCTIONS analytic pavement design FWD D 0 cores for ITS-testing R 0 R 0 homogeneous sections 37 RECONSTRUCTIONS Dehnungsabhängige Ermüdungskurven S 26 E-Moduln aus Spaltzugschwellversuchen ST ETO y = 0,976x -,0229 R 2 = 0,9555 abs. E-Modul [N/mm²] AB EB ETO Lastwechselzahl N Makro [-] Temperatur [ C] 0 0,01 0, 1,00 elastische Anfangsdehnung ε el [ ] 3 19

20 ANALYTIC PAVEMENT DESIGN METHOD Advantages of analytic pavement design method consideration of material characteristics calculation of required layer thicknesses consideration of extreme traffic growth application for NEW CONSTRUCTIONS and RECONSTRUCTION Disadvantages of analytic pavement design method expensive and time-consuming contractual arrangements are revised actual research results have to be integrated (e.g. probabilitistic, non linear elastic material properties, FEM) 39 The end Thank you for your attention! Dipl.-Ing. Jan Jähnig 0 20

21 Mix Desgin Asphalt Binder Courses 1. Results from TU Dresden Stiffness Fatigue Low temperature performance High temperature performance Typ AC 16 B S (TL) AC 16 B S - SMA BiMi /0-65 A /0-65 A Raumdichte 2,50 2,513 B,5 5,6 V (MPK) 5,6% 3,5% BV (MPK) 11,0% 13,7% VFB 66,3% 79,6% V1 V2 2. Prognosis of lifetime mit PaDesTo 1 Mix Desgin Stiffness absoluter E-Modul [MPa] Typ AC 16 B S (TL) AC 16 B S - SMA BiMi /0-65 A /0-65 A T f IEI IEI [ C] [Hz] [MPa] [MPa] BiMi A A Typ std SMA AC 16 B S (TL) /0-65 A AC 16 B S -SMA /0-65 A Temperatur[ C] 2 21

22 Mix Desgin Fatigue AC 16 B S (TL) /0-65 A AC 16 B S - SMA /0-65 A y =,03x -3,96 R² = 0,99 Lastwechselzahl NMakro y = 7,39x -3, R² = 0, ,0 0,0 1,000 elastische Anfangsdehnung [promille] improvement of fatigue 3 Mix Desgin Conclusion Typ AC 16 B S (TL) AC 16 B S - SMA BiMi /0-65 A /0-65 A Raumdichte 2,50 2,513 B,5 5,6 V (MPK) 5,6% 3,5% BV (MPK) 11,0% 13,7% VFB 66,3% 79,6% Ermüd. / Steifigkeit 0,0% 201,5% σ Z [MPa] 3,7,5 T [ C] -19,1-19,3 PRD_Luft 2,6% 2,9% Tendenz: AC B S -SMA o o 22

23 Mix Desgin,0 9,0 H M,bit,0 % H M,bit 17,5 % H M,bit 20,0 % H M,bit 22,5 % H A 60 %,0 H A 65 % Hohlraumgehalt H bit [Vol.-%] 7,0 6,0 5,0,0 3,0 H M,bit 12,5 % H M,bit,0 % H A 70 % H A 75 % H A 0 % H A 5 % AC 16 B S 2,0 H A 90 % AC 22 B S 1,0 H A 95 % AC 22 B S AC 16 B S 0,0 H A 0 % Bindemittelgehalt H B [Vol.-%] 5 Mix Desgin,0 9,0 H M,bit,0 % H M,bit 17,5 % H M,bit 20,0 % H M,bit 22,5 % H A 60 %,0 H A 65 % Hohlraumgehalt H bit [Vol.-%] 7,0 6,0 5,0,0 3,0 2,0 H M,bit 12,5 % H M,bit,0 % dichteabi SMA-Binder H A 70 % H A 75 % H A 0 % H A 5 % H A 90 % AC 16 B S AC 22 B S stetige ABi SMA-Binder 1,0 H A 95 % AC 22 B S AC 16 B S 0,0 H A 0 % Bindemittelgehalt H B [Vol.-%] 6 23

24 The end Thank you for your attention! Dipl.-Ing. Jan Jähnig 7 ANNEX 2

25 ANNEX 9 25