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УДК 693.5:625.7/ 8 DOI: 10.30977/АТ.2219-8342.2018.42.0.126
ON THE ISSUE OF THE USE OF ROLLER-COMPACTED CEMENT-CONCRETE MIXTURES FOR CONSTRUCTION OF ROAD PAVEMENTS
Bugaevsky S.A., Korzun S.N., KhNAHU Vinnikov A.V., Semyonenko V.S., LTD «SK Fortis Group», Bugaevsky M.S., Kharkiv National University of Radio Electronics
Abstract. Problem. At present, on the existing roads of Ukraine the construction of road pavement does not meet the requirements for durability and load-carrying capacity, because of constant increase in traffic intensity, the emergence of new types of vehicles with increased axle loads and uncontrolled transport overload. The widespread use of roller-compacted cement mixes (RCC mixes) in the construction of road pavements for highways will solve these problems. Goal. The aim of the work is to study the effect of the components of a rigid cement-concrete mixture on the physical and mechanical properties of concrete, as well as the industrial introduction of the technology of RCC in Kharkiv. Methods. The methods for assessing RCC characteristics allow to carry out all necessary research on the basis of existing regulations in Ukraine. Results. As a result of the studies carried out, compositions of RCC mixtures on local materials with compressive strengths of 60 MPa were obtained, with a bending strength of more than 4.5 MPa, density of2420 kg/m3 and frost resistance of F200. Novelty. The scientific novelty of the construction works is in the selection of the compositions of RCC mixes by applying high-quality cement, fine sand, two (or three) fractions of rubble, mineral additives, complex additives and nonmetallic fibers, which leads to an increase in the density and strength of the RCC, and also increases the durability of the cement concrete coatings compacted. Practical value. Laboratory research and selection of cement-concrete mixes for production of RCC used in the construction of road pavements were carried out to prove the aims of the work, as well as industrial introduction of the technology of RCC mortar has been carried out by laying the road section on the territory of the enterprise in Kharkiv city.
Key word: composition of cement-concrete mixture, stiffness of cement-concrete mixture, roller-compacted cement concrete mix (RCC mix), compressive strength, tensile strength at bending.
Introduction
At present, on the existing roads of Ukraine the construction of road pavement does not meet the requirements for durability and load-bearing capacity, because of the constant increase in traffic intensity, the emergence of new types of vehicles with increased axle loads and uncontrolled transport overload.
A consequence of this situation is the rapid destruction of asphalt-concrete road surface coatings and rutting. At the same time, it is necessary to repair the surface of non-rigid road coating more often, the repairing time is shortened, so the costs for the maintenance and subsequent repair of road clothes are increased.
Analysis of publications
Construction of monolithic cement-concrete coatings is carried out by concrete rollers on wheel-rail or sliding formwork, as well as of hard concrete mixes, which are compacted by rolling with heavy road rollers [1-10].
The disadvantages of the technology for the construction of monolithic cement concrete pavements with the compacting of concrete mixtures by concrete pavers on wheel-rail or sliding formwork include a longer term for the care of freshly laid concrete, which is at least 28 days, associated with the process of concrete strength hardening; high initial cost of the cement concrete pavement, in comparison with asphalt concrete, at the expense of additional expenses for the admission of motor transport with the existing network of roads, which is especially critical in the construction of road clothes in cities and towns; low comfort of travel on roads with cement concrete coating.
Roller-compacted concrete mixes, on the contrary, allow to obtain a variety of monolithic cement-concrete with the minimum possible water-cement ratio (W/C), at which the maximum degree of compaction of the material by rollers is possible which provides formation of a dense structure. The consistency of the cement-concrete mixture should be such that it can with-
stand the mass of the vibrating roller, and also provide the required degree of compaction [7-9].
When hydrating cement, about 15 % of the water from its mass is needed. Therefore, at a cement consumption of 300-400 kg/m3, 45-60 liters of water are required for chemical interaction. The rest of the water gives the cement-concrete mixture such technological qualities as workability and handling. Reduction of water consumption reduces shrinkage and temperature deformations of cement concrete [7, 10].
Another advantage of using rigid cement-concrete mixtures is the possibility of compacting with the help of the most common machines: motor graders, rubble-spreaders and asphalt rollers. There is no need to use expensive concrete rollers, as well as reinforcement with flat or rolled welded nets.
The technology of RCC includes the following: mixture preparation, transportation, packing, compaction and maintenance. A large spread of RCC received during the construction of dams and retaining walls of dams.
In the countries of Europe and the USA RCC mixtures in road construction are used in the arrangement of layers of road coating intended for the movement of heavy vehicles (container trucks, military vehicles, forestry machinery); container terminals, car parking; access roads, rural, forest roads with high traffic loads; minor roads and lanes, local roads and highways, road access to airports, runways of airfields; as a reinforcement layer in the reconstruction of old road surfaces [9].
Such road coatings are much stronger and more durable than asphalt concrete, in addition, much less time is spent on their compacting than in traditional technologies of monolithic cement-concrete coatings [7-10].
In the road construction, the cement mixes used include Portland cement with the addition of a microfiller, in many cases fly ash (15-20 % of the cement consumption). Such cement-concrete mixture should have a rigid consistency (the workability index on a standard technical viscometer is not less than 30 s), so that it can be laid with asphalt pavers and compacted to the required density by rollers. In Germany, this consistency is classified from earthy-damp to hard, in the USA - as «non-slump». The components of cement-concrete mixture are joined in stationary concrete mixing plants, and after delivery the mixture is placed and pre-compacted by asphalting machines having a large mass. Final compaction is achieved by
means of vibrating, pneumatic or combined rollers [7-10].
The existing experience in the production of road pavements of RCC mixes has shown the possibility of their application in the construction of roads on which vehicles with a large axial load move, for example, in the construction of access roads for super-heavy vehicles on industrial enterprises; sites for parking of fueling and military vehicles, including military and transport aircraft [7-10].
Compressive strength of the RCC can be obtained at the rate of more than 50 MPa. The flexural strength is directly related to the com-pressive strength and, depending on the type of concrete mix, is 3.5-7.0 MPa. The modulus of elasticity is similar or slightly higher than that of conventional cement concrete, if the mixtures have the same cement content. The abrasion of the coating from the RCC and ordinary cement concrete is also similar. A higher percentage of the mortar (micronutrient, cement and sand), as compared to conventional cement concrete, will allow mechanical processing to cure the surface. The bond strength at the joint of layers is sufficient for the placing of layers of the road surface during 1 hour, but may require a reduction in the interval in warmer weather. The mark for the frost resistance of the RCC is higher than that of the conventional concrete, the shrinkage values are usually lower because of the lower W/C, and the permeability (the SP test showed less values) is comparable to that of conventional concrete
[9].
To assess the consistency of the cement concrete mix, a modified WEBE device is used. Effective roller compaction of a rigid cement-concrete mixture is achieved with the rigidity of the mixture by a modified WEBE device from 30 to 40 s [7].
To assess the compatibility of the cement-concrete mixture, the modified Proctor method is used, which is usually applied to determine the compactness of the cement mortar [7].
One of the main advantages of using rigid cement-concrete mixtures as a material for the construction of road coating is the possibility of opening for traffic vehicles in 2 days at temperatures above 20 °C and in 3-4 days at lower temperatures (5-20 °C) [9].
Aims and stating the problem
The aim of the work is to study the influence of the components of a rigid cement-concrete mixture on the physical and mechanical properties of concrete, as well as the industrial applica-
tion of the technology of RCC in Kharkiv. The main task is to obtain the compositions of roller-compacted cement-concrete mixtures for production of coating and foundation of road pavements using local materials.
The Basics of Acquiring RCC
One of the vectors for obtaining cement-concrete mixes for RCC is the use of various industrial wastes to minimize the cost of the final product [11-13].
We know the methods of preparing a cement concrete mixture [11] for the construction of road and airfield coatings, including mixing cement, ash and slag waste incineration, fillers, additives, modifiers, detoxifying additives and water at the following ratio of components (wt. %): Cement 20-25; ash and slag wastes of incineration 40-60; filler 0-30; additive-modifier of concrete 0.02-0.075; additive-detoxicant 0-0.35 and water.
As a modifier additive, a mixture of additives is used: siliceous, plasticizing and curing agent in the ratio, wt. %: siliceous additive 0-58, plas-ticizing additive 17-35 and curing agent 25-65. In this case, the modifier MB 10-01 or microsil-ica or marshalite is used as a siliceous additive.
As additives, detoxicants the following substances are used: SDO, SNB, SGK or their double or triple mixtures, at a weight ratio of 1:(0.5-1) or 1:1:(0.25-0.3), respectively.
The disadvantage of this method of preparing cement-concrete mixture is the need for sorting and separation from metal inclusions and un-burned fractions of waste incineration, as well as their detoxification. The instability of the physic-mechanical characteristics of waste incineration can lead to a significant spread of strength and frost resistance of the RCC.
The procedure of preparing a cement concrete mixture is known [12], which involves mixing cement, fly ash, sand, coarse aggregate and water with the following component ratio, wt. h.: cement 270-340; fly ash 60-130; sand 510; a large aggregate 1260 and water 200. Various functional additives are added to the ash slurry during the activation and/or after its termination: plasticizing and water-reduction, water-retaining or pumping improvers, retarders and/or accelerators of setting and curing, colma-tizing pores, gas forming, air-entraining and anti-freezing.
The disadvantage of this method of preparation of cement-concrete mixture is a wide spread of cement consumption and fly ash, which affects the amount of fine and coarse aggregate.
Additional activation of the ash is necessary for a twofold increase in the specific surface area of the ash particles. The composition uses a large amount of water (W/C = 0.42-0.50), which reduces the stiffness of the concrete mixture, and therefore cannot be used as a high-strength roller-compacted cement mortar for road surfaces.
Another method of preparing cement-concrete mixture [13] for the construction of road and airfield coatings is to mix cement, activated fly ash, sand, coarse aggregate, fine fraction up to 3 mm and coarse fraction from 5 mm to 20 mm of asphalt concrete granulate (AG) with water at the following ratio of components, wt. h.: cement 356; fly ash 89; sand 561; large filler 685; AG (fine) 50; AG (large) 468; water 180. The superplasticizer C-3 is used as the plas-ticizing additive.
The disadvantage of this method of preparation of the mixture is a large number of components in its composition, the need for additional activation of the fly ash in the pebble mill, as well as crushing followed by screening along the fractions of the milled asphalt concrete. In this case, the strength class of concrete does not exceed B25, and the frost resistance of F100. The method of preparing a mixture of this type is very complex, along with the breakdown of all the aggregates into three parts and with the phased introduction of each component into the mixer, with the necessary subsequent processi-ing.
To select the composition of the roller-compacted cement-concrete mix, laboratory tests were performed with different types of cements, gravel, sand and additives (Table 1).
The optimum water-cement ratio was selected for the formation of samples from a rigid cement-concrete mixture (Fig. 1).
The basis for obtaining a cement-concrete mixture is the use of high-cement cement, fine sand, two (or three) fractions of rubble, mineral additives, complex additives and nonmetallic fibers, which will lead to an increase in the density, RCC compressive strength, waterproofness and frost resistance, and also increase the durability of the produced road coatings.
As complex additives, depending on the temperature conditions of laying the roller-compacted cement-concrete mixture, there can be the following components: plasticizing and water-reducing; water-retaining or improving pumping capacity; retarders of setting and curing; accelerators for setting and curing; colored pores; gas-forming additives; air-entraining and anti-freezing components.
Table 1 - Selection of the composition of the roller-compacted cement-concrete mixture for coating and base
Components Composition variations
I II III IV V VI VII VIII IX X
Cement PC I-500R-N Ivano-Frankivsk + + + + + +
Cement PC II/B-S-400 Krivoy Rog + +
Cement PC II/A-S-500 Belorus + +
Sand Mk = 1.4-1.6 Kremenchuk + +
Sand Mk = 0.6-0.9 Unspecified + + + + + + + +
Crushed granite. 5-10 mm "Quartz" + + + + +
Crushed granite. 5-20 mm "Quartz" + + + + + + + + + +
Ground granulated slag +
Universal Additive-Accelerator Uni-versal-BM (metakaolin) + + + + + + + +
Quantec PL-421 Additive + +
Polyplast additive PFM-NLK + +
Complex additive Plasticent BV-41 (lignosulfanate with air-entraining component) + + + + + +
Basalt fiber 24 mm + +
Propylene fiber 10 mm + + +
Strength (class) of concrete, MPa 69.4 C50/60 21.8 С16/20 66.7 C50/60 21.2 С16/20 66.6 C50/60 20.2 С16/20 61.4 C50/60 20.8 С16/20 62.8 С50/60 20.4 С16/20
Fig. 1. Selection of the composition of the roller-compacted cement-concrete mixture: a -mixing cement-concrete mixture in the laboratory; b - laying of the cement-concrete mixture in the form-prism; c - laying cement-concrete mixture in a cube-shape
In the method of preparing cement-concrete mixture, which received the patent of Ukraine [14], the order is as follows: two fractions of rubble 5-10 and 5-20 mm are mixed with sand and nonmetallic fiber 10-25 mm long, then cement and mineral additive with a specific surface of not less than 3-5 thousand cm2/g is tak-
en, followed by mixing, Subsequently, mixing water with a complex additive is added and all the components are finally mixed.
Compositions of rigid cement-concrete mixtures, offered for the construction of road coatings for motor roads, are given in Table 2.
Table 2 - Compositions of rolled cement for concrete and coating
Components and properties of concrete
Cement PC 500
Crushed stone 5-20 mm
Crushed stone 5-10 mm
Sand
Mineral additive
Complex additive Plas-ticent BV41
Basalt fiber 24 mm
Water
Density
Characteristic cubic strength 3 days
Characteristic cubic strength 28 days
Tensile strength for bending 28 days
Frost resistance
Units of measurement
kg/m
3
kg/m
T"
kg/m3
kg/m3
kg/m3
kg/m3
kg/m3
kg/m3
kg/m3
MPa
MPa
MPa
brand
Composition
1
420
770
480
550
25
2.1
1.5
151
2420
12.0
60.0
4.5
F200
2
180
1400
702
1.1
58
2350
6.0
20.0
2.0
F100
c
In the laboratory of the Department of Building Constructions of the KhNUUE named after O.M. Beketov tests were conducted with cement concrete-type prism specimens, molded in an insheet metal formwork during the laying of the experimental section of the road from the rolled concrete, located at: Babayi, Soborna st., 18. Experimental site is chosen at the entrance to the territory of industrial warehouses, where intensive traffic of freight transport is carried out.
On the construction site, prism samples were made in an inventory metal formwork measuring 15x15x60 cm, which were stored in conditions close to reality. The seal was carried out using a HILTI TE 76 perforator with a special packing (two layers 7-8 cm thick, Fig. 2).
Fig. 2. Forming of a prism sample
Tests of cement-concrete prism samples on stretching during bending as well as on compression were carried out at a temperature of 18 °C on a hydraulic press PSU-250 in accordance with the requirements of DSTU B V.2.7-214: 2009. The compression test was carried out by means of two metal plates measuring 15 cm by 15 cm in thickness, 1 cm thick by loading the end part of the half-prisms (Fig. 3).
a b
Fig. 3. Strength tests: a - sample-prism; b -sample-cube
Below in Figures 3 and 4 the processing data of the test results for cement-concrete samples are shown.
To assess the consistency of a rigid cement-concrete mixture, only the WEBE device was used, the Krasnyi device and the Skramtaiev method did not allow to obtain reliable data for determining the grades of concrete mixes according to the workability of L3-L4. Effective placement of cement concrete mix with a vibration plate was achieved with a stiffness of 25-30 s.
The main technological operations performed during the laying of the roller-compacted cement-concrete mixture on the test site:
1. Cutting old asphalt concrete on an area of 36 m2.
2. Overplacement and leveling as the base of the crushed stone, with thickness of 20 cm.
3. Compacting of crushed stone with a vibration plate weighing 450 kg (Fig. 4, a).
4. Irrigation of the upper layer of the base before placing the cement-concrete mixture (Fig. 4, b).
5. Delivery of cement concrete mix covered with a tarpaulin to the construction site with an onboard dump truck (Fig. 4, c).
6. Unloading cement-concrete mixture in the middle of the compacted section (Fig. 4, e).
7. Leveling the cement-concrete mixture and cutting off the surplus small-sized caterpillar excavating machine (Figure 4, f).
8. Compacting RCC mix with a vibration plate weighing 450 kg (Fig. 4, e).
9. After compaction, apply RCC Surfase Pro (grouting agent) to improve surface treatment and cure it (Fig. 4, g).
10. Mechanical surface treatment was carried out using a two-rotor concreting machine with a disc diameter of 900 mm. In places where old asphalt-concrete is interfaced with a new cement-concrete coating, the mechanical treatment was carried out by a single-rotor concrete cutting machine with a disk diameter of 600 mm (Fig. 4, h).
11. To enhance the bond strength, the surface of the coating was applied with a special metal brush.
12. After the processing of concrete machines and the creation of a smooth surface, the Sinak S-102 concrete care agent was applied to prevent early evaporation of water and additional hardening of the surface, which is equivalent to 14 days of watering (Fig. 4, k).
Table 3 - Determination of the strength of cement concrete for bending elongation
№ Area A, cm2 Moment of resistance W, cm3 Destructive force Л kgs Bending moment M, kgs-cm Bending tensile strength kgs/cm2 (MPa)
1 225 562.5 4800 24000 4.27
2 225 562.5 5700 28500 5.07
3 225 562.5 5200 26000 4.62
The average value of the tensile strength at bending 4.65
Table 4 - Determination of the compressive strength of cement concrete
№ Area А, cm2 Destructive force P, kgs Compressive strength, cube R, MPa ( R - Rm ), MPa Mean square deviation, MPa The coefficient of variation , % Strength (class) of concrete , MPa
1 225 132000 58.7 -0.9 2.83 4.8 54.7 (C40/50)
2 225 142500 63.3 +3.7
3 225 129000 57.3 -2.3
4 225 132500 58.9 -0.7
5 225 127500 56.6 -3.0
6 225 141500 62.9 +3.3
The average value, Rm 59.6
The coefficient of variation for heavy cement concrete is adopted, % 5.0
g h i Fig. 4. Compacting of cement-concrete mixture using technology of roller-compacted cement-concrete in the experimental section: a-i - sequence of technological operations
After a set of 70-75 % concrete strength on the fourth day, the traffic was opened on a stretch of road laid with the roller-compacted cement mix.
Conclusions
The use of high-strength Portland cement with a mineral additive in the form of metakaolin or ground granulated slag, nonmetallic fiber, fine sand and two (or three) fractions of
coarse aggregate made it possible to obtain the compositions of the roller-compacted cement mix for the construction of road coating of highways with high strength and density of cement concrete.
It should be noted that the use of such a concrete mix requires a low energy intensity, provides less shrinkage due to a low water-cement ratio (V/C = 0.23-0.36), increases the distance between the expansion joints, and, most importantly, shortens construction time.
The conducted laboratory and pilot tests confirmed the possibility of widespread use of roller-compacted concrete mixtures for the construction of cement concrete roads in Ukraine and the need to develop local regulatory documents for the selection of the composition and technology of laying on the basis of the experience of the United States and European countries.
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Bugaevsky Sergey Alexandrovich, Ph.D., Associate Professor of Department Bridges and structures and structural mechanics, +38050-937-90-16, bugaevskiysa@gmail.com,
Korzun Sergey Nikolaevich, graduate student, +38050-756-62-99, asanstalker@gmail.com Kharkov National Automobile and Highway University, 61002, Ukraine, Kharkov, Yaro-slav Mudryi st., 25,
Vinnikov Alexey Vladimirovich, director, Semyonenko Vyacheslav Sergeevich, engineer,
+38057-727-07-87, mailfortiskh@gmail.com LTD «SK Fortis Group», 61001, Ukraine, Kharkov, Zdoroviya Na-bereгhnaya st., 12.
Bugaevsky Mikhail Sergeevich, student, +38066-693-79-27, bugaevsky73@gmail.com Kharkov National University of Radio Electronics, 61166, Ukraine, Kharkov, Nauki Ave., 14.
ДО ПИТАНИЯ ПРО ЗАСТОСУВАННЯ ЦЕМЕНТОБЕТОННИХ СУМ1ШЕЙ, ЩО
УКОЧУЮТЬСЯ ДЛЯ БУДГОНИЦТВА ДОРОЖН1Х ОДЯГГО АВТОМОБШЬНИХ ДОР1Г
Бугаевський С.О., Корзун С.М., ХНАДУ, Вшников О.В., Семененко B.C., ТОВ «БК "Фортк Груп"», Бугаевський М.С., Харшвський нащональний ушверситет радшелектрошки
Анотащя. У наш час на iснуючих автомобг-льних дорогах Украши конструкцИ дорожнъого одягу не вгдповгдають еимогам за довговгчтстю i несучою здатнгстю, у зв 'язку з постшним зрос-танням ттенсивностг руху, вантажонапруже-Hocmi перевезень, пояеою нових eudie транспортних засобгв 31 збшьшеними наеантаженнями на oci и неконтролъоеаним перееантаженням транспорту. Широке застосування цементобетонних сумгшеи, що укочуються при будгвництвi дорож-Hix одяггв автомобшьних dopiz, дозволить eupi-шити u,i проблеми. Метою роботи е дослгдження впливу компонентгв жорстког цементобетонног cyMirni на ф1зико-мехатчт властивостг цементобетону, а також дослгдно-промислове впрова-дження технологи цементобетонну, що укочу-еться в м. XapKoei. Методика оцгнки характеристик укочуваних цементобетонгв виконувалася на основ! дгючих норматиених документгв в Укра'тг. В результатi проеедених дослгджень отримано склади укочуваних цементобетонних сумгшеи на вгтчизняних матергалах ¡з мщтстю на стиск 60 МПа, при розтягуваннi на еигин бгльше 4,5 МПа, 3i щглъшстю 2420 кг/м3 i морозо-стшюстю F200. Наукова новизна роботи полягае в nid6opi склаЫе укочуваних цементобетонних сумгшеи шляхом застосування високомарочного цементу, дргбного теку, двох (або тръох) фрак-цш щебеню, мтеральног добавки, комплексноi добавки i неметалевог фгбри, що приводить до збгльшення щгльностг и мгцностг цементобетону, що укочуеться, а також тдвищуе довговгч-тстъ noKpummie, що зводяться. Проведено лабо-
раторн/ дослгдження / тдб1р склаЫе цементо-бетонних сумгшей для отримання цементобетону, що укочуетъся та застосовуетъся при будгвництв! дорожнгх одяггв. Виконано дос-лгдно-промислове впровадження технологи цементобетона, що укочуетъся, шляхом укладання Ылянки дороги на територи тдприемства в м. ХарковI.
Ключoвi слова: склад цементобетонног сумг-Ш1, жорстюсть цементобетонног сумшг; цементобетон, що укочуетъся, мщнгсть на стиск, мщтсть на розтяг при згинг.
К ВОПРОСУ ОБ ИСПОЛЬЗОВАНИИ УКАТЫВАЕМЫХ ЦЕМЕНТОБЕТОННЫХ
СМЕСЕЙ ДЛЯ СТРОИТЕЛЬСТВА ДОРОЖНЫХ ОДЕЖД АВТОМОБИЛЬНЫХ ДОРОГ
Бугаевский С.А., Корзун С.Н., ХНАДУ, Винников А.В., Семененко B.C., ООО «СК "Фортис Групп"», Бугаевский М.С., Харьковский национальный университет радиоэлектроники
Аннотация. Проведены лабораторные исследования и подбор составов цементобетонных смесей для получения укатываемого цементобетона, применяемого при строительстве цементобетонных покрытий. Выполнено опытно-промышленное внедрение технологии укатываемого цементобетона путем укладки участка дороги на территории предприятия в г. Харькове.
Ключевые слова: состав цементобетонной смеси, жесткость цементобетонной смеси, укатываемый цементобетон, прочность на сжатие, прочность на растяжение при изгибе.
