1. HVS Testing at ERDC – Last Five Years
J. Kent Newman, PhD
Larry Lynch, PhD
Geotechnical and Structures Laboratory
Engineer Research and Development Center

2. Outline Introduction HVS Studies Summary APB Mission and History HVS-A
Selected projects from last five years
Summary

3. Introduction APB Mission
Performs research and development studies for the purpose of developing new and improved methods for the design, construction, evaluation, rehabilitation, and maintenance of structural systems for pavements, rails, and other transportation facilities in support of DOD and USACE.
Serves a Tri-Service (Army, Navy, and Air Force) lead for research and development for airfields and pavements by providing technology to support DOD doctrine of global force projection.
Responsible for developing models for improved performance prediction; identification of deterioration rates, failure modes, mechanisms, and establishing performance criteria for transportation systems.

4. History of Corps Airfields and Pavements Research
Introduction
History of Corps Airfields and Pavements Research
HVS-A Testing
AAF Evaluation program
Railroad program
RCC, RMP pavements
Polymer-Modified Asphalts
Design and construction criteria for B-29
C-5A, B-747 criteria
Vietnam
Unsurfaced criteria
1940
1950
1960
1970
1980
1990
2000
2010
Heavy-load (B-52) pavements
Landing mats
Fuel and blast resistant pavements
Airfield evaluations
Nondestructive testing procedures
PCI
Bomb-damage repair
FRC pavements
Layered-elastic design
3-D finite element modeling
Advanced materials characterization
Rapid Airfield Construction
CBR design Improvement
Rapid Airfield Repair
AM-X Mat Program

5. Introduction HVS-A Acquired 1998
Purchased to primarily conduct full-scale high traffic testing of airfield pavements
Max load 100,000lbs
Range of Wheels
C-17 single and dual
Dual to gauge multiple wheel interactions
B-52 Dual
C-130 Single
F-15 Single
Truck
Super Single
Standard Dual

6. Last Five Years - HVS Studies
Flexible Pavements
B-52, C-130, C-17, F-15, Truck Traffic
Marginal Bases for Asphalt
Revision of CBR Design
Geosynthetics
Concrete Pavements
F-15, C-17 Traffic
Rapid Repair – PUR Foams
Stabilized Surfaces
C-130 Traffic
Fiber-Cement
Polymer-Cement
C-17 Traffic
Dust control

7. Marginal Bases for Asphalts
C F-15E
Aircraft Weight 586,000 lbs 81,000 lbs
Wheel Load 44,930 lbs 35,235 lbs
Gross Gear Load 269,560 lbs ,235 lbs
Tire Pressure 142 psi 325 psi
Single-Wheel Load
Trapezoidal Distributed Traffic Pattern
40’ traffic; 4’ wander width
Failure criteria 2” of rutting
At selected traffic intervals, the surface will be inspected for distress, permanent deformation will be measured, and falling weight deflectometers tests will be performed. The failure criterion for asphalt concrete pavements is typically based upon 1-in. of permanent deformation or rutting. Each item will be trafficked with about 10,000 passes of the HVS. Upon completion of traffic tests, a forensic investigation will be conducted to determine the failure mechanisms and influence on overall pavement performance.

8. Marginal Bases for Asphalts
Base Course Type
Measured Coverage's to Failure
Predicted Coverage's to Failure (1” AC Rutting)
PCASE
CBR
LEEP
GW (1)
650
560
2300 GM
700
668
1947 SM
450 16
1224
(1) Data obtained from the “Minimum Asphalt Thickness Project ”
At selected traffic intervals, the surface will be inspected for distress, permanent deformation will be measured, and falling weight deflectometers tests will be performed. The failure criterion for asphalt concrete pavements is typically based upon 1-in. of permanent deformation or rutting. Each item will be trafficked with about 10,000 passes of the HVS. Upon completion of traffic tests, a forensic investigation will be conducted to determine the failure mechanisms and influence on overall pavement performance.

9. Revision of CBR Equation
Move to a a more mechanistic CBR design
Stress-based using Frolich’s approach
Eliminates need for α and ESWL
ITEM2, ETC
ITEM1 5’ 5’
TRAFFIC LANE 1 : F15E TIRE 5’
TRAFFIC LANE 2 : C17 DUAL TIRES
40’
10’ 5’ 5’
TRAFFIC LANE 3 : C17 SINGLE TIRE 5’
ACTUAL HVS 40’ TRAVEL 5’ 5’ 5’
LENGTH OF EACH ITEM=50’

10. Tensar Geosynthetics 10,000 lb load Dual Truck Tires at 80 psi
NOT TO SCALE 2”
57.5’
3 CBR
CH Subgrade
2” AC
8 CBR
12”
24”
Geogrid
Where Applicable
Structural Number = 1.6
Structural Number = 2.4
CBR Crushed Stone 6”
30”
10,000 lb load
Dual Truck Tires at 80 psi
32 in. Wander Width
Failure Criteria:
1” Rut Depth

11. Concrete Rapid Repair – PUR Foams
Basic Concept
Remove Ruptured Soil without Compaction
Backfill with HD Polyurethane Foam
Cover with Rapid Set® Concrete Cap

12. Rapid Repair – PUR Foams
Heavy Vehicle Simulator (HVS) Trafficking
Method
Traffic repairs with HVS after caps are fully cured
Observe repairs at regular intervals to chronicle pavement distresses
Loads
Configuration: Tandem axles with dual tires
Axle loads: 10,000 pounds per axle
Traffic up to 50,000 passes or failure
Failure Criteria
Repair exhibiting cracking or spalling with roughness >1in
Crack or Spall widening enough to allow foreign object insertion
Section of slab breaking and able to be pried loose

13. Rapid Repair – PUR Foams
ALL craters at Vicksburg and Port Hueneme surpassed the single axle pass limit without distresses causing failure
Crater 3
50,000 Passes
Virtually no distresses
The worst damage observed
~ 1 in
Damages are limited to minor hairline cracks
Crater 4
50,000 passes
Virtually no distresses

14. Conclusions – Rapid Repair
Polyurethane foam and Rapid Set Concrete performed well in conjunction as a Rapid Crater Repair Technique
Crater repairs able to withstand in excess of 50,000 single axle passes (1 year of light duty road)
Little training required (4 hrs)
4 hr complete repair time (Site prep until ready to traffic)
Foam materials must be between 65oF and 85oF (heated or cooled storage necessary) for acceptable foam performance

15. Stabilized Surfaces C-130 Wheel load 30,000 lb 750 Passes One Day Cure
Apron 1
Fiber/Cement
Polymer/Cement
No Cracks, ½” Rut
Cracked at Edge of
Wheel Path, 3” rut
Unmodified Soil – 6” rut

16. Dust Control Studies C-17 Wheel Load 38,000 lbs, 142 psi
Channelized Traffic
Comparing dust on stabilized surfaces
Polymer Emulsion
Synthetic Oils
Heavy Applications vs. Reapplications
Gravimetric and Optical Data

17. Dust Control Studies Conclusions
Polymer emulsion best for stabilized surfaces
High app rate best when possible
Synthetic oils best for unmodified soils
Softened cement-stabilized surface
Optical data from Hazdust monitors provide real time dust levels
Maybe subject to overranging with fine soils

18. Conclusion HVS very useful for wide-range of studies Durable
Multifunctional
Adaptable

19. Questions?