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Sustainable Methodologies for Long-Lasting and High-Performance Transportation Infrastructures Filippo Giustozzi, Ph.D. Assistant Professor @ D.I.C.A November 10, 2014 THE RESEARCH GROUP [ICAR/04] 1 Full Professor 3 Assistant Professors 3 Temporary Research Associates 6 PhD candidates November 10, 2014 Cesare Alippi Filippo Giustozzi 1 Lab. Chief Operating Officer Administrative & Lab. Staff MAIN AREAS of RESEARCH ROAD & AIRPORT MATERIALS PAVEMENT DESIGN ASSETS MANAGEMENT INNOVATIVE CONSTRUCTION & MAINTENANCE TECHNIQUES ROAD SAFETY RISK ASSESSMENT for ROAD INFRASTRUCTURES November 10, 2014 Cesare Alippi Filippo Giustozzi TODAY’s PRESENTATION November 10, 2014 Filippo Giustozzi KEYWORDS 1. SUSTAINABILITY 2. RECYCLING 3. PERFORMANCE November 10, 2014 Filippo Giustozzi Life Cycle Management of a road project… Technical Feasibility Environmental Impacts (LCA) Costs (LCCA) Durability (LCPA) Risk Analysis Societal Benefits Integrated Decision-Making November 10, 2014 Cesare Alippi Filippo Giustozzi Sustainability… United Nations World Commission on Environment and Development (1987) Sustainable Development definition: “… development that meets the needs of the present without compromising the ability of future generations to meet their own needs.” November 10, 2014 Cesare Alippi Filippo Giustozzi Life Cycle Thinking A project or network-level approach environmental management approach to look holistically at products, processes, and activities. End-of-Life Management Raw Material Acquisition Reuse Recycling Use Phase & Maintenance November 10, 2014 Construction Cesare Alippi Filippo Giustozzi Cradle-to-Gate LCA approach transport refinery transport oil extraction Aggregate Quarry transport Asphalt plant Possible Outputs emissions waste hazardous waste November 10, 2014 Cesare Alippi Filippo Giustozzi construction transport Cradle-to-Grave LCA approach … Disposal Asphalt plant Use phase & Maintenance construction End-of-life November 10, 2014 Cesare Alippi Filippo Giustozzi transport Cradle-to-Cradle LCA approach … RECYCLING Asphalt plant Use phase & Maintenance construction End-of-life November 10, 2014 Cesare Alippi Filippo Giustozzi transport WHY ARE RECYCLING AND SUSTAINABLE MANAGEMENT FUNDAMENTAL? November 10, 2014 Filippo Giustozzi The ROAD PAVEMENT ≈ 95 % aggregate November 10, 2014 ≈5% Bitumen Cesare Alippi Filippo Giustozzi FACTS & STATS • Almost 65 million km of roads worldwide (≈ 1625 times the World circumference) • Roadway conditions are a significant factor in about one-third of traffic fatalities. In the U.S.: • Poor road conditions cost U.S. motorists $67 billion a year in repairs and operating costs---$ 333 per motorist every year • 33% of America's major roads are in poor or mediocre condition and 36% of the nation's major urban highways are congested. • $186 billion needed annually to substantially improve the nation's highways Grade: D- • 27% of U.S. GHG emissions from road transportation Data from: Report Card for America's Infrastructure, ASCE. November 10, 2014 Cesare Alippi Filippo Giustozzi FACTS & STATS • Pavement construction is one of the largest consumers of natural resources U.S. - Virgin Aggregates Consumption 1.800.000.000 1.600.000.000 1.400.000.000 Tons “80% is1.200.000.000 used as construction aggregate, mostly for highway and 1.000.000.000 road construction and maintenance, as well as for a wide variety of building and other non-building construction.” 800.000.000 600.000.000 7.5 kg (16.5 lbs) of CO2e per ton of material 400.000.000 Crushed stone 200.000.000 Sand and Gravel 0 1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000 2010 Year Data from: U.S. Department of the Interior; U.S. Geological Survey [November, 2012] November 10, 2014 Cesare Alippi Filippo Giustozzi FACTS & STATS • Italy has 487’000 km of roads (≈ 12 times the World circumference) and 70’500 km of them are located in the Lombardy region • 2,96 km of roadways per km2 • 6500 €/lane∙km only for maintenance purposes Data from: Regione Lombardia. November 10, 2014 Cesare Alippi Filippo Giustozzi FACTS & STATS…current upshots VERY LARGE AREAS INVOLVED MASSIVE AMOUNT OF MATERIALS REDUCED BUDGET FOR MAINTENANCE & REPLACING WASTED TIME AND FUEL DUE TO TRAFFIC CONGESTION FROM POOR ROAD CONDITIONS • ADDITIONAL ENERGY AND MATERIALS CONSUMED FOR ROAD REPAIRS • ADDED EMISSIONS AND WASTE GENERATED BY REMOVAL AND REPLACEMENT OF SHORT LIVED INFRASTRUCTURE SOLUTIONS • • • • UN-SUSTAINABLE! November 10, 2014 Cesare Alippi Filippo Giustozzi PROBLEM STATEMENT MISSION: scientific breakthroughs toward reducing carbon footprint and life-cycle costs of road and airport pavements for sustainable transportation infrastructures Breakthroughs would imply: Strength and Durability with less virgin material including recycling (short/long-term PERFORMANCE) Lower energy processing and emissions (ENVIRONMENT) Reduced life-cycle expenditures (COSTS) November 10, 2014 Cesare Alippi Filippo Giustozzi 1. LOWERING THE ENVIRONMENTAL IMPACTS: RECYCLING PRACTICES INTO ROAD PAVEMENTS November 10, 2014 Filippo Giustozzi What a pavement is… November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING IN-SITU SOIL & AGGREGATES Soil Stabilization All soil modification benefits, and permanently increase compressive strength, increase load-deformation properties, and improve durability during freeze-thaw and wet-dry cycles, to be incorporated into structural design. November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING IN-SITU SOIL & AGGREGATES Recycled Aggregates C&D (Construction & Demolition) material November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING IN-SITU SOIL & AGGREGATES Area of the intervention: 60’000 sqm 85 % of recycled materials was adopted TWY W - Malpensa Airport November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING IN-SITU SOIL & AGGREGATES ALTERNATIVE #1 (innovative): ALTERNATIVE #2: (from current airport practice) 6 cm 30 cm 30 cm 25 cm 40 cm 35 cm Tot. Thickness: 76 #1 cm was chosen Tot.after Thickness: 90 cm ALTERNATIVE an in-depth characterization of in situ soils and recycled aggregates mechanical performance (lab tests + full scale tests) November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING IN-SITU SOIL & AGGREGATES Surface Course Porous Asphalt Cement Mortar November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING IN-SITU SOIL & AGGREGATES RECYCLED AGGREGATES: RWY head demolition November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING IN-SITU SOIL & AGGREGATES Cement bound base (recycled aggregates from C&D) November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING IN-SITU SOIL & AGGREGATES Sub-base Layer: In situ cement stabilized soil + recycled aggregates November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING IN-SITU SOIL & AGGREGATES November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING IN-SITU SOIL & AGGREGATES STEP #1: Emissions related to materials manufacturing (i.e.; raw material extraction, etc.) Crispino M.; maurizio.crispino@polimi.it November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING IN-SITU SOIL & AGGREGATES STEP #2: Emissions related to transportation & processes Plug mill and screening plant November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING IN-SITU SOIL & AGGREGATES STEP #2: Emissions related to transportation & processes e e November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING IN-SITU SOIL & AGGREGATES STEP #3: Computation of the total environmental burden and analysis of the alternatives ALTERNATIVE #1: - 35% of total emissions N.B.: up to - 60% of emission saving if a standard granular unbound layer was adopted for Alternative #2 as foundation layer instead of stabilizing in situ soil Crispino M.; maurizio.crispino@polimi.it November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING IN-SITU SOIL & AGGREGATES MAIN ADVANTAGES: - Lower environmental impacts Lower material consumption (virgin aggregates, bitumen) Less material to handle within the construction site Less material to be transported to/from the quarry/plant Landfill was minimized Construction time was shortened Cost of materials was reduced Performance comparable to other airport pavements (PCN ≈ 120) November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING of ASPHALT PAVEMENTS RAP (Reclaimed Asphalt Pavement) November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING of ASPHALT PAVEMENTS A closer look at the numbers… Currently, almost 100 million tons of asphalt concrete are reclaimed each year only in the United States, of which, roughly 80% can be reused as RAP The volume of reclaimed asphalt pavement is … 13 TIMES greater than recycling of newsprint 27 TIMES greater than recycling of glass bottles 89 TIMES greater than recycling of aluminum cans 267 TIMES greater than recycling of plastic containers November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING of ASPHALT PAVEMENTS November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING of ASPHALT PAVEMENTS Warm-Mix Asphalt (20-30% RAP allowed) • May Reduce Mixing and Compaction Temperatures (up to 30 – 40ºC) Temp. = 160º C November 10, 2014 Cesare Alippi Filippo Giustozzi Temp = 120º C RECYCLING of ASPHALT PAVEMENTS Warm-Mix Asphalt Highway A4 (Italy) - 20% of emissions and long-term performance November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING of ASPHALT PAVEMENTS Cold-Mix Asphalt (100% RAP) November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING of ASPHALT PAVEMENTS Foamed-asphalt (100% RAP) November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING of ASPHALT PAVEMENTS Foamed-asphalt (100% RAP) November 10, 2014 Cesare Alippi Filippo Giustozzi 43 RECYCLING of ASPHALT PAVEMENTS November 10, 2014 Cesare Alippi Filippo Giustozzi 44 RECYCLING of ASPHALT PAVEMENTS Foamed-asphalt production in the lab: 100% RAP + foamed-asphalt are mixed Asphalt is foamed into the mixing chamber November 10, 2014 Cesare Alippi Filippo Giustozzi RECYCLING of ASPHALT PAVEMENTS Foamed-asphalt (100% RAP) Malpensa Airport (RWY) Only 40 days of closure to reshape the entire 4400 m runway! November 10, 2014 Cesare Alippi Filippo Giustozzi 2. INCREASING PERFORMANCE for LONGTERM DURABILITY November 10, 2014 Filippo Giustozzi LONG-TERM PERFORMANCE of RECYCLED MIXES Polymers Fibers RHEOLOGY OF MODIFIED MASTICS • Preparation of mastics • Evaluation of mixing conditions • Penetration and softening point • Viscosity (Brookfield) • Evaluation of rheological parameters (Rheometer) • Stiffness master curves November 10, 2014 Cesare Alippi Filippo Giustozzi LONG-TERM PERFORMANCE of RECYCLED MIXES Fibers Cellulose – Fiber A 6% - 9% on bitumen weight Cellulose/glass – Fiber B 9% on bitumen weight Synthetic – Fiber C 3% on bitumen weight Sintetiche reclaimed – Fiber D 3% - 9% on bitumen weight November 10, 2014 Cesare Alippi Filippo Giustozzi LONG-TERM PERFORMANCE of RECYCLED MIXES COMPOUND B: plastomeric polymer + cellulose-glass fibers COMPOUND A: plastomeric polymer + synthetic fibers COMPOUND C: elastomeric polymer + cellulose-synthetic fibers + paraffin November 10, 2014 Cesare Alippi Filippo Giustozzi LONG-TERM PERFORMANCE of RECYCLED MIXES RHEOLOGY OF MODIFIED BITUMEN November 10, 2014 Cesare Alippi Filippo Giustozzi LONG-TERM PERFORMANCE of RECYCLED MIXES Dynamic viscosity RAMPA DI VISCOSITA' - Bitume B1/Fibra A 1000000 100000 Viscosità [cP] Viscosity [cP] 10000 12% 1000 9% 6% 3% 1,5% “Base” mastic Bitumen 100 10 1 90 100 110 120 130 140 150 160 170 Temperatura [°C] Temperature [°C] November 10, 2014 Cesare Alippi Filippo Giustozzi 180 190 200 210 220 230 LONG-TERM PERFORMANCE of RECYCLED MIXES Indirect Tensile Strength INDIRECT TENSILE STRENGTH 1,50 Fiber A ITS [MPa] 1,30 “Base“ mix Fiber D 1,10 Fiber B Fiber C 0,90 0,70 0 3 6 Fiber/Bitumen Ratio [%] November 10, 2014 Cesare Alippi Filippo Giustozzi 9 12 LONG-TERM PERFORMANCE of RECYCLED MIXES Stiffness STIFFNESS - T = 20°C_f = 2,02Hz 9000 8500 Stiffness [MPa] 8000 7500 Fiber A 7000 6500 Fiber D 6000 “Base“ mix 5500 5000 4500 4000 Fiber B 3500 Fiber C 3000 2500 2000 0 3 6 Fiber/Bitumen Ratio [%] November 10, 2014 Cesare Alippi Filippo Giustozzi 9 12 LONG-TERM PERFORMANCE of RECYCLED MIXES RUTTING RESISTANCE • Evolution of permanent deformation • Rate of rutting (WTS) and final rut depth (RD) • Validation of theoretical models (calibration of coefficients) • Fitting experimental data November 10, 2014 Cesare Alippi Filippo Giustozzi LONG-TERM PERFORMANCE of RECYCLED MIXES FATIGUE RESISTANCE • Evaluation of fatigue life (number of load cycles) • ITFT (indirect tensile fatigue test) • 4-PBFT (four point bending fatigue test) • Comparison between additives • WTOT (total dissipated energy) • DE (dissipated energy) • Validation of theoretical procedure for PV Load Cycle to Failure at 300 kPa 1.0E+06 1.0E+05 1.0E+04 1.0E+03 1.0E+02 1.0E+01 1.0E+00 November 10, 2014 Cesare Alippi Filippo Giustozzi (a) BO BCS3 BCS6 BCS9 BPS3 BPS6 BPS9 BPI3 BPI6 BPI9 LONG-TERM PERFORMANCE of RECYCLED MIXES Fiber reinforced cement sub-base materials Polyolefin Fibers Polypropylene Fibers Fibers create internal additional links that allows to avoid the division between the two portions, guaranteeing a residual collaboration WITHOUT November 10, 2014 Cesare Alippi Filippo Giustozzi WITH FIBERS LONG-TERM PERFORMANCE of RECYCLED MIXES MILANO MALPENSA AIRPORT TWY H November 10, 2014 Cesare Alippi Filippo Giustozzi MORE ABOUT RECENT RESEARCH… November 10, 2014 Filippo Giustozzi PERVIOUS CONCRETE EVA modification November 10, 2014 SBR - latex Cesare Alippi Filippo Giustozzi PERVIOUS CONCRETE November 10, 2014 Cesare Alippi Filippo Giustozzi 60 PHOTOCATALYTIC PAVEMENTS Photocatalysis: convert pollutants (NOx) into inert material due to reactions with TiO2 and UV radiations. November 10, 2014 Cesare Alippi Filippo Giustozzi PRECAST CONCRETE PAVEMENTS November 10, 2014 Cesare Alippi Filippo Giustozzi PRECAST CONCRETE PAVEMENTS November 10, 2014 Cesare Alippi Filippo Giustozzi ASPHALT REJUVENATORS November 10, 2014 Cesare Alippi Filippo Giustozzi CLEAR BINDERS November 10, 2014 Cesare Alippi Filippo Giustozzi FIRE-RESISTANT PAVEMENTS Carbon Oxide (CO) death faint November 10, 2014 Cesare Alippi Filippo Giustozzi FIRE-RESISTANT PAVEMENTS Before Concrete Porous Asphalt + cement mortar Asphalt November 10, 2014 Cesare Alippi Filippo Giustozzi After 30 mins After 120 mins WHAT MIGHT BE INTERESTING IN COLLABORATING WITH @ D.I.C.A… November 10, 2014 Filippo Giustozzi STRUCTURAL ENGINEERING… FEM modeling of lab tests November 10, 2014 Cesare Alippi Filippo Giustozzi 69 HYDRAULIC ENGINEERING… 70 Hydraulic assessment of porous materials November 10, 2014 Cesare Alippi Filippo Giustozzi ENVIRONMENTAL ENGINEERING… Carbon footprinting of processes and materials November 10, 2014 Cesare Alippi Filippo Giustozzi 71 Thanks for listening! Sustainability is the next great game in transportation. The game becomes serious when you keep score. PoliMI keeps score! November 10, 2014 Cesare Alippi Filippo Giustozzi
