Concrete roads – construction in Russia and the CIS, pros and cons

In Russia and the CIS, concrete roads are becoming a more and more common option for infrastructure projects. They are a useful alternative for managing heavy traffic and inclement weather because of their strength and durability. This article will examine the methods and supplies utilized in the construction of concrete roads in these areas, as well as the difficulties encountered.

We’ll also compare the benefits and drawbacks of concrete roads with alternative paving choices. Although concrete roads have a long lifespan and require little upkeep, there are expenses and factors to be taken into account. Having a thorough understanding of these variables can aid in making wise choices regarding road construction projects.

This article attempts to provide a thorough overview of the reasons behind and methods used in the construction of concrete roads in Russia and the CIS today by delving into the details of concrete road construction and assessing their performance in various environments.

Advantages and disadvantages

There are benefits and drawbacks to concrete roads. The following are some of the positive aspects:

1. Concrete structures are highly durable and do not require repair. The declared service life exceeds 40 years. For comparison, asphalt pavement will last only 10 years.
2. When moving on a concrete road, vehicles consume less fuel. This feature is due to the fact that when heavy special equipment moves, concrete does not deform.
3. The coating is not afraid of aggressive influences and climate changes. It demonstrates high resistance to heavy precipitation or sudden temperature changes.
4. Protection of the environment from harmful emissions. Since fuel consumption when driving on a concrete road is reduced, the amount of exhaust gases emitted into the atmosphere is also reduced decreases.

The economical use of natural resources is another benefit of concrete roads. The raw material used to produce the material is limestone, not oil. Nevertheless, the technology has drawbacks in addition to benefits.

1. High cost. Concrete pavement is much more expensive than the asphalt version.
2. Difficulties in repairing road surfaces. In case of damage to the base, the entire concrete slab will need to be replaced.
3. Probability of slipping. During heavy precipitation, the surface becomes slippery.

Differences between asphalt and concrete

The following characteristics of asphalt contribute to its shorter lifespan than that of concrete:

1. Asphalt is produced on the basis of sand, crushed stone and mineral additives, and bitumen polymers are used as a binding component.
2. The production of concrete involves the use of a sand and gravel mixture, which consists of cement and additives.

The type of binders used in the composition is the primary distinction between the two coatings. Bitumen raw materials, in contrast to cement mixture, do not offer a monolithic connection and may sink as a result of heavy loads or soil subsidence. Concrete has none of these drawbacks.

Roadbed structure

It’s important to comprehend the characteristics of the roadbed structure before beginning to build concrete roads. The following layers are part of it:

1. Underlying. Consists of drainage crushed stone and sand, which compensates for the loads from the lower and upper parts.
2. Reinforcing. Low-grade concrete is used to make this layer. It is intended to bind the backfill.
3. Main layer. It is made on the basis of concrete.

It is common practice to use non-stressed and stressed reinforced concrete with reinforced reinforcement when designing highways used by heavy vehicles. Under the influence of heavy loads, the stone won’t deform because of the presence of metal elements.

In order to accomplish particular goals and set up a web on soil with a high groundwater table, intricate web waterproofing must be done. This base is composed of roofing felt. It keeps stone from corroding and keeps concrete from getting wet.

How terrain affects construction

Various technologies are used to create concrete road pavement. It should replicate the terrain in its entirety if it was created in a mountainous region. When building a highway, the ground is leveled. Hills are removed and depressions filled in if any exist. Sharp turns are avoided when building bridges and tunnels.

Due to their longevity and low maintenance requirements, concrete roads are becoming more popular in Russia and the CIS; however, there are certain drawbacks, including higher initial costs and unique construction requirements. This article will examine the benefits and drawbacks of building concrete roads in these areas in order to determine whether they are cost-effective and what factors affect their effectiveness.

Materials for the construction of concrete pavement

The primary material for organizing road surfaces is concrete grade M400. Because of its strength, it can withstand heavy loads from cars and trucks to the fullest.

Portland cement that resists water and water are the basic ingredients of concrete mortar. Sand (2 parts) and crushed stone (5 parts) are added to the composition along with plasticizing additives that increase strength and hydrophobicity.

It is best to use prefabricated factory material for concreting because even a small area needs a lot of solution, which is poured piecemeal.

The performance characteristics of the materials used for the road vary based on the loads and the laying technique.

Technology for using slabs

The following procedure is used to produce road slabs using specialized technology:

1. Creation of expansion joints.
2. Arrangement of the bedding layer.
3. Compacting the layer.

Making expansion joints to divide the sections for pouring is a prerequisite first. Soft wood or cardboard fills all the gaps and absorbs energy. Using a sealed material, the waterproofing layer is applied at a depth of 40–50 mm. It will stop stones or other debris from penetrating beneath the coating, which could destroy it.

When there are no abrupt changes in the climate, there is a gap of 20–30 m between the seams. Long slabs have a 50% strength, and short slabs have an 85% strength. Strength indicators are evaluated based on the coating’s ability to withstand cracking.

Through the side faces, steel elements are guided by a unique mechanism. There must be two 6 to 9 m wide road lanes. Additionally, a shrinkage-temperature joint is fixed between them to prevent crack formation.

The next step involves installing a bedding layer that has been moistened and waterproofed. Since the solution is temporary, the concrete must be poured all at once. Water dilution of the composition is prohibited as it will destroy the material’s original performance attributes.

Factory material is transported straight from the plant where mixing takes place to the construction site. The mixture is unloaded, and then the surface is leveled using specialized blade-equipped machinery. To keep each layer at the same density, careful processing is required. It is necessary to pour a 40 mm layer before securing the formwork and mesh when using reinforcement.

Using vibration equipment, concrete is compacted in the final stage. Mobility affects the degree of plasticity. To avoid cracks, the concrete needs to be watered if it hardens. After that, sand is added, and burlap is fastened to stop evaporation.

Construction

Every concrete road is constructed in phases. You need to know the ins and outs of every event as well as step-by-step instructions for the best possible coverage.

Soil preparation

Prior to cultivating the land, there are some preparations that must be made. They get started after developing the project and obtaining the findings of a geological assessment of the area. In this instance, small hills will be removed and concreting will be done horizontally.

Fertile soil needs to be completely removed in order to build a major highway. Additionally, it only takes 15 to 20 centimeters of soil removal to arrange access to the yards. A roller and a large vibratory compactor are required for compacting the generated cushion.

Making sure a drainage system is in place that can efficiently drain rainwater and groundwater should be a priority during the planning phase. For this, either a small slope of two to four degrees is made, or concrete gutters are fixed in the side of the road.

Laying the bedding layer

A sand cushion is then arranged. It can range in thickness from 20 to 40 cm. Although some businesses skip this step, bedding helps with drainage and stops soil erosion in extremely cold temperatures.

A road built on clay, peat, or any other type of soil that prevents moisture from passing through needs to have this kind of layer as well. Large stones and gravel are frequently used to cover the bedding, which is subsequently leveled with a roller.

It is important to keep in mind the intended slopes when leveling the surface. In addition, granulated slag mixed with quicklime and ash or cement mortar is used to reinforce the stone backfill.

Installation of formwork and reinforcement

You will need to use wooden boards to construct the formwork; these boards should be 10-15 cm tall to match the height at which the mixture is being poured. Once the ideal measurements have been determined, stiffeners must be installed along the concrete’s edges. To enable speedy detachment from the hardened concrete, a unique solution is applied to each section of the formwork.

Wooden panels have to meet a lot of strength standards. It is preferable to create steel formwork if specialized machinery is utilized during the construction process. It is more robust and long-lasting. Every component is built around a sole that can withstand larger weights.

Sections of the formwork are fastened firmly and arranged in a single line. When using heavy machinery to vibrate, this requirement must be met.

A metal mesh with 150 mm cells is used in the reinforcing process. This kind of material will stop the canvas from expanding or deforming while it’s in use.

Metal components are fixed at a height of 3–4 cm from the lower level by reinforcing the concrete during the pouring stage. The material is leveled first.

Laying the concrete pavement

Pouring concrete mortar around the perimeter is the next step. When it comes to reinforcement, the action needs to be carried out all at once or in phases.

Concrete must be applied as quickly and effectively as possible because it hardens quickly. If not, the material’s performance characteristics will decline. Heavy special equipment is used to transport factory-made concrete to the construction site, where it is arranged for highways.

To achieve the same density, the solution is leveled and unloaded in increments of 1 m³. Laying the canvas in two or three layers is advised by experts. To compact the mixture, specialized mechanisms and vibration equipment are employed. Specialists proceed to the next site after processing the first.

In case of reinforcement, the vibration device is positioned approximately 5-7 centimeters above the upper border. Furthermore, the apparatus is furnished with leveling mechanisms. Though not liquid, the concrete mixture needs to be malleable and plastic. Should it not, it will seep through the formwork panels and degrade.

Cutting and sealing expansion joints

Cutting and setting up expansion joints is a crucial step in the building of new roads. After the canvas reaches 50–60% strength and can support the weight of the special equipment and working equipment with ease, they are installed.

In addition to mitigating the issue of thermal expansion, these seams shield the coating from harm during particularly strong frosts. The slabs are cut with a specialized tool, and the project determines how far apart each zone should be. The thickness of the monolith should typically be multiplied by thirty.

Road surface maintenance

It is essential to give the concrete surface the necessary upkeep to prevent premature destruction. The road cannot be opened to the public for use for more than 28 days following the pouring date, per current regulations, as this is the time when the solution reaches its factory strength.

The road surface is additionally treated with polymers that form a waterproof film in order to prevent deformation. But because they make the road less rough, they make it harder for the wheels of the car to stick to it. Since this characteristic is viewed negatively for high-speed highways, some businesses choose to ignore it. The slabs will last for many years in perfect condition if the guidelines for laying and preparing the soil are followed.

If the coating develops cracks, they need to be properly removed. Putty is used to seal small flaws, and concrete mortar is used for larger deformations. But first, the crack needs to be cleaned and wet.

The entire section must be eliminated if a break occurs. The issue arises when there is not enough compaction.

Aspect	Details
Construction in Russia and CIS	Concrete roads are increasingly used in Russia and CIS countries due to their durability and low maintenance needs. They are particularly suitable for high-traffic areas and harsh climates.
Pros	Durable and long-lasting, requires less maintenance compared to asphalt, can handle heavy loads, resistant to extreme temperatures, and reflective which helps in night visibility.
Cons	Higher initial cost, longer curing time, potential for cracking if not properly constructed, and can be noisy under vehicle tires.

For infrastructure, concrete roads are a strong and long-lasting choice, especially in Russia and the CIS. They are a sensible option in many areas because of their resilience to large loads and inclement weather. On the other hand, there may be substantial disadvantages, such as the high initial cost and the intricate construction process. When considering concrete for road projects, it is imperative to take these factors into account.

Concrete roads can have longer lifespans and require less maintenance in the long run, but each project needs to be assessed individually due to their unique set of circumstances. Whether concrete is the best option for a particular location will depend on a number of factors, including traffic volume, climate, and financial limitations.

To sum up, there are advantages and disadvantages to concrete roads. Stakeholders can balance cost, practicality, and durability by carefully evaluating the unique requirements and conditions of a project.

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