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Proper Maintenance for the Long Life of Concrete Pavements
- 1. Gordon Smith, P.E. glsmith@iastate.edu Proper Maintenance for the Long Life of Concrete Pavements 40th Annual Concrete Paving Workshop January 22, 2019 Lincoln, Nebraska
- 2. Outline • Service Life • Typical Treatments Diamond Grinding Full Depth Repairs Partial Depth Repairs Dowel Bar Retrofit Joint Sealing or Resealing Slab Stabilization/Jacking Cross stitching • Concrete Overlays • References/Guides/Aides • Early Opening • Summary 2
- 3. Maintaining the Service and Investment of a Concrete Pavement by Improved Designs and Cost-Effective PAVEMENT PRESERVATION TECHNIQUES Service/Investment 3
- 5. Why Concrete Pavement Preservation Bellefontaine, OH 1925 5
- 6. Service Life 6 LONG-TERM PAVEMENT PDR and/or DG
- 7. 2018 = 125th Anniversary 7
- 8. Typical Concrete Preservation Activities • Diamond Grinding or Diamond Grooving • Full Depth repairs • Partial Depth Repairs • Dowel Bar Retrofit • Joint Sealing or Resealing • Slab Stabilization/Jacking • Cross stitching 8
- 9. Concrete Pavement Preservation Guide 2014 http://www.cptechcenter.org/technical-library/documents/preservation_guide_2nd_ed_508_final.pdf Contains 12 Chapters on Preservation Techniques • Introduction • Preventive Maintenance and Pavement Preservation Concepts • Concrete Pavement Evaluation • Slab Stabilization and Slab Jacking • Partial-Depth Repairs • Full-Depth Repairs • Retrofitted Edgedrains • Dowel Bar Retrofit, Cross Stitching, and Slot Stitching • Diamond Grinding and Grooving • Joint Resealing and Crack Sealing • Concrete Overlays • Strategy Selection 9
- 10. Diamond Grinding • Removal of thin surface layer of hardened PCC using closely spaced diamond saw blades • Results in smooth, level pavement surface • Provides a longitudinal texture with desirable friction and low noise characteristics • Frequently performed in conjunction with other CPP techniques, such as full- depth repair, dowel bar retrofit, and joint resealing 10
- 12. International Roughness Index (IRI) I-10, Katy Freeway, Houston 701,900 sq yds 12 0 20 40 60 80 100 120 140 160 180 Left Right Average Left Right Average Left Right Average Left Right Average R1 R2 L1 L2 IRI(in/mi) Pre-NGDG 3-mo Post-NGDG 6-mo Post-NGDG Avg. Post-NGDG
- 13. OBSI Data (Level by Lane) I-10, Katy Freeway, Houston 701,900 sq yds 13
- 14. Full-Depth Repair Key Factors for Success • Removal (4’ min.) • Dowel bar holes (grout vs. epoxy) • Proper material selection • Proper placement and curing • Include as part of Partial-Depth Repair 14
- 16. Partial-Depth Repair Key Factors for Success • Proper selection of candidate projects • Proper material selection • Identification of repair boundaries • Use of joint/crack reformers • Achieving good bond • Proper placement and curing 16
- 18. Dowel Bar Retrofit • Restores load transfer • Reduces probability of pumping, faulting, and corner breaks • Improves long-term rideability • Increases service life 18
- 20. 0 10 20 30 40 50 60 70 4107 4235 4340 4616 4706 4902 5009 5122 5144 5193 5270 5686 5712 5827 5926 5968 5981 6025 6334 6473 6520 6529 6757 6883 6916 7084 7293 Age(years) Contract Number – Washington DOT PCC Age at DBR DBR In-Service (2018) Portion DBR Out-of-Service) HMA Overlay Reconstructed Pavement Age vs. DBR Placement 20
- 21. Slab Stabilization/Jacking • Used for Sub Grade Repair Soil collapse Poor Compaction Loss of fines • Restore support of slabs • Reduce progression of Pumping Joint faulting Corner breaks Fill Void or Level Slab Grout 21
- 23. Joint and Crack Resealing Minimize infiltration of water and incompressibles • Types Hot pour Silicone Compressive seals • Reservoir preparation Clean Shape • Reduces: Subgrade softening Erosion of fines Spalling 23
- 25. Cross Stitching • Used for longitudinal cracks that are in good condition • Used to maintain aggregate interlock and provide added reinforcement to crack Strengthen longitudinal cracks Prevent slab migration Maintain aggregate interlock Prevent lane separation Prevent longitudinal joint faulting 25
- 27. Concrete Overlays # of miles in Iowa • 1204 on asphalt • 734 on concrete Oldest road • On asphalt - 1977 • On concrete - 1980 Average age – half of projects constructed since 2005 • 12 on asphalt (25.1 prior to 2005) • 13.5 on concrete (20.1 prior to 2005) Range in thickness 2” - 12” Range in panel size 3’ - 40’ 27 http://www.cproadmap.org/publications/MAPbriefApr2018.pdf
- 28. 28 IA 13 - 2002OK I-35 - 2004 LeMars, IA - 2010 Washington Co, IA - 1977 General Aviation - 2000 Grundy Co, IA - 1978 Buchannan Co, IA - 2006 Storm Lake, IA - 1971
- 29. References/Guides/Helpful Aides Best Practice Technology Briefs: Missouri DOT (complete) • #1 Cross stitching • #2 Dowel bar retrofit • #3 Diamond grinding • #4 Full depth repair • #5 Partial depth repair • #6 Slab stabilization https://www.fhwa.dot.gov/pavement/preservation/resources.cfm 4 Regional Pavement Preservation Partnership Workshops 10 Peer-to-Peer Exchanges and database of treatments Update checklist series 29
- 30. Concrete Repair Best Practices: A Series of Case Studies Published Nov 2017 Michael Darter, Ph.D., P.E., Applied Research Associates, Inc. 119 pages Links to the 6 tech briefs 27 figures 13 tables
- 31. Concrete Checklists • Inspection Checklist #06 Joint Sealing Portland Cement Concrete Pavements • Inspection Checklist #07 Diamond Grinding of Portland Cement Concrete Pavements • Inspection Checklist #08 Dowel-Bar Retrofit of Portland Cement Concrete Pavements • Inspection Checklist #09 Partial-Depth Repair of Portland Cement Concrete Pavement • Inspection Checklist #10 Full-Depth Repair of Portland Cement Concrete Pavements • Being developed: cross-stitching and grooving 31
- 32. Modernizing Checklist Series App based • Phone • Tablet • Print • Link to supporting document • See if can link to AASHTO edocument • Accept photos • Brief videos 32
- 33. Free WBT Preservation Courses NHI 134207 Courses (coming in the Spring) Rigid Pavements • Diamond grinding • Partial-depth repair • Full-depth repair • Dowel bar retrofit/cross stitching • Joint sealing 33
- 35. 1. Surface Defects 2. Surface Delamination 3. Material Related Cracks 4. Transverse & Diagonal Cracking 5. Longitudinal Cracking 6. Corner Cracking 7. Spalling 8. Faulting 9. Joint Warping and Curling 10. Blowups 11. Settlement and Heaves 12. Subgrades & Base Support Conditions 13. CRCP 14. Concrete Overlays, BCOA, BCOC, UBCOA, UBCOC 15. Laboratory & Field Testing Concrete Pavement Distress Assessments and Solutions Guide Focus: • Identification • Causes • Prevention • Rehabilitation https://intrans.iastate.edu/app/uploads/2018/12/concrete_pv mt_distress_assessments_and_solutions_guide_w_cvr.pdf
- 36. International Grooving and Grinding Assoc https://www.igga.net/ July 2009 4 lane section • Inner 2 lanes built in 1950s • Outer 2 lanes built in 1970s • 18,000 square yards • Patching and diamond grinding Under Resources • Case studies • Fact sheets • Technical information • Specifications
- 37. Minnesota - The Experiment, 6” slab 124 224 324 424 524 3 hrs. 5-3/4 hrs. 8-1/3 hrs. 10-1/2 hrs. No Load Concrete Age: Burnham - NCC 2017 37
- 38. MnROAD – Early Opening 38
- 39. 3 hours 39
- 40. Summary • This is a challenging time for the transportation industry • Innovative, cost-effective solutions are needed to meet these challenges • Concrete Pavement Preservation (CPP) can extend pavement life significantly at a competitive cost • Many CPP techniques provide sustainable benefits such as increased friction (safety), reduced noise, improved smoothness and long life • When building roadways we must begin with the end in mind to ensure durable pavements are constructed 40
- 41. Thank You www.cptechcenter.org Kevin Merryman, Iowa DOT, 2016 41 Dallas Co, IA - 1977