Witold Zapasnik "Ülevaade betoonteede ehitamisest Poolas viimase 25 aasta jooksul"

D e p a r t a m e n t T e c h n o l o g i i
An overview of the
construction of concrete
roads in Poland over the past
25 years.
„Introducing foreign experience in the
construction of concrete pavements”
Conference in Tallinn, Estonia, 7June 2016
Witold Zapaśnik, GDDKiA, DT- WBiNB,

Plan of presentation
1. Organization of GDDKiA - General Directorate for National Roads and
Motorways.
2. Program of Construction of National Roads for the years of 2015 – 2023
according to the Council of Ministers’ Act from 24th August 2015. State-of-art.
for the 1st October 2015.
2.1. National road sections (motorways and expressways) planned to be
constructed in the years of 2015-2023 (circa 1670 km – including
800km in concrete).
3. Existing road projects executed and under execution in Poland on the network
of motorways and expressways with concrete pavements.
3.1. Existing and planned road projects executed in bituminous and concrete
technology in Poland on the network of motorways and expressways (2015-
2023).
4. Pavement structures and types of concrete pavements.
2

Plan of presentation continued
5. Examples of choosen, existing concrete pavements taking into account their
present technical condition (photos).
5.1. By-pass of Młodzieszyn in the route of DK 50 (section Wyszogród-Sochaczew)
– an example of too fast pavement deteroriation.
5.2. Sections on motorway A4/A18 (Wrocław-Krzyżowa-Olszyna, Krzyżowa –
Zgorzelec) executed in continuous reinforced cement concrete (CRCC).
5.3. The section on DK S8 Wolbórz-Polichno executed in the technology of
Whitetopping (WT).
5.4. Concrete pavement section executed in whitetopping technology on municipal
road section in the town of Żory.
5.5. Refurbishment of S8 at the section Piotrków Tryb - Rawa Maz. – border of
voivodeship of łódz/maz., 2013 road works – laying concrete pavement,
section of km 323+700 left carriageway.
5.6. Motorway A-2 at the section of Nowy Tomyśl – Świecko.
3

5.6.1. The section with the pavement of exposed aggregate (the so called
Washbeton).
5.6.2. The section with the pavement of continuous reinforced cement concrete
(CRCC) without transverse joints, executed as whitetopping on existing
asphalt pavement DK2 at the section from km 0+000 to km 1+100 (north
carriageway).
6. Roads of other categories executed in cement concrete technology – around 700
km of voivodeship and communal roads (the 90ties of XX century and beginning
of XXI century).
7. The sections of motorways, other roads and infrastructural objects planned in the
nearest future to be constructed in cement concrete technology.
8. Updating of GDDKiA technical documents (OST, STWIORB, WWIORB, WT,
Technical Cataloques, 2012).
4

9. Examples of application of new concrete technologies in construction of road
pavements.
9.1. French sliding technology to lay down continuous concrete road curbs along
road edges, on Motorists Service Points, (MOP) parkings and other areas and also
separating barriers on speed traffic roads.
9.2. Technology of RCC (Roller Compacted Concrete).
10. Conclusions. Why is it worth to construct concrete roads ?
11. Summary of main advantages of concrete pavements.
5

Zachodnio-
pomorskie
Pomorskie
Warmińsko-mazurskie
Podlaskie
Lubelskie
Podkarpackie
Mazowieckie
Łódzkie
Wielkopolskie
Kujawsko-
pomorskie
Lubuskie
Dolnośląskie
Opolskie
Śląskie
Małopolskie
Świętokrzyskie
1. Organization of GDDKiA
- 16 Provincial Regions of GDDKiA and 16 WT-LD
(technological units/road laboratories)
6
GDDKiA
Headquarters
in Warsaw

2. Program of construction of national roads in the
years of 2015 – 2023. State-of-art for the 1st October,
2015.
7

2.1. National road sections (motorways and
expressways) planned (in green colour) to be
constructed in the years of 2015-2023 (circa 1670 km –
including 800 km in concrete)
8

3. Existing road projects executed and under
execution in Poland on the network of motorways and
expressways with concrete pavements.
9
Total length of concrete motorway sections
Total length of concrete expressway sections
TOTAL

D e p a r t a m e n t T e c h n o l o g i i 10
expressways with concrete pavements .
1. Modernization of motorway A4 at the section of Golnice-Krzywa, two
carriageways with the length of 17,0 km (1995-1996),
2. Toll Collections Stations on motorway A4: Brzęczkowice, Balice, Karwiany
(1999-2000),
3. DK50, By-pass of Młodzieszyn, the length of 4,0 km, 2002,
4. DK8, the section Wolbórz-Polichno, (whitetopping) two carriageways, the
length of 11,0 km, 2002-2003,
5. Intersection of DK1 at the town of Siewierz, 2003,
6. Modernization of motorway A4 at the section of Krzywa-Wądroże Wlk. –
Bielany Wrocławskie, two carriageways, the length of 92 km (2003-2006),

expressways with concrete pavements.
7. Modernization of DK18 (A18), the section of Królów-Golnice, north
carriageway, the length of 64 km (2005-2006),
8. Construction of motorway A4, section of Jędrzychowice-Krzyżowa, two
carriageways, the length of 51 km (2006-2008),
9. Motorway A4, construction of additional traffic and emergency lane at the
section of Wrocław-Legnica 2010,
10. Construction of motorway A2, the section of Nowy Tomyśl-Świecko, two
carriageways, the length of 105,9 km, 2010,
11. DK S8, the length of 61 km, the section of Piotrków Trybunalski – Rawa
Mazowiecka, 2008-2012,

3.1. Existing and planned road projects executed in
bituminous and concrete technology in Poland on the
network of motorways and expressways.
LEGEND
Existing bituminous
Existing concrete
Planned concrete
Planned bituminous

4. Pavement structures and types of concrete
pavements.
13

ASPHALT CONCRETE
FLEXIBLE RIGID
Wearing course
Binder course
Base course
(mechanically
compacted aggregate)
Asphalt and concrete road structure cross-sections
Cement concrete slab
Base course (lean
concrete)
Subgrade
(mechanically
compacted aggregate)

Podstawowa konstrukcjaBasic structure of concrete pavement
Concrete slab
Base course
Capping layer (frost-
protection)
Cement stabilised soil layer
Natural soil (virgin soil)
Desined
thicknessess of
layers
Artificial soil layer

Concrete pavement nawierzchni betonowej
16
CONCRETE PAVEMENT CROSS-SECTION
Method of exposing fine
aggregate in upper layer
„Sand paper”
Asphalt shoulder
Dowels
Longitudinal joint
Transversal joints
Tie bars
Cement concrete
Base course
Side drainage
Subgrade
From 4 to 6 m

TYPES OF CONCRETE PAVEMENTS
Unreinforced and undowelled pavements
Unreinforced pavements but with dowels and tie bars
Reinforced pavements with dowelled joints
Continuously reinforced pavaments
Pavements with scattered fibres
Pavements with rolled concrete
Pavements with porous concrete
Pavements with pre-stressed concrete
Prefabricated pavements
Mixed (composite pavements) – pavements in which on the
ccmmmmmm
concrete base course the thin layer of asphalt-mineral mixture is
placed

Konstrukcja z płytą betonową
niedyblowaną
PAVEMENT STRUCTURE WITH CONCRETE
UNDOWELLED SLAB
1 Concrete slab
2 Geosynthetics
3 Lean concrete or crushed
aggregate stabilised with cement
4 Subgrade

Konstrukcja z płytą betonową niedyblowanąPAVEMENT STRUCTURE WITH CONCRETE UNDOWELLED SLAB
1 Thick concrete slab
2 Drainage layer of crushed aggregate or geosynthetics
3 Subgrade

Konstrukcje z płytami dyblowanymiSTRUCTURES WITH DOWELLED SLABS
1 Concrete slab dowelled and
tied
2 Lean concrete
3 Subgrade

Konstrukcje z płytami zbrojonymiPAVEMENT STRUCTURES WITH REINFORCED SLABS
1 Concrete slab with continuous reinforcement
2 Lean concrete
3 Subgrade

Zużycie betonu na budowie autostrady
Assuming the average thickness of a concrete slab in the pavement structure to be about 25
cm and a typical cross-section of a dual-carriageway motorway, the estimate usage is about
5000 cubic meters of concrete /1km of a new motorway under construction.
Assuming on average 1 engineering structure /700 m of a motorway (e.g. viaduct, animal
crossing) with dimensions of 60 x 15 x 1,2 m (the bigger structure thickness has been
assumed to consider intermediate supports and piles under foundation), about 1100 cubic
meters of concrete is used in their low-bearing structure. Of course, smaller and bigger
objects exist which consume other quantities of concrete (eg. road culverts, retaining walls).
22
AVERAGE CONCRETE CONSUMPTION ON MOTORWAY
CONSTRUCTION SITE

5. Examples of chosen, existing concrete pavements
taking into account their present technical condition
(photos).
23

5.1. By-pass of Młodzieszyn in the route of DK 50
(section Wyszogród – Sochaczew) – an example of too
fast pavement deterioriation.
24

Mazowieckie Voivodeship
By-pass of Młodzieszyn
Length – 3000 m
Width – 7,0 m
Executed – 2002 year

5.2. Sections on motorway A4/A18 (Wrocław-Krzyżowa-
Olszyna, Krzyżowa –Zgorzelec) executed in technology of
dowelled concrete slabs and continuously reinforced
concrete slabs (CRCC).
MOTORWAY A4/A18

Motorway A4 - Construction of additional traffic and
emergency lane at the section of Wrocław-Legnica 2010
34

4.5. Autostrada A4/a18
35

4.5. Autostrada A4/A18
36

4.5. Autostrada A4/A18
37

Motorway A4 Laying of concrete on the pavement with
continuous reinforcement, section of Bielany
Wrocławskie – Wądroże Wlk.- north carriageway
38

Motorway A4 contd.
39

5.3. Section on DK S-8 Wolbórz-Polichno executed in
Whitetopping technology.
DK S8 , Section of Wolbórz – Polichno, Whitetopping 2002

•grunt stabilizowany cementem grub.15cm,
•podłoże z gruntu G1.
Technological cross-section of DK8, Wolbórz-
Polichno on soil of G1 type
Cement concrete B-40, thickness 27 cm
Separation membrane (slipping layer) – surface treatment
Existing pavement structure:
a)Bituminous layer 13-20 cm thick,
b)Lean concrete layer 15 cm thick,
Soil of G1 type
Cement concrete B-40 thickness 27 cm
Separation membrane (slipping layer) – surface treatment
New pavement structure:
a)Lean concrete base course, thickness 18 cm,
b)Cement stabilised soil, Rm= 2,5 Mpa,
Soil of G1 type

Odcinek nawierzchni betonowej zrealizowany w
technologii Whitetopping na drodze miejskiej w
miejscowości Żory
46
5.4. CONCRETE PAVEMENT SECTION EXECUTED IN
WHITETOPPING TECHNOLOGY ON MUNICIPAL ROAD SECTION IN
THE TOWN OF ŻORY
Whitetopping 2007, KR6,
Length 7,0 km
Width 2 x 3,5 m
- Concrete slab dowelled and tied,
- Upper base course of asphalt mixture,
- Lower base course, mechanical stabil.,
- Drainage course,
- Cement stabilised soil

5.5. REFURBISHMENT OF S8 AT THE SECTION PIOTRKÓW
TRYB - RAWA MAZ - GR. WOJ. ŁÓDZ/MAZ., 19.06.2013 ROAD
WORKS – LAYING CONCRETE PAVEMENT, SECTION OF A1 KM
323+700 LEFT CARRIAGEWAY
47

5.5. REFURBISHMENT OF S8 AT THE SECTION
PIOTRKÓW TRYB - RAWA MAZ - GR. WOJ. ŁÓDZ/MAZ.
48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

64

65

5.6 Motorway A-2 at section Nowy Tomyśl – Świecko,
2010 - 106 km.
66
Section of A-2 Nowy Tomyśl - Świecko

5.6.1. Motorway A-2 at section of Nowy Tomyśl –
Świecko. Concrete pavement section with exposed
aggregate (the so called WASHBETON)
67
Concrete pavement
surface executed in
the technology of the
so called Washbeton.

68
Upper and lower layer of
concrete slab

69
Layer structure and concrete pavement construction equipment

5.6.2. The section with the pavement of continuous
reinforced cement concrete(CRCC) without transverse
joints, executed as whitetopping on existing asphalt
pavement DK2 at the section from km 0+000 to km 1+100
(north carriageway).
70
PAVEMENT STRUCTURE
-Concrete slab with continuous reinforcement C35/45 – 23 cm
-Separation membrane mma AC 11S – 4 cm
-Profiling layer mma AC 16W – 11-14 cm
-Existing mma layer 18 cm (milled to the depth 0-5 cm)
-Existing lean concrete layer - 24 cm
-Soil layer of G1 type
WIDENING
-Separation membrane mma AC 11S - 4 cm
-Profiling layer mma AC 16W – 11-14 cm
-Lean concrete - 20 cm
-Frost protection layer - 35 cm
CBR > 30, k>3m/day,
0,075 mm particles content<5%
- Soil layer of G1 type
Variable
width
„stair-like” shaping of pavement structure edge
120 MPa
60 MPa
2,5%
2,5%

6. Roads of other categories executed in cement concrete
technology – around 800 km of voivodeship and communal
roads (the 90ties of XX century and beginning of XXI century)
71

7. The sections of motorways, other roads and
infrastructural objects planned in the nearest future to
be constructed in cement concrete technology.
1. Motorway A1, section Stryków-Tuszyn, two carriageways 40 km (under
construction),
2. Motorway A1, odcinek Piotrków Tryb-Pyrzowice, length 140 km,
3. Motorway A18, refurbishment and reconstruction of north carriageway,
section Golnice-Olszyna, 70km,
4. Motorway A4, section to the border with Ukraine at Korczowa, 4,5 km
(under construction),
5. Exspressway S10 Toruń-Bydgoszcz,67km,
6. By-pass of Suwałki S61, 10 km (under construction),part of Via Baltica,
7. Other national roads (810 km) to be constructed in the perspective of
2015-2023(2024) planned to be constructed according to the decission of
GDDKiA of November 2014 (among the others, sections of S2-POW, S6, S7,
S8, S17, S61),
5. Extension and modernisation of national airports (W-wa, Gdańsk,
Katowice, Kraków, Poznań, Rzeszów, Szczecin, Wrocław, Radom, Lublin),
6. Voivodeship, communal and municipal roads.
72

8. Updating of GDDKiA technical documents (OST,
STWIORB, WWIORB, WT, Technical Cataloques, 2012).
73
Expert teams called-up by GDDKiA
1.Team for environment protection and road furniture,
2.Team for pavement diagnostics (DSN),
3.Team for bridge works and engineering structures,
4.Team for stabilised and unstabilised base courses,
5.Team for concrete and concrete pavements,
6.Team for soil subgrade and earthworks,
7.Team for reconstruction, renovation and rehabilitation of roads,
8.Team for preliminary, land-surveying and drainage works,
9.Team for road maintenance,
10.Team for asphalt pavements,
11.Team for road traffic safety.

8.1. New GDDKiA documents relating to cement
concrete pavements.
- Updating of „Cataloque of typical structures for rigid pavements”,
- Updating of OST, STWIORB, WWIORB, WT for structural, pavement
concrete and concrete prefabricated elements (curbs, sidewalks slabs,
concrete blocks).
74

8.1. Updating of „Cataloque of typical
structures for rigid pavements”,

8.1. Updating of „Cataloque of typical structures for
rigid pavements”,
76

8.1 Updating of OST (General Technical Specifications)
for structural, pavement concrete and prefabricated
concrete elements (curbs, sidewalk slabs,
77

9. Examples of application of new concrete
technologies in construction of road pavements.
9.1. French sliding technology to lay down continuous
concrete road curbs along road edges, on Motorists
Service Points, (MOP) parkings and other areas and
also separating barriers on speed traffic roads.
78

9.1. Execution of continuous concrete curbs and
asphalt rims
79

9.1. Execution of isles at the motorway toll collection
station
80

9.1. Execution of isles at the motorway toll collection
station
81

9.1. A trial with sliding technology on S8 road near
Piotrków Trybunalski on the access to the petrol
station.
82

.
83

10.Budownictwo nawierzchni betonowych u naszych
sąsiadów.
87

10.Budownictwo nawierzchni betonowych u naszych
sąsiadów.
88

Results of laboratory tests of sliding concrete curbs at
MOP Guzew (construction of S8, section 8)
89
Crushing strength (formulated samples)
Bending strength of ready curb (piece cut)
Crushing strength of ready curb (core 100 x 100 taken from the curb)
Average
Average

Results of laboratory tests of sliding concrete at MOP
Guzew (construction of S8, section 8)
90
Water
penetration
Abrasion (Boehme test)
Freeze and thaw resistance with deicing salt in 3% solution of NaCl
Mass loss

9.2. Technology of RCC (Roller Compacted Concrete)
91

92
Concrete with composition of aggregate and moisture content
chosen in such a way, that before setting it shows properties close
to a soil in a moist condition and is susceptible to compacion by
the rolling method.

93
Beginning of RCC technology –
water dams (RPA 1990,USA, 2004),
USA and Canada – first road
pavements in this technology
constructed in the 70 ies of the XXth
century,
Since the 80ies of the XXth century
the RCC pavements are widely used
in America and in Europe,
In Europe – the RCC technology
mosty used in Germany and France.

94
Properties of Roller Compacted Concrete
 Little batch water content, 90-120 kg/m ,ᵌ
 High content in the aggregate mixture of silty fraction (<0,075
mm), 2 – 8%,
 High sand equivalent,
 Possibility to use of not washed aggregates,
 Typical cement content 240-320 kg/m ,ᶟ
 Water/cement ratio (w/c) in the range of 0,30 – 0,45,
 Maximum aggregate particle size 25 mm for crushed aggregate
and 19 mm for natural aggregate,
 Lack of aeration.

95
 Strict relationship of roller compacted concrete strength and durability to proper
compacion,
 Required compacion index Is = 0,98

96
RCC concrete in spite of lack of
aeration shows high durability and
frost resistance
Frost resistance of RCC
pavement
Frost resistance of pavement
constructed of vibro-pressed
concrete blocks
Pavement of a test section
after 2 years

97
Aggregate choice on the base of the limit curves of good
gradation envelope

9.2. Technology of RCC (Roller Compacted Concrete))
98
Aggregate choice by means of iteration method
K1 – gravel 8/16
K2 – gravel 2/8
K3 – sand 0/2

99
 Choice of cement content, 10-17% of aggregate mass,
 Choice of water content by means of Proctor method.

100
Workability testing by means of a modified Ve-Be apparatus
Load 9,1 kg
Load 22,7 kg

101
 Production of concrete mixture in a way, ensuring its steady and
unchangable moisture content,
 Maximum transport time 60 min,
 Laying concrete mixture with pavers ensuring possibly the highest
preliminary compaction,
 Thickness of concrete pavement laid, should be from 12 to 25 cm,
 Additional compation of concrete mixture by means of heavy rollers, Is =
0,98,
 Curing of freshly performed concrete pavement.

102

103
Miastko, Fabryczna st., Pomorskie voivodeship, first roller compacted concrete
pavement performed in Poland, 2009

104
Basic parameters of RCC used to construct the pavement in
Fabryczna st., in Miastko. Results from cores.
Property RCC 25/30
Density (in natural moisture condition)
Water content
Average compressive strength

105
Miłocice, Pomorskie voivodeship, a pavement in a village street performed of RCC, the length of
800 m, 2012.

106
Chances and possibilities for development of RCC technology in
Poland.
RCC Technology is a durable and economical solution for
construction of:
Road pavements of KR1 and KR2 traffic categories,
Local and access road pavements,
Forest roads,
Treatment of exploited soil roads,
Pavements on squares and parkings,
Base course layers for roads of higher technical categories.

107
Chances and possibilities for development of RCC technology in
Poland.
Expectations and requirements of Polish market (self-governing
territorial state units, road authorities, state forest units) in
relation to local roads : construction of durable roads with low
cost
RCC technology
Creation of Polish technical guidelines and construction of testing sections

10. Conclusions. Why is it worth to construct concrete
roads?
Basic advantages:
1. Concrete pavements have a number of advantages such as: high bearing
capacity, high ability to carry out loads, resistance to permanent strains, good
drainage properties, good visibility at night, high skid resistance, low
maintenance costs, long operation period, relative ease of current repairs,
possibility of usage in recycling process the material from crushed concrete
slabs.
2. Cement concrete pavements prevail on motorways in the countries of
developped road network such as USA, Germany, France, Denmark, Holland,
Belgium, Austria and Czech Republic.
3. Real exploatation time of concrete pavements is about twice as long as in the
case of pavements performed of mineral-bituminous mixtures.
4. Concrete pavements are resistant to strains in the whole range of
temperatures, there is no phenomemon of rutting on them and the rain water
flows well off the pavement.
5. According to the foreign research (German studies), the amount of road traffic
accidents on concrete pavements is less by about one third than the one on
asphalt pavements.
108

10. Conclusions. Why is it worth to construct concrete
roads? cntd
6. Availability of domestic resources, relatively simple and efficient technology to
produce concrete and its resistance to temperature conditions during its laying
process cause, thatconcrete pavements can be performed on national as well as
on local roads.
7. Due to the bright colour of the pavements, lighting costs of motorway
pavements of cement concrete (according to the research studies e.g. in
Germany, Belgium) accout for less than 60% of lighting costs of asphalt
pavements.
Basic disadvantages :
1. Construction cost higher than for asphalt pavements for lower categories of
traffic (KR1, KR2),
2. Necessity to strictly obey the construction technological regimee,
3. Long time from construction to start operation (minimum 28 days, after
obtaining standard crushing strength of pavement concrete),
4. Increased operational noise (possibility to reduce it by using the so called
Washbeton, narrow expansion jints and appropriate pavement texturing),
5. Lower riding comfort (transversal joits).Necessity to maintain joints. 109

The costs
110
11. SUMMARY OF MAIN ADVANTAGES OF CONCRETE PAVEMENTS
LOWER INFLUENCE ON NATURAL ENVIRONMENT (LCA ANALYSES, USA,
GERMANY)
The research LCAs (Life Cycle Analyses) show that the social costs and the influences on the environment
(harmful emissions) during the whole (30-year) operation period is even 5 times less for concrete than for asphalt.
LOWER CONSTRUCTION COST
Starting from KR3 traffic category the cost to construct a concrete pavement is lower that an asphalt one by
around 17-20% (data from the Polish Cement Association,The study by the Wrocław Technical Uniwersity 2016).
LOWER MAIMTENANCE COST
Concrete road maintenance cost is about 28-30% lower than for asphalt road.Full exchange of concrete road (all
layers) is required after 30 years, whereas asphalt road requires replacement of wearing course after 8-10 and 20
years and after 30 years it is necessary ro replace its whole structure.
LACK OF RUTTING PHENOMENON
Thanks to such properties as resistsnce to atmospheric conditions (temperature changes, freeze/thaw cycles) and
to high axle loads. With the usage of moder tecjhnological solutions and good execution and maintenance, the 30
or 40 year - concrete pavement operational life is guaranteed even with axle loads of 130kN/axle.
LOWER CONSUMPTION OF FUEL
Reduction in fuel consumption for truck vehicles due to the beter mechanical-physical properties of concrete
pavements (lower rolling resistance). Research in Western Europe (Belgium, Denmark, Germany) specifies this
reduction to around 2- 5%, in case of American studies this reduction is specified as even reach 8 – 10%.
HIGHER TRAFFIC SAFETY, LOWER ENERGY CONSUMPTION
High gripping power of concrete. German studies show that the traffic accident rate on concrete motorways is less
by around 32% than on asphalt ones. In addition, the visibility of other road users is better at night on concrete
pavements than on asphalt ones, and the lighting costs of concrete roads is less (up to even 60%).

Thank you for your
attention !!!
111

Witold Zapasnik "Ülevaade betoonteede ehitamisest Poolas viimase 25 aasta jooksul"

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