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JRI + LOAD TRANSFER DEVICE F A R O B E L CIVIL WORK TECHNOLOGY Concrete pavement Asphalt.

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Presentation on theme: "JRI + LOAD TRANSFER DEVICE F A R O B E L CIVIL WORK TECHNOLOGY Concrete pavement Asphalt."— Presentation transcript:

1 JRI + LOAD TRANSFER DEVICE F A R O B E L CIVIL WORK TECHNOLOGY Concrete pavement Asphalt surface layer Cheaper and more Durable Pavements

2 Highways & Roads Introduction to JRI+ load transfer device Application fields Trains Airport Esplanades Harbour Esplanades Industrial pavements Streets …all concrete surfaces resting on the ground Water courses Industrial parkings

3 This is a new system based on using the JRI+ load transfer devices in concrete pavements There are two JRI load transfer devices, which work with analogous characteristics: JRI+4 JRI+ The final solution is a concrete pavement Introduction to JRI+ load transfer device Object A proper asphalt layer on top of concrete slabs improves I.R.I and noise levels Other layer Concrete pavement Other layer Concrete pavement with NEW SYSTEM Bituminous layer Other layer Bituminous layer Other layer New SYSTEM

4 Three-dimensional polypropylene surfaces remain embedded in concrete So, a weak section has been created in concrete Shrinkage crack follows the tridimensional surface Introduction to JRI+ load transfer device Basic Concepts Shrinkage cracks appear in the surface following the JRI+ shape, which is divided in alternating horizontal surfaces

5 Concrete slabs with alternate indentation have been created Concrete teeth end with horizontal surfaces responsible of load transfer Shrinkage cracks become watertight through a rubber profile at the top Basic Concepts Introduction to JRI+ load transfer device

6 Test-tube manufactured with JRI+ device inside it The system leads the crack of concrete produced by shrinkage and loads. It is a three-dimensional load transfer system The horizontal surface can be noticed observing the crack shape Introduction to JRI+ load transfer device Basic Concepts

7 Above: JRI+4. Notice the alternate trays and rubber profile on top. The height of the JRI+4 device will be shorter than the thickness of the concrete slab Images JRI+4 Introduction to JRI+ load transfer device

8 The picture shows the JRI+ device placed on the esplanade while pouring concrete The height of the JRI+ device is shorter than the thickness of the concrete slab Images Project with JRI+ Introduction to JRI+ load transfer device

9 Detail JRI+ Introduction to JRI+ load transfer device

10 Both JRI+4 & JRI+ have a rubber profile at the top that makes the shrinkage cracks become watertight The picture on the right side shows the rubber profile. The upper grey line is the top of the concrete slab. All the rubber gum is embedded inside concrete, protected from the atmosphere and traffic The zigzag surface at the bottom ensures a watertight crack Images Top Watertight rubber gum Introduction to JRI+ load transfer device

11 The JRI+ devices have alternate trays on either sides of the superficial crack line where the rubber is placed Details Plan view JRI+4 Introduction to JRI+ load transfer device Plan view JRI+

12 JRI+4 device with the rubber to watertight the crack on its top Images JRI+4 Introduction to JRI+ load transfer device

13 Once works were finished, the slabs were separated to observe the JRI+ In this case the concrete slab thickness is the height of the JRI+ Notice the horizontal trays in the concrete alternate teeth It is proved that the shrinkage crack follows the JRI+ surface Images JRI+ Introduction to JRI+ load transfer device

14 JRI+ load transfer devices are located on the esplanade and concrete is directly poured on them Images Project with JRI+ Introduction to JRI+ load transfer device

15 JRI+4 load transfer devices are inserted automatically into the fresh concrete right after pouring it, using a screed and needle vibrators ImagesJRI+4 Introduction to JRI+ load transfer device

16 Index -Introduction to JRI+ load transfer device -JRI+ Characteristics -Tests & trials -Projects -Pavement designing -Conclusions J R I+ LOAD TRANSFER DEVICE

17 JRI+ Characteristics JRI+ watertights the crack + The load transfer capacity is almost 100% for the whole lifespan. No vertical relative displacement between adjacent slab edges General No fine material pumping and ground erosion Layers with high elastic modulus are not required No impact between layers Less stress

18 JRI+ Characteristics As the rubber guarantees a watertight surface, sealing is not needed General JRI+ system leads the crack through the whole section No cut required The longitudinal compression due to thermal expansion is produced in the whole section so the axial load is centered. There is no buckling because of the compression exerted by the side slabs. No maintenance required

19 Stresses on the horizontal surface are lower because there is a larger contact area: The load transfer capacity doesnt depend on base and sub-base layers Comparison with dowel bars Load carrying capacity is improved with base and/or sub-base layers to reduce contact stress in concrete Dowel bar System requires a good base layer JRI+ Characteristics

20 The durability of the JRI+ System is higher than the dowel bars one because of the lower tensile values achieved in the concrete transfer in the contact surface by the former system. Eventually, dowel bars will break the concrete due to the high strength causing vertical displacement and lower Load Transfer Efficiency. Dowel bars can be oxidized while JRI+ polypropylene devices cannot be oxidized. With JRI+ System load is transferred by the concrete teeth instead of the bars. The rubber profile embedded into the concrete guarantees a watertight system, so water doesnt reach the esplanade. No seal maintenance required With JRI+, the pavement doesnt lose the flat surface in case of a breakage. Fast concrete crack repair, with no demolition required. No base layer required Comparison with dowel bars JRI+ System: cheaper system with a faster execution

21 JRI+ Characteristics Concrete pavements with JRI+ joints don´t need base granulate layers. Thinner concrete slabs with JRI+ joints thanks to the lower critical stress. The critical stress is centered in the slabs, not on the edges The concrete pavements with JRI+ and same thickness are more durable. Shorter slab lengths. This fact also reduces stress. The road shoulders are built with the same system. This increase of slab width avoids critical stress on slab edges. It also allows future road widening. JRI+ is a transverse joint system. External longitudinal joints (pavement machine edges or construction joints) are built with modified JRI+ joints. Interior longitudinal joints use steel bars. Cutting and sealing with the JRI+ specific rubber Structural design considerations

22 JRI+ Characteristics JRI+: Polypropylene tray material Elastic modulus of polypropylene: MPa Elastic modulus of concrete: MPa It is checked that polypropilene deformation is not an important factor to take into account when calculating deflection JRI+ device thickness = 2 mm stress = 1MPa deformation = 0,002 mm Deflections are 100 times larger Because of the different order of magnitude, the deformation of the polypropylene is a factor that doesnt have to be considered in deflection with JRI+ system Polypropylene joint allows rotation in one direction (2 degrees maximum) Polypropylene joint allows free rotation in the other one direction

23 JRI+ Characteristics 1.Lower land occupation 2.Lower excavation 3.Lower transportation 4.Lower execution time 5.Higher durability due to lower stress 6.Lower energy consumption and lower CO 2 emission 7.More convenient repair 8.Lower maintenance costs Lower Environmental Impact

24 JRI+ Characteristics 1.The JRI+ system pavement is cheaper than current ones, either asphalt either concrete 2.Aggregate base layers are saved 3.Building roads with just one concrete layer shorten the execution times 4.Cut and sealing are saved 5.Depth drainage is decreased 6.Excavations are decreased 7.JRI+ joints are cheaper than bars 8.Maintenance costs are decreased Cost reduction

25 JRI+ Characteristics JRI+4 Placed after concrete pouring, behind the paving machine Not anchored to the floor Located from the top into fresh concrete through needle vibrators Higher control of execution. Higher Load Transfer Efficiency Rubber profile placed regarding the concrete top surface No Spalling JRI+ Placed before concrete pouring Anchored to the floor, tight to esplanade reference Holes avoid being pushed by concrete Spalling when the rubber profile is below the concrete top surface In pavement executed with asphalt wearing course, spalling doesn´t affect

26 JRI+ Characteristics Asphalt Pavement on concrete base I.R.I. and noise are improved with a proper asphalt layer on top of concrete slabs. Shrinkage cracks in concrete slab finally appear in asphalt layer. We have observed in our projects that these cracks dont do any damage or spalling, even after 13 years of use. Crack edges dont erode because there are no relative vertical movements between slabs. No sealing required. JRI+ joint is already sealed. Cracks are thin enough they cannot be noticed from the vehicles.

27 Index -Introduction to JRI+ load transfer device -JRI+ Characteristics -Tests & trials -Projects -Pavement designing -Conclusions F A R O B E L CIVIL WORK TECHNOLOGY

28 Tests & trials Concrete slab directly executed on top of base course Falling Weight Deflectometer (FWD) tested in 12 JRI+ in both sides The average Load Transfer Efficiency (LTE ) > 98 % The LTE is the ratio between deflections of points which are at the same distance from the applied load (30 cm). The crack is located between both points. Average deflections in the boundaries of the slabs = 0,164 mm. FWD results M503 Highway Madrid, May 2006

29 Tests & trials A 200 meters stretch was tested. After the results, the relevant gouvernmental agency (Autoridad del Transporte Metropolitano de Barcelona, ATM) decided to build 30 km of double track. The FWD tested 31 joints JRI+ of concrete directly placed on top of the base course with California Bearing Ratio, CBR = 5. Results: 1.The load transfer average was 99.3%. 2.The deflection average in the center and boundaries of the slabs was 1,13mm and 1,24mm respectively. 3.The difference between the deflection in the center and in the boundaries of the slabs was lower than 10%. FWD results Barcelona Streetcar 2002

30 Tests & trials Break strength in boundaries is between 5 and 6 times service strength When real scale test has been done in order to reach the slab break, it always breaks due to bending moments in the center of the slab. Teeth dont break System strength

31 Tests & trials JRI+ projects have been carried out since One of these projects with the higher traffic intensity, more than 4000 trucks per day (Highway A2, Madrid-Barcelona, 1998). It is still in good conditions, no reparations have been required. In the Barcelona Harbour dynamic tests were made with 45 Tonnes axes. There werent any damages with slabs of 16 cm of thickness. Another example of how the JRI+ system is suitable for high traffic is road in Gijon Harbour built in Since then, the road has operated. The pavement is in good conditions, no repairs have been required. Real projects

32 Index -Introduction to JRI+ load transfer device -JRI+ Characteristics -Tests & trials -Projects -Pavement designing -Conclusions J R I+ LOAD TRANSFER DEVICE

33 M503 Highway, Madrid, 2006

34 Olean Highway, New York, US, 2006

35 Tortosa Freeway, Spain, 2004

36 Airport esplanade, Barcelona, Spain, 2004

37 Barcelona Streetcar, Spain, 2003

38 Projects PROJECTS IMPLEMENTED WITH JRI LOAD TRANSFER DEVICE PROJECTTYPEADMINISTRATIONCONTRACTORYEAR JRI PROTOTYPE Las PalmasHarbour esplanadeAUTORIDAD PORTUARIANECSO1998 CastellbisbalRoadGISAFREYSSINET1998 VigoHarbour esplanadeAUTORIDAD PORTUARIACOVSA1999 BarcelonaIndustrial esplanadeZALCORSAN-CORVIAM1999 BarcelonaHarbour esplanadeAUTORIDAD PORTUARIASATO RUBAU2000 Sant Carles de la RàpitaHarbour esplanade PUERTOS DE LA GENERALIDAD LUBASA2000 AjalvirRoadCOMUNIDAD MADRIDFERROVIAL2000 JRI + CardedeuEsplanadeATLLBECSA2001 Santiago de CompostelaEsplanadeRENFEALDESA2001 BarcelonaStreetAUTORIDAD PORTUARIA UTE DRAGADOS SATO RUBAU El GolosoAcces roadCOMUNIDAD DE MADRIDA.C.S.2002 BarcelonaHarbour esplanadeAUTORIDAD PORTUARIARUBAU2003 BarcelonaIndustrial esplanadeAUTORIDAD PORTUARIARUBAU2003 Vilanova y la GeltrúHarbour esplanade PUERTOS DE LA GENERALIDAD SATO2003 Barcelona Baix Llobregat StreetcarATM Barcelona UTE COMSA-FCC- NECSO-ALSTOM Bogotá (Colombia)StreetHOLCIM 2003 Barcelona (Besòs)StreetcarATM Barcelona UTE COMSA-FCC- NECSO-ALSTOM

39 Projects PROJECTS IMPLEMENTED WITH JRI LOAD TRANSFER DEVICE PROJECTTYPEADMINISTRATIONCONTRACTORYEAR JRI + Roses (Girona)Coast Esplanade PUERTOS DE LA GENERALIDAD F.C.C.2004 St.Carles de la RàpitaHarbour esplanade PUERTOS DE LA GENERALIDAD CISTERÓ2004 BarcelonaTrucks parking slot AUTORIDAD PORTUARIA RUBAU2004 BarcelonaEsplanadeZ.A.L.CORSAN-CORVIAM2004 Valls (Tarragona)RoadGISAROMERO POLO2004 Tortosa (Tarragona)FreewayGISARUBAU Bogatell ( Barcelona)EsplanadeBarcelona City HallUTE ESTRUCTURES2004 Victoria (Australia)Industrial esplanadePOLYROAD S.A Valls (Tarragona)EsplanadeGISAVICSAN-TEYCO2004 Aeropuerto de Barcelona EsplanadeAENARUBAU BarcelonaEsplanadeZALBENJUMEA2005 BadalonaHarbour esplanade City Hall, Autoridad Portuaria, FCC Construcciones2005 BarcelonaEsplanadeZALCORSAN-CORVIAM2005 Mahón (Menorca)RoadCONSEJO INSULAR UTE ACSA - TOLO PONS 2005 St. Feliu de Llobregat (Barcelona) StreetcarATM Barcelona UTE COMSA-FCC- NECSO-ALSTOM 2005 BarcelonaStreetPuerto de BarcelonaMEPSA2005

40 Projects PROJECTS IMPLEMENTED WITH JRI LOAD TRANSFER DEVICE PROJECTTYPEADMINISTRATIONCONTRACTORYEAR JRI + Bellvei (Tarragona)EsplanadeGISARUBAU2005 Parla (Madrid)StreetcarCity HallFCC-ACCIONA2006 GijónRoadAutoridad PortuariaFCC2006 Olean (New York)HighwayNew York StateSurianello2006 Madrid (M503)HighwayComunidad de MadridDRAGADOS2006 BarcelonaStreetPuerto de BarcelonaCOPISA2006 Sagunto (Valencia)Harbour esplanadePuerto de SaguntoECISA2006 Mollerusa (Lleida)EsplanadeGISAACSA-SORIGUÉ2006 SevillaStreetcarCity HallUTE METRO CENTRO2006 Mexicali (México)Road Secretaría Transporte de México 2006 St.Feliu Buixalleu (Girona) Race CircuitAutodromo S,L.Autodromo, S.L.2007 MurciaStreetcarCity Hall STREETCAR MURCIA UTE 2007 BarcelonaStreetcar (Tramo)ATM BarcelonaFCC- Construcciones2008 Argelaguer (Girona)Urban RoadMinisterio de FomentoServiá-Cantó2008

41 Projects PROJECTS IMPLEMENTED WITH JRI LOAD TRANSFER DEVICE PROJECTTYPEADMINISTRATIONCONTRACTORYEAR JRI + 4 Tàrrega (Lleida)Urban RoadCity HallDragados2009 Castellfollit de la Roca Urban RoadMinisterio de FomentoMOVITERRA (FCC)2009 Llobregat sewage treatment plant Industrial poolGISAU.T.E. Rio Llobregat2009 JRI + Estepona (Málaga)Bicycle LaneCity HallU.T.E. BECSA-ITUVAL2009 Polígono Segre (Lleida) EsplanadeGISACisteró-Cobra2009 Castellar del VallèsEsplanadeGISAROGASA2009 JRI + 4 Alpicat (Lleida)FreewayMinisterio de FomentoFCC2009 TortosaLand developmentCity Hall UTE VICSAN- Hidrocanal 2010 ZaragozaStreetcar (stretch)City HallFCC2010 MálagaStreetcar-SubwayJunta Andalucía- Ayunt.UTE Metro- Málaga2010-…. MallorcaStreetcar- Train Consejo insular de Baleares Dragados, Ferrovial, FCC 2010-…. TárregaParking slotCity HallDragados2010 Alcoletge (Lérida)Esplanade - Industrial poolPrivateInnoferti2010

42 Projects Catalonia (Spain) Government projects for truck parking slots are designed with JRI+ system. JRI+4 system is approved and legalized in Romania Legal issues

43 Index -Introduction to JRI+ load transfer device -JRI+ Characteristics -Tests & trials -Projects -Pavement designing -Conclusions J R I+ LOAD TRANSFER DEVICE

44 Pavement design The pavement is design considering: Traffic intensity and loads Soil characteristics Concrete characteristics Thermal conditions Life span (fatigue) The JRI+ load transfer device transfers perfectly the shear stress Every project should have its specific design. Other layer Concrete pavement Other layer Concrete pavement with NEW SYSTEM Bituminous layer Other layer Bituminous layer Other layer New SYSTEM

45 Pavement design The optimal solution would be: Concrete slabs on top of the esplanade using JRI+4, placed behind the paving machine into the fresh concrete Asphalt layer on top to improve the noise level

46 Pavement design General design: Natural esplanade levelled and compacted. CBR>3 (K>3Kg/cm 3 ), obeying the organic contain and swelling 4,5MPa flexural strengthen concrete at 28 days Slab dimensions: 1,32*1,32m 2. Ground reaction in 3,96*3,96m 2 Thickness: 16 cm when over 4000 trucks per day &lane 16 cm when trucks per day &lane 15 cm when trucks per day &lane 14 cm when trucks per day &lane 13 cm when trucks per day &lane 13 cm when trucks per day &lane (if using bigger slab dimensions and low strength concrete then the slab thickness should be increased) 3cm asphalt layer with modified bitumen

47 Conclusions High Load Transfer Efficiency during the whole lifes pan Watertight cracks Lower execution and maintenance costs Faster execution Lower environmental impact Higher durability J R I+ LOAD TRANSFER DEVICE J R I+ LOAD TRANSFER DEVICE

48 Thank you for your attention We are at your disposal to design the specific JRI+ solution for your needs F A R O B E L CIVIL WORK TECHNOLOGY


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