Rigid Overlay Design
FAARFIELD 1.3 Workshop
Federal Aviation Administration
Presented to: IX ALACPA Seminar on Airport Pavements Ciudad de Panam, Panam
By: David R. Brill, P.E., Ph.D. Date: September 13, 2012
FAARFIELD Overlay Design
HMA Overlays on Flexible Pavement
Same as designing a new flexible pavement, except the design layer is the HMA overlay.
PCC Overlays on Flexible Pavement
Same principle as new rigid design.
HMA Overlays on Rigid Pavement PCC Overlays on Rigid Pavement
More complex than new rigid pavement design. Both slabs (base PCC and overlay) deteriorate with applied traffic. Stresses are computed for both slabs. E-modulus of the base slab is a function of reduced SCI. Subroutines were completely rewritten for FAARFIELD.
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FAARFIELD Overlay Design PCC on Rigid Overlays
Fully bonded overlays
Treat as a new rigid pavement design. Thickness of overlay slab is hoverlay = hdesign hexist.
Unbonded overlay
Bond breaker or leveling course is used.
Partially bonded overlay
No longer a standard design in AC 150/5320-6E. Default in FAARFIELD is off. May be enabled from the Options window, but displays a Non Standard Structure message.
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FAARFIELD Overlay Design Required Inputs
Existing rigid pavement condition is characterized by the Structural Condition Index (SCI). SCI derived from PCI as determined by ASTM D 5340 Airport Pavement Condition Index Surveys. The new AC gives guidance on SCI. SCI is computed using only structural components from the PCI survey. SCI = 80, FAA definition of structural failure (50% of slabs with structural crack) For existing pavements with structural damage (SCI < 100)
The user inputs a value of SCI for the existing pavement. The range of allowable values depends on the overlay type:
Rigid on Rigid Overlays: SCI 40100 Flexible on Rigid Overlays: SCI 67100 (was 50-100)
The Help file gives approximate formulas for relating SCI to Cr and Cb factors in earlier method.
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FAARFIELD PCC Unbonded Overlay Design Structural Condition Index (SCI)
Rigid Pavement Distress Types Used to Calculate SCI
Distress Corner Break Longitudinal/Transverse/Diagonal Cracking Shattered Slab Shrinkage Cracks (cracking partial width of slab)* SpallingJoint Severity Level Low, Medium, High Low, Medium, High Low, Medium, High Low Low, Medium, High
SpallingCorner
Low, Medium, High
* Used only to describe a load-induced crack that extends only part of the way across a slab. The SCI does not include conventional shrinkage cracks due to curing or other non load-related problems.
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Cumulative Damage Factor Used (CDFU)
For existing pavements where SCI=100 (no structural distress):
There is no visible distress contributing to reduction in SCI (no structural distress types). However, some pavement life has been consumed by the applied traffic. The amount of pavement life consumed is the percent CDF Used (%CDFU). Need to estimate a value of %CDFU. The Help file gives guidance on estimating %CDFU using the Life key.
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Cumulative Damage Factor Used (CDFU)
CDFU defines the amount of structural life used. For structures with aggregate base:
LU = number of years of operation of the existing pavement until overlay LD = design life of the existing pavement in years
FAARFIELD modifies this relationship for stabilized subbases to reflect improved performance.
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HMA on Rigid Overlay Example
Pavement Structure:
Flexible Overlay (P-401) PCC Slab (P-501), 400 mm, R = 4.85 MPa, SCI = 70 Cement Treated Base (P-304), 150 mm Crushed Aggregate Base (P-209), 200 mm Subgrade k = 27 MPa/m
Traffic Mix:
Use the traffic mix from the new rigid design example, but remove B777 and A380 from the mix.
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HMA on Rigid Example Set-Up
Create a new section in job Workshop by dragging section AConRigid in Samples to Workshop.
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Change Pavement Structure
Double click on the job Workshop. (The section AConRigid is highlighted.) Click the Structure button to open the Structure window.
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Change Pavement Structure
Click Modify Structure. Make changes to the PCC, base, subbase and subgrade layer properties.
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Change Pavement Structure
Click on the label SCI=67 at the top of the display. In the Changing Existing SCI dialog box enter 70 and click OK.
Click End Modify then Save Structure to save changes.
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Copy Airplane List
Click on Airplane
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Copy Airplane List
Click Clear List to remove the sample airplanes.
Then click Add Float to add the float airplanes.
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Modify Airplane List
Double-click on the A380-800 and B777300ER. This will remove those airplanes from the design list. (Alternatively, highlight the airplane and click Remove once.)
When done, click Save List then Back.
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Run Design
Click Design Structure to run the overlay design.
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HMA on Rigid Overlay Final Design
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PCC on Rigid Overlay Example
Existing PCC structure will receive a P-501 PCC overlay to support additional traffic.
Assume R for new concrete = 4.65 MPa
Existing Pavement Structure:
PCC Slab, 400 mm, R = 4.85 MPa SCI = 100. Estimate %CDFU from traffic history. Cement Treated Base, P-304, 150 mm Crushed Aggregate Base, P-209, 200 mm Subgrade k = 27 MPa/m
Design Traffic Mix:
Use same traffic mix as in the new rigid pavement design example.
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Estimate %CDFU (Example)
Assume the following traffic mix was applied to the existing pavement: No. 1 2 3 Name Adv. B727-200C Basic B737-700 DC8-63/73 Gross Wt., Tonnes 78.000 70.000 161.000 Annual Departures 1,200 500 260
Assume that at the time of the overlay the pavement will have been in operation 12 years.
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Procedure to Estimate %CDFU
Input the original pavement structure. Estimate the annual traffic applied to the existing pavement up to the time of the overlay. Set Design Life to the number of years the pavement will have been in operation at the time of the overlay. Assume that at the time of the overlay the pavement will have been in operation 12 years. Run Life to obtain %CDFU.
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Estimate %CDFU (Example)
In the Workshop job, open the section NewRigid. In the Structure window, enter the existing pavement structure (no overlay). Change the design life to the number of years that the pavement will have been in service at the time of overlay (12 years in this example.) Click Airplane to go to the Airplane window.
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Estimate %CDFU (Example)
Enter the annual traffic applied to the existing pavement structure.
Click Back to return to the Structure window.
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Estimate %CDFU (Example)
Click Life to run Life.
The calculated %CDFU will appear on the Structure window, at the lower left of the pavement section. %CDFU = 54.58 (Say 55%).
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PCC on Rigid Overlay Change Structure
In the Structure window, click Modify Structure.
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PCC on Rigid Overlay Change Structure
Click Add/Delete Layer.
Select the PCC surface layer by clicking on it with the mouse. In the dialog box, select Add and click OK. A new PCC surface layer appears.
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PCC on Rigid Overlay Change Structure
You must change the top layer to an overlay. Click on the Layer Material box.
In the Layer Type Selection Box, select Overlay Fully Unbonded and click OK.
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PCC on Rigid Overlay Change Structure
In the upper right corner of the Structure window:
- Change Design Life to 20 years (standard). - Change SCI to 100. - Change %CDFU to 55.
Change R (overlay) to 4.65 MPa. Click End Modify.
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PCC on Rigid Overlay Change Structure
Click Save Structure.
Click Airplane to go to the Airplane window.
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PCC on Rigid Overlay Change Airplane List
Click Clear List to clear all aircraft from the list. Add the design aircraft list manually or using the Add Float function.
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PCC on Rigid Overlay Change Airplane List
Click Save List
Click Back to return to the Structure window.
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Run Overlay Design
Click Design Structure to run the overlay design.
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Example: PCC on Rigid Overlay Final Design
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Thank You
Questions?
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