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Whitetopping: The Minnesota Experience
- 1. Whitetopping: The Minnesota Experience Matthew (Matt) Zeller, PE Concrete Paving Association of MN Nebraska Concrete Paving Association 39th Annual Concrete Paving Workshop Tuesday January 16th, 2018 Cornhusker Marriott Hotel, Lincoln, NE
- 2. Concrete Overlays: The Minnesota Experience Nebraska Concrete Paving Association 31st Annual Concrete Paving Workshop Tuesday January 19th , 2010 Cornhusker Hotel, Lincoln, NE Matt Zeller, PE Concrete Paving Assoc. of MN
- 3. Concrete Overlays Concrete over existing asphalt or concrete Ultra-thin (less than 4”) Thin (4” to 6”) Conventional (greater than 6”) Old Teminology Unbonded Overlay (UBOL) Whitetopping
- 4. Minnesota Market Year TOTAL CONCRETE PAVING - S.Y. Rolling 3 Year Average STATE AIRPORT COUNTY 2007 1,489,201 1,312,562 1,015,999 217,564 167,308 2008 1,597,218 1,275,176 980,122 129,748 309,898 2009 3,695,387 2,260,602 2,816,691 251,378 490,290 2010 3,055,392 2,782,666 2,137,367 68,775 782,697 2011 2,557,705 3,102,828 1,975,435 78,132 396,982 2012 3,170,562 2,927,886 2,241,083 58,721 729,953 2013 1,936,729 2,554,999 1,218,095 60,787 522,028 2014 3,602,432 2,903,241 2,863,843 8,038 586,750 2015 3,025,504 2,933,807 2,061,774 114,083 748,356 2016 2,084,330 2,763,911 1,181,931 91,590 702,394 2017(est.) 3,125,876 2,754,974 2,228,992 24,995 837,568
- 5. 2017 Overlay Breakdown Market SY Air 24,995 City 34,321 County 837,568 595,523 SY OL 595,523 Thin OL MnDOT 2,228,992 1,026,406 SY OL 680,000 Thin OL TOTAL: 3,125,876 52% overlays 41% Thin Overlays
- 9. Website Tools www.concreteisbetter.com Case Studies Recent Abstracts Sample Plans Workshop Presentation
- 10. Recent Abstracts
- 11. Sample Plans
- 12. Overlays PCC vs ACC Concrete Over concrete Over asphalt Short life Long life Asphalt Over concrete Reflective cracks Over asphalt Reflective cracks Short life (typical) Long life ???
- 15. MnROAD MnROAD
- 16. MnROAD Phase II Mainline Details Cell 5 Unbonded Overlay 300’ – 4” 300’ – 5” 1” asphalt bond breaker or fabric bond breaker No steel 15’ joint spacing Unbonded PCC Overlay 105 205 305 405 5 5 5 5 1" PSAB 1" PSAB 1" PSAB 1" PSAB Oct 08 Oct 08 Oct 08 Oct 08 Current Current Current Current Clay LTine Clay LTine 7.1" cracked '93 PCC 3"cl4sp 27" Cl3sp Orig 20x14 20x13 HMA Should 1" dowel Clay LTine 5"4" 7.1" cracked '93 PCC 5" 7.1" '93 PCC 3"cl4sp 27" Cl3sp Orig 20x14 20x13 HMA Should 1" dowel 7.1" '93 PCC 3"cl4sp 27" Cl3sp Orig 20x14 20x13 HMA Should 1" dowel 4" 3"cl4sp 27" Cl3sp Orig 20x14 20x13 HMA Should 1" dowel Clay LTine
- 17. MnROAD 2017 Cell 5 (705 & 805) Old cells 305 & 405 were in service for 9 years (9 million ESALs) 5” Unbonded Overlay 250’ – Fibers/Long joints 300’ – No Fibers/ Short Joints Fabric Bond Breaker Note cells 505 & 605 replaced Cells 105 & 205 (4” UBOL) in 2011
- 22. 3” FRC 6’x6’ panels, 6.5 lb/yd3 Propex fibers Fabric interlayer (standard/thin) Silty/Clay Thickened-edge PCC 5.5-7” design (1993) 5” Class 5 Sp (1993) Silty/Clay Cell 40: Faulted joints (undoweled), cracked panels, skewed joints Ultrathin Unbonded Concrete Overlay Cells 140 and 240 Constructed in 2013 over LVR Cell 40 Nonwoven geotextile fabric interlayer Standard weight (Cell 240) ½ of standard weight (Cell 140)
- 23. MnROAD Results
- 24. MN TH 65 Whitetopping
- 25. MN TH 59 4.5” Whitetopping
- 26. MN TH 59 4.5” Whitetopping
- 27. McLeod Co 3
- 28. Steele Co 45
- 29. Cottonwood Co 1
- 30. I-35 North of Twin Cities “6 x 6 x 6”
- 31. I-35 North of Twin Cities “6 x 6 x 6”
- 32. Anoka Co
- 33. Anoka Co
- 34. Anoka Co
- 35. Clay Co
- 36. Scott Co
- 37. Washington Co
- 38. Washington Co
- 39. Washington Co
- 40. Moorhead
- 41. Moorhead
- 42. Olmsted Co
- 43. Olmsted Co
- 44. Olmsted Co
- 45. Benefits of Concrete Overlays Provides cost effective solutions - $ for $ the best long term rehabilitation option Construct quick and conveniently Typically, no need to remove existing pavement Little pre-overlay repairs required in most cases Uses standard concrete paving equipment Accelerated practices can be used - can be opened in a day
- 46. Benefits of Concrete Overlays Can be repaired easily Durable - Olmsted Co 10 (1982 – 35 years old) One major repair after 33 years Looking for 20+ more years Inherent sustainable properties Cool Long life Improved mileage
- 47. Benefits of Concrete Overlays Increased safety Better skid resistance No rutting or shoving Improved visibility Partial bond creates composite section adding to design life Short panels reduce curling and warping stresses as well as minimizing expansion/contraction
- 48. P.S. In one two minutes or less…
- 50. MnROAD – City Street Section
- 51. MnROAD – Early Opening
- 52. The Experiment • Paved Cells 524 to 124, so 124 was the youngest before loading • Cells 124 to 524 Longitudinal Test • Cell 124 – Torture test • Cell 224 – 5-3/4 hours old • Cell 324 – 8-1/3 hours old • Cell 424 – 10-1/2 hours old • Cell 524 – Control • Cell 624 Transverse Test
- 54. The Experiment – Longitudinal 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
- 55. 3 hours
- 56. 2 hours
- 57. MnROAD – Early Opening
Hinweis der Redaktion
- When I visited 8 years ago… Today I will have a bunch of words first, then a lot of photos of what we did.
- We (Minnesota) typically talk in UBOL and WT terms still. But as you will see in the next few slides overlays are becoming a very large part of our program.
- Thin overlays are 6” or less
- Our county market has really grown in the past several years and a big part of that growth is due to whitetopping projects.
- One of the tools we provide our counties is a price trend based on recent lettings
- Some other tools we have on our website to help designers
- Now, let’s talk a little more about overlays. I’m going to focus more on whitetopping type projects today since we discussed the UBOL’s a few year ago and not a lot has changed. I do have a couple UBOL related slides though to hit what we are doing there.
- UBOL on the interstate where we removed the shoulder full depth to add a new lane. UBOL was 3 years old.
- We have started using fabric as our bond breaker almost exclusively now for UBOLs
- Many of you have heard about MnROAD, but just a reminder where it is.
- Built in 2008 after I presented in the Winter.
- Built in 2008.
- MnROAD Cell 5 UBOL – original concrete broken with guillotine before UBOL
- 3” FRC UBOL on city street design
- Much of the information we have learned at MnROAD has gone into the Overlay Guide and the BCOA design methodology. The new UBOL design methodology will also incorporate much of what we have learned at MnROAD.
- And now some recent projects. Dueling contractors – PCi Roads one direction, Shafer the other.
- Note sealing the joints. We believe it is worth the time and money to seal. Efforts being made to ensure all joint deploy so we do not have only some joints taking up all the movement of the pavement.
- Their first concrete overlay project, 7.5 miles
- Built in 2009. Still very smooth.
- Built under traffic. One way loop. Very well signed.
- Quite heavy trucks
- Widened old slab – 20’ to 24’. Tie bar issues?
- Another one lane at a time. Remained open to local traffic including apple orchard and gravel pit.
- Inlay left C&G in.
- Inlay down to old gravel.
- Inlay. Lesson learned – isolate C&G so joints do not reflect through.
- Briefly cover different overlay types. Note difference in thickness and joint spacing between different overlay types.
- MnDOT letting 12.5 mile 5” FRC project February 2018