Construction and Testing of Construction Cycle 2 (CC2) Overlay Murphy Flynn FAA Airport Technology R&D Branch, AAR-410 William J. Hughes Technical Center, Atlantic City, NJ 29 th Annual Airport Conference Hershey, Pennsylvania – March 1, 2006 Lia Ricalde SRA International 3120 Fire Road, Egg Harbor Twp., NJ 08234

AAR Outline  Construction Cycle 2 (CC2) Overview  CC2 Rubblization  CC2 Flexible Overlay  Pre-traffic Testing  CC2 Overlay Traffic  Post-traffic Testing

AAR NAPTF Construction Cycle

AAR Outline  Construction Cycle 2 Overview  CC2 Rubblization  CC2 Flexible Overlay  Pre-traffic Testing  CC2 Overlay Traffic  Post-traffic Testing

AAR Plan View of All CC2 Test Items

AAR Profile of CC2 Test Items

AAR CC2 Concrete Mix  Cementitious Aggregate:  50% Portland Cement Type I  50% Class “C” Flyash Mix  50% Natural Sand  50% #57 Crushed Stone

AAR Traffic Parameters  North side 6-wheels (3D)  South side 4-wheels (2D)  Dual distance 54 inches (1372 mm)  Tandem distance 57 inches (1448 mm)  55,000 lbs (25 t) load per wheel  210 psi (1.45 MPa) tire pressure  Traffic speed 2.5 mph (855 m/sec)  Standard wander pattern, 66 passes per cycle.

AAR Applied Traffic – Wander Pattern

AAR MRC North MRC South MRC North MRC South First crack on south outer lane at 992 Passes April 29, 2004 First crack on south inner lane at 2,458 passes May 10, 2004 First crack on north outer lane at 3,653 passes May 21, 2004 North side distress at 6,085 passes similar to south side at 4,720 (06/02/04). South side traffic stopped at 4,720 passes (05/20/04). North side traffic 3,331 passes. First crack on north inner lane at 3,273 passes May 19, 2004 Final traffic on MRC north side 12, 675 passes and south side 5,405 passes (06/30/04). CC2 MRC Traffic

AAR Typical Severity of Cracks

AAR CC2 Test Items – Applied Traffic Full-scale traffic testing began on 4/27/04 and ended 12/10/04. Section Number of Passes MRCMRGMRS North5,40531,02020,262 South12,67531,02031,020

AAR Rubblized Section 01/25/05  12/29/04, 5’x5’x12” cut- out on PCC slab.  01/12/05, P-154 removed, CBR on Subgrade top.  01/17/05, Subgrade removed (1 ft.), CBR test.  01/19/05, Subgrade and P-154 filled back into pit.  PCC cut-out put back into pit.  12/29/04, 5’x5’x12” cut-out on PCC slab.  01/12/05, P-154 removed, CBR on Subgrade top.  03/07/05, Plate Load Test on Subgrade top.  Subgrade removed (1 ft.), CBR test, torvane on lateral walls and shelby tubes. N MRC Material Characterization MRC Flexural Strength Sawed Beams: 617 psi Molded Beams: 744 psi North Traffic DT (2D) Abbreviated Wander 12,675 passes (3,336 coverages) South Traffic DT (2D) 5,405 passes (1,138 coverages) 04/21/05, 4’x4’x12” pit sawed-cut for material gradation. 05/23/05, roofing membrane placement.

AAR Rubblized Section 01/25/05  03/02/05, 7’x4’x12” cut-out on PCC slab.  CBR on Subgrade top and one foot below, torvane on Subgrade lateral walls.  Plate Load Test on Subgrade top.  Shelby tubes.  PCC cut-out put back into pit. N MRG Material Characterization MRG Flexural Strength Sawed Beams: 675 psi Molded Beams: 833 psi North Traffic TDT (3D) 31,020 passes South Traffic DT (2D) 31,020 passes 04/22/05, 4’x4’x12” pit sawed-cut for material gradation. 05/23/05, roofing membrane placement.

AAR Rubblized Section 01/25/05 N MRS Material Characterization 04/22/05, 4’x4’x12” pit sawed-cut for material gradation.  10/14/04, 7’x7’x12” cut-out on PCC slab.  01/17/05, Plate Load Test (PLT) on P-306.  5’x5’x6” cut-out on P-306, PLT on P-154.  P-154 removed, PLT on Subgrade top.  01/19/05, P-154 filled back into pit, new 6” P-306 placed.  PCC cut-out put back into pit, completed with hand mix concrete. MRS Flexural Strength Sawed Beams: 688 psi Molded Beams: 691 psi  12/30/04, 5’x5’x18” cut-out on PCC slab.  01/18/05, P-154 removed, CBR on Subgrade top.  01/19/05, P-154 refilled and 6” new P-306 placed, PCC cut-out put back into pit.  03/02/05, 8’x4’x18” cut-out on PCC slab.  P-154 removed, CBR on Subgrade top and one foot below, torvane on Subgrade lateral walls.  P-154 refilled and 6” new P-306 placed, slab put back into pit. South Traffic DT (2D) 31,020 passes North Traffic TDT (3D) 20,262 passes 05/23/05, roofing membrane placement.

AAR Outline  Construction Cycle 2 Overview  CC2 Rubblization  CC2 Flexible Overlay  Pre-traffic Testing  CC2 Overlay Traffic  Post-traffic Testing

AAR FAA Guidelines for Rubblization  Engineering Brief No. 66 (February, 2004) “Rubblized Portland Cement Concrete Base Course”  Interim guidance  Based on broad industry experience  Full-scale testing is still needed to develop design standards for the use of this technology at airports under heavy aircraft loading

AAR Rubblization of CC2 Test Items  January, 2005 – Concrete slabs in the north traffic lane, including those in the transition sections, were rubblized with an RMI RB-500 resonant breaker operating at 44 Hz.

AAR RMI RB 500

AAR Rubblization Video

AAR CC2 South Side  South half of all test items overlaid in the “as trafficked” condition.  Some anti reflective cracking measures applied in key areas.  Roofing membrane applied over larger cracks and saw cuts.

AAR CC2 Before Overlay Rubblized on the Left (North) and As-Trafficked on the Right (South)

AAR Test Pits in Rubblized Test Items  4-foot (1.22 m) long by 4-foot (1.22 m) wide test pit was saw cut in each test item for visual examination of the rubblized concrete (extent of fractures from rubblization process, particle sizes, etc.).

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AAR Outline  Construction Cycle 2 Overview  CC2 Rubblization  CC2 Flexible Overlay  Pre-traffic Testing  CC2 Overlay Traffic  Post-traffic Testing

AAR Compacting Rubblized Lane

AAR Roofing Membrane (South Lane)

AAR Roofing Membrane Before Overlay

AAR CC2 Prepared for Overlay

AAR CC2 Flexible Overlay  5 in. (12.7 cm) of FAA P-401 Hot Mix Asphalt (HMA) applied in two 2.5 in (6.3 cm ) lifts.  Tack coat (emulsion) between lifts

AAR Construction Cycle 2 Overlay (CC2-OL)

AAR HMA First Lift on Rubblized Lane

AAR Tack Coat Application  Tack coat (emulsion) applied at end of first lift.  Allowed to break overnight

AAR Final Lift Placement

AAR Outline  Construction Cycle 2 Overview  CC2 Rubblization  CC2 Flexible Overlay  Pre-traffic Testing  CC2 Overlay Traffic  Post-traffic Testing

AAR Uniformity of Pavement Structures  Heavy-weight deflectometer (HWD) tests were performed using the FAA’s HWD equipment on a 10-foot (3.05 m) grid to study the uniformity of the pavement structures.  12-inch diameter segmented load plate at three different load levels – 12,000, 24,000, and 36,000 lbs (53.4, 106.8, and kN).

AAR Uniformity of Pavement Structures

AAR Portable Seismic Pavement Analyzer (PSPA)

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AAR Outline  Construction Cycle 2 Overview  CC2 Rubblization  CC2 Flexible Overlay  Pre-traffic Testing  CC2 Overlay Traffic  Post-traffic Testing

AAR CC2 Overlay Gear Configurations 4-Wheel Landing Gear Configuration Wheel Load = 55,000 lbs Tire Pressure = 220 psi

AAR North Wheel Track Wheel Load = 65,000 lbs Tire Pressure = 260 psi South Wheel Track CC2 Overlay Gear Configurations After 5,000 Passes

AAR Traffic Summary Dates (from-to) Passes (Total)Test Items Load on North Lane Load on South Lane 07/07/05 07/25/05 5,082 (5,082) MRG-N, MRC-N, MRS-N MRG-S, MRC-S, MRS-S 55,000 lbs. (4-Wheels) 55,000 lbs. (4-Wheels) 07/26/05 08/12/05 6,732 (11,814) MRG-N, MRC-N, MRS-N MRG-S, MRC-S, MRS-S 65,000 lbs. (6-Wheels) 65,000 lbs. (4-Wheels) 08/15/05 08/18/05 2,442 (14,256) MRG-N, MRC-NW, MRS-N MRG-S, MRC-S, MRS-S 08/19/05 08/24/05 2,046 (16,302) MRG-N, MRS-N MRG-S, MRC-S, MRS-S 09/13/05 10/06/05 9,306 (25,608) MRG-N, MRS-N MRG-S, MRS-S

AAR Rut Measurement

AAR Rubblized Section (North Side) Area of Prior Test Pit

AAR South Side Area of Prior Test Pit

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AAR Longitudinal Joint Failure

AAR Outline  Construction Cycle 2 Overview  CC2 Material Characterization  CC2 Rubblization  Test Pits  CC2 Flexible Overlay  Surface Preparation  CC2 Overlay  Pre-traffic Testing  Uniformity Test  PSPA Test  CC2 Overlay Traffic  Post-traffic Tests in Trenches

AAR P-401 Asphalt Concrete Surface  Cores.  Visual examination for cracks.  Lab tests – air voids, dynamic modulus.

AAR Rubblized Concrete Layer (North Lane)  Visual examination.  Plate load Tests  Inside wheel track  Outside wheel track

AAR Plate Load Tests - Rubblized Concrete

AAR MRC – Rubblized Concrete

AAR MRG – Rubblized Concrete

AAR MRS – Rubblized Concrete

AAR P-306 Econocrete Subbase  Plate load tests  Inside wheel track  Outside wheel track

AAR P-154 Subbase  Plate load tests  Inside wheel track  Outside wheel track  CBRs  In-situ density (sand cone)

AAR Subgrade  Plate load tests  Inside wheel track  Outside wheel track  CBRs  In-situ density (drive cylinders)  Shear Strength (vane shear)

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AAR MRC-E

AAR MRC-E: Layer Profiles

AAR MRC-E

AAR MRC-W

AAR MRC-W: Layer Profiles

AAR MRC-W

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AAR MRG

AAR MRG: Layer Profiles

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AAR MRS

AAR MRS

AAR MRS: Layer Profiles

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