INDUSTRIAL CONCRETE BLOCK
PAVING
A VALID ALTERNATIVE
Concrete Segmental Paving offers a good
alternative to asphalt or cast-in-place
concrete because it provides :
Dr Brian Shackel
1. Excellent Operational Characteristics
Professorial Visiting Fellow
2 Cost Effectiveness
2.
School of Civil & Environmental Engineering
University of New South Wales
Sydney, Australia
3. Well-Developed Technology based on:
™ Full-scale tests
™ Established mechanistic design procedures
© B Shackel 2009
All Rights reserved
4. Good Precedents over more than 20 years of
use
OPERATIONAL CHARACTERISTICS
OPERATIONAL CHARACTERISTICS
Property
Durability
PAVERS
Good
ASPHALT CONCRETE
Moderate
Good
™ PAVERS
are the only surfacing made
under controlled factory conditions
Property
Durability
Resistance to
Heavy Axle Loads
PAVERS
ASPHALT CONCRETE
Good
Very Good
Moderate
Poor
Good
Very Good
SALDANHA STEEL
SOUTH AFRICA
LADLE CARRIER
(Kress RBC-410)
120 TONS/Wheel
OPERATIONAL CHARACTERISTICS
Property
Durability
Resistance to
Heavy Axle Loads
Resistance to
Slewing Loads
PAVERS
ASPHALT CONCRETE
Good
Very Good
Moderate
Poor
Good
Very Good
Very
y Good
Poor
Very
y Good
OPERATIONAL CHARACTERISTICS
Property
Durability
PAVERS
Good
Resistance to
Very Good
Heavy Axle Loads
Resistance to
Very
y Good
Slewing Loads
Resistance to
Very Good
Concentrated Loads
Container Feet
ASPHALT CONCRETE
Moderate
Poor
Good
Very Good
Poor
Very
y Good
Poor
Very Good
Dolly Wheels
1
OPERATIONAL CHARACTERISTICS
Property
Durability
PAVERS
Good
Resistance to
Very Good
Heavy Axle Loads
Resistance to
Very
y Good
Slewing Loads
Resistance to
Very Good
Concentrated Loads
Resistance to fuel & Very Good
oil spillage
FUEL & OIL SPILLAGE
ASPHALT CONCRETE
Moderate
Poor
Good
Very Good
Poor
Very
y Good
Poor
Very Good
Poor
Very Good
Hydraulically
operated straddle
carriers
oil
COSTS
COSTS
Energy
Consumption
Initial Costs
M i t
Maintenance
COSTS
PAVERS ASPHALT CONCRETE
LOW
HIGH
LOW
LOW
LOW
LOW
HIGH
HIGH
HIGH
Maintenance cost studies have been made for:
More than 500 lane-km of roads
COSTS
Energy
Consumption
Initial Costs
M i t
Maintenance
Salvage Value
PAVERS ASPHALT CONCRETE
LOW
HIGH
LOW
LOW
LOW
HIGH
LOW
HIGH
MEDIUM
HIGH
HIGH
LOW
More than 5 million m2 of industrial paving
These studies show that pavers have only about
30% of the maintenance costs of asphalt surfaces or
concrete rafts
COSTS
COSTS
Energy
Consumption
Initial Costs
M i t
Maintenance
Salvage Value
Life Cycle Costs
COST EFFECTIVENESS
PAVERS ASPHALT CONCRETE
LOW
HIGH
LOW
LOW
LOW
HIGH
LOW
LOW
HIGH
MEDIUM
MEDIUM
HIGH
HIGH
LOW
MEDIUM
Overall, Pavers can provide the best economic solution
™ PAVERS
are often more cost-effective
than asphalt or concrete paving on the
basis of both
ƒ Initial (Construction) Costs
ƒ Whole-of-Life Costs
™ PROJECTS need to be assessed on a
case-by-case basis
2
CONSTRUCTION COSTS
90
90
80
80
70
70
60
60
50
50
40
COST COMPARISONS FOR AIRPORTS
Flexible
40
30
30
20
20
10
Pavers
10
0
0
AUSTRALIA
HOLLAND
20
Rigid
Concrete
Asphalt
15
Pavers
10
5
0
Concrete
0
50
UNIT COSTS
$/m2
100
150
SOUTH AFRICA
B747/400 pavements at Cairns International Airport
COMPARATIVE COSTS FOR INDUSTRIAL PAVEMENTS
APPLICATION
Europe Container
Terminus, Rotterdam
Terminal Yard A,
Port of New Orleans
Berth 208, Port of
Tampa, Florida
PAVERS
Type of
Cost
Initial
Cost
Present
Worth
(4%)
Present
Worth
(6%)
Present
Worth
Units
Pavers
Asphalt
Concrete
fl/m2
55-58
55-61
80-84
2
44.1
-
54.0
US$/m2
43.6
-
52.9
US$
(total)
150000
m2
3.8
million
4.7
million
6.4- 6.9
million
US$/m
80 mm
25 mm
230 mm
Geogrid
230 mm
45
300 mm
compacted
PORT OF TAMPA
3
COST- EFFECTIVENESS
Cost-Effectiveness of concrete
block paving increases with:
Increase in Traffic Loads
™ Increase in Repetitions
™ Reduction in Soil Strength
™ Increase in Design Life
™
FACTORS NEEDING STUDY
FULL-SCALE TESTS OF BLOCK PAVING
Pavement Testing
& Evaluation
ACCELERATED
TRAFFICKING
LABORATORY TESTS
200+ tests
University of N.S.W.
Road Simulator
(Test Track)
Trucks
UNSW SIMULATOR
Industrial
Vehicles
South African
Heavy Vehicle
Simulator
HEAVY VEHICLE SIMULATOR (HVS)
4
HEAVY VEHICLE SIMULATOR (HVS)
Accelerated Loading Facility, ALF
Accelerated Loading Facility
ARRB Transport Research, Australia
NASA TEST
FACILITY
LANGLEY,
VIRGINIA
NASA TESTS
FAST HEAVY SLEWING LOAD
5
NASA TRIALS, LANGLEY, Va
FRONT AXLE LOAD = 22 TONNES
80 mm PAVERS RESISTED
100 CYCLES OF HEAVY
SLEWING LOAD
6
FULL-SCALE HEAVY
FULLDUTY PAVING TESTS
PORT OF FREMANTLE
FULL-SCALE TESTS
PORT OF FREMANTLE
FRONT AXLE LOAD
90 TONNES
LABORATORY TESTS OF BLOCK PAVING
Pavers resist
punching damage
by container feet
Pavement Testing
& Evaluation
ACCELERATED
TRAFFICKING
LABORATORY TESTS
300+ tests
Asphalt exhibits severe
punching damage
University of New South Wales
University of South Australia
7
LABORATORY TESTS
LABORATORY TESTS OF PAVERS
FALLING WEIGHT DEFLECTION (FWD) TESTS
Accelerometers
Loading Plate
PAVER MODULI FOR DESIGN
Test Condition
Moduli (MPa)
FWD tests of trafficked rectangular pavers
500-700
FWD tests of trafficked pavers
720-9600
FWD tests of trafficked shaped pavers
75-19000
Laboratory tests of rectangular pavers
600-750
Laboratory tests of shaped pavers
400-6000
Known
?
Deflection Bowl
Calculated
Recommended E = 3200 MPa - shaped pavers
E = 2500 MPa - rectangular pavers
PERFORMANCE FACTORS
DESIGN CONSIDERATIONS
Both full-scale and laboratory tests
have established the importance of :
1. Spectrum of load magnitudes
not just one "Design Load"
™ PAVER SHAPE
™
™
™
™
™
™
PAVER THICKNESS
LAYING PATTERN
BEDDING & JOINTING MATERIALS
TYPE & THICKNESS OF BASE
TYPE & THICKNESS OF SUB-BASE
SUBGRADE
2. Repetitions of each load in
spectrum
t
nott just
j t Maximum
M i
or
"Equivalent" repetitions
Ideal for computer-based
MCHANISTIC DESIGN
8
DESIGN SOFTWARE
MECHANISTIC STRUCTURAL DESIGN OF
CONCRETE BLOCK PAVEMENTS
• Roads
PAVERS
• Airports
• Industrial
SAND COURSE
Horizontal Tensile Strains
- Predict Fatigue Cracking
+ Cost Analyses
+ Specifications
BASE COURSE
SUB-BASE COURSE
(If Needed)
COMPACTED
SUBGRADE
Structural
Design
Vertical Compressive Strains
Hydraulic
Design
- Predict Rutting
DESIGN LOADINGS
Used in Australia, USA, Canada,
South Africa etc.
REFERENCES
LOCKPAVE uses:
1. Spectrum of load magnitudes
2. Repetitions of each load in
spectrum not just Maximum
loads
REFERENCES
www cmaa com au
www.cmaa.com.au
CASE
HISTORIES
S O
S
Listed in order of increasing loads:
- Roads
- Airports
www.brianshackel.com
www.sept.org
- Industrial Pavements
9
PAVER USAGE IN EUROPE
ROAD
ROADS 36%
INDUSTRIAL 29%
65% of all pavers are used in Engineered Pavements
AIRPORTS
- TERMINAL APRONS
- TAXIWAYS
- TURNING CIRCLES
- HANGARS
- AIR-SIDE ROADS
- HELIPADS
> 80 airports now use
concrete segmental
paving
Howe
CHEK LAP KOK AIRPORT, HONG KONG
CHEK LAP KOK AIRPORT, HONG KONG
> 100 000 m2 of airside paving
10
CHEK LAP KOK AIRPORT, HONG KONG
CAIRNS INTERNATIONAL AIRPORT
INDUSTRIAL APPLICATIONS
- Factory & warehouse
floors
- Container yards
- Intermodal facilities
- Ports
Warehouse floor, Holland
Warehouse floor, Queensland
Factory Yard using Permeable Paving,
Germany
11
EUROPE
CONTAINER
TERMINUS
Rotterdam
100 mm Category A pavers in herringbone bond over Granular Base & Sub-base
SALDANHA STEEL, SOUTH AFRICA
LADLE CARRIER (Kress RBC-410)
Axle Load > 240 tonnes
ECT ROTTERDAM
120mm pavers
50mm sand
350mm CTB
Vertical drains
@ 2m c/c
Hydraulically
pumped sand
fill
Melbourne
PORTS - CASE HISTORIES
Proc 8th International Conf on Concrete Block Pavements, 2003
Brisbane
12
AUSTRALIAN PORT PAVEMENTS
FACILITY
A
Identification
No.
Operational
Mode
C
D
2
3
4
5
6
7
8
9
10
11
FLT
SC
+
TT
SC
+
TT
SC
+
Trucks
SC
+
Trucks
SC
+
Trucks
SC
SC
SC
SC
SC
80
80
80
80
80
80
80
80
80
30
25
20
20
20
20
20
30
30
Pavers
80
Bedding Sand
25
Unbound
Granular Base
Cement
modified
granular base
B
1
280
100
200
250
100
260
370
370
490
HOWLAND HOOK MARINE TERMINAL, NY
80
20
140
560
Cement
treated base
250
Granular subbase
150
Cement
treated subbase
150
280
Granular
working
platform
100
100
Fill materials
Sand
Over
Mud
Subgrade
CBR (%)
15-20
SC = Straddle Carrier
400
Sand
Over
Mud
Sand
Over
Mud
-
15-20
15-20
>25
TT = Transtainer
170
-
Granular
-
-
sand
sand
-
>5
>25
>5
>5
1625
16-25
15
Demonstration Project
Permeable Paving
FLT = Front Lift Truck
5.3 ha of paving
including test area of
0.1 ha of PICP.
Laid mechanically
by 2 machines
installing 1500m2
per day.
HOWLAND HOOK MARINE TERMINAL, N Y
Ecoloc
200 000 passes of Top Pick with wheel loads > 23 000 kg
13
Concrete Block
Paving
PROVEN
STRONG
ECONOMIC
SUSTAINABLE
14