AAPA 2011 Study Tour Agenda

Wednesday, 7 September 2011

09:00 09:30 Welcome & introduction to CSIR R&D projects (including APT) B Verhaeghe

09:30 10:15 Part B: Binders - Specifications for bituminous binders J O'Connell

10:15 11:00 Part B: Binders - Bitumen-rubber/Sasobit J Muller11:00 11:15

11:15 13:15 Part C: Improving pavement performance - SAPDM and management of the road network

L Kannemeyer H Theyse

13:15 13:45

13:45 14:30 Part C: Improving pavement performance - High Modulus Asphalt and Agrement South Africa E Denneman

Coffee break

Lunch

Welcome!

Overviews of CSIR Activities

Benoît Verhaeghe

Development - new

technologies, products or

services

Directed research

- new understanding

of research domains

Implementation - impact on

economy and society

Basic research

- advancement of knowledge

Industry/ Public Sector

CSIR

Tertiary Education Institutes

The CSIR spans the research and innovation value chain but its role is differentiated from universities and commercial R&D

Strategic Position in the National System of Innovation

• CSIR head office in Pretoria • 10 regional offices across the country

© CSIR 2009

• 2 400 staff • 1 500 staff in science, engineering

and technology base • 757 staff with Master’s and PhDs

degrees

CSIR People

• Total operating income: R1 723.6 m – Parliamentary Grant: R535.3 m – Contract research: R1 175.1 m – Royalty income: R8.7 m – Other income: R4.5 m

CSIR financials

CSIR at a glance

(figures as at 31 March 2011))

Our foot print

The brand story

• The brand story

CSIR Architecture

CSIR Research Impact Areas

CSIR Built Environment

Core focus: Support South Africa’s competitive performance and welfare through development of efficient and globally competitive built environment systems; appropriate and efficient components and relevant technologies to support, through R&D, technological innovation and selected specialised value-added services Competence areas

– Planning support systems – Infrastructure engineering – Building science and technology – Infrastructure systems and operation – Logistics and quantitative methods

Executive Director: Hans Ittmann

Planning Support Systems

Louis Waldeck

Urban and Regional Planning

Maria Coetzee

Building Science & Technology

Theuns Knoetze Architectural

Engineering Peta de Jager

Construction Industry Development

Sihle Dlungwana

Construction Materials and Methods

Joe Mapiravana

Infrastructure

Systems & Operations Derick Matthee

Passenger & Freight Transport Operations Mathetha Mokonyama

Intelligent Systems &

Traffic Management Kobus Labuschagne

Network Asset Management Systems

Paul Nordengen

Logistics and

Quantitative Methods Theo Stylianides

Statistical Modelling and Analysis

Pravesh Debba

Advanced Modelling & Supply Chain Research

Gert Engelbrecht

BE Fellows: Antony Cooper, Morris de Beer, Phil Paige-Green, Louis Waldeck, Kevin Wall

CSIR BUILT ENVIRONMENT – JUNE 2011

Coastal Engineering & Port Infrastructure

Dave Phelp

Infrastructure Engineering

Benoit Verhaeghe

Transport Infrastructure Engineering

James Maina

Advanced Material

Testing Dave Ventura

Accelerated Pavement Testing Louw du Plessis

Rock Mechanics

Laboratory Sarel Coetzer

Hydraulic Laboratory Kishan Tulsi

Outcomes Management

Venantio Mzenda

Strategic Research

Management Chris Rust

Strategic Contract R&D Management

Kenny Kistan

Quality Management Mary Mabuse

Technical Assessment

Benson Wekesa

Drawing Office Isabella Thysse

Agrément South Africa Joe Odhiambo

ACTP

Llewellyn van Wyk

Sustainable Human

Settlements Tinus Kruger

Infrastructure engineering

R&D areas within infrastructure engineering: Transport infrastructure engineering and accelerated road testing (e.g. design, construction and maintenance of transport infrastructure assets - roads and airports; sustainable and cost-effective transport network; accelerated testing of roads and advanced testing of materials, including traditional, waste and novel materials; engineering design, analysis and modelling; vehicle-pavement and infrastructure-environment interaction; geotechnical engineering and rock mechanics; environmental engineering and sustainable construction; performance data capturing techniques and instrumentation; international research collaboration in accelerated pavement testing)

Coastal engineering and port infrastructure (e.g. predictive engineering solutions and decision support for safe and cost-effective development and operation of ports and coastal structures; physical modelling of environmental impact on ports and coastal structures; physical and numerical modelling of moored and manoeuvring ships; wave fore and hind-casting, and wave diffraction, refraction and reflection modelling; collect and manage real-time environmental data on waves, tides, currents, wind, weather and bathymetry for ship and port operations; monitor impact of marine environment on coastal structures specialist support to local and international port/harbour authorities, consultants and contractors)

Staff complement

• 71 permanent staff members

• Qualifications • 7 staff members holding a PhD • 9 staff members holding a Masters degree

• 3 staff members studying towards a PhD • 6 staff members studying towards a Masters degree

• Location

• Transport Infrastructure engineering • Research staff & laboratories : CSIR Campus (Bld 2) • Satellite office : UCD, California • HVS activities : Field test sites

• Costal engineering & port infrastructure : CSIR, Stellenbosch

Research Areas • Recycled Materials - Secondary cementation • Chemical and liquid stabilisers - physical bonding • Durability and performance of stabilised materials - carbonation

Theories • Stabilised material curing – Laboratory versus field • Application of soil mapping to infrastructure/geotechnical

engineering • Structural failures in the road environment: Slope stability • Climate Change mitigation and adaptation • Nano technology applications in pavement materials technology • Performance prediction of bitumen based on chemical analysis • Chemical properties of materials- Accelerated laboratory ageing –

long-term performance • Environment-friendly materials and processes

– Alternative materials and by-products – Cold-mix technology – Warm-mix technology – Manufacturing process

Nano-Technology Applications • Visibility of roads and road furniture is vital for road safety • New developments in nano-technology investigates the development of

nano-phosphors – Nano-phosphors can be synthesized, blended and engineered for

specific properties – Ability to engineer a material to be luminescent in terms of colour,

duration and intensity – Activated by UV through the day, luminescent at night (broadly

speaking) – Add to cement, road binder, transparent paint etc

• Combination of nano-phosphors and infrastructure materials may lead to low-energy visibility

Agriculture-Based Binders

• Findings – Proven in principle – Similar to bitumen in some

respects, cementitious materials in other respects

– Properties (example): • ITS > 1700 kPa • E > 10 GPa

• Spin-offs

– Processing of waste produce from agriculture

– Small agricultural industries (local producers/farmers of solid and solvent)

Research Areas (advanced measurements)

• Advanced observational techniques of materials – 3D laser scanning, CT Scans, SEM and Atomic Force Microscopy

• Advances in existing test methods – i.e. strain-at-break, tri-axial, shear testing, DSR, etc

• Concept development of new-generation HVS & associated equipment

Research Areas (pavement engineering)

• FEM development and verification, including development/improvement of PADS suite

• Limit state design of concrete & fracture mechanics • Advanced deflection analyses - Differences between the

deflection and hence stiffness results from different devices • Concrete pavement studies – focus on environmental issues • Mitigation of solar radiation – focus on temperature and

durability • Long-life pavements

www.sapdm.co.za

Accelerated Pavement Testing

• Rigid pavements – Structural design

– Ultra-thin reinforced concrete

– Fibre-reinforced concrete

– Roller compacted concrete

• Flexible pavements – Stabilisation technology

– HMA grading optimisation

– Binder technology

– HiMA technology

Vehicle-Pavement Interaction and Full-Scale Assessment

• Heavy Vehicle Simulator (HVS)

Ultra-Thin Reinforced Concrete

– 20 to 60 mm Layer Thickness (160 – 230) – 50 x 50 mm (Ø4mm to Ø8mm) Welded Mesh

• Up to 4.5% Steel (0.6% for Traditional CRCP) – Ultra High Strength Cement (UHSC) Paste

• Compressive Strength = 120 - 140 MPa (35 – 40) • Flexural Strength = 7 – 15 MPa (4.2 - 4.5)

– Water Cement Ratio = 0.27- 0.30 (0.32 – 0.40) – Steel- and polypropylene fibres.

Ultra Thin Continuously Reinforced Concrete Pavement

GFIP – N12 Freeway N1 Freeway

Cold in-place recycling

• Deep in-situ recycling with cement, bitumen emulsion and foamed-bitumen

• Advantages – Conservation of natural

aggregates – Energy savings – Minimises traffic disruption

and time delays – Wide range of distresses can

be rectified – Significant cost savings

Vehicle-Pavement Interaction and Full-Scale Assessment • Stress-in-Motion (SIM)

Road R80

• 7-day average maximum temperature: 58 ºC • Minimum surface temperature: -0.6 ºC • Test conducted over 40 ºC to 60 ºC temperature range

Accelerated Pavement Testing site

Standard versus n- and M-shape contact stresses

INFLATION PRESSURE = 420 kPa

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 200

200

400

600

800

1000

1200

1400

1600

PIN NUMBER ACROSS VRSPTA

Tyre width: 220 mm

20kN 30kN 40kN 50kNWHEEL LOAD:

CO

NTA

CT

STR

ESS

(kPa

)

INFLATION PRESSURE = 420 kPa

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 200

200

400

600

800

1000

1200

1400

1600

PIN NUMBER ACROSS VRSPTA

Tyre width: 220 mm

20kN 30kN 40kN 50kNWHEEL LOAD:

CO

NTA

CT

STR

ESS

(kPa

)

1000

1200

1400

1600

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 200

200

400

600

800

720 kPa620 kPa520 kPa420 kPa

Tyre width: 220 mm

PIN NUMBER ACROSS VRSPTA

INFLATION PRESSURE::

Tyre Load = 18 kN

1000

1200

1400

1600

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 200

200

400

600

800

720 kPa620 kPa520 kPa420 kPa 720 kPa620 kPa520 kPa420 kPa

Tyre width: 220 mm

PIN NUMBER ACROSS VRSPTA

INFLATION PRESSURE::

Tyre Load = 18 kN

Uni- versus bi-directional traffic

Bi-directional traffic

-10

-8

-6

-4

-2

0

2

4

6

8

10

900 1000 1100 1200 1300 1400 1500 1600 1700 1800

Cross Sectional Distance (mm)

Perm

anen

t Def

orm

atio

n (m

m)

446A4 447A4

Caravan side Traffic side

Standard versus n- and M-shape contact stresses

-8

-6

-4

-2

0

2

4

6

8

900 1000 1100 1200 1300 1400 1500 1600 1700 1800

Cross Sectional Distance (mm)

Perm

anen

t Def

orm

atio

n (m

m)

446A4 447A4 448A4 445A4A

Standard load

n-shape load

m-shape load

Assessment of rut-resistant mixes

• Bailey method:

Fine-graded mixes: <90% of loose unit weight Coarse-graded mixes: 95-105% of loose unit weight Stone-mastic asphalt: >100% of rodded unit weight

Aggregate packing

Mix Bailey CA CUW DASR porosity

Reference 74 % (fine) 52 % (fine)

East Rand 99 % (coarse) 48.3 % (coarse)

West Rand 105 % (coarse) 46.9 % (coarse)

ØCA CUW: Coarse Aggregate Chosen Unit Weight ØDASR: Dominant Aggregate Size Range

Gradings

0

10

20

30

40

50

60

70

80

90

100

0

Sieve size (raised to power 0.45)

perc

enta

ge p

assi

ng

Reference mix Rut challenge E-Rand Rut challenge W-Rand

PCS

(2.3

6 m

m).

SCS

(0.6

0 m

m).

TCS

(0.1

5 m

m).

Hal

f sie

ve (4

.75

mm

).

0.075 0.300 1.18 2.36 4.75 6.7 9.5 13.2 0.015 0.600

Comparison (channelised)

60C vs 70C Rut resistant summary

0.0

0.5

1.0

1.5

2.0

2.5

0 10000 20000 30000 40000 50000 60000 70000 80000 90000 100000

Repetitions

Ave

rage

tota

l sur

face

rut [

mm

]

451A4 TOTAL AVG CS 451A4 AVG TS 452A4 TOTAL AVG CS 452A4 AVG TS

Comparison (channelised)

Comparison between STD and RR1 HMA mixes - Temperature

0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

16.0

18.0

0 20000 40000 60000 80000 100000 120000

Repetitions

Tota

l sur

face

rut [

mm

]

441A4 TOTAL CS 441A4 TOTAL TS 451A4 TOTAL CS 451A4 TOTAL TS 452A4 TOTAL CS 452A4 TOTAL TS

60C and 70C

58.5C

60.9C

HVS International Alliance

HVSIA Activity Matrix (www.hvsia.co.za)

Benefits of the HVS Programme

Impact and Benefits of the SA HVS Programme

üGauteng, national & SADC pavement design standards and guidelines üMaterial specifications and guidelines üDevelopment of human resources üCapacity building in industry üInnovative products and designs

Breadth of benefits Materials/methods development of a new large-stone mix

design method; use of modified binders in mixes; in situ recycling of materials (using cement, lime, foamed bitumen and bitumen emulsion); block paving (masonry and concrete); coarse power station generator ash; roller compacted concrete; slag; bitumen-rubber; waterbound macadam; recycled asphalt base; upgrading of gravel roads; marginal natural aggregates with various additives; high quality granular bases; evaluation of drainage layers as structural layers; lime-stabilized sand subbases under bitumen; design and rehabilitation procedures for concrete roads; lightly-cemented base pavements; identification and evaluation of cost-effective rehabilitation techniques; evaluation of labour-intensive construction methods; testing various asphalt base pavements and improving the design, analysis and understanding of the behaviour of such pavement types; porous asphalt

Breadth of benefits Materials/methods development of a new large-stone mix

design method; use of modified binders in mixes; in situ recycling of materials (using cement, lime, foamed bitumen and bitumen emulsion); block paving (masonry and concrete); coarse power station generator ash; roller compacted concrete; slag; bitumen-rubber; waterbound macadam; recycled asphalt base; upgrading of gravel roads; marginal natural aggregates with various additives; high quality granular bases; evaluation of drainage layers as structural layers; lime-stabilized sand subbases under bitumen; design and rehabilitation procedures for concrete roads; lightly-cemented base pavements; identification and evaluation of cost-effective rehabilitation techniques; evaluation of labour-intensive construction methods; testing various asphalt base pavements and improving the design, analysis and understanding of the behaviour of such pavement types; porous asphalt

3.52.9

2.4

6.1

5.1

4.2

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

4% 8% 12%

Discount Rate

Ben

efit

Cos

t Rat

io

Gautrans & SANRAL Combined

Formal impact on : SA pavement design and analysis

• Structural design manual (TRH4) Rehabilitation design manual (TRH12)

• SA mechanistic design and analysis method • The determination of the equivalent damage exponent

SA materials characterization • Asphalt mix design manual • Materials classification and selection (TRH14) • Sabita/AsAc manuals, bituminous stabilised materials,

large aggregate mixes for bases (LAMBS)

Product Development

Vehicle-Pavement Interaction and Full-Scale Assessment

• HVS: Export of technology (in association with Dynatest®)

Questions?