RPA – P1National Airport Pavement Test Facility(NAPTF)

Presented To:  REDAC

By:  Ryan Rutter

Date:  August 2017

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RPA P1 Overview – NAPTF

FY 2017 Accomplishments

Research Goals

Funding Requirements 
        - Research Goals
        - Better prediction of pavement service life
        - Accurate assessment of aircraft-pavement compatibility
        - Validation of performance prediction model for HMA Overlays
        - Milestones
        - Complete Reconstruction of CC8 by the end of 2017
        - Complete CC7 Forensic Testing by late early Fall 2017
        - Complete construction of outside Reflective Cracking slabs by Fall 2017
        - Complete remaining Reflective Cracking websites by end of 2017.  
        - Deliverables
        - Reports, Technical Papers, and databases as required.
        - Standard Operating Procedures developed to help streamline procedures at the NAPTF
        - Reconstruction of the Overlay and Joint Comparison sections of CC8 Phase 2
        - Subgrade preparation and acceptance  for the Strength/Fatigue section of CC8 Phase 2
        - CC7 Forensic testing underway.   Trenches 5 & 6 are completed
        - Completion of Phase 5 Reflective Cracking testing
        - Reflective Cracking websites for test Phases 1 to 4 completed.  Databases for Phase 1 and 3 are complete.

Need

	The National Airport Pavement Test Facility (NAPTF) provides full-scale test data needed to support new FAA design procedures for rigid & flexible pavements.

	RPA P1 funds construction, operations, and maintenance at the NAPTF.  It also funds the Reflective Cracking Project.  
| FY 2017                       | FY 2018 | FY 2019 |
|-------------------------------|---------|---------|
| P1.1 -- Pavement Construction | $928K   | $620K   | $760K |
| P1.2 -- Facility Operation    | $2.21M  | $2.8M   | $2.935M |
| P1.3 -- Facility Maintenance  | $366K   | $540K   | $550K |
| TOTAL                         | $3.5M   | $3.86M  | $4.245M |

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RPA P1 NAPTF Budget Chart

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RPA – P1 NAPTF Breakdown

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RPA – P1  NAPTF

P1.1  Pavement Construction

P1.2  Facility Operation

P1.3  Facility Maintenance  

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RPA – P1.1  Pavement Construction

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        - Construction money funds both the NAPTF & Reflective Cracking projects
        - CC7 forensic trenching will be completed by early Fall 2017.
        - CC8 Phase 2 – Strength/Fatigue Area reconstruction currently underway
        - CC9 reconstruction planning underway.  Demolition/reconstruction anticipated by late 2017.
        - Reflective Phase 6 reconstruction due to possibly begin in late 2017. 
        - Outside reflective cracking slabs to be proposed and built at NAPMRC Facility.
| 2017               | 2018  | 2019  |
|--------------------|-------|-------|
| Construction Money | $928K | $520K | $760K |

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RPA – P1.1  Pavement Construction

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CC7 – NORTH PRIMARY OBJECTIVE   
        - Develop Perpetual Pavements Design criterion for airport pavements. 

CC7 – SOUTH PRIMARY OBJECTIVE   
        - Determine allowable overload criteria for flexible pavements.

Results from CC7 Traffic Testing presented at March 2017 REDAC.

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RPA – P1.1  Pavement Construction

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CC8 OBJECTIVES
        - Overlay Test Area – to evaluate PCC overlay on existing PCC with SCI in 50-80 range.  Determine allowable overload criteria for rigid pavements.
        - Joint Comparison Test Area – Comparison of the performance of Type E and nonstandard sinusoidal keyed longitudinal joints.
        - Strength/Fatigue Test Area – Obtain slab strengths for full scale slabs under load, evaluation of fatigue performance, and evaluation of the effect of fatigue performance of higher strength/thinner slabs versus lower strength/thicker slabs.

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RPA – P1.1  Pavement Construction  CC8 Overlay Test Area

Asphalt Interlayer

P-501 Concrete Placed with Conveyor

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RPA – P1.1  Pavement Construction  CC8 Overlay Test Area

Concrete Sampling 

PCC Placed in Lanes

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RPA – P1.1  Pavement Construction  CC8 Joint Comparison Test Area

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Dowel Joint

Sinusoidal Joint

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RPA – P1.1  Pavement Construction  CC8 Strength/Fatigue Test Area – Area 1 of 2

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PCC Placed in Checker Board Pattern

PCC Acceptance Tests

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RPA – P1.1  Pavement Construction  CC8 Strength/Fatigue Test Area – Area 2 of 2

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        - Excavation of CC6 resumed on June 26, 2017.
        - P-154 material was removed from station 5+65 to 6+55
        - Excavation of high strength subgrade was required to achieve depth for new test item structure

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RPA – P1.1  Pavement Construction  CC8 Strength/Fatigue Test Area – Area 2 of 2

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        - A 30 mil liner was placed directly on top of the high strength subgrade
        - The 30 mil liner was placed to serve as a moisture and material containment barrier for the low strength subgrade placed on top of it
        - The low strength subgrade is currently being placed in 8”-10” lifts
        - Expected subgrade completion late August 2017

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Issues Encountered
        - Existing subgrade was not uniform in moisture / CBR.  
        - Water intrusion discovered from separated instrumentation conduit
        - Moisture from subbase migrated down
        - Processing subgrade to uniform moisture content – Difficult in Winter to evaporate moisture.	
        - Compensated by mixing dryer sections with wetter sections
        - Equipment Issues
        - Sheared a drive shaft on older smaller tiller – Difficult to get parts
        - Larger tiller sinks in subgrade if tilled more than once
        - Construction sub contractor change

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RPA – P1.2  Facility Operation

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This task includes:

Traffic Testing & Pavement Monitoring

Data Collection, Data Analysis, Databases, and Website content – NAPTF and Reflective Cracking

Reflective Cracking – Phase 5 Testing completed on March 20, 2017.

Maintenance -- Test Machine, NAPTF project computers & networks, and all other supporting equipment

NAPTF Upgrades – Design and implementation of new data collection systems – CC8 proof of concept
| 2017               | 2018   | 2019  |
|--------------------|--------|-------|
| Facility Operation | $2.21M | $2.8M | $2.935M |

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RPA – P1.2  Facility Operation  CC7 Forensic Trenching

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        - 6 Forensic Trenches in CC7 test pavements
        - Tests performed at different layers.  Tests to include:  PSPA, CBR, Sand Cones, LWD, Nuclear Gauge Density, DCP, and other tests.
        - Expected completion by end of August 2017.

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RPA – P1.2  Facility Operation  Reflective Cracking Website

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        - Reflective Cracking websites developed and added to the FAA Website.
        - Currently Reflective Cracking Project Phases 1-5 have been completed.  Phases 1-4 have websites.
        - Phase 1 and Phase 3 have searchable databases of testing data
        - FAA Website Address: 

http://www.airporttech.tc.faa.gov/Airport-Pavement/National-Airport-Pavement-Test-Facility-/Reflective-Cracking/Phase-1

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RPA – P1.3  Facility Maintenance

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This task includes:
        - Maintaining the overall building structure and drainage
        - Providing building upgrades to support the testing program
        - Addressing safety issues
        - Currently working with FAA Facilities to get NAPTF Roof coated.  Expected start early spring 2018
        - Deficiencies to be addressed with 2017-2019 funding
| 2017                 | 2018  | 2019  |
|----------------------|-------|-------|
| Facility Maintenance | $366K | $540K | $550K |

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RPA P1 - NAPTF

Questions?

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