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Federal Highway Administration Report FHWA-RD-98

1. 6 12 18 24 30 36 42 69 48 54 60 66 72 45 40 357 30 25 20 15 10 5 0 5 10 Degrees C
2. Figure 13 HIPERPAV Version 2 1 HIPERPAV analysis options 13 C Hiperpav Texas_IH35_MP225 hpyv E John W Smith Lane 2 NB Interstate 35 Austin Constructed 6 7 94 a New BCO Existing JCP Layer Figure 14 HIPERPAV Version 2 1 HIPERBOND analysis options 3 2 HIPERPAV Module Inputs The HIPERPAV module contains four categories of input data including general design mix design environmental and construction parameters These input boxes can be opened from the buttons on the document window menu items or toolbar Note that the default units for each of the inputs is based upon the value selected in the user preferences box however the units for any specific input can be modified by clicking on the units button next to the desired input 14 JCP General Design Parameters figure 15 Subbase Type Flexible Unbound Aggregate Use Default Slab Subbase Friction Yes No Use Friction Force 85 psi Transverse Joint Spacing fis set Movement at Sliding o inches Design Reliability o x 28 Day PCC Flexural Strength pon psi 28 0 Modulus of Elasticity 5000000 Thickness 2 inches Figure 15 HIPERPAV Version 2 1 general design parameters Subbase Type choose from various default subbase types Default Slab Subbase Friction select whether the friction value used in the ana
3. 1 S 5 9 5 o E H 72 2 2 Figure 35 HIPERPAV module postprocessor output screen of poor performance 37 Figure 36 HIPERBOND module postprocessor output screen of good performance Figure 37 HIPERBOND module postprocessor output screen of poor performance 38 CHAPTER 5 SAMPLE APPLICATION OF THE HIPERPA V MODULE In order to improve the implementability of the end products of this study an example is given in this chapter of the proper use of the HIPERPAV module The purpose of the module 15 to verify the selection of a set of design and construction inputs for JCP paving The example includes a typical set of inputs and the results of modifying some of those inputs is subsequently described 5 1 Introduction A consistent methodology should be followed by the user of these guidelines and corresponding software Although inputs will vary with each analysis the steps used in the analysis should be similar The steps for this analysis are as follows 1 Data Collection The user must begin by collecting the most current and accurate data available related to the mix design pavement design construction procedures and expected environmental conditions during paving for the PCCP 2 Identify Analysis Combinations The user should assemble possible combinations of the design and construction inputs by identifying those inp
4. 2 04 gt 00 0 0 10 20 30 Elapsed Time Since Construction hours Display Units p Time Display x axis Windspeed Legend mph Start Analysis 2 Elapsed Time Since 105 Customer Construction 0 5 10 15 20 5 2 Exit C Metric ka m hr C Time of Day Figure 31 HIPERPAV Version 2 1 moisture loss distress analysis control panel When the Start Analysis button is pressed the analysis routine will initiate The analysis is computationally intensive but relatively fast An example of the resulting plot can be seen in figure 32 The plotted lines be compared to a critical value shown as a red and yellow horizontal line Above this critical value the potential for the development of early age moisture loss related distress is high It is at this these times that special measures should be taken to minimize the moisture loss In many cases the application of a proper curing method is satisfactory for this purpose 3 7 Printing Reports Following the analysis the user can print a report of the output using the print menu option or the Print toolbar button Figure 33 is an example of the window that will appear The user may preview different pages of the report two pages are shown In addition the printer to which the report will be sent to can be selected 32 Moisture Loss Evaporation Rate Analysis
5. WF u C 65 Bonded Concrete Overlay Coarse Aggregate Type Check Box 1 Limestone Dolomite Sandstone 1 Granite Gneiss 1 Siliceous Gravel 1 Basalt Use Default Aggregate Thermal Coefficient of Expansion o Yes CI No Use Aggregate Thermal 1 WF PC Cement Content 771 lb yds kg m Silica Fume Content Ib yd kg m Fly Ash Content Ib yd8 kg m Ground Slag Content Water Content lb yds kg m Coarse Aggregate Ib yd3 kg m Coarse Aggregate Content Ib yd kg m Fine Aggregate Content kg m Chemical Admixtures C1 water Reducer O Super Water Reducer C1 Retarder C1 Accelerator Cement Chemical Composition Bogue Compounds 2 DEFAULT VALUES or 2 Enter the Percentage by Weight of the Cement Composition Tricalcium Silicate CS 1 Dicalcium Silicate C2S 771 Tricalcium Aluminate C3A x Tetracalcium Aluminoferrite C4AF Hk 66 Free Lime 71 Magnesium Oxide MgO PCC Laboratory Maturity Data Number of Maturity Data Points Please Circle 2345 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Datum Temperature Please Circle 4321012345678 9 10 11 12 13 14 F or 20 19 18 17 16 15 14 13 12 11 10 C o N o o N Environmental Parameters Daily Maximum High Temp
6. No Please refer to Hourly Temperature Data Sheet Daily Maximum Humidity Daily Minimum Humidity Late Afternoon Overcast Conditions Sunny 1 Partly Cloudy Cloudy Overcast Average Wind Speed 771 kph mph JCP Construction Parameters Curing Method Check Box 1 None A Single Coat Liquid Curing Compound Double Coat Liquid Curing Compound O Triple Coat Liquid Curing Compound 1 Polyethylene Sheeting Cotton Mats or Burlap A Polyethylene Sheeting Cotton Mats Time of Day of Construction 771 Initial Mix Temperature F c Age of Opening to hours Age at Sawcutting hours Initial Subbase Temperature Note Enter a value of 0 zero in Age at Sawcutting to perform at the optimum time 61 1 2 DEFAULT TREND Draw Chart to represent Degrees Y vs Hours X Ambient Air Temperatures 6 12 18 24 30 36 42 62 48 54 60 66 72 45 40 357 30 25 20 15 10 5 0 5 10 Degrees C APPENDIX HIPERBOND MODULE INPUT FORM 63 General Input Date of Analysis Default Units us Customary metric 05 Customary amp Metric I will specify which ones for each input BCO General Design Parameters S
7. Use Default Overlay Bond Strengths Yes 7 No Use Bond Shear Strength 400 psi Bond Tensile Strength 200 psi Figure 26 HIPERPAV Version 2 1 HIPERBOND construction parameters Curing Method select the curing method to be used on the overlay Time of Day of Construction select which hour of the day or night that the concrete was placed calculations are valid only for slabs placed at the time specified multiple runs must be used to cover a range of placement times Initial PCC Mix Temperature enter the mix temperature of the BCO PCC at the time of placement Age of Opening to Traffic enter the age of the BCO PCC at the time that the curing method is removed if applicable Age at Sawcutting enter the age of the overlay at the time that sawcutting is performed Initial PCC Surface Temperature enter the surface temperature of the existing pavement prior to construction of the overlay Surface Preparation select the type of surface preparation which is conducted on the existing pavement prior to the overlay placement Bonding Agent select the type of bonding agent if any which is applied prior to placement of the overlay Default Overlay Bond Strengths select whether the overlay bond strengths used in the analysis are the default values for the selected surface preparation and bonding agent or if values will be entered directly 26 Bond Shear Strength if the overlay bond strengths measure
8. Evaporation Rate Ib ft inr Elapsed Time Since Construction hours Display Units U S Customary Exit Metric Figure 32 HIPERPAV Version 2 1 moisture loss distress analysis example Time Display x axis Windspeed Legend mph yi zal ea c Elapsed Time Since Construction Time of Day F Print HIPERPAY Report 7 Print HIPERPAV Report x Printer Printer 6 HP LaserJet 4L 2 HP LaserJet 4L Cancel View Page Number Figure 33 HIPERPAV Version 2 1 report print preview 33 3 8 Selection of Proper Input Values The key to the proper use of these guidelines is proper selection of the input values The recommendations made in chapter 3 of the final report for this project should be used in connection with this software to select the most relevant input values However trial sets of inputs which cover a range of values should also be identified and tested in order to assess their potential impact This allows the user to determine the sensitivity of the results to various inputs and allows the potential for an economic analysis of the various input combinations For clarity the input values for HIPERPAV are listed in appendix A Most inputs to the HIPERBOND module are similar to those of the module The additional inputs relate to the existing PCCP as well as characteristics about the bonding
9. CHAPTER 1 INTRODUCTION TO HIPERPAV VERSION 2 1 1 1 4 Background and 1 1 2 Introduction ra 1 CHAPTER 2 SYSTEM REQUIREMENTS AND INSTALLATION OF HIPERPAV VERSION 3 2 System Configuration and Requirements 2 2 22 4 2 2 1 2 3 2 2 Performa aan a Ra NN BBB SRA 3 2 3 Installing Uninstalling HIPERPAV Version 2 1 2222 2 2 2 1 5 CHAPTER USING HIPERPAV VERSION 2 1 2 40 22 2 1 7 M1 Getting Started 7 32 HIPERPAV Module Inputs 5 nee tote tanaman 14 33 HIPERBOND Module 22 3 4 HIPERPAV Module Control Panel 27 3 5 HIPERBOND Module Control Panel 28 3 6 Moisture Loss Analysis Control Panel ooooooooooo 31 3 7 Printing BO POLS snara Le natn 32 3 8 Selection of Proper Input Values ooooo oo 34 CHAPTER 4 INTERPRETATION OF ANALYSIS RESULTS ooooo 35 41 Analysis Results Interpretation 35 4 2 HIPERBOND Analysis Results Interpretation ooooooo 36 CHAPTER 5 SAMPLE APPLICATION OF THE MODULE 39 Sd Introduction o ooo na t UM m I Moe IEE
10. Input Category Input Parameter Typical Values Selected Value or Range Mix Design Cement Type I IP II IIL V L III Inputs Design Inputs Flexural Strength at 28 days psi 500 to 1200 800 600 Subbase Type HMAC Granular Flexible Asph Stab Cement Stabilized Cement Stab Lime Treated None Granular Flex Joint Spacing feet 12 to 30 15 25 Environmental Maximum Daily Temperature F 30 to 120 90 90 60 change 36 hrs Inputs Minimum Daily Temperature F 0 to 100 70 70 40 change 36 hrs Construction Curing Method None Wax Membrane Inputs Wax Membrane Cotton Mat Poly Sheet Cotton Mat Poly Mat Start Time of Paving hr 0 to 23 9 A M 0900 3 P M 1500 Table 5 Summary of HIPERPAV example cases Case Figure Modified Value Baseline Case Modified Number Number Value Value Baseline 38 n a n a n a 2 39 Cement Type I 3 40 28 day Flexural 800 600 Strength 4 41 Subbase Type Granular Cement Flexible Stabilized 5 42 Minimum Ambient 70 F 40 F at 36 Temperature hours 6 43 Curing Method Wax Membrane Cotton Mats 7 44 Start Time of Paving 9 A M 3 P M 8 45 Joint Spacing 15 feet 25 feet 41 Step 5 Following the analyses a prioritization of the results is warranted For example purposes the following is a summary of the seven cases which were analyzed e Case 1 Baseline This case demonstrated average behavior during the early age period The maximum stress to strength ratio during this period is approxima
11. Moisture Loss Distress Analysis Shear Stress po psi Figure 30 HIPERPAV Version 2 1 HIPERBOND analysis example 3 6 Moisture Loss Analysis Control Panel The user may also execute a moisture loss distress analysis This analysis will predict the evaporation rate of an open body of water as a function of the calculated concrete temperature the air temperature humidity and for various windspeeds Appendix B of the final report describes the correlation between this parameter and the potential for plastic shrinkage cracking The analysis control panel for the moisture loss distress module can be initiated using the buttons in either the HIPERPAV or HIPERBOND control panels The moisture loss distress analysis control panel can be seen in figure 31 The HIPERBOND control panel consists of several controls including Start Analysis Button executes the analysis routine Exit closes the control panel and returns the user to the document window Display Units Option Buttons allow the user to select in what units the analysis results will be plotted only one option can be selected for a run Time Display Option Buttons allow the user to select the style of the time horizontal axis only one option can be selected for a run Windspeed Legend denotes the colors for the resulting evaporation rate based on seven different levels of wind speed 31 Moisture Loss Evaporation Rate Analysis x 08 8 P a a
12. The various items can be seen in figure 3 Depending on the state of the program some of these items may be disabled shown in gray This is due to the fact that the current version of the software allows only one analysis to be performed at a time 7 HIPERPAV LE inputs Run View Help New El Open tri ohn w Lane 241 fi 0 12 39 AV New Figure 3 HIPERPAV Version 2 1 File menu items Inputs This menu item provides access to the dialog boxes to prompt for design mix design environmental and construction inputs These can be seen in figure 4 HIPERPAY Run View Help JCP Design JCP Mix Design JCP Environmental JCP Construction BCO Design BCO Mix Design BCO Environmental BCO Construction Figure 4 HIPERPAV Version 2 1 Inputs menu items Run This menu item provides the analysis execution options These can be seen in figure 5 HIPERPAV File Inputs View Help HIPERPAY HIPERBOND Figure 5 HIPERPAV Version 2 1 Run menu items View This menu item contains options to hide or show the status bar and toolbar These can be seen in figure 6 This option is convenient if the user is executing from a computer with poor graphics resolution 640x480 pixels File Input Run pels El v Toolbar Status Bar Help This menu item contains the Help menu options This can be seen in figure 7 At this time only one option is enabled whi
13. construction 3 3 HIPERBOND Module Inputs The HIPERBOND module contains four categories of input data including general design mix design environmental and construction parameters These input boxes can be opened from the buttons on the document window menu items or toolbar Note that the default units for each of the inputs is based upon the value selected in the user preferences box however the units for any specific input can be modified by clicking on the units button next to the desired input The majority of the input screens are identical to those in the HIPERPAV module and explanations can be found in the preceding section The following sections describe those input screens which differ from the HIPERPAV module BCO General Design Parameters figure 24 Subbase Type choose from various subbase types beneath the existing pavement Default Slab Subbase Friction select Yes to use default friction parameters for the selected subbase or select No to enter the friction parameters directly Slab Subbase Friction Force if the slab subbase friction is measured enter the friction force Slab Subbase Friction Movement Force if the slab subbase friction is measured enter the amount of movement at sliding 22 Subbase Type Flexible Unbound Aggregate a Use Default Slab Subbase Friction Yes Use Friction Force B5 si Cancel Transverse Joint Spacing 5 set Movement at Sliding 2 i
14. 12 Clear Data OK Datum Temperature 14 F Sort Data Cancel Point 1 Age E Point Age hours Maturity F hours Strength psi 750 1000 1300 1750 2200 2650 3100 3500 3900 4300 4700 5000 Figure 17 HIPERPAV Version 2 1 PCC maturity data input screen 17 Cement Chemical Composition figure 18 Cement Chemical Composition Bogue Compounds Ed Enter the Percentage by Weight of the Cement Composition Tricalcium Silicate C S 50 z Dicalcium Silicate C 5 25 z D Tricalcium Aluminate C A fi 2 z Tetracalcium luminoferrite C AF e z Magnesium Oxide 0 z NN Default for Sum of Percentages 000 x Cement Type Cancel Figure 18 HIPERPAV Version 2 1 chemistry data input screen Tricalcium Silicate enter the C3S value estimated or directly from a laboratory test or the cement tag Dicalcium Silicate enter the C2S value estimated or directly from a laboratory test or the cement tag Tricalcium Aluminate enter the C3A value estimated or directly from a laboratory test or the cement tag Tetracalcium Aluminoferrite enter the C4AF value estimated or directly from a laboratory test or the cement tag Free Lime enter the C or CaO value estimated or directly from a laboratory test or the cement tag Magnesium Oxide enter the MgO value estimated or directly from a laboratory test or the cement tag Default Value press to reset
15. Finally restraint to free movement due to slab base friction and curling are modeled directly The end product from this research is a comprehensive software package termed HIgh PERformance PAVing HIPERPAV This package which incorporates the complex models developed can be used as a stand alone product to verify the overall effect of specific combinations of design construction and environmental inputs on early age behavior of a PCCP and This report serves as the user s manual for the HIPERPAV software This report is the second in series The other report in the series is FHWA RD 98 Final Report 17 Key Words 18 Distribution Statement No Restrictions This document is available to the public through the National Technical Information Service Springfield Virginia 22161 High Performance Concrete Pavements Fast Track Bonded Concrete Overlay Jointed Concrete Pavement Early Age HIPERPAV HIPERBOND Mechanistic and Mechanistic Empirical Models Temperature Heat of Hydration Slab Shrinkage Relaxation Creep Thermal Expansion Slab Base Friction Curling Warping Plastic Shrinkage Cracking JCP JPCP Delamination BCO PCCP Debonding Cement 19 Security Classif of this report 20 Security Classif of this page 21 No of Pages 22 Price Unclassified Unclassified 77 Form DOT F 1700 7 8 72 Reproduction of completed page authorized TABLE OF CONTENTS Section Page
16. analysis that is performed is termed the baseline analysis It is performed using the most feasible input values For those values with ranges that are listed in table 6 the first values listed were used Subsequent analyses will utilize the other values listed Results from the HIPERBOND analysis using the baseline inputs is shown in figure 46 Table 7 outlines other cases analyzed here HIPERBOND results for these cases are shown in figures 47 through 22 Table 6 HIPERBOND data for this example Input Category Typical Values Selected Range of Values Mix Cement Type I IP IL HI V I III Design BCO Coarse Aggregate Type Limestone Dolomite Limestone Dolomite Sandstone Siliceous Gravel Granite Gneiss Siliceous Gravel Basalt Environmental Overcast Conditions Sunny Partly Cloudy Sunny Inputs Partly Cloudy Cloudy Inputs Surface Preparation Cold Milling Cold Milling Hvy Shotblasting Hvy Shotblasting Lgt Shotblasting Water Air Blasting None Bonding Agent PCC Grout PCC Grout None Latex Epoxy None 50 Number 1 Baseline 2 3 4 Bond Stress or Strength psi Table 7 Summary of HIPERBOND example cases Figure Number 46 47 48 49 50 51 52 Modified Value Baseline Case Value n a n a Cement Type I Overcast Partly Cloudy PCC Mix 70 F Temperature BCO Aggregate Limestone Dolomit e Surface Preparation Cold Method Milling Bonding Agent PCC Grout Elapsed Time Si
17. and click Remove CHAPTER 3 USING HIPERPA V VERSION 2 1 This chapter describes the use of the HIPERPAV software The interface of the software package was made to be as practical and user friendly as possible 3 1 Getting Started Upon execution the user will be displayed introductory information via a splash screen as shown in figure as the software is loaded Version 2 10 beta SA pii FOR THE FEDERAL HIGHWAY ADMINISTRATION DEVELOPED AND COPYRIGHT 1997 BY TRANSTEC INC Figure 1 HIPERPAV Version 2 1 splash screen After the software is loaded the user will be displayed the main menu form as shown in figure 2 This form consists of three key features the menu items which allow the user to control the behavior of the program during execution the toolbar which allow the user to execute commonly used commands and the status bar which provides some feedback to the user as to the current status of the program and the computer Status Bar Status 10 12 37 11 02 CAPS NUM INS SCRL 4 Figure 2 HIPERPAV Version 2 1 main menu components Menu Items There are five menu items Each menu item contains functions which allow the user to navigate easily through the analysis process The menu item groups are as described as follows File This menu item contains features related to opening saving and closing data files as well as printing and defining user preferences
18. cement 43 2 e amp t a 0 2 aH 2 E c Tensile Stress or Strength psi Elapsed Time Since Construction hours Figure 41 HIPERPAV output for case 4 baseline with cement stabilized subbase 44 Tensile Stress Strength psi Elapsed Time Since Construction hours Figure 42 HIPERPAV output for case 5 baseline with minimum ambient temperature of 40 F after 36 hours Tensile Stress or Strength psi Elapsed Time Since Construction hours Figure 43 output for case 6 baseline with cotton mat curing 45 Exceeds LL TALA Tensile Stress or Strength psi LL NI RT A 12 24 3 36 42 48 54 60 66 72 Elapsed Time Since Construction hours Stress Exceeds Strength Warning Exceeds Strength Tensile Stress or Strength psi Elapsed Time Since Construction hours Figure 45 HIPERPAV output for case 8 baseline with 25 foot joint spacing 46 e strength violations can be observed as result therefore this joint spacing is not to be recommended for this pavement Step 6 Based upon the selection and analyses of the various cases a prioritization of their respective benefits versus costs can be made A prioritization for this example is 1 Case 1 average cost low potential for early age damage 2 Case 6 much more expensive than baseline wi
19. found to be insensitive it can most likely be ignored during the analysis 5 Prioritize Analysis Results Following the analyses the various combinations of inputs should be sorted as to their potential for early age damage Any combinations that result in the prediction of early age damage should be rejected and marginal cases should be flagged for possible rejection unless economic or other pressures warrant their use 6 Finalize Selection of Inputs The final selection s of inputs should be based on a comparison of the results of the ranking analysis with the original ranking that was based on economic and other factors The final selection should be based on the results of the HIPERBOND analysis as well as on sound engineering judgment 49 6 2 HIPERBOND Analysis Example Steps and 2 For the example this appendix the user must first identify the input values shown in appendix B This table may be reproduced and used as a guide during the data collection phase of the analysis Table 6 shows a subset of the corresponding data inputs which are used in this example Each of these inputs are flexible and may be modified during the analysis procedure Step 3 The inputs with their corresponding ranges are ranked in table 6 The first value of any input range is the most feasible and the last is the least feasible This selection is based on experience of the user as well as on economic considerations Step 4 The first
20. inputs for bonded concrete overlay construction The example includes a typical set of inputs and the results of modifying some of those inputs is subsequently described 6 1 Introduction A consistent methodology should be followed by the user of these guidelines and corresponding software Although inputs will vary with each analysis the steps used in the analysis should be similar The steps for this analysis are as follows 1 Data Collection The user must begin by collecting the most current and accurate data available related to the mix design pavement design and construction procedures and expected environmental conditions during paving for the BCO 2 Identify Analysis Combinations The user should assemble possible combinations of the design and construction inputs by identifying those inputs that are flexible to modification and then selecting an appropriate range for these values 3 Rank Analysis Combinations Before performing the verification analysis the user should prioritize possible combinations of design and construction inputs This ranking should be accomplished by examining economic availability and other direct and indirect considerations 4 Analyze Combinations The user should begin analyzing the combinations of inputs by analyzing the most probable feasible set of inputs first Subsequent analyses should then be done to determine sensitivity of the inputs to the overall behavior If a particular variable is
21. parameters 2 15 HIPERPAV Version 2 1 HIPERPAV mix design parameters 16 HIPERPAV Version 2 1 PCC maturity data input 17 HIPERPAV Version 2 1 cement chemistry data input screen eese 18 HIPERPAV Version 2 1 environmental eeen 19 Default time temperature 20 Time temperature distribution with varying high and low temperatures 20 Time temperature distribution subjected to a cold 21 HIPERPAV Version 2 1 HIPERPAV construction parameters 21 HIPERPAV Version 2 1 HIPERBOND general design parameters 23 HIPERPAV Version 2 1 HIPERBOND mix design parameters 24 HIPERPAV Version 2 1 HIPERBOND construction parameters 26 HIPERPAV Version 2 1 HIPERPAV control panel 27 HIPERPAV Version 2 1 HIPERPAV analysis 0 0 1 00000 0 29 HIPERPAV Version 2 1 HIPERBOND control panel 29 HIPERPAV Version 2 1 HIPERBOND analysis Example 31 Section 31 32 33 34 35 36 37 38 39 40 41 22 43 44 45 46 47 48 49 50 51 52 LIST FIGURES CONTINUED Page HIPERPAV Version 2 1 moisture loss distress analysis control panel 32 HIPERPAV Version 2 1 moisture loss distress analysis example sese 33 HIPERPAV Version 2 1 report print preview eene eren tenente trennen 33 HIPERPAV mod
22. the values to the default values for the given cement type 18 Environmental Parameters figure 19 Daily Maximum High Temperature SS Daily Minimum Low Temperature NL Use Default Temperature Distribution Yes No Define Hourly Temperatures Daily Maximum Humidity Sunrise Daily Minimum Humidity Late Afternoon 40 D D Overcast Conditions Sunny Partly Cloudy C Cloudy Overcast Average Wind Speed s mph Figure 19 HIPERPAV Version 2 1 environmental parameters Daily Maximum High Temperature enter the average high temperature for the 72 hour period following construction Daily Minimum Low Temperature enter the average low temperature for the 72 hour period following construction Default Temperature Distribution select whether the default time temperature distribution will be used sinusoidal or if hourly temperatures will be entered directly Daily Maximum Humidity enter the average maximum humidity for the 72 hour period following construction Daily Minimum Humidity enter the average minimum humidity for the 72 hour period following construction Overcast Conditions select the average degree of cloud cover during the analysis period Average Wind Speed enter the average wind speed for the analysis period The temperature distributions for the 72 hour period following construction can be defined using the ambient ai
23. 20 2 3 Installing Uninstalling Version 2 1 Version 2 1 is distributed on six diskettes diskettes contain the executable files and custom libraries as well as several shared libraries which may or may not already be installed on the user s system The installation procedure has been designed to be as user friendly as possible To install Version 2 1 do the following 1 2 Exit any applications you are running Insert diskette 1 of 6 into drive A of your PC Then select Run from the Start menu enter a setup exe and click OK 3 Insert diskette 2 of 6 into drive A when prompted and click OK Read the welcome screen then click OK Specify the directory to install HIPERPAV by clicking on Change Directory then click on the large button to begin the installation process You will be prompted for the remaining diskettes When prompted insert the appropriate disk into drive A and click OK Note You may not be prompted for all six diskettes This is normal If you are installing a newer version of HIPERPAV you may be warned about overwriting existing files You can ignore these warnings HIPERPAV Version 2 1 is now installed in the destination directory You can uninstall HIPERPAV Version 2 1 by using the tools provided with your Windows operating system Open the control panel double click on the Add Remove Programs select
24. E 39 5 2 HIPERPAV Analysis Example esee enne 40 iii TABLE OF CONTENTS CONTINUED Section Page CHAPTER 6 SAMPLE APPLICATION OF THE HIPERBOND MODULE 49 6 1 Introduc On unie kana 49 6 2 HIPERBOND Analysis Example 50 APPENDIX A HIPERPAV MODULE INPUT FORM 2 57 APPENDIX HIPERBOND MODULE INPUT FORM 63 iv Section 4 A KR x OU N N h NH bh NB bh NHB Be N NK N N N M N NO Oo A tA XI DDO Oo A WA ALUNNO LIST FIGURES Page HIPERPAV Version 2 1 splash 5 soassa isesi trennen eene ene 7 HIPERPAV Version 2 1 main menu components 22 200000000000000 8 HIPERPAV Version 2 1 File menu 8 HIPERPAV Version 2 1 Inputs menu 9 HIPERPAV Version 2 1 Run menu 9 HIPERPAV Version 2 1 View menu 9 HIPERPAV Version 2 1 Help menu 10 HIPERPAY Version 2 1 About box se eie m a tee ble i 10 HIPERPAV Version 2 1 toolbar siete t tete aan eee RH Ss 10 HIPERPAV Version 2 1 Open dialog box neee 11 HIPERPAV Version 2 1 main menu with open document essere 12 HIPERPAV Version 2 1 Properties dialog 13 HIPERPAV Version 2 1 HIPERPAV analysis Options 13 HIPERPAV Version 2 1 HIPERBOND analysis Options 14 HIPERPAV Version 2 1 HIPERPAV general design
25. Note values in specifications are often much lower than mean values for the in place PCC Bonded Concrete Overlay 28 Day PCC Modulus of Elasticity enter the mean 28 day BCO PCC modulus of elasticity which can be measured in lab tests performed according to ASTM C 469 or similar or estimated Bonded Concrete Overlay Thickness enter the mean thickness of the BCO layer 23 Mix Design Parameters figure 25 BCO Mix Design Parameters Ed Cement Type Normal Use Default Strength Gain Yes C No Use Laboratory Maturity Data Enter Maturity Data Use Default Heat of Hydration Yes C No Use Cement Chemical Composition Data Enter Cement Data Existing Pavement Coarse Aggregate Type Limestone Dolomite Use Default Thermal Coeff of Expansion Yes No Use Aga Thermal Coeff LAR Bonded Concrete Overlay BCO Coarse Aggregate Type Limestone Dolomite Use Default Thermal Coeff of Expansion Yes C No Use Thermal Coeff fE _w Chemical Admixtures t Content 525 lak bid Water Reducer Silica Fume Content rs Ib ycf PER TUN bie Super Water Reducer Type F Fly Ash Content 200 Retarder Ground Slag Content 100 s tae 0 Accelerator Water Content 296 by p Volumetrics Water C t w e Ratio 5 Coarse Aggrega
26. Technical Report Documentation Page 1 Report No 2 Government Accession No 3 Recipient s Catalog No 4 Title and Subtitle FAST TRACK PAVING CONCRETE TEMPERATURE CONTROL AND TRAFFIC OPENING CRITERIA FOR BONDED CONCRETE OVERLAYS Volume II HIPERPAV User s Manual 5 Report Date 6 Performing Organization Code 7 Author s B Frank McCullough and Robert Otto Rasmussen 8 Performing Organization Report No 9 Performing Organization Name and Address Transtec Inc 1012 East 38 Street Austin TX 78751 10 Work Unit No 11 Contract or Grant No DTFH61 93 C 00106 12 Sponsoring Agency Name and Address Office of Engineering and Highway Operations R amp D 13 Type of Report and Period Covered Software User s Manual Federal Highway Administration October 1993 to January 1998 6300 Georgetown Pike 14 Sponsoring Agency Code McLean VA 22101 2296 15 Supplementary Notes Contracting Officer s Technical Representative Stephen W Forster HNR 20 16 Abstract It has been theorized that early age behavior due to temperature and moisture changes can significantly affect the performance of a Portland cement concrete pavement PCCP or bonded concrete overlay BCO over its service life During the first 72 hours following placement the strength of PCC is relatively low in comparison to the strength that it will eventually achieve During this early age period criti
27. agent and surface preparation used at the bond between the and the existing pavement The inputs for the HIPERBOND module are summarized in appendix B 34 4 INTERPRETATION OF ANALYSIS RESULTS 41 HIPERPAV Analysis Results Interpretation HIPERPAV executes a series of powerful algorithms which calculate the PCC pavement stress and strength development in a continuous manner for the first 72 hours following placement The user is presented with a graphical screen which plots the results of the analysis as they are computed in real time The user can observe the trend of the strength and stress development and assess the behavior of the pavement based on the specific user inputs Following processing will then identify possible problem areas and inform the user that the potential for early age damage is present with the given set of inputs Figure 34 shows an output screen from a typical run that demonstrates mix design pavement design and construction during PCC pavement placement that lead to a high probability of good performance The strength curve is the top curve which remains above the stress curve at all times during the first 72 hours Note the cyclical manner in which the critical stress occurs Peaks in the stress curve occur at critical periods when either the axial stresses are dominant or when curling stresses are dominant The former being in the early morning hours and the latter just after mid
28. ated shear strength of the bond between the existing pavement and the BCO Shear Stress Legend denotes the color of the plotted line which represents the calculated maximum shear stress of the bond between the existing pavement and the BCO When the Start Analysis button is pressed the analysis routine will initiate The analysis is computationally intensive therefore the computer may be slow to respond to user actions during the analysis period The results of the analysis are plotted in real time as they are calculated by the analysis routine The estimated run times for various computers can be found in section 2 2 An example of the resulting plot can be seen in figure 30 Two flags can be seen in the plot in figure 30 The first flag shows the estimated time at which the potential for a reflection crack to occur at the joint is high Therefore if the second flag representing the proposed sawcut time occurs much later then the potential is high for an uncontrolled or partially controlled crack 30 HIPERBOND Control Panel ic x 200 Proposed Potential Joint Reflection Bond Stress or Strength psi Elapsed Time Since Construction hours Display Units Time Display x axis Legend and Current Values s 2 Elapsed Time Since Tensile Strength psi U S Customary psi te Exit Tensile Stress fis psi C Metric kPa C Time of Day DLL Shear Strength 136 psi
29. cal stresses can develop which may lead to pavement damage and ultimately a loss of performance This research focuses on modeling early age behavior of both concrete pavements and bonded concrete overlays subjected to stresses from moisture and thermal changes It includes the development of a two part versatile comprehensive set of guidelines which provide direction in the proper selection of design and construction variables to minimize early age damage to the PCCP and BCO The first part of these guidelines is qualitative in nature and is based upon the results of this effort past experience and engineering judgment They are intended to identify design and construction inputs which are most likely to lead to good behavior during the early age period The second part of the guidelines is comprised of many complex models which have been developed to predict early age behavior in jointed plain concrete pavements and bonded concrete overlays These models are used to verify good behavior from the selection of inputs made using the qualitative guidelines These models include a PCC temperature development model which accounts for heat generation from the hydrating paste solar insolation surface convection irradiation and dynamic specific heat and thermal conductivity values Several mechanical properties are also modeled including thermal coefficient of expansion drying shrinkage creep strength and modulus of elasticity using maturity methods
30. ch provides access to the dialog box shown figure 8 HIPERPAV File Inputs View Run View Olsisla aj About HIPERPAV Figure 7 Version 2 1 Help n menu items About HIPERPAV Ni HIPERPAV Version 2 1 74 a2 High Performance Paving Software System Info Warning The procedures contained herein are preliminary and for evaluation purposes only amp ny duplication or dissemination of this software without express written consent of Transtec Inc and the Federal Highway Administration is strictly prohibited This software is protected by the U S copyright laws and any breach will be in violation of such statutes yr Vransicc EF OPERA IE Figure 8 HIPERPAV Version 2 1 About box Toolbar The tool bar of HIPERPAV Version 2 1 contains buttons corresponding to the most commonly used commands This provides the user with a simple way to navigate through the software The tool bar can be seen in figure 9 S Figure 9 Version 2 1 toolbar The following describes the function of each of the buttons in the toolbar Dj Creates a new data input file sl Opens an existing data input file 10 Closes the existing data input file Saves the current data input file to disk Prints the results of the current analysis Opens the General Design Parameters dialog box for the
31. coarse aggregate type or if it will be entered directly BCO Aggregate Thermal Coefficient of Expansion if measured or estimated enter this value directly Cement Content enter the cement content in the mix design Silica Fume Content enter the silica fume content in the mix design Type F Fly Ash Content enter the type F fly ash content in the mix design Ground Slag Content enter the ground slag content in the mix design Water Content enter the water content in the mix design Coarse Aggregate Content enter the coarse aggregate content in the mix design Fine Aggregate Content enter the fine aggregate content in the mix design Water Reducer check if a water reducer is used in the mix Super Water Reducer check if a super water reducer is used in the mix Retarder check if a retarder is used in the mix Accelerator check if a accelerator is used in the mix 25 Construction Parameters figure 26 BCO Construction Parameters Curing Method Sinale Coat Liquid Curing Compound Time of Day of Construction 6 00 m Initial PCC Mix Temperature 7D ME Age of Opening to Traffic 24 hrs 28 Enter value of 0 zero in Age at Sawcutting 0 hrs Age at Sawcutting to erform at the optimum time Initial PCC Surface Temperature ro Surface Preparation Heavy Shotblasting Bonding Agent Pcc Grout
32. current analysis module Opens the Mix Design Parameters dialog box for the current analysis module Opens the Environmental Parameters dialog box for the current analysis module Opens the Construction Parameters dialog box for the current analysis module Executes the current analysis opens the control panel Es s the About dialog box Upon execution of the software the user must either start a new data inputs file or open an existing data input file This can be done via the menu items or the toolbar If the user opens an existing file they will be prompted with a dialog box similar to figure 10 Note that the default file extension for inputs files is HPV Open HIPERPAY Yersion 2 1 Input File Look in IB Texas IH35 MP225 hpv File name Files of type HiPERPAV Files hpv Cancel Open read only Figure 10 HIPERPAV Version 2 1 Open dialog box Once a file is opened a child window a smaller window within the main window will appear in the windows as in figure 11 The window shown contains several features The engineer s name project name and the date of analysis can be entered directly 11 here button to enter user preferences 15 provided as well dialog box which appears when pressing this button is seen figure 12 Options for the level of detail desired for the report can be selected here The defa
33. d enter the mean shear strength of the bonded interface at 28 days under standard laboratory curing conditions Bond Tensile Strength if the overlay bond strengths measured enter the mean tensile strength of the bonded interface at 28 days under standard laboratory curing conditions 3 4 HIPERPAV Module Control Panel After entering the various analysis inputs the user may execute the analysis The analysis control panel for the HIPERPAV module can be initiated using the menu command toolbar button or the Begin Analysis button in the document window The control panel can be seen in figure 27 HIPERPAY Control Panel Fill 5 a 5 a 2 2 5 36 42 48 54 Elapsed Time Since Construction hours Display Units Time Display x axis Legend and Current Values es gt Elapsed Time Since Strength p psi Constructi Exit anta p psi Metric kPa Time of Day of Slab Moisture Loss Distress Analysis Bottom of Slab Figure 27 HIPERPAV Version 2 1 HIPERPAV control panel The HIPERPAV control panel consists of several controls including Start Analysis Button executes the analysis routine Exit closes the control panel and returns the user to the document window Moisture Loss Distress Analysis opens the Moisture Loss Evaporation Rate Distress Analysis control
34. day In this scenario the probability for PCC pavement distress random transverse cracking is low since the stress does not exceed the strength during the first 72 hours after placement Figure 35 shows an output screen from a typical run where the combination of mix design pavement design construction and the conditions during placement are such that the probability of a poorly performing PCCP is significant The inputs for this particular run differ from that in figure 34 only by the minimum ambient temperature A lower value was used for the scenario presented in figure 35 thus resulting in a thermal shock which can lead to premature cracking The objective of the HIPERPAV guidelines and the accompanying computer software module is to minimize damage to the PCCP during early ages first 72 hours after placement By utilizing the general recommendations made in chapter 3 of the final report in conjunction with the software described in this manual the chances for achieving this objective are substantially increased 35 4 2 HIPERBOND Analysis Results Interpretation The HIPERBOND module plots a total of four values during the execution of the analysis two stress values representing the critical shear and tensile stresses at the bond interface and two corresponding strength values in the shear and tensile directions with the module the corresponding stress and strength values compared The shear str
35. e Granite Gneiss O Siliceous Gravel 1 Basalt Use Default Aggregate Thermal Coefficient of Expansion ves C vo Use Aggregate Thermal Coefticient Content 771 lb yds kg m Silica Fume Content Ib yd kg m Fly Ash Content Ib yd kg m Ground Slag Content Ib yd Water Content kg m Coarse Aggregate Ib yd kg m Coarse Aggregate Content Ib yd kg m Fine Aggregate Content Ib yd kg m Chemical Admixtures C1 water Reducer O Super Water Reducer C1 Retarder C1 Accelerator Cement Chemical Composition Bogue Compounds 1 DEFAULT VALUES or 2 Enter the Percentage by Weight of the Cement Composition Tricalcium Silicate 8 11 Dicalcium Silicate C2S 771 Tricalcium Aluminate C3A Tetracalcium Aluminoferrite C4AF Free Lime Magnesium Oxide MgO Laboratory Maturity Data Number of Maturity Data Points Please Circle 2345 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Datum Temperature Please Circle 4321012345678 9 10 11 12 13 14 F or 20 19 18 17 16 15 14 13 12 11 10 b o N o la o m Environmental Parameters 60 Daily Maximum High Temperature F C Daily Minimum Low Temperature F Use Default Temperature Distribution Yes
36. e an assessment of the adequacy of the predicted pavement performance based on the given inputs In addition the moisture loss distress plastic shrinkage cracking potential prediction analysis includes the calculation of the evaporation rate of the young concrete as a function of the predicted concrete temperature the ambient air temperature relative humidity and a range of windspeeds CHAPTER 2 SYSTEM REQUIREMENTS AND INSTALLATION OF VERSION 2 1 2 1 System Configuration and Requirements and HIPERBOND were developed using Digital Fortran Version 5 0 and Microsoft Developer Studio Version 5 0 on a Windows NTTM based system They have been compiled to optimize the capabilities of a Pentium system or better Since the core of both the and HIPERBOND systems are finite element analysis models that perform large numbers of mathematical calculations during the analyses the software requires the presence of a math coprocessor therefore running this application on an older machine is not recommended The following are required in order to execute the software successfully and efficiently Minimum configuration required 80486 Based Processor or Better with an 80x87 math coprocessor Windows 95 98 or Windows NT Operating System 640x480x4bpp or higher resolution monitor Recommended configuration e Pentium P5 80586 100MHz Processor or Better SVGA 800x600x8b
37. e based on the results of the HIPERPAV analysis as well as on sound engineering judgment 39 5 2 Analysis Example Steps 2 For the example in this chapter the user must first identify the input values found in appendix A This appendix may be reproduced and used as a guide during the data collection phase of the analysis A set of baseline data inputs has been developed for this example Seven selected input values will be modified from the baseline for the purpose of this analysis in order to demonstrate the sensitivity of the results to these variables Step 3 The variable inputs with their corresponding ranges are ranked in table 4 The first value of any input range is the most feasible and the last is the least feasible This selection is based on experience of the user as well as on economic considerations The remaining values were held constant at reasonable values Step 4 The first analysis that is performed is termed the baseline analysis It is performed using the most feasible input values For those values with ranges that are listed in table 4 the first values listed were used Subsequent analyses will utilize the other values listed Results from the HIPERPAV analysis using the baseline inputs is shown in figure 38 Table 5 outlines other cases analyzed here HIPERPAV results for these cases are shown in figures 39 through 45 40 Table 4 data for this example
38. ement during early ages and ultimately its long term performance The HIPERBOND systems include computerized processes to assess the effects of varying pavement construction materials and methods in a range of climatic conditions in which users provide specific but practical inputs The computer software is easy to use and its operation will be discussed in greater detail in the following chapters The use of the guidelines is straightforward They determine stress and strength values which can be used to determine the suitability of the design and construction scenario For HIPERPAV these values are as follows e Critical Stress the tensile stress condition in the pavement which occurs at the center of a slab and can occur at either the top or bottom of the slab depending on the curling or warping state e Strength the tensile strength of the pavement For HIPERBOND the values include the following e Bond Tensile Stress the critical tensile stress condition in the bond between the BCO and the existing PCCP Bond Tensile Strength the tensile bond strength between the BCO and PCCP Bond Shear Stress the critical shear stress condition in the BCO PCCP bond Bond Shear Strength the bond shear strength at the BCO PCCP interface and HIPERBOND calculate these values on a continuous basis and display the results as they are calculated The resulting plots can then be used to mak
39. erature 1 F oG Daily Minimum Low Temperature F C Use Default Temperature Distribution ves No Please refer to Hourly Temperature Data Sheet Daily Maximum Humidity Sunrise F C Daily Minimum Humidity Late Afternoon F C Overcast Conditions Sunny O Partly Cloudy 1 Cloudy Overcast Average Wind Speed kph mph 67 Construction Parameters Curing Method Check Box 1 None A Single Coat Liquid Curing Compound Double Coat Liquid Curing Compound O Triple Coat Liquid Curing Compound Polyethylene Sheeting Cotton Mats or Burlap A Polyethylene Sheeting Cotton Mats Time of Day of Construction 771 Initial Mix Age of Opening to Traffic hours Age at Saweutting hours Note Enter a value of 0 zero in Age at Sawcutting to perform at the optimum time Initial Existing Pavement Surface Temperature F C Surface Preparation 1 Milling A Light Shotblasting 1 Water Air Blasting A Heavy Shotblasting A None Surface Preparation pcc Grout O Epoxy Latex A None Use Default Bond Strengths C ves Use Bond Shear Strength psi kPa Bond Tensile Strength psi 68 3 4 DEFAULT TREND Draw Chart to represent Degrees Y vs Hours X Ambient Air Temperatures
40. ermal coefficient of expansion of the coarse aggregate is based on the coarse aggregate type or if it will be entered directly Aggregate Thermal Coefficient of Expansion if measured or estimated enter this value directly Cement Content enter the cement content in the mix design Silica Fume Content enter the silica fume content in the mix design Type F Fly Ash Content enter the type F fly ash content in the mix design Ground Slag Content enter the ground slag content in the mix design 16 Water Content enter the water content in the mix design Coarse Aggregate Content enter the coarse aggregate content in the mix design Fine Aggregate Content enter the fine aggregate content in the mix design Water Reducer check if a water reducer is used the mix Super Water Reducer check if a super water reducer is used in the mix Retarder check if a retarder is used in the mix Accelerator check if a accelerator is used in the mix PCC Maturity figure 17 Number of Maturity Data Points identify the number of measured maturity data points to be entered Datum Temperature enter the datum temperature to be used in the Nurse Saul maturity equation Age enter the age of the PCC for the maturity point Maturity enter the maturity value Strength enter the PCC flexural strength corresponding to the maturity point Laboratory Maturity Data Number of Maturity Data Points
41. esses are compared with the shear strengths and the tensile stresses are compared with the tensile strengths scenario which the stress exceeds the strength for either the shear or tensile values may constitute a potential for delamination Figure 36 presents a typical run with a set of inputs corresponding to good performance As be observed neither of the stress plots exceeds the corresponding strength plot thus good performance is anticipated Figure 37 however demonstrates a typical run for inputs conducive to a poorly performing BCO system which is predicted to have a tensile bond failure during the first 72 hours This bond failure could lead to excessive delamination and thus a shorter pavement life Several sets of inputs should be analyzed with the HIPERBOND module in order to determine the sensitivity of the variables involved In addition if several combinations of inputs are found to be satisfactory other factors can then be used to govern the selection of the final combination of inputs These factors may include economics or materials and or labor availability 36 IR isd 1o asua L MEE o fl S o 9 o I 2 D 5 D Figure 34 HIPERPAV module postprocessor output screen of good performance 111 isd 10 asua 1000 o
42. g surface preparation method ie sei aee er OH ROBUR TUS eq E NN 54 HIPERBOND output for case 7 baseline with no bonding 54 vi Section N DA NH LIST TABLES Page Summary of HIPERPAV analysis performance results eese enne 4 Summary of HIPERBOND analysis performance results 4 Summary of evaporation rate analysis performance results 4 HIPERPAV data for this Example ss t a S ee v ab 41 Summary of HIPERPAV example 41 HIPERBOND data for this example 50 Summary of HIPERBOND example 51 vii CHAPTER 1 INTRODUCTION TO HIPERPAV VERSION 2 1 1 1 Background and Purpose As a result of the Federal Highway Administration FHWA study entitled Fast Track Paving Concrete Temperature Control and Traffic Opening Criteria for Bonded Concrete Overlays a general set of practical guidelines were developed for the design and construction of Portland cement concrete PCC pavements and bonded concrete overlays BCOs In order to maximize their efficiency optimize their use and facilitate their implementation these guidelines have been made available in an automated format This automation has been achieved by incorporating the guidelines into a user friendly computer software application termed HIgh PERformance PAVing The software contains two primary mod
43. gh and low temperatures 20 Ambient Air Temperatures 6 00 AM Figure 22 Time temperature distribution subjected to a cold front In addition the Default Trend button can be used to reset the temperature distribution to the default sinusoidal distribution defined using the maximum and minimum temperatures from the Environmental Inputs dialog box JCP Construction Parameters figure 23 JCP Construction Parameters Single Coat Liquid Curing Compound v 6 00 AM B Figure 23 HIPERPAV Version 2 1 HIPERPAV construction parameters 21 Curing Method select the curing method to be used the slab Time of Day of Construction select which hour of the day or night that the concrete was placed calculations are valid only for slabs placed at the time specified multiple runs must be used to cover the range of placement times Initial PCC Mix Temperature enter the mix temperature of the PCC at the time of placement Age of Opening to Traffic enter the age of the PCC at the time that the curing method is removed if applicable Age at Sawcutting enter the age of the PCC at the time that sawcutting is performed A value of zero 0 can be entered to simulate sawcutting performed at the time of final set in reality only green sawing may be done at this point Initial Subbase Temperature enter the surface temperature of the subbase layer prior to
44. ing an assumption that a cold front or other climatological event has occurred after 36 hours The result was a temperature drop of 30 F This case decreases the minimum ambient temperature to 40 F which results in two significant strength violations during the early age period Therefore if the possibility of a cold front or other temperature anomaly is expected other measures should be taken to minimize the potential for damage e Case 6 This case utilizes a cotton mat form of curing Stresses experienced in the pavement during the first 72 hours are similar or slightly better lower than those in the baseline case Due to the minimal effect and potentially large cost involved in using this type of curing method it may not be favorable Case 7 The start time of paving in this case was set at 3pm versus 9am for the baseline case The overall effect of this modification is moderately significant for this combination of inputs One stress violation at about 24 hours following construction can be observed as a result Case 8 The transverse joint spacing for this case was increased to 25 feet from 15 feet As could be expected this resulted in an increased potential for early age damage Three 42 2 e amp t d 0 2 aH 2 E c Tensile Stress or Strength psi Elapsed Time Since Construction hours Figure 39 HIPERPAV output for case 2 baseline with type III
45. lt Strength Gain Yes No Use Laboratory Maturity Data Enter Maturity Data Use Default Heat of Hydration Yes Use Cement Chemical Composition Data Enter Cement Data Coarse Aggregate Limestone Dolomite 71 Use Default Thermal Coeff of Expansion Yes Use Agg Thermal Coeff wr Cement Content 5 byr Silica Fume Content 5 Type Fly Ash Content o Ground Slag Content 100 U Water Content 296 Ib yd Accelerator B Chemical Admixtures Iv Water Reducer Super Water Reducer Retarder Volumetrics W ater Cement Ratio 564 Water Cementitious Materials w cm Ratio 414 Fine Aggregate Content 900 Ib ycf Cancel Figure 16 HIPERPAV Version 2 1 HIPERPAV mix design parameters Cement Type choose from various cement type options Default Strength Gain select whether default strength gain prediction methods are to be used or if maturity data entered by the user will be used see figure 17 Default Heat of Hydration select whether the default heat of hydration for the specified cement type will be used or if the heat of hydration will be predicted from cement chemistry data entered by the user see figure 18 Coarse Aggregate Type choose from various coarse aggregate type options Default Aggregate Thermal Coefficient of Expansion select whether default th
46. lysis control panel for the HIPERBOND module can be initiated using the menu command toolbar button or the Begin Analysis button in the document window The control panel can be seen in figure 29 28 Control Panel Figure 28 HIPERPAV Version 2 1 HIPERPAV analysis example 5 1 HIPERBOND Control Panel Figure 29 HIPERPAV Version 2 1 HIPERBOND control panel 20 HIPERBOND control panel consists of several controls including Start Analysis Button executes the analysis routine Exit closes the control panel and returns the user to the document window Moisture Loss Distress Analysis opens the Moisture Loss Evaporation Rate Distress Analysis control panel see section 3 6 Display Units Option Buttons allow the user to select what units the analysis results will be plotted only one option can be selected for a run Time Display Option Buttons allow the user to select the style of the time horizontal axis only one option can be selected for a run Tensile Strength Legend denotes the color of the plotted line which represents the calculated tensile strength of the bond between the existing pavement and the BCO Tensile Stress Legend denotes the color of the plotted line which represents the calculated maximum tensile stress of the bond between the existing pavement and the BCO Shear Strength Legend denotes the color of the plotted line which represents the calcul
47. lysis is the default value for the selected subbase or a value entered directly the default value will be shown in the box when Yes is selected Friction Force if the slab subbase friction is measured enter the friction force Movement at Sliding if the slab subbase friction is measured enter the movement when sliding begins Transverse Joint Spacing enter the distance between transverse contraction joints or the average distance if the spacing is variable Design Reliability enter the desired value The reliability level adjusts the stress and strength values so that the values displayed represent values other than the mean values defined as 50 Reliability As the reliability level is increased the predicted stresses will increase and the predicted strengths will decrease thus increasing the probability of a strength violation 28 Day PCC Flexural Strength enter the mean 28 day PCC flexural strength value from lab tests performed according to ASTM C78 or similar Note values in specifications are often much lower than mean values for the in place PCC 28 Day PCC Modulus of Elasticity enter the mean 28 day PCC modulus of elasticity which can be measured in lab tests performed according to ASTM C 469 or similar or estimated Thickness enter the mean as constructed slab thickness 15 JCP Mix Design Parameters figure 16 JCP Mix Design Parameters xi Cement Type Type Normal Use Defau
48. nce Construction hours Modified Value n a Sunny 90 F Siliceous Gravel Heavy Shotblasting None Figure 46 HIPERBOND output for case 1 baseline case 51 Figure 47 HIPERBOND output for case 2 with type Figure 48 HIPERBOND output for case 3 baseline with sunny clear skies 52 Figure 49 HIPERBOND output for case 4 baseline with PCC mix temperature of 90 F Figure 50 HIPERBOND output for case 9 baseline with siliceous BCO coarse aggregate 53 Figure 51 HIPERBOND output for case 6 baseline with heavy shotblasting surface preparation method Figure 52 HIPERBOND output for case 7 baseline with no bonding agent Step 5 Following the analyses a prioritization of the results is warranted For example purposes the following is a summary of the seven cases which were analyzed e Case 1 Baseline This case demonstrated average behavior during the early age period The other cases will be compared to this case Case 2 This case included a Type III cement in place of the Type I that was used in the baseline mix The observed strength gain is accelerated in this case however the stress level also increases more dramatically As a result a bond strength violation is observed at a very early age e Case 3 The baseline analysis includes the assumption of partly cloudy skies during the analysis period This analysis ass
49. nches Design Reliability E Existing Pavement Bonded Concrete Overlay BCO Flexural Strength 800 psi 28 day Flexural Strength 800 psi Modulus of Elasticity 5000000 psi 28 day Modulus of Elasticity E 4500000 psi Thickness 12 inches Thickness fa inches Figure 24 HIPERPAV Version 2 1 HIPERBOND general design parameters Transverse Joint Spacing enter the distance between transverse contraction joints or the average distance if the spacing is variable Design Reliability enter the desired value The reliability level adjusts the bond stress and strength values so that the values displayed represent values other than the mean values defined as 50 Reliability As the reliability level is increased the predicted bond stresses will increase and the predicted bond strengths will decrease thus increasing the probability of a bond strength violation Existing Pavement PCC Hlexural Strength enter the mean in place flexural strength value of the existing slab Existing Pavement PCC Modulus of Elasticity enter the mean in place modulus of elasticity of the existing slab which can be measured or estimated Existing Pavement Slab Thickness enter the mean thickness of the existing slab Bonded Concrete Overlay 28 Day PCC Flexural Strength enter the mean 28 day PCC flexural strength value of the BCO PCC from lab tests performed according to ASTM 78 or similar
50. panel see section 3 6 Display Units Option Buttons allow the user to select in what units the analysis results will be plotted only one option can be selected for a run 27 Time Display Option Buttons allow the user to select the style of the time horizontal axis only one option can be selected for a run PCC Strength Legend denotes the color of the plotted line which represents the calculated strength of the PCC PCC Critical Stress Legend denotes the color of the plotted line which represents the calculated critical stress the slab of Slab Legend denotes the color of the area below the stress curve which indicates if the position of critical stress is located at the top of the slab Bottom of Slab Legend denotes the color of the area below the stress curve which indicates if the position of critical stress is located at the bottom of the slab When the Start Analysis button is pressed the analysis routine will initiate The analysis is computationally intensive therefore the computer may be slow to respond to user actions during the analysis period The results of the analysis are plotted in real time as they are calculated by the analysis routine The estimated run times for various computers can be found in section 2 2 An example of the resulting plot can be seen in figure 28 3 5 HIPERBOND Module Control Panel After entering the various analysis inputs the user may execute the analysis The ana
51. pp or higher resolution monitor 2 2 Performance Tables 1 2 and 3 contain the approximate run times of the analysis modules using different computer platforms for the HIPERPAV HIPERBOND and moisture loss prediction systems respectively As can be seen a fast Intel Pentium M processor or equivalent significantly improves the overall performance of the software and is therefore recommended Table 1 Summary of HIPERPAV analysis performance results Processor Manufacturer Type Intel Pentium PS 80586 Intel Pentium PS 80586 Intel Pentium PS 80586 Intel Pentium PS 80586 Intel 486DX Processor Clock Speed MHz 200 120 100 75 100 Execution Time Minutes Seconds 0 22 0 42 0 47 1 10 1 55 Table 2 Summary of HIPERBOND analysis performance results Processor Manufacturer Type Intel Pentium PS 80586 Intel Pentium PS 80586 Intel Pentium PS 80586 Intel Pentium PS 80586 Intel 486DX Processor Clock Speed MHz 200 120 100 75 100 Execution Time Minutes Seconds 0 33 1 00 1 06 1 32 2 35 Table 3 Summary of evaporation rate analysis performance results Processor Manufacturer Type Intel Pentium PS 80586 Intel Pentium PS 80586 Intel Pentium PS 80586 Intel Pentium PS 80586 Intel 486DX Processor Clock Speed MHz 200 120 100 75 100 Execution Time Minutes Seconds 0 04 0 08 0 09 0 12 0
52. r temperature control panel seen in figure 20 In the control panel the time of day of construction can be modified and three tools are available to modify the temperature distribution The tools include e A Point tool which when selected allows the user to slide individual point temperature values higher and lower High Low tool which allows the user to select alternate high and low temperatures for the various days during the analysis period The result of using this tool can be seen in figure 21 19 Cold Front tool which allows the user to simulate a dramatic drop in temperature followed by a slow recovery period The result of using this tool can be seen in figure 22 120 F 110 F 100 F 30 F a a 80 F Tangan ELE anun 60 F 50 F 40 F 30 F 20 F 10 F 0 12 18 24 30 36 42 48 54 60 66 72 Selected Time of Day 0500 Time of Day of Construction 1 Selected Hour p Selected Temperature ip Default Trend Temperature Adjustment Tools VW a zm Figure 20 Default time temperature distribution F Ambient Air Temperatures 0 12 18 24 30 36 42 48 54 0 72 Selected Time of Day 17 00 Time of Day of Construction Temperature Adjustment Tools Selected Hour m oos GI cou Selected Temperature 95 F Default Trend Figure 21 Time temperature distribution with varying hi
53. te Content 1100 bye iru Water Cementitious Fine Aggregate Content 900 bye Materials Ratio 414 Figure 25 HIPERPAV Version 2 1 HIPERBOND mix design parameters Cement Type choose from various cement types Default Strength Gain select whether default strength gain prediction methods are used or if maturity data entered by the user will be used see figure 17 Default Heat of Hydration select whether the default heat of hydration for the specified cement type will be used or if the heat of hydration will be predicted from cement chemistry data entered by the user see figure 18 Existing Pavement Coarse Aggregate Type choose from various coarse aggregate types used in the existing pavement if the exact coarse aggregate type is not shown choose the listed item that is most similar Default Thermal Coefficient of Expansion select whether default thermal coefficient of expansion of the coarse aggregate in the existing pavement is based on the coarse aggregate type or if it will be entered directly 24 Existing Pavement Aggregate Thermal Coefficient of Expansion if measured or estimated enter this value directly BCO Coarse Aggregate Type choose from various coarse aggregate types used in the BCO layer BCO Default Thermal Coefficient of Expansion select whether default thermal coefficient of expansion of the coarse aggregate in the BCO layer is based on the
54. tely two thirds The other cases will be compared to this case Case 2 This case included a Type III cement in place of the Type I from the baseline mix The observed strength gain is accelerated with this case however the stress level is also slightly greater due to the heat buildup resulting in a higher temperature zero stress gradient A failure may occur at a very early age if proper precautions are not taken Because of this a preliminary conclusion may be drawn that the additional cost of the Type III cement may not be justified Case 3 A lower flexural strength grade of PCC was used in this case A 28 day value of 600 psi instead of 800 psi resulted in a decreased strength gain with a maximum stress to strength ratio of approximately 110 percent Although a modification to the mix design would probably be necessary for this decrease in the 28 day strength all of the mix design parameters were held constant for simplicity Preliminarily this case is not recommended due to its three strength violations Case 4 The subbase for this case is changed from that of a granular flexible type to one that is cement stabilized This resulted in a higher stress level due to the additional restraint from the subbase Three large strength violations are observed in this case Because of these violations this particular combination of inputs should be rejected Case 5 This analysis differs from the baseline analysis by includ
55. th only marginal improvements over the baseline case 3 Case 3 Rejected less expensive than baseline however behavior approaches borderline case 4 Case 7 Rejected behavior slightly worse than baseline as well as being a potentially more expensive option due to the unconventional time of paving 5 Case 2 Rejected more expensive than baseline with similar behavior 6 Case 8 Rejected less expensive due to the fewer number of joints however much more prone to damage than baseline 7 Case 4 Rejected more expensive due to the stabilization as well as much more prone to damage than baseline 8 Case 5 Rejected other measures must be taken if this case is encountered The purpose of this example is to clarify a possible set of procedures which can be followed when using the verification guidelines Although a single example cannot demonstrate the full use of the various features of the software it can serve as a basis from which a verification analysis program can be built Individual agencies should establish standardized procedures for analysis based upon local experience 47 CHAPTER 6 SAMPLE APPLICATION OF THE HIPERBOND MODULE In order to improve of implementability of the end products of this study an example is given in this chapter of the proper use of the HIPERBOND software The purpose of the HIPERBOND software is to verify the identification of a set of design and construction
56. thus the cost may be warranted Heavy shotblasting therefore should be considered as a surface preparation technique in the final selection 2 Case 7 behavior better than the baseline case as well as less expensive option due to the elimination of the Portland cement grout as a bonding agent 3 Case 1 baseline case average cost no early age damage 55 4 Case 4 Rejected be less expensive due to the lack of control of the PCC mix temperature however it will result in poor behavior and an increased potential for early age delamination 5 Case 5 Rejected behavior worse than baseline case Although using a siliceous aggregate may be a less expensive option in some locales preventing poor performance may justify a higher cost 6 Case 3 Rejected other measures should be taken if this case is encountered 7 Case 2 Rejected this alternative exhibited poor behavior during the early age period In addition is will be more expensive during the initial construction therefore it should be eliminated from consideration unless other measures are taken to minimize the adverse effects The purpose of this example is to clarify a possible set of procedures which can be followed when using the HIPERBOND verification guidelines Although a single example cannot demonstrate the full use of the various features of the software it can serve as a basis from which a verification analysis program can be built Indi
57. ubbase Type Check Box C Flexible Unbound Aggregate 1 Untreated Clay Subgrade No Subgrade 1 Lime Treated Clay Subgrade C1 Cement Stabilized Asphalt Stabilized Hot Asphalt Concrete Use Default Slab Subbase Friction 1 Yes No Use Friction Foce psi kPa Movement at Sliding inches Transverse Joint Spacing feet meters Design Reliability 771 Existing Pavement 28 Day PCC Flexural Strength 28 Day Modulus of Elasticity E inches 64 Bonded Concrete Overlay 28 Day PCC Flexural Strength psi kPa 28 Day Modulus of Elasticity Jpsi kPa Thickness inches BCO Mix Design Parameters Cement Type Check Box 1 Type I Normal O Type IP Normal with Pozzolans Moderate Sulfate Resistance A Type High Early Strength A Type V High Sulfate Resistance 1 Hot Mix Asphalt Concrete HMAC Use Default Strength Gain M Yes CI No Use Laboratory Maturity Data Please refer to Maturity Data form Use Default Heat of Hydration 1 Yes C Use Cement Chemical Composition Data Please refer to Cement Data form Existing Pavement Coarse Aggregate Type Check Box 1 Limestone Dolomite 1 Sandstone 1 Granite Gneiss Siliceous Gravel 1 Basalt Use Default Aggregate Thermal Coefficient of Expansion 1 Yes CI No Use Aggregate Thermal
58. ule postprocessor output screen of good performance 37 HIPERPAV module postprocessor output screen of poor performance 37 HIPERBOND module postprocessor output screen of good performance 38 HIPERBOND module postprocessor output screen of poor performance 38 HIPERPAV output for case 1 baseline Case eeen 43 HIPERPAV output for case 2 baseline with type Cement 43 HIPERPAV output for case 3 baseline with 600 psi 28 day flexural strength 44 HIPERPAV output for case 4 baseline with cement stabilized subbase sss 44 HIPERPAV output for case 5 baseline with minimum ambient temperature of 40 F after Rn m 45 HIPERPAV output for case 6 baseline with cotton mat 45 HIPERPAV output for case 7 baseline with 3pm start Of paving eee 46 HIPERPAV output for case 8 baseline with 25 foot joint spacing esee 46 HIPERBOND output for case 1 baseline 51 HIPERBOND output for case 2 baseline with type III Cement 52 HIPERBOND output for case 3 baseline with sunny clear 52 HIPERBOND output for case 4 baseline with PCC mix temperature Of 90 F oa 53 HIPERBOND output for case 5 baseline with siliceous BCO coarse aggregate 53 HIPERBOND output for case 6 baseline with heavy shotblastin
59. ules for the analysis of new construction jointed concrete pavements and HIPERBOND HIgh PERformance BONDed Concrete Overlays for the analysis of bonded concrete overlays The purpose of the HIPERPAV and HIPERBOND guidelines is to verify pre selected design and construction variables related to fast track PCC pavements and bonded concrete overlays The intent is to predict the potential for pavement damage during the first 72 hours after placement Damage is defined as the development of uncontrolled transverse cracking for and the development of bond delamination for HIPERBOND In addition the potential for plastic shrinkage cracking can be predicted for either pavement type The final report from this study is an overview of the work conducted in this study and also serves as a guide for the proper selection of inputs to the HIPERPAV and HIPERBOND guidelines The computer software description herein should be used only as a supplement to the general guidelines presented in that report 1 2 Introduction The and HIPERBOND guidelines have been developed in order to facilitate the decision making process regarding the optimal combination of materials and methods for limiting pavement damage with a given set of weather conditions The software described here allows for the selection and evaluation of various combinations of inputs to determine their overall effect on the behavior of the concrete pav
60. ult units for the analysis inputs and output can also be selected Finally the current inputs as defined in the various dialog boxes described in the next section can be saved as the default values by clicking on the Save Inputs as Default Values button The user is encouraged to use the latter feature to save time in entering the inputs The two types of analyses HIPERPAV and HIPERBOND can be selected via the tabs figures 13 and 14 On each tab the various input screens can be initiated and the analysis executed via the buttons This box also displays a graphic with the typical pavement cross section for the specified analysis File Inputs Run View Help S C Hiperpav T IH35 MP225 hpv Name of Engineer lohn W Smith Project Name Lane 2 NB Interstate 35 Austin Constructed 6 7 94 Date of Analysis fi 0 12 97 Change User Preferences HIPERBOND High Performance Paving Verification Guidelines Design Inputs Environmental Inputs Construction Inputs Begin Analysis Status 10 12 97 11 28 CAPS NUM INS SCRL Figure 11 Version 2 1 main menu with open document 12 HIPERPAV Properties Figure 12 HIPERPAV Version 2 1 Properties dialog box C AHiperpaviTexas IH35 MP225 hpv Lane 2 NB Interstate 35 Austin Constructed 6 7 94 New PCCP Layer SETS
61. umes that the skies will remain clear during the analysis period resulting in a sunny condition The result of this is a bond stress peak in the very early age which can possibly lead to delamination e Case 4 This case assumes an increase in the PCC mix temperature from 70 F to 90 F This results in an adverse condition which can possibly lead to delamination in the early hours e Case 5 This case assumes that a coarse aggregate which is siliceous in nature is used By comparison the baseline case assumed a limestone BCO coarse aggregate The result is an increased potential for early age damage due in large part to the higher thermal coefficient of expansion e Case 6 The baseline case assumes that the surface of the existing pavement is prepared by milling This case utilizes heavy shotblasting which results in a slightly higher bond strength and a lower potential for delamination e Case 7 This case utilizes no bonding agent as opposed to the baseline case which utilized a Portland cement grout bonding agent It is observed to have a slightly better bond and thus an improved overall behavior of the BCO system during the early age period Step 6 Based upon the selection and analyses of the various cases a prioritization of their respective benefits versus costs can be made A prioritization for this example is 1 Case 6 this alternative is generally more expensive than cold milling but results in better behavior and
62. uts that are flexible to modification and then selecting an appropriate range for these values 3 Rank Analysis Combinations Before performing the verification analysis the user should prioritize possible combinations of design and construction inputs This ranking should be accomplished by examining economic availability and other direct and indirect considerations This gives the user the ability to know which variables are more or less difficult to modify due to constraints not directly considered by the software 4 Analyze Combinations The user should begin analyzing the combinations of inputs by analyzing the most probable feasible set of inputs first Subsequent analyses should then be done to determine sensitivity of the inputs to the overall behavior If a particular variable is found to be insensitive it can most likely be ignored during the analysis 5 Prioritize Analysis Results Following the analyses the various combinations of inputs should be sorted as to their potential for early age damage Any combinations that result in the prediction of early age damage should be rejected and marginal cases should be flagged for possible rejection unless economic or other pressures warrant their use 6 Finalize Selection of Inputs The final selection s of inputs should be based on a comparison of the results of the ranking analysis with the original ranking that was based on economic and other factors The final selection should b
63. vidual agencies should establish standardized procedures for analysis based upon local experience 56 APPENDIX HIPERPAV MODULE INPUT FORM 57 General Input Date of Analysis Default Units us Customary Metric v s Customary amp Metric I will specify which ones for each input JCP General Design Parameters Subbase Type Check Box C Flexible Unbound Aggregate 1 Untreated Clay Subgrade No Subgrade 1 Lime Treated Clay Subgrade C1 Cement Stabilized Asphalt Stabilized Hot Mix Asphalt Concrete Use Default Slab Subbase Friction 1 Yes C Use Friction Force psi kPa Movement at Sliding inches cm Transverse Joint Spacing feet meters Design Reliability 1 28 Day PCC Flexural Strength psi kPa 28 Day Modulus of Elasticity psi kPa Thickness 58 JCP Mix Design Parameters Cement Type Check Box O Type I Normal O Type IP Normal with Pozzolans Type Moderate Sulfate Resistance A Type High Early Strength O Type V High Sulfate Resistance Hot Mix Asphalt Concrete Use Default Strength Gain CI No Use Laboratory Maturity Data Please refer to Maturity Data form Use Default Heat of Hydration 1 Yes Use Cement Chemical Composition Data Please refer to Cement Data form Coarse Aggregate Type Check Box 1 Limestone Dolomite 1 Sandston

Federal Highway Administration Report FHWA-RD-98

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