Sep 25 2012
Joint Seminar on Concrete Technology
for Construction of Transportation and Civil Infrastructure(Hanoi, Vietnam)

Design and Construction ofAirport Concrete Pavement in JAPAN

Yukitomo TSUBOKAWA, Dr. Eng.
National Institute for Land & Infrastructure Management
Ministry of Land, Infrastructure, Transport & Tourism, JAPAN1

Contents
Summary of Airport Concrete Pavement in JAPAN
Design of Airport Concrete Pavement
Empirical Design Method
Mechanistic-Empirical Design Method

Construction of Airport Concrete Pavement
Material
Mix DesignConstruction2

Summary of Airport Concrete Pavement

Old A-RWY
Old C-RWY

Old B-RWY

Tokyo International (Haneda) Airport(offshore extension project in 1980’s)

3Summary of Airport Concrete Pavement
B-RWY

Concrete Pavement

C-RWY

A-RWY

D-RWY

Tokyo International (Haneda) Airport(Aprons are concrete pavement)

4Summary of Airport Concrete Pavement
B-RWY

Concrete Pavement

A-RWY

Kansai International Airport(Aprons and ends of runways are concrete pavement)

5

Summary of Airport Concrete Pavement

Concrete Pavement

RWY

Fukuoka Airport(Aprons and a part of taxiway are concrete pavement)

6

Summary of Concrete Pavement
Asphalt pavement is used atrunwaytaxiway
apron for small aircraft

Concrete pavement is used atapron
taxiway for large trafficend of runway (a few of large airports)
Pavement type is selected based on many factors such as
objective of facilities
initial cost (concrete > asphalt in JAPAN)
easiness of rehabilitation
construction condition etc…
7

Type of Concrete Pavement
NC - Non-Reinforced (Plain) Concrete Pavement
Almost all apron in JAPAN are NC Pavement
CRC - Continuously Reinforced Concrete Pavement
Reinforced with longitudinal steel
No transverse joint
Used in NARITA International Airport
PPC - Precast Prestressed Concrete Pavement
PRC - Precast Reinforced Concrete Pavement
Constructed in midnight -> Opened in morning
Used as rehabilitation work in busy airports

8Type of Concrete Pavement
NC - Non-Reinforced (Plain) Concrete Pavement
Thickness : 37 – 45cm (for Code E and F aircraft)
Maximum joint spacing : 8.5m
Flexural strength of concrete : 5N/mm2

Dowel bar or Tie bar

Concrete SlabAsphalt
StabilizedBaseSubbase9Type of Concrete Pavement
CRC - Continuously Reinforced Concrete Pavement
Thickness : 30 – 35cm (for Code E and F aircraft)
Expansion joint spacing : about 200m
Reinforcement ratio : 0.65% (longitudinal)
0.09% (transverse)
Transverse reinforcing steel bar
Crack (less than 0.5mm in width)

Longitudinal reinforcing
steel barConcrete SlabCement
Stabilized
BaseSubbase
10Type of Concrete Pavement
PPC - Precast Prestressed Concrete Pavement
Thickness : 24cm (for Code E and F aircraft)
Slab size : 15m x 7.5m (10m x 2.5m x 3 slabs)
PC cable : φ12.7mm @150 mm (longitudinal)
φ23.0mm @500 mm (transverse)
Cement Grout
Transverse PC cable

Dowel bar
Longitudinal PC cable

Concrete SlabAsphalt
Stabilized
BaseSubbase
11

PPC Lift-UpConcreteSlabGrout

BaseSoon after construction

Uneven settlement

Lift up and grouting

PPC slabs can be lifted up by the jacks andthe void beneath PPC slabs is grouted.
-> Lift-up is used for rehabilitation ofan apron on reclaimed land.
12

PPC Lift-Up
Drilling

Levelling
PC slabBase Course

Excavation

Assembly of installation
fitting for jackLift-up operation

Grouting

Φ160mmCore boringmachineConstruction of reaction Setup ofconcrete bedjack

Lift-up jack

Grout

PPC is “flexible concrete slab”, Lift-up can be done.

13

PPC Lift-Up

Lift-up jackLift-up jacks are controlled by personal computer.

14

Type of Concrete Pavement
PRC - Precast Reinforced Concrete Pavement
Thickness : 24cm (for Code E and F aircraft)
Slab size : 15m x 2.5m
Flexural strength of concrete : 6.4N/mm2
Reinforcing steel bar : D13 @ 75mm (upper)
D16 @ 75mm (lower)
Cement Grout

Cotter joint

Lattice truss
reinforcing steel bar

Concrete SlabAsphalt
Stabilized
BaseSubbase
15

PRC

Cotter joint

16

PRC

Construction

17Design of Concrete Pavement

18Design of NC Pavement
Empirical Design Method (till 2008)
Slab thickness is designed based on loading stress.
σ<f/a
σ : loading stress at bottom of slab due to aircraft loadf : design flexural strength of concretea : safety factor(=1.7 to 2.2, depending on traffic volume)
Mechanistic-Empirical Design Method (after 2008)
Slab thickness is designed based on fatigue degree
due to loading stress and thermal stress.
FD : fatigue degree at bottom of slab
= Σ(Nd / Nf)
Nd : design number of load repetition
Nf : number of failure
19

Empirical Design of NC Pavement

Flexural strength of concrete / safety factor

f = 5.0N/mm2 and safety factor = 2.0 thenσ due to aircraft load must be less than 2.5N/mm2Relationship between
slab thickness and σ
due to B747-400 landing gearin case K=70MN/m3

slab thickness (cm)
Safety factor considers “effect of load repetition” and“thermal stress at the bottom of slab due to daily temperature change”.

20Mechanistic-Empirical Design of NC Pavement
Loading stress :loading stress at center of slab
due to aircraft gear load is calculated by FEM.

Main gear load
Loading stress
Concrete slab
Elastic spring as base21

Mechanistic-Empirical Design of NC Pavement
Thermal stress :thermal stress at center of slab is calculated
by equation based on long term observation
High temp.

Constraint due to self weight of slab

SlabLow temp.

BaseThermal stressEαθσt = β2(1 −ν )β : -0.772h+0.854
h : slab thickness (m)E : elastic modulus of concrete (N/mm2)
α : coefficient of thermal expansion (1/oC)
θ : temperature difference between top and bottom of slab (oC)
ν : poisson’s ratio of concrete
22Mechanistic-Empirical Design of NC Pavement
Number of failure :number of failure is calculated bytotal stress and fatigue failure criteria

1.19614 − σ / f bd ,hlog N f =0.08672
Nf : Number of failure
σ : total stress (=loading stress and thermal stress, N/mm2)
fbd,h : flexural strength with design slab thickness h (N/mm2)
σ/f
Fatigue failure criteria
σ/f = 0.8

FD = Nd / Nf < 1.0-> OK
FD = Nd / Nf > 1.0-> RedesignLog NdLog NfLog N23

Mechanistic-Empirical Design of NC Pavement
0.5
B747-400
B747-400D
B777-300
A300-600
B767-300
Total

Fatigue Degree, FD

0.4
0.3

Maximum FD

0.2
0.1
0.0

0200
400600Distance from Centerline (cm)800

Fatigue degree have to be calculated in transverse direction
because gear location and lateral deviation of each aircraft
is different.

24Construction of Concrete Pavement

25

Materials
Cement :Portland cement
Blast-furnace slag cement

are used usually.

Aggregate :Maximum aggregate size : 40mm

Sieve size (mm)

(%)

53100

37.5

95-1001950-100

2.36

20-60

0.0750-1526

Mix DesignStandard of mixture
Design flexural strength : 5.0 N/mm2 (28 day)Slump : 2.5 ± 1 cm
Air : 4.5 ± 1.5 %W/C : less than 50% (generally about 40%)
Cement per unit volume
C = 300-350kg/m3 is better.
C<300 kg/m3 -> Bloom finishing may be difficult.
C>350 kg/m3 -> Initial crack may occur.
Water per unit volume
W =130-140kg/m3 is better.
W<120 kg/m3 -> Const. may be difficult in summer.
27

Mix Design
Flexural strength test (test piece size : 15x15x53 cm)
1. Average strength in 3 test pieces
shall be grater than design strength.
2. Each strength shall be grater than
0.85*design strength.

Coefficient of Variation

10%

12.5%

15 %

Overdesign Factor

1.21

1.36

1.55

Target Strength
when Design Strength is 5N/mm2

6.05N/mm2

6.80N/mm2

7.75N/mm228

Construction
Quality control item for subgrade
water content
optimum value
1time / 1day
degree of compaction
98%
1time / 2000m2
Plate loading test
design K75
1time / 2000m2
Quality control item for concrete
SlumpAir
Temperature
Flexural strength

1time / 1 day or 150m329Construction
Transfer from concrete plant (in case of slump < 2.5cm)
Dump truck should be used.
Paving should be started within 1 hour.
Vibrator
Inner vibrator shall be used in case slab thickness
is larger than 30cm.
Mesh steel
Mesh steel is inserted at (slab thickness/4+2)cm
depth from surface of slab.
Curing
Initial curing : membrane curing
After curing : mat curing
Curing term : 70% of target flexural strength30

Slip Form Paving“Slip form paver” does not require any steel set forms.
Merit : large construction area per dayDemerit : need to pay attention toconcrete mixture specification (slump, air).
No steel form

31Concrete Bonded Overlay
Thin concrete layer is constructed on existing slab in caseexisting slab is sound andslope and height have to be modified.

Replacement

Unbonded OL
New ConcreteSlab

New ConcreteSlabConcrete SlabAsphalt Concrete

Bonded OL

New ConcreteSlabSurfacetreating

Concrete SlabConcrete Slab

BaseBase

New Base
BaseBase32

Concrete Bonded Overlay
Bonded strength between new and old layer
1.6 N/mm2 tensile strength is needed.
Surface treating
1. Water Jet + Shot Blast
2. Shot Blast + Glue Soaking
3. Other ? (1.6 N/mm2 tensile is needed)
Concrete mixture of new layer
Usual concrete mixture for airport concrete pavement
except for maximum aggregate size (40mm -> 20mm)
Overlay thickness
Minimum 5cm
33

Concrete Bonded Overlay
Example of concrete bonded overlay in New Chitose Airport.

Slope modificationby concrete bonded overlay

New Concrete Slab34

Concrete Bonded Overlay
Surface treating by Water Jet (WJ)

After WJ

Before WJ35

Concrete Bonded Overlay
Surface treating by Shot Blast (SB)

AggregateAggregate

36Concrete Bonded Overlay
Surface treating by Shot Blast + Glue Soaking
Shot Blast

Glue Soaking

37