Soil Treatment.

Base Layers
with Hydraulic Binders
Contents

1 Soil Treatment 11

1.1 Definition of terms 12

1.1.1 Definitions according to the “Directives for the standardization of the superstructures
of trafficked surfaces” (RStO 12) 12
1.1.2 Terms and body of rules and regulations for soil treatment 14
1.1.3 Correlating rules and regulations with the different layers 16
1.2 Definition of terms in soil treatment 18
1.2.1 Soil stabilization 18
1.2.2 Soil improvement 18
1.2.3 Qualified soil improvement 18
1.2.4 Base layers with hydraulic binders 18
1.3 Geotechnical investigations 19
1.3.1 General 19
1.3.2 Description of soil types according to DIN EN ISO 14688-1 (old: 4022, Part 1) 19
1.3.3 Soil classification according to DIN 18196 20
1.3.3.1 Soil groups 20
1.3.3.2 Principles of soil classification 21
1.3.3.3 Coarse-grained soils 22
1.3.3.4 Mixed-grained soils 22
1.3.3.5 Fine-grained soils 22
1.3.3.6 Organogenic and organic soils 22
1.3.3.7 Chart 23
1.3.3.8 Classifying soils according to their plastic properties 24
1.3.3.8.1 Determining consistency 24
1.3.3.8.2 Plasticity chart for classification of fine-grained soils 25
1.3.3.9 Classifying soils according to DIN 18196 26
1.4 Frost susceptibility of soils and rock of variable strength 30
1.4.1 Classifying soil groups in accordance with frost susceptibility 30
1.4.2 Frost susceptibility after soil improvement with binders 31
1.5 Application 32
1.5.1 Soil improvement 32
1.5.2 Qualified soil improvement 32
1.5.2.1 Reducing pavement thickness by means of qualified soil improvement 34
1.5.2.2 Requirements on qualified soil improvement at subgrade level 35
1.5.3 Soil stabilization 36
1.5.3.1 Soil stabilization not counting toward the pavement 36
1.5.3.2 Soil stabilization counting toward the pavement 37
1.5.3.3 Excerpt from the “Directives for the standardization of the superstructures of
trafficked surfaces” (RStO 12), Chart 1 38
1.5.3.4 Excerpt from the “Directives for the standardization of the superstructures of
trafficked surfaces” (RStO 12), Chart 2 40
1.6 Basic principles of earthworks 42
1.6.1 Compaction 42
1.6.2 Compaction requirements on subsoil and subgrade 42
1.6.3 Requirements on the subgrade 43
1.6.4 Deformation modulus on the subgrade (minimum 10 percentile) 44
1.6.5 Requirements on compaction characteristics 45
1.7 Quality assurance 46
1.7.1 Tests to be performed prior to construction 46
1.7.1.1 Tests to be performed by the client 46
1.7.1.2 Tests to be performed by the contractor 46
1.7.1.3 Testing specifications for mix designs 49
1.7.2 Tests to be performed during construction 50
1.7.2.1 Type and scope of tests to be performed in soil treatment operations 50
1.7.2.2 Testing methods and testing procedures 52
1.7.2.2.1 Testing methods for testing compaction characteristics 53
1.7.2.2.2 Testing procedures for determining compaction parameters 54
1.7.2.2.3 Testing deformation modulus, correct vertical and horizontal position
and evenness on the subgrade 57
1.8 Soils and mineral construction materials for soil treatment 58
1.8.1 Suitable soils (according to DIN 18196) 58
1.8.2 Soils (according to DIN 18196) and construction materials suitable to a limited extent 58
1.8.3 Non-suitable soils 58
1.8.4 Natural and artificial aggregates and recycled construction materials 59
1.8.5 Sulphate influence 59
1.9 Binders 60
1.9.1 General 60
Contents

1.9.2 Types of binder 60

1.9.3 Mode of binder action 60
1.9.3.1 Building limes 60
1.9.3.2 Cements 62
1.9.3.3 Mixed binders 62
1.9.4 Binders with special properties 63
1.9.4.1 Low-dust binders 63
1.9.4.2 Hydrophobic binders 63
1.9.5 Binder applications 64
1.9.6 Binder processing times 66
1.9.7 Binder reaction times 66
1.10 Water 68
1.11 Effects of weather 70
1.11.1 Precipitation 70
1.11.2 Wind 70
1.11.3 Temperature 71
1.12 Soil treatment – Construction 72
1.12.1 Mixing procedures 72
1.12.2 Dust-free addition of binder 72
1.12.3 Mixed-in-place process 74
1.12.3.1 Principles of construction for the mixed-in-place process (all fields of soil treatment) 74
1.12.4 Requirements for soil treatment 80
1.12.4.1 Binder quantity 80
1.12.4.2 Compaction characteristics 80
1.12.4.3 Verification of binder quantity 82
1.12.4.4 Surface 82
1.12.4.5 Evenness 82
1.12.4.6 Paving thickness 82
1.13 Structural backfills 84
1.13.1 Terms 84
1.13.2 Construction materials 84
1.13.2.1 Drainage area 84
1.13.2.2 Backfill and cover fill areas 84
 1.13.3 Compaction 85
1.14 Refilling utility trenches 86
1.14.1 General 86
1.14.2 Working in the binder 86
1.14.3 Compaction 86

2 Base Layers with Hydraulic Binders 91

2.1 General 91
2.2 Terminology 92
2.3 Base layers with hydraulic binders in accordance with the “Additional technical
conditions of contract and directives for the construction of base layers with hydraulic
binders and concrete pavements” (ZTV Beton-StB) and soil stabilization in accordance
with the “Additional technical conditions of contract and directives for earthworks in
road construction” (ZTV E-StB) 93
2.4 Principles of production 94
2.4.1 General 94
2.5 Tests – Definitions 95
2.5.1 Initial testing (mix design) 95
2.5.2 Factory production control 95
2.5.3 Internal control testing 97
2.5.4 Compliance testing 97
2.6 Construction materials 98
2.6.1 Soils and aggregates for soil stabilization 98
2.6.2 Aggregates and construction material mixtures for hydraulically bound base layers 99
2.6.3 Aggregates and construction material mixtures for concrete base layers 102
2.6.4 Hydraulic binders 103
2.6.5 Water 104
2.6.6 Concrete admixtures / Concrete additives 104
2.7 Requirements on base layers with hydraulic binders 105
2.7.1 Design 105
2.7.2 Pavement layers with binders 105
Contents

2.7.3 Minimum paving thicknesses 105

2.7.3.1 Stabilized layers 105
2.7.3.2 Hydraulically bound base layers 105
2.7.3.3 Concrete base layers 106
2.7.4 Edge design of base layers 106
2.7.4.1 Details of edge design 107
2.7.5 Drainage of base layers 108
2.7.6 Execution at low / high temperatures and frost 108
2.7.7 Correct vertical and horizontal position 108
2.7.8 Evenness 108
2.7.9 Tolerances of paving thickness 109
2.7.10 Grooves or joints 109
2.7.11 Curing 110
2.7.11.1 Table: Summary of requirements on base layers with hydraulic binders in accordance
with the “Additional technical conditions of contract and directives for the construction
of base layers with hydraulic binders and concrete pavements” (ZTV Beton-StB) 112
2.8 Producing stabilized layers 114
2.8.1 Requirements on paving mixes for stabilized layers 114
2.8.2 Production 114
2.8.3 Mixed-in-place process 114
2.8.4 Mixed-in-plant process 115
2.8.5 Placing and compaction 116
2.8.6 Requirements on the degree of compaction 116
2.9 Producing hydraulically bound base layers 117
2.9.1 Requirements on the paving mix 117
2.9.2 Production, transport and placing 117
2.9.3 Requirements on the finished layer 118
2.10 Type and scope of testing 119
2.10.1 Initial testing for stabilized layers 119
2.10.2 Initial testing for hydraulically bound base layers 121
2.10.3 Internal control and compliance testing for stabilized layers 122
 2.10.4 Internal control and compliance testing for hydraulically bound base layers 124
2.10.5 Internal control and compliance testing for concrete base layers 125
2.11 Using reclaimed asphalt and reclaimed tar-bound road construction materials
in base layers with hydraulic binders 126
2.11.1 General 126
2.11.2 Source materials – Aggregates 126
2.11.3 Additives 126
2.11.4 Storing reclaimed tar-bound road construction materials 127
2.11.5 Construction material mixtures 127
2.11.6 Requirements 127
2.11.7 Initial testing 127

References 128

Body of technical rules and regulations 129

1.6 Basic principles of earthworks

1.6.1 Compaction

At the start of compaction, the contractor has to Special conditions for compaction or construction
complete a trial field to verify that the compaction apply to embankment shoulders. This may influ-
requirements will be met. ence the bulk width of an embankment in case of
soil stabilization or stabilization of the pavement.
The maximum bulk thickness (or maximum thick-
ness of the improved layer respectively) must be When placing weather-sensitive construction
such that the specified degree of compaction is materials, the bulk surfaces have to be built with a
achieved over the entire layer thickness. cross slope of no less than 6%.

1.6.2 Compaction requirements on subsoil and subgrade

The subsoil or subgrade of roads and paths has the degree of compaction DPr or the maximum
to be compacted so as to meet the following 10 percentile for the air voids ratio na respectively.
requirements on the minimum 10 percentile for

na in % by
Area Soil groups DPr in %
volume
Subgrade to a depth of 1.00 m for GW, GI, GE
embankments SW, SI, SE 100 –
Subgrade to a depth of 0.50 m for cuts GU, GT, SU, ST
GW, GI, GE
1.00 m below grade to embankment base SW, SI, SE 98 –
GU, GT, SU, ST
Subgrade to embankment base GU*, GT*, SU*, ST*
97 122)
Subgrade to a depth of 0.50 m for cuts U, T, OU1), OT1)
1) These requirements apply to soils of groups OU and OT only if their 2) If the soils are not improved by means of soil stabilization or quali-
suitability and placing conditions have been investigated separately fied soil improvement, a requirement on the maximum
and determined in consultation with the client. 10 percentile for the air voids ratio is recommended as follows:
· 8% by volume when placing water-sensitive mixed-grained or
fine-grained soils; and
· 6% by volume when placing rock of variable strength.
This has to be indicated in the specification of works.
1.6.3 Requirements on the subgrade

The subgrade must comply with specifications in

Reducing the cross slope after soil
terms of correct vertical and horizontal position,
treatment results in huge potential savings in
evenness and bearing capacity.
pavement material.
Requirements on the correct vertical and horizon-
tal position:
Deviation: ± 3 cm from design level Example: qPavement = 2.5%
± 2 cm if the subgrade is to be qSubgrade = 4.0%
overlaid with a bound base layer Width of subgrade = 6.00 m
The subgrade must have the following cross slope: € Savings: approx. 0.30 m3 / m
> * 4.0% for water-sensitive soils and construc-
tion materials At the raised edge of the carriageway, the sub-
> * 2.5% after soil treatment with binders grade has to be designed with a reverse gradient.

Shoulder Traffic lane Traffic lane Shoulder

* 2.5 % 6%
12 %

1.5
1:

When performing soil improvement operations at

subgrade level, the edge design of embankment
structures may require excess profiling due to the
production methods and equipment used.

42 l 43
1.12 Soil treatment – Construction

1.12.1 Mixing procedures

A general distinction is made between two differ- The mixer travels on the layer prepared for treat-
ent procedures which can be used to produce a ment, working in the previously spread binder
soil-binder mixture. and, where appropriate, the required quantity of
water.
> Mixed-in-plant process
Where the mixed-in-place process cannot be Variations in the sequence of the individual
used for technical reasons (due to, for exam- operational steps are possible depending on the
ple, existing manholes, gullies, road widenings, location of the excavation and paving sites.
structures, trenches etc.) or is uneconomical,
soil-binder mixtures produced using the mixed- > Special process
in-plant process can be placed instead. Where the paving site does not allow for a mixer
In soil treatment operations, it is usually not to be used (in case of road widenings, refilling of
economically feasible to produce soil-binder utility trenches or structural backfills, or in areas
mixtures using the mixed-in-plant process. or locations where binder drifts must be avoided
etc.), the binder can be spread and mixed in at
the excavation site. The soil-binder mixture is
> Mixed-in-place process then transported to the paving site, placed and
The mixed-in-place process is the standard compacted.
construction method used in soil treatment
operations.

1.12.2 Dust-free addition of binder

The “S-Pack” (Spreader-Pack), which can be The “S-Pack” spreader is loaded to capacity in
integrated into the WR 240, WR 240i or WR 250 as less than five minutes. A standard 27-tonne silo
an optional feature, is the ideal candidate for the transporter is emptied within two hours. The
dustless addition of binding agents in cold recyc- spreading process is controlled and monitored
ling or soil stabilization. Lime or cement is spread intuitively via the integrated control screen. Paired
right in front of the milling and mixing rotor in a with the outstanding all-terrain mobility of the WR
microprocessor-controlled operation. “S-Pack” is model range, the “S-Pack” allows binders to be
synonymous with the reliable and dustless proces- spread reliably and precisely even in those places
sing of binders especially on motorways, in indust- which are not suitable for the use of heavily loa-
rial estates specifying strict emission requirements, ded, self-propelled binder spreaders.
residential areas or nature reserves.
72 l 73
2.2 Terminology

Depending on the technology, source material and - Mixed-in-plant process

mixing process used, base layers with hydraulic The soil or aggregate mixture is mixed with
binders are distinguished into: the specified binder and required quantity
of water (mixing water) in stationary mixing
> Stabilized layers with hydraulic binders plants, transported to the construction site
Soil stabilization comprises a range of construc- and placed.
tion processes aiming at increasing the resist-
ance of granular base layers to stresses caused > Hydraulically bound base layers
by traffic loading and climate. (produced using the mixed-in-plant process
The construction material mixture is compacted only)
after completion of the stabilizing operation. Hydraulically bound base layers consist of un-
In the process, hydraulic binders and water are crushed and / or crushed construction material
added to the soils and / or construction material mixtures and hydraulic binders.
mixtures using the mixed-in-place or mixed-in- Grading of the construction material mixture
plant process. must be within specified grading ranges. The
paving mix must be produced in mixing plants.
- Mixed-in-place process
The mixer travels on the layer prepared for > Concrete base layers
soil stabilization, scarifying it and mixing in Concrete base layers are base layers of con-
the specified hydraulic binder and required crete in accordance with DIN EN 206-1 and
quantity of water. DIN 1045-2.
2.3 Base layers with hydraulic binders in
accordance with ZTV Beton-StB 1) and soil
stabilization in accordance with ZTV E-StB 2)

Position of the stabilized layer

Position of the base layer with hydraulic binders according
in the subsoil or subgrade
to ZTV Beton-StB 1)
according to ZTV E-StB 2)

Asphalt surfacing Asphalt surfacing

Concrete surfacing Stone paving Concrete pavement Concrete surfacing
Asphalt base Asphalt base

Frost-proof design

Frost-proof design

Frost-proof material Base layers with Stabilization of Subsoil Deformation modulus Degree of compaction
[frost blanket] hydraulic binders subsoil or subgrade (F2 / F3 soils) on subgrade of stabilized layer
(paved or native) Ev2 * 45 MN / mm² DPr * 98 %

1)
Additional technical conditions of contract and directives for the construction of base layers with hydraulic binders and concrete pavements
2)
Additional technical conditions of contract and directives for earthworks in road construction

92 l 93
2.6.3 Aggregates and construction material mixtures for concrete base layers

Aggregates as described in section 2.6.2, as an addition to the aggregates but as an additive

Aggregates and construction material mixtures for only. The grading curves to be complied with are
hydraulically bound base layers, the only restric- based on the requirements of DIN EN 206-1 and
tion being that suitable coal fly ash cannot be used DIN 1045-2.
2.6.4 Hydraulic binders

Cements in accordance with DIN EN 197 or with DIN 18506 (strength classes 12.5 and 32.5)
DIN 1164-10 as shown in the table below or are used as binders.
hydraulic soil and road binders in accordance

Main types of cement Designation of cement types Main constituents

CEM I Portland cement

Portland blast-furnace slag cement A/B S Granulated blast-furnace slag

Portland silica fume cement A D Silica fume

Portland pozzolanic cement A/B P/Q Pozzolans

CEM II
Portland fly ash cement A V Fly ash

Portland burnt shale cement A/B T Shale

Portland limestone cement A LL Limestone

S-D, S-T, S-LL

S-P, S-V

D-T, D-LL, D-P

A D-V

T-LL
CEM II-M Portland composite cement
P-V, P-T, P-LL

V-T, V-LL

S-D, S-T, S-P

B D-T, D-P

P-T

A S
CEM III Blast-furnace slag cement
B S

CEM IV Pozzolanic cement B P 1)

A
CEM V Composite cement S-P 2)
B
1)
Applies only to trass according to DIN 51043 as the main constituent of up to max. 40% by mass
2)
Applies only to trass according to DIN 51043 as the main constituent

102 l 103