1. Folie 1 siegfried.riffel@heidelbergcement.com NATIONAL MEETING ON CONCRETE ROADS 18th December 2002, Ankara „CONCRETE ROAD CONSTRUCTIONS State of the Art and new Development“ by Jürgen Halm HeidelbergCement Technology Center GmbH Department Concrete and Application

2. Folie 2 siegfried.riffel@heidelbergcement.com Table of Contents - New Regulations in Germany (Requirements to be met) - Placement of Concrete / Laying Technology - Paver Compacted Concrete - Noise-reduced Traffic / Open porous Concrete (Draining Concrete)

3. Folie 3 siegfried.riffel@heidelbergcement.com New Regulations ZTV Beton – StB 01 (StB = Road Construction) (Supplementary Technical Conditions of Contract, Specifications and Guidelines for the Construction of Concrete Pavements) The new Edition 2001 Includes new technical developments in the construction of concrete pavements

4. Folie 4 siegfried.riffel@heidelbergcement.com New Regulations The ZTV Beton - StB 01 includes: - Modifications of the VOB Part C (12.2000) (VOB = General Technical Conditions of Contract) - ZTV Fug-StB 01 (Supplementary Technical Conditions of Contract, Specifications and Guidelines for sealants and joint fillings in traffic areas) - Description of burlap (Special kind of surface treatment) - Construction method using geotextil as a layer between concrete pavement and road base - Cement requirements - New construction methods (two layer – wet in wet) - Skid resistance requirements

5. Folie 5 siegfried.riffel@heidelbergcement.com  45 MN/m 2 New Regulations Pavement construction: - The concrete pavement can consist of one or two layers - Thickness of top layer > 4 cm - The thickness of total pavement depends on the RStO 01 (RStO = Guidelines for the Standardization for Pavement Structures for Traffic Areas) 3 examples for construction class SV (heavy traffic load) concrete pavement geotextil  120 27 cm 15 cm 42 cm asphalt stabilized base  120  45 MN/m 2 26 cm 10 cm 36 cm crushed-rock base  150  45 MN/m 2 30 cm 60cm concrete pavement cement stabilized base (HGT) subbase frost-resistant material subbase frost-resistant material subbase frost-resistant material

6. Folie 6 siegfried.riffel@heidelbergcement.com New Regulations Alternative concrete construction method: 2 layer-concrete on standard-pavement structure crushed-rock base The advantages of thick concrete pavement with a thin upper layer of concrete are: - Improved skid resistance - Reduction of noise - Guarantee of covered dowels - Use of recycled broken-up material in the lower concrete layer concrete pavement frost-resistant material 27 cm 15 cm 42 cm crushed-rock base (unbound base) 30 cm 60 cm 4 cm = top layer geotextil concrete pavement cement stabilized base (HGT) frost-resistant material 26 cm = bottom layer

7. Folie 7 siegfried.riffel@heidelbergcement.com  C ement - CEM I 32,5 R (DIN EN 197-1) - upon coordination with the customer the following cements can also be used: - CEM II/A-Soder CEM II/B-S - CEM II/A-T oder CEM II/B-T - CEM II/A-L - CEM III/A - for CEM I 32,5 R- < 28 % required water (DIN EN 196-3) - compressive strength, 2 days < 29 N/mm² (DIN EN 196-1) - 3.500 cm²/g fineness of grinding (DIN EN 196-6) - requirements for all cements - total alkali content < 1,0 M% (required) - cement temperature < 80°C (if possible) New Regulations

8. Folie 8 siegfried.riffel@heidelbergcement.com New Regulations  concrete aggregates- DIN 4226-1 (German Industrial Standard) - TL Min – StB (Technical Conditions for the Supply of Minerals for Road Construction) - Limitation of swelling components - Increased frost resistance requirements - A percentage of crushed aggregates is required - High quality crushed aggregates with resistance to polishing (PSV = polished stone value) - The alkali guidelines of DAfStb shall be included

9. Folie 9 siegfried.riffel@heidelbergcement.com New Regulations Concrete requirements Construction class Minimum values of 28-day-old- concrete Size of aggregates-groupes [mm] Compressive strength on the cube with 20 cm edge lengths [N/mm²] Beam-tensile strength [N/mm²] 1 2 345 SV, I - IV 35 40 5,5 0/2, 2/8, > 8 0/4, 4/8, > 8 0/2, < 8* *for 8 mm maximum aggregate size V - VI 25 304,00/4, > 4 - Cement content of construction class SV, I, II, III: > 350 kg/m³ - Water-cement ratio in tests for construction classes SV, I, II, III: < 0,45 - Mixing time: > 45 seconds ZTV Beton Tab.1 traffic load

10. Folie 10 siegfried.riffel@heidelbergcement.com New Regulations Concrete requirements Air void volume of fresh concrete Micro air void with air-entraining agent guarantee a high frost-deicing salt- resistance in the concrete. Minimum air void volume of fresh concrete daily average individual values [Vol.-%] [Vol.-%] Concrete without plasticizer (BV) or plasticizing agent (FM) 4,03,5 Concrete with plasticizer (BV) and/or plasticizing agent (FM) 5,04,5 ZTV Beton Tab. 2

11. Folie 11 siegfried.riffel@heidelbergcement.com New Regulations Concrete requirements  Observing minimum strengths (table 1)  Observing the air void volume (table 2)  Tolerance of the pavement thickness (< 5 mm on the test specimen)  Max. 20 (50) mm shifting of the positon of the dowles  < 0,5 % deviation for the crossfall  < 4 mm evenness with 4m-long-measuring rod  Observing values for skid resistance TP Griff-StB (SCRIM) (table 4) Measuring speeds [km/h] Limiting values µ SCRIM Acceptance Until expiry of term of limitation 40 60 80 0,60 0,56 0,53 0,50 0,46 0,43 ZTV Beton Tab. 4

12. Folie 12 siegfried.riffel@heidelbergcement.com New Regulations Surface treatment and curing  Construction classes SV, I, II, III  Final polishing element = longitudinal polisher  Finishing surface treatment by means of 300 g/m² burlap or 45 cm wide steel broom  Wider new methodes for finishing surface are burlap with comp artificial grass and „wash concrete“ (remove the fine mortar) -  When the surface is completed, a curing agent as per TL NBM-StB shall be applied. Densifying coefficient: S > 75 %  It is suitable to use curing agents with increased brightness referenz value (with colour value) VH-W oder VM-W.  Joint cutting Transverse joint: cutting depth 25 - 30 % of the thickness Longitudinal joint: cutting depth 40 - 45 % of the thickness

13. Folie 13 siegfried.riffel@heidelbergcement.com longitudinal smoother Laying technology

14. Folie 14 siegfried.riffel@heidelbergcement.com Laying technology burlap

15. Folie 15 siegfried.riffel@heidelbergcement.com transverse „steel-broom line“ Laying technology

16. Folie 16 siegfried.riffel@heidelbergcement.com Laying technology „wash-concrete“ surface (Germany)

17. Folie 17 siegfried.riffel@heidelbergcement.com application curing-agent Laying technology

18. Folie 18 siegfried.riffel@heidelbergcement.com 2,504,253,754,50 2,50 m 12,50 m 5,00 m 12 % frost-resistant gravel and sand material Transverse contraction joint, with dowels Spacing of dowels 25 cm shoulder lane external lane central lane internal lane Longitudinal contraction joints, 3 or 5 tie bars per slab Laying technology Example of BAB 5 expresshighway: concrete pavement structure + positions of dowels and tie bars concrete pavement 26 cm (19+7) cement stabilized base

19. Folie 19 siegfried.riffel@heidelbergcement.com dummy joint-cut (to prevent wild cracks) bituminous joint filler or joint profile notch cement stabilized base (HGT) Joint technology

20. Folie 20 siegfried.riffel@heidelbergcement.com Joint technology dummy joint - longitudinal - transverse for expansion

21. Folie 21 siegfried.riffel@heidelbergcement.com pressed joint „sinus profil“ wich does not allow expansion (only in aircraft movement areas) Joint technology

22. Folie 22 siegfried.riffel@heidelbergcement.com Mixing plant / supply of cement

23. Folie 23 siegfried.riffel@heidelbergcement.com Stockpile of aggregates

24. Folie 24 siegfried.riffel@heidelbergcement.com Laying technology concrete pavement - two layers slipform paver

25. Folie 25 siegfried.riffel@heidelbergcement.com dowel setting machine Laying technology

26. Folie 26 siegfried.riffel@heidelbergcement.com Reinforced concrete pavements 1921First continuously reinforced pavements in United States – Virginia (60 m long slabs of different reinforcements) from 1947Inter-States network in the United States is partly produced with reinforcement until 199416.000 km of the Inter-States network are reinforced from 1970BelgiumBrussel-Lüttich motorway further applications in Belgium, Spain, UK until 1994Belgium 2.950 km from 1982France10 km of the A 6 motorway near Auxerre until 19943,5 Mio m² of reinforced pavement Reinforced pavements

27. Folie 27 siegfried.riffel@heidelbergcement.com Reinforced pavements (France) Reinforcement - 16 mm-dia. round steel, longitudinal/transverse - percentage of reinforcement 0,6 - 0,8 % alternatively: - flat rolled steel bands 40 - 44 mm wide 2 - 3 mm thick (galvanized, with knobs) - percentage of reinforcement0,30 % (higher tensile yield point) Layout: 1/3 1/2 > 60-70 mm  reinforcement layer in the compression zone

28. Folie 28 siegfried.riffel@heidelbergcement.com Laying technology reinforced concrete pavement (slipform paver)

29. Folie 29 siegfried.riffel@heidelbergcement.com Laying technology control of reinforcement (slipform paver)

30. Folie 30 siegfried.riffel@heidelbergcement.com Concrete pavement „Paver Compacted Concrete“

31. Folie 31 siegfried.riffel@heidelbergcement.com Paver Compacted Concrete (PCC) PCC is laid with conventional road pavers equiped with High-Power- Compaction Screeds (HPCS) PCC is compacted from the surface with tamping,vibrating and pressing compacting systems Construction - Single-layer or two-layer construction (fresh on fresh) - For use as base course or combined base and wearing course - Favorable paving depth (15 – 20 cm) Construction material - PCC 0/16 mm, if required with air entraining agent - Aggregate > 8 mm double screened chippings, or chippings (eFT) - Concrete strength C25/30 up to C40/50 are achievable Cost - Substantially lower cost compared with conventional concrete - About 8 - 13 €/qm without joints (depending: concrete strength, paving depth, working width)

32. Folie 32 siegfried.riffel@heidelbergcement.com Paver Compacted Concrete (PCC) Applications - Base for roads and traffic surfaces built in two-layer construction according to RStO-Class SV, I – VI - Industrial roads; bus lanes; draw-ins - Farm tracks; footpaths and cycle paths - Crossings; yards; car parks - Industrial surfaces; exhibition grounds Advantages - High quality achieved with low requirement for equipment and personnel - Very good surface accuracy (longitudinal and traversal) - Suitable for two-layer construction (pavers operating in echelon) - Density of >98% achieved right behind the High-Power-Compaction Screed - Very good „green-stability“ (90°edge) - High resistance to wear - High paving performance (60 – 120 m/h) - Joints can be produced or cut in the fresh concrete - Distance between joints 5 – 7 m - Easy, efficient, economical

33. Folie 33 siegfried.riffel@heidelbergcement.com Noise-reduced traffic Noise-reduced concrete pavement - „ draining-concrete“

34. Folie 34 siegfried.riffel@heidelbergcement.com „Draining-concrete“ pavement

35. Folie 35 siegfried.riffel@heidelbergcement.com „Draining-concrete“ pavement

36. Folie 36 siegfried.riffel@heidelbergcement.com draining-concrete = top layer Concrete pavement „draining-concrete“ concrete or PCC (Paver Compacted Concrete) or cement stabilized base = bottom layer

37. Folie 37 siegfried.riffel@heidelbergcement.com Pavement „draining-concrete“ (special slipform paver)

38. Folie 38 siegfried.riffel@heidelbergcement.com Surface and structure of „draining-concrete“

39. Folie 39 siegfried.riffel@heidelbergcement.com Surface and structure of „draining-concrete“

40. Folie 40 siegfried.riffel@heidelbergcement.com Open porous concrete „draining concrete“ Advantages - very high noise reduction possible by 7 dB(A) - high sound absorption (up to 98 % within critical frequency ranges) - good drainage characteristics, i.e. no splash water jets, no aquaplaning - high level of road safety on dry and wet roads - very good transverse and longitudinal evenness - high skid resistance - good non-skid qualities in respect of dry and wet roadway surfaces - good reflections properties - good brightness of surface - high load-bearing capacity (ß D, ß BZ, ß HZ at cavity content > 20 Vol.-%) - high deformation stability, i.e. no tracking grooves, consistently freely accessible pore space - favourable thermal properties, i.e. high driving safety in dark and wet conditions - top concrete layer can be constructed without joints - old, loud pavings can be built over (wearing course, superimposition of top layers)

41. Folie 41 siegfried.riffel@heidelbergcement.com Draining concrete composition Concrete strength class: > C 25/30 Aggregates: double crushed and screend chippings 5/8 mm 1450 – 1500 kg/m 3 Cement: CEM I 32,5 R 300 – 350 kg/m 3 Water: only fresh water 50 – 55 kg/m 3 Plastic dispersion: 20% of cement weight (10% solids) 60 – 70 kg/m 3 Water-cement ratio: 0,24 – 0,26 (effective) Consistency: (Compacting factor test) v 1,30 – 1,34 Cavity content: P > 20 Vol.-% Compressive strength: ß D > 25 N/mm 2 Beam-tensile strength: ß BZ > 4,5 N/mm 2 Tensile splitting strength: ß SZ > 2,7 N/mm 2 Adhesive pull strength: ß HZ > 3,0 N/mm 2 Static modulus of elasticity: E B 16000 – 18000 N/mm 2

42. Folie 42 siegfried.riffel@heidelbergcement.com Laying of „draining-concrete“ on test section A5

43. Folie 43 siegfried.riffel@heidelbergcement.com Noise measurement results

44. Folie 44 siegfried.riffel@heidelbergcement.com Measurement „noise spectrum“

45. Folie 45 siegfried.riffel@heidelbergcement.com Measurement „absorption spectrum“

46. Folie 46 siegfried.riffel@heidelbergcement.com HeidelbergCement AG Thank you very much!