Preservation
RAPID CONCRETE PAVEMENT REPAIRS RMWPPP 10/25/2017 SEATAC, WASHINGTON JIM POWELL, P.E.
Why ?
Traffic
I-5 sections 220,000 ADT
User delays
Safety
Faster repairs = less exposure for:
Public
Agency personnel
Contractor personnel
What ?
Full depth repairs
Partial depth repairs
Key Factors to Consider
Staging
Materials
Procedures
Staging
Supply the longest work window possible
More repairs in a given time/Higher production rate
Reduces costs
Increases safety
Supply the largest work area possible
Improves efficiency/Higher production rate
Reduces costs
Increases safety
Perform as much work as possible prior to placement
Reduces user impacts
Staging
Consider increasing the length of the work zone to allow completion of as many repairs as possible in the time given
A slightly longer closure may greatly increase productivity
8 hour work window = 6 hours production
10 hour work window = 8 hours production
25% increase in work window = 33% increase in production time
Tacoma Panel Replacement
40+ year old existing PCCP
Exhibiting random panel cracking
Approximately 2.5 miles
29 panels to be replaced
580 square yards
6 separate locations
Project Requirements
12 Working Days (4 three day weekends)
Thurs 11:00 pm – 5:00 am
Fri 10:00 pm – 10:00 am
Sat 10:00 pm – 10:00 am
Traffic restricted to one lane
Proposed Changes
One weekend closure
Fri. saw cutting and drilling
Sat. 8:00 pm – 12:00 noon Sun.
Use the collector distributors for thru traffic
Close mainline
One lane of mainline open on south end of project
Benefits
SAFETY!
Less public exposure
Less worker exposure
More uniform mix
Better ride
Traffic impacts
Public Perception
Construction Schedule
Friday night
Saw cut panels
Drill lift points
Saturday Night
8:00 pm – Set traffic control
9:00 pm – Begin panel removal
9:30 pm – Begin prep (Install tie bars, install dowel bars, grade and compact base)
12:30 am – First concrete pour
4:00 am – Final concrete pour
12:00 noon – Open to traffic
7:00 am – Saw and seal
Materials
Full depth repairs
High early strength Portland cement mixes
Lower materials cost ?
Opening strength in approximately 4 hours
High early strength non-Portland hydraulic cements
Higher materials cost ?
Opening strength in 1 hour or less
Materials
Partial depth repairs
High early strength Portland cement mixes
High early strength non-Portland hydraulic cements
Polymers
Urethane
Epoxies
Polyester
Materials
Polymer concrete materials
Rapid strength gain ( 1-2 hours at moderate temperatures )
Flexible and durable
Not all suitable for application in damp conditions
Typically mixed in small quantities
Polymer Repair Materials
Polymer Repair Materials
Procedures
All of the materials discussed can perform well provided proper procedures are followed
Removal of existing/adjacent material
Preparation of patch area
Placement of material
Partial Depth Repairs
Repairs deterioration in the top 1/3 of the slab.
Generally located at joints, but can be placed anywhere surface defects occur.
. .
.
.
.
.
Partial-Depth Patch Layout 2 - 6 in. min.
Spall
2 - 6 in. min.
Patch
2 in. (min.) - t/3 (max.)
t
19
Sawing & Chipping
20
21
22
Point Bearing
Pop out & Breakage
Joint Closure Expansion
Debonding Expansion
Placing Material
24
25
Full-Depth Repair • Purpose – Restore structure – Restore ride
• Used for – – – –
Joint/crack deterioration Broken slabs Corner breaks Utility cuts
26
Full-Depth Repair Joint Deterioration –Spalling (below surface) –Cracking
27
Full-Depth Repair
Corner Breaks
Transverse Cracks
28
Repair Layout L
M
29
L
H L
M
M
H
M-H
Isolate longitudinal repair boundaries
H
• Minimum length is 1.8 m (6 ft). • Check distance between patches and nearby joints. • Replace the entire slab if there are multiple intersecting cracks.
30
31
Full Depth Repair
32
Utility Patches: Good Practice
Utility Trench 9-10 in. rim
Poor Practice
Utility Trench
33
Load Transfer Jointed Pavements: Patch
12 in. c-c typ. spacing
Top View
Optional Dowels 12 in. typ.
d/2
Side View Remove loose material and fill any depressions with concrete
34
Placement of Bond-Breaking Board
35
36
37
Why ?
Traffic
I-5 sections 220,000 ADT
User delays
Safety
Faster repairs = less exposure for:
Public
Agency personnel
Contractor personnel
What ?
Full depth repairs
Partial depth repairs
Key Factors to Consider
Staging
Materials
Procedures
Staging
Supply the longest work window possible
More repairs in a given time/Higher production rate
Reduces costs
Increases safety
Supply the largest work area possible
Improves efficiency/Higher production rate
Reduces costs
Increases safety
Perform as much work as possible prior to placement
Reduces user impacts
Staging
Consider increasing the length of the work zone to allow completion of as many repairs as possible in the time given
A slightly longer closure may greatly increase productivity
8 hour work window = 6 hours production
10 hour work window = 8 hours production
25% increase in work window = 33% increase in production time
Tacoma Panel Replacement
40+ year old existing PCCP
Exhibiting random panel cracking
Approximately 2.5 miles
29 panels to be replaced
580 square yards
6 separate locations
Project Requirements
12 Working Days (4 three day weekends)
Thurs 11:00 pm – 5:00 am
Fri 10:00 pm – 10:00 am
Sat 10:00 pm – 10:00 am
Traffic restricted to one lane
Proposed Changes
One weekend closure
Fri. saw cutting and drilling
Sat. 8:00 pm – 12:00 noon Sun.
Use the collector distributors for thru traffic
Close mainline
One lane of mainline open on south end of project
Benefits
SAFETY!
Less public exposure
Less worker exposure
More uniform mix
Better ride
Traffic impacts
Public Perception
Construction Schedule
Friday night
Saw cut panels
Drill lift points
Saturday Night
8:00 pm – Set traffic control
9:00 pm – Begin panel removal
9:30 pm – Begin prep (Install tie bars, install dowel bars, grade and compact base)
12:30 am – First concrete pour
4:00 am – Final concrete pour
12:00 noon – Open to traffic
7:00 am – Saw and seal
Materials
Full depth repairs
High early strength Portland cement mixes
Lower materials cost ?
Opening strength in approximately 4 hours
High early strength non-Portland hydraulic cements
Higher materials cost ?
Opening strength in 1 hour or less
Materials
Partial depth repairs
High early strength Portland cement mixes
High early strength non-Portland hydraulic cements
Polymers
Urethane
Epoxies
Polyester
Materials
Polymer concrete materials
Rapid strength gain ( 1-2 hours at moderate temperatures )
Flexible and durable
Not all suitable for application in damp conditions
Typically mixed in small quantities
Polymer Repair Materials
Polymer Repair Materials
Procedures
All of the materials discussed can perform well provided proper procedures are followed
Removal of existing/adjacent material
Preparation of patch area
Placement of material
Partial Depth Repairs
Repairs deterioration in the top 1/3 of the slab.
Generally located at joints, but can be placed anywhere surface defects occur.
. .
.
.
.
.
Partial-Depth Patch Layout 2 - 6 in. min.
Spall
2 - 6 in. min.
Patch
2 in. (min.) - t/3 (max.)
t
19
Sawing & Chipping
20
21
22
Point Bearing
Pop out & Breakage
Joint Closure Expansion
Debonding Expansion
Placing Material
24
25
Full-Depth Repair • Purpose – Restore structure – Restore ride
• Used for – – – –
Joint/crack deterioration Broken slabs Corner breaks Utility cuts
26
Full-Depth Repair Joint Deterioration –Spalling (below surface) –Cracking
27
Full-Depth Repair
Corner Breaks
Transverse Cracks
28
Repair Layout L
M
29
L
H L
M
M
H
M-H
Isolate longitudinal repair boundaries
H
• Minimum length is 1.8 m (6 ft). • Check distance between patches and nearby joints. • Replace the entire slab if there are multiple intersecting cracks.
30
31
Full Depth Repair
32
Utility Patches: Good Practice
Utility Trench 9-10 in. rim
Poor Practice
Utility Trench
33
Load Transfer Jointed Pavements: Patch
12 in. c-c typ. spacing
Top View
Optional Dowels 12 in. typ.
d/2
Side View Remove loose material and fill any depressions with concrete
34
Placement of Bond-Breaking Board
35
36
37
