Sustainable Methodologies for Long-Lasting and High ... · and High-Performance Transportation Infrastructures . Filippo Giustozzi, ... bitumen) - Less material to ... MIXES Fibers

Sustainable Methodologies for Long-Lasting and High-Performance Transportation Infrastructures

Filippo Giustozzi, Ph.D. Assistant Professor @ D.I.C.A November 10, 2014

Cesare Alippi November 10, 2014 Filippo Giustozzi

THE RESEARCH GROUP [ICAR/04] 1 Full Professor

3 Assistant Professors

3 Temporary Research Associates

6 PhD candidates Administrative & Lab. Staff

1 Lab. Chief Operating Officer


ROAD & AIRPORT MATERIALS

ROAD SAFETY

MAIN AREAS of RESEARCH

PAVEMENT DESIGN

ASSETS MANAGEMENT

INNOVATIVE CONSTRUCTION & MAINTENANCE TECHNIQUES

RISK ASSESSMENT for ROAD INFRASTRUCTURES

November 10, 2014 Filippo Giustozzi

TODAY’s PRESENTATION


KEYWORDS

1. SUSTAINABILITY 2. RECYCLING 3. PERFORMANCE


Life Cycle Management of a road project…

Technical Feasibility

Environmental Impacts (LCA)

Costs (LCCA)

Integrated Decision-Making

Societal Benefits

Risk Analysis

Durability (LCPA)


Sustainability…

United Nations World Commission on Environment and Development (1987) Sustainable Development definition:

“… development that meets the needs of the present without compromising the ability of future generations to meet their own needs.”


A project or network-level approach environmental management approach to look holistically at products,

processes, and activities.

Raw Material Acquisition

Construction Use Phase & Maintenance

End-of-Life Management

Reuse Recycling

Life Cycle Thinking


oil extraction

Aggregate Quarry

transport refinery transport

transport

construction transport emissions waste hazardous

waste

Possible Outputs

Asphalt plant

Cradle-to-Gate LCA approach


…

construction transport

Asphalt plant

Cradle-to-Grave LCA approach

Use phase & Maintenance

End-of-life

Disposal


construction transport

Asphalt plant

Cradle-to-Cradle LCA approach

Use phase & Maintenance

End-of-life

…

RECYCLING


WHY ARE RECYCLING AND

SUSTAINABLE MANAGEMENT

FUNDAMENTAL?


The ROAD PAVEMENT

≈ 95 % aggregate

≈ 5 % Bitumen


FACTS & STATS • Almost 65 million km of roads worldwide (≈ 1625 times the

World circumference) • Roadway conditions are a significant factor in about one-third

of traffic fatalities. In the U.S.: • Poor road conditions cost U.S. motorists $67 billion a year in

repairs and operating costs---$ 333 per motorist every year • 33% of America's major roads are in poor or mediocre

condition and 36% of the nation's major urban highways are congested.

• $186 billion needed annually to substantially improve the nation's highways

• 27% of U.S. GHG emissions from road transportation

Data from: Report Card for America's Infrastructure, ASCE.

Grade: D-


• Pavement construction is one of the largest consumers of natural resources

0

200.000.000

400.000.000

600.000.000

800.000.000

1.000.000.000

1.200.000.000

1.400.000.000

1.600.000.000

1.800.000.000

1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000 2010

Tons

Year

U.S. - Virgin Aggregates Consumption

Crushed stone

Sand and Gravel

“80% is used as construction aggregate, mostly for highway and road construction and maintenance, as well as for a wide variety

of building and other non-building construction.”

7.5 kg (16.5 lbs) of CO2e per ton of material

Data from: U.S. Department of the Interior; U.S. Geological Survey [November, 2012]

FACTS & STATS


FACTS & STATS • Italy has 487’000 km of roads (≈ 12 times the World circumference)

and 70’500 km of them are located in the Lombardy region • 2,96 km of roadways per km2

• 6500 €/lane∙km only for maintenance purposes Data from: Regione Lombardia.


FACTS & STATS…current upshots • VERY LARGE AREAS INVOLVED • MASSIVE AMOUNT OF MATERIALS • REDUCED BUDGET FOR MAINTENANCE & REPLACING • WASTED TIME AND FUEL DUE TO TRAFFIC CONGESTION

FROM POOR ROAD CONDITIONS • ADDITIONAL ENERGY AND MATERIALS CONSUMED FOR

ROAD REPAIRS • ADDED EMISSIONS AND WASTE GENERATED BY REMOVAL

AND REPLACEMENT OF SHORT LIVED INFRASTRUCTURE SOLUTIONS

UN-SUSTAINABLE!


PROBLEM STATEMENT MISSION: scientific breakthroughs toward reducing carbon footprint and life-cycle costs of road and

airport pavements for sustainable transportation infrastructures

Breakthroughs would imply:

Strength and Durability with less virgin material including recycling (short/long-term PERFORMANCE)

Lower energy processing and emissions (ENVIRONMENT)

Reduced life-cycle expenditures (COSTS)


1. LOWERING THE

ENVIRONMENTAL IMPACTS: RECYCLING PRACTICES

INTO ROAD PAVEMENTS


What a pavement is…


Soil Stabilization All soil modification benefits, and permanently increase compressive strength, increase load-deformation properties, and improve durability during freeze-thaw and wet-dry cycles, to be incorporated into structural design.

RECYCLING IN-SITU SOIL & AGGREGATES


Recycled Aggregates

C&D (Construction & Demolition) material




Area of the intervention: 60’000 sqm 85 % of recycled materials was adopted

TWY W - Malpensa Airport


6 cm

30 cm

40 cm

ALTERNATIVE #1 (innovative):

30 cm

25 cm

35 cm

ALTERNATIVE #2: (from current airport practice)

Tot. Thickness: 76 cm Tot. Thickness: 90 cm ALTERNATIVE #1 was chosen after an in-depth characterization of in situ soils and recycled

aggregates mechanical performance (lab tests + full scale tests)



Porous Asphalt

Cement Mortar

Surface Course



RECYCLED AGGREGATES: RWY head demolition



Cement bound base (recycled aggregates from C&D)



Sub-base Layer: In situ cement stabilized soil +

recycled aggregates





Crispino M.; [email protected]

STEP #1: Emissions related to materials manufacturing (i.e.; raw material extraction, etc.)


mailto:[email protected]


STEP #2: Emissions related to transportation & processes

Plug mill and screening plant



STEP #2: Emissions related to transportation & processes

e e



Crispino M.; [email protected]

STEP #3: Computation of the total environmental burden and analysis of the alternatives

ALTERNATIVE #1: - 35% of total emissions

N.B.: up to - 60% of emission saving if a standard granular unbound layer was adopted for Alternative #2 as foundation layer instead of stabilizing in situ

soil


mailto:[email protected]


MAIN ADVANTAGES: - Lower environmental impacts - Lower material consumption (virgin aggregates, bitumen) - Less material to handle within the construction site - Less material to be transported to/from the quarry/plant - Landfill was minimized - Construction time was shortened - Cost of materials was reduced - Performance comparable to other airport

pavements (PCN ≈ 120)



RECYCLING of ASPHALT PAVEMENTS

RAP (Reclaimed Asphalt Pavement)


A closer look at the numbers… Currently, almost 100 million tons of asphalt

concrete are reclaimed each year only in the United States, of which, roughly 80% can be reused as RAP

The volume of reclaimed asphalt pavement is … 13 TIMES greater than recycling of newsprint 27 TIMES greater than recycling of glass bottles 89 TIMES greater than recycling of aluminum cans 267 TIMES greater than recycling of plastic containers





Warm-Mix Asphalt (20-30% RAP allowed)

• May Reduce Mixing and Compaction Temperatures (up to 30 – 40ºC)

Temp. = 160º C Temp = 120º C



Warm-Mix Asphalt


Highway A4 (Italy) - 20% of emissions and long-term

performance


Cold-Mix Asphalt (100% RAP)




Foamed-asphalt (100% RAP)





43 RECYCLING of ASPHALT PAVEMENTS


44

Asphalt is foamed into the mixing

chamber

100% RAP + foamed-asphalt are

mixed

Foamed-asphalt production in the lab:





Malpensa Airport (RWY) Only 40 days of closure to reshape the entire

4400 m runway!


2. INCREASING PERFORMANCE for LONG-

TERM DURABILITY


Fibers Polymers

RHEOLOGY OF MODIFIED MASTICS

• Preparation of mastics • Evaluation of mixing conditions • Penetration and softening point • Viscosity (Brookfield) • Evaluation of rheological parameters (Rheometer)

• Stiffness master curves

LONG-TERM PERFORMANCE of RECYCLED MIXES



Fibers Cellulose – Fiber A

6% - 9% on bitumen weight

Cellulose/glass – Fiber B 9% on bitumen weight

Synthetic – Fiber C 3% on bitumen weight

Sintetiche reclaimed – Fiber D 3% - 9% on bitumen weight


COMPOUND A: plastomeric polymer + synthetic fibers

COMPOUND B: plastomeric polymer + cellulose-glass fibers

COMPOUND C: elastomeric polymer + cellulose-synthetic fibers + paraffin



RHEOLOGY OF MODIFIED BITUMEN



Dynamic viscosity

1

1000

1000000

90 100 110 120 130 140 150 160 170 180 190 200 210 220 230

Visc

osità

[cP]

Temperatura [°C]

RAMPA DI VISCOSITA' - Bitume B1/Fibra A

Bitumen

10

100000

10000

100 “Base” mastic

1,5% 3% 6% 9%

12%

Visc

osity

[c

P]

Temperature [°C]



Indirect Tensile Strength

0,70

0,90

1,10

1,30

1,50

0 3 6 9 12

ITS

[MPa

]

Fiber/Bitumen Ratio [%]

INDIRECT TENSILE STRENGTH

“Base“ mix

Fiber B

Fiber D

Fiber A

Fiber C



Stiffness

200025003000350040004500500055006000650070007500800085009000

0 3 6 9 12

Stiff

ness

[MPa

]

Fiber/Bitumen Ratio [%]

STIFFNESS - T = 20°C_f = 2,02Hz

“Base“ mix

Fiber B

Fiber D

Fiber A

Fiber C



RUTTING RESISTANCE

• Evolution of permanent deformation • Rate of rutting (WTS) and final rut depth (RD)

• Validation of theoretical models (calibration of coefficients)

• Fitting experimental data



FATIGUE RESISTANCE

• Evaluation of fatigue life (number of load cycles)

• ITFT (indirect tensile fatigue test) • 4-PBFT (four point bending fatigue test) • Comparison between additives • WTOT (total dissipated energy) • DE (dissipated energy) • Validation of theoretical procedure for PV

1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

1.0E+05

1.0E+06

BO BCS3 BCS6 BCS9 BPS3 BPS6 BPS9 BPI3 BPI6 BPI9

Load

Cyc

le to

Fai

lure

at 3

00 k

Pa

(a)



Fiber reinforced cement sub-base materials Polyolefin Fibers

WITHOUT WITH FIBERS

Fibers create internal additional links that allows to avoid the division between the two portions, guaranteeing a residual collaboration


Polypropylene Fibers


MILANO MALPENSA AIRPORT TWY H



MORE ABOUT RECENT

RESEARCH…


PERVIOUS CONCRETE

EVA modification SBR - latex


60 PERVIOUS CONCRETE


PHOTOCATALYTIC PAVEMENTS

Photocatalysis: convert pollutants (NOx) into inert material due to reactions with TiO2 and UV radiations.


PRECAST CONCRETE PAVEMENTS


PRECAST CONCRETE PAVEMENTS


ASPHALT REJUVENATORS


CLEAR BINDERS


FIRE-RESISTANT PAVEMENTS

Carbon Oxide (CO)

death

faint


Before After 30 mins After 120 mins

Concrete

Asphalt

Porous Asphalt + cement mortar

FIRE-RESISTANT PAVEMENTS


WHAT MIGHT BE INTERESTING IN COLLABORATING WITH @ D.I.C.A…


69 STRUCTURAL ENGINEERING…

FEM modeling of lab tests


70 HYDRAULIC ENGINEERING…

Hydraulic assessment of

porous materials


71 ENVIRONMENTAL ENGINEERING…

Carbon footprinting of processes and

materials


Sustainability is the next great game in transportation. The game becomes serious when you keep score.

PoliMI keeps score!

Thanks for listening!

Documents

Sustainable Methodologies for Long-Lasting and High ... · and High-Performance Transportation Infrastructures . Filippo Giustozzi, ... bitumen) - Less material to ... MIXES Fibers