1. 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

2. AAR-410 2 Outline  Construction Cycle 2 (CC2) Overview  CC2 Rubblization  CC2 Flexible Overlay  Pre-traffic Testing  CC2 Overlay Traffic  Post-traffic Testing

3. AAR-410 3 NAPTF Construction Cycle

4. AAR-410 4 Outline  Construction Cycle 2 Overview  CC2 Rubblization  CC2 Flexible Overlay  Pre-traffic Testing  CC2 Overlay Traffic  Post-traffic Testing

5. AAR-410 5 Plan View of All CC2 Test Items

6. AAR-410 6 Profile of CC2 Test Items

7. AAR-410 7 CC2 Concrete Mix  Cementitious Aggregate:  50% Portland Cement Type I  50% Class “C” Flyash Mix  50% Natural Sand  50% #57 Crushed Stone

8. AAR-410 8 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.

9. AAR-410 9 Applied Traffic – Wander Pattern

10. AAR-410 10 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

11. AAR-410 11 Typical Severity of Cracks

12. AAR-410 12 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

13. AAR-410 13 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.

14. AAR-410 14 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.

15. AAR-410 15 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.

16. AAR-410 16 Outline  Construction Cycle 2 Overview  CC2 Rubblization  CC2 Flexible Overlay  Pre-traffic Testing  CC2 Overlay Traffic  Post-traffic Testing

17. AAR-410 17 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

18. AAR-410 18 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.

19. AAR-410 19 RMI RB 500

20. AAR-410 20 Rubblization Video

21. AAR-410 21 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.

22. AAR-410 22 CC2 Before Overlay Rubblized on the Left (North) and As-Trafficked on the Right (South)

23. AAR-410 23 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.).

24. AAR-410 24

25. AAR-410 25

26. AAR-410 26

27. AAR-410 27

28. AAR-410 28

29. AAR-410 29

30. AAR-410 30 Outline  Construction Cycle 2 Overview  CC2 Rubblization  CC2 Flexible Overlay  Pre-traffic Testing  CC2 Overlay Traffic  Post-traffic Testing

31. AAR-410 31 Compacting Rubblized Lane

32. AAR-410 32 Roofing Membrane (South Lane)

33. AAR-410 33 Roofing Membrane Before Overlay

34. AAR-410 34 CC2 Prepared for Overlay

35. AAR-410 35 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

36. AAR-410 36 Construction Cycle 2 Overlay (CC2-OL)

37. AAR-410 37 HMA First Lift on Rubblized Lane

38. AAR-410 38 Tack Coat Application  Tack coat (emulsion) applied at end of first lift.  Allowed to break overnight

39. AAR-410 39 Final Lift Placement

40. AAR-410 40 Outline  Construction Cycle 2 Overview  CC2 Rubblization  CC2 Flexible Overlay  Pre-traffic Testing  CC2 Overlay Traffic  Post-traffic Testing

41. AAR-410 41 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 160.2 kN).

42. AAR-410 42 Uniformity of Pavement Structures

43. AAR-410 43 Portable Seismic Pavement Analyzer (PSPA)

44. AAR-410 44

45. AAR-410 45

46. AAR-410 46 Outline  Construction Cycle 2 Overview  CC2 Rubblization  CC2 Flexible Overlay  Pre-traffic Testing  CC2 Overlay Traffic  Post-traffic Testing

47. AAR-410 47 CC2 Overlay Gear Configurations 4-Wheel Landing Gear Configuration Wheel Load = 55,000 lbs Tire Pressure = 220 psi

48. AAR-410 48 North Wheel Track Wheel Load = 65,000 lbs Tire Pressure = 260 psi South Wheel Track CC2 Overlay Gear Configurations After 5,000 Passes

49. AAR-410 49 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

50. AAR-410 50 Rut Measurement

51. AAR-410 51 Rubblized Section (North Side) Area of Prior Test Pit

52. AAR-410 52 South Side Area of Prior Test Pit

53. AAR-410 53

54. AAR-410 54 Longitudinal Joint Failure

55. AAR-410 55 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

56. AAR-410 56 P-401 Asphalt Concrete Surface  Cores.  Visual examination for cracks.  Lab tests – air voids, dynamic modulus.

57. AAR-410 57 Rubblized Concrete Layer (North Lane)  Visual examination.  Plate load Tests  Inside wheel track  Outside wheel track

58. AAR-410 58 Plate Load Tests - Rubblized Concrete

59. AAR-410 59 MRC – Rubblized Concrete

60. AAR-410 60 MRG – Rubblized Concrete

61. AAR-410 61 MRS – Rubblized Concrete

62. AAR-410 62 P-306 Econocrete Subbase  Plate load tests  Inside wheel track  Outside wheel track

63. AAR-410 63 P-154 Subbase  Plate load tests  Inside wheel track  Outside wheel track  CBRs  In-situ density (sand cone)

64. AAR-410 64Subgrade  Plate load tests  Inside wheel track  Outside wheel track  CBRs  In-situ density (drive cylinders)  Shear Strength (vane shear)

65. AAR-410 65

66. AAR-410 66 MRC-E

67. AAR-410 67 MRC-E: Layer Profiles

68. AAR-410 68 MRC-E

69. AAR-410 69 MRC-W

70. AAR-410 70 MRC-W: Layer Profiles

71. AAR-410 71 MRC-W

72. AAR-410 72

73. AAR-410 73 MRG

74. AAR-410 74 MRG: Layer Profiles

75. AAR-410 75

76. AAR-410 76 MRS

77. AAR-410 77 MRS

78. AAR-410 78 MRS: Layer Profiles

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