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Precast Concrete Pavement Systems for Rapid Repair, Rehabilitation, and Construction

Precast Concrete Pavement Systems for Rapid Repair, Rehabilitation, and Construction. Presented by: Gary L. Hoffman Principal Engineer Applied Res. Assocs. HfL Project Manager. Highways for LIFE.

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Precast Concrete Pavement Systems for Rapid Repair, Rehabilitation, and Construction

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  1. Precast Concrete Pavement Systems for Rapid Repair, Rehabilitation, and Construction Presented by: Gary L. Hoffman Principal Engineer Applied Res. Assocs. HfL Project Manager

  2. Highways for LIFE • HfL Program Description • Quickly Implement Innovation • $75M SAFETEA-LU line item • Demo Projects/Showcases • Technology Transfer Efforts

  3. More cars and trucks Old highways and bridges

  4. Too many crashes and injuries

  5. We can build highways: • Faster • With less congestion • With better safety and quality • At lower cost

  6. Vanguard Technologies • Prefabricated bridge elements and system (PBES) • Road safety audits (RSA) • Making work zones work better • Precast concrete pavements system (PCPS)

  7. Highways for LIFE • Technology Transfer Actions • Workshops/open-houses • Vanguard Technologies • Technical Briefs • Webinars (Two-Lift, Precast Pavements) • Toolkit DVD’s (PBES, RSA,PCPS,HfL) • Display Booth

  8. Highways for LIFE •  Videoconference •  DVD of videoconference •  Marketing plan •  Regional showcases (3) •  Webinars •  Toolkit DVD

  9. Highways for LIFE • Demonstration Projects • Performance goals for safety, quality, construction congestion and user satisfy • Innovations to achieve goals • Showcases/Workshops

  10. Highways for LIFE Demonstration Projects HfL Project Recipient

  11. PCPS Projects in 2008 & 2009 NYSTA I-95(CT-State line/Mamaroneck River to Cross Bronx Expressway) NYSDOT – Nassau-Queens Expressway, Staten Island-West shore Expressway, Approach to Alexander Hamilton Bridge NY City DOT- Approach to Brooklyn Bridge NJDOT I-280 & Rt.21(Newark) Toronto, Canada (Downtown, Hwy 427) Iowa DOT (precast bridge approaches) DELDOT, intersection Rt.896 & Rt. 40 (Bear, DE) Highways for Life Projects Virginia DOT I-66 Mainline & Interchange Ramp Florida DOT (Daytona) - Intersections CALTRANS I-15 - Mainline NYSDOT I-88 Bridge Approach Slabs (Central NY)

  12. Benefits of PCPS Cast under ideal conditions Long life expectancy with low maintenance Placement in a short time frame – congestion & safety Less Risk to owner/contractor Growing documentation of performance history Established industry, method and technology Staged construction is possible Installation not affected by adverse weather conditions Supported by FHWA, AASHTO, ACPA, NPCA, PCI Reduced Work Zone timeframe Choice of surface Textures Pre-approval of PCPS System is possible Pre-existing specifications are available Generic specifications are available Economically competitive with alternative PCC pavement treatments

  13. Paving and Pavement Rehabilitation Applications Continuous Paving Intermittent Full Depth Repairs of PCC Pavements Applications: airport runways & taxiways, heavily traveled highways, ramps, toll plazas, intersections, crosswalks, ports-docks, bus pads, smart-sensor embedment's, bridge approach slabs, pavement under bridges – vertical clearance

  14. PCPS Basics • Fabricated off-site • Transported to the project site • Installed on a prepared foundation • No field curing or time to achieve strength • Two main categories • Jointed Systems • Prestressed Systems

  15. PCPS General Terminology PCC thickness, material properties Structural capacity for handling Existing structure Friction reducing interlayer or filler material (N.T.S.) Slab length Grouting materials Load transfer mechanism with new or existing pavement Pretension in transverse direction option (PPCP) Post-tensioning option (PPCP)

  16. Key Features • High performance concrete • Embedded dowels and tie bars • Matching inverted dovetail slots • Thickness as required • Length and width as required

  17. Grout DistributionChannel FoamGasket Proof Bedding Grout Distribution System Positive Distribution to Entire Under-Surface Pumping Bedding Grout • Used only to fill voids • Flow rate : 17 – 20 seconds • 600 psi in 12 hours

  18. Single Plane Two Types of SlabsSelection depends on pavement surface Warped Plane

  19. Small Scale Grader Rail Supported and Hand Operated

  20. Typical PPCP Panel Layout

  21. Pavement service life and objectives Current & projected traffic density Slab replacement criteria Estimated project duration Work window options Project Scope

  22. General rules of thumb, based on lane occupancy times Pavement Treatment Alternatives Cast in place HES VHES PCPS 0 4 8 12 16 20 24 Hours

  23. Need for accelerated construction M&PT considerations, seasonal restrictions, stakeholder impact Funding guidelines Design and engineering data requirements Construction risk Specifications Maintenance and protection of traffic Project Specific Considerations

  24. Specification Options Sole Source Specification: Preselect PCPS system and work directly with provider Multiple Source Specification: Use PCPS with general performance guidelines Generic Specification-Prequalification: Use generic performance specifications = Prequalification of Precast Concrete Paving Systems (www.aashtotig.org)

  25. AASHTO TIG Specifications & Guidelines for PCPS 1.Guidance and Considerations for the Design of Precast Concrete Pavement Systems 2.Generic Specification for Fabricating and Constructing Precast Concrete Pavement Systems 3.Generic Specification for Precast Concrete Pavement System Approval 4.Precast Concrete Pavement Systems for Rapid Pavement Repair and Replacement: Basic Information and Commentary Available at www.AASHTOTIG.org under the PCPS dropdown menu

  26. What’s available online? www.aashtotig.org • Detailed information about each of these 5 leading Precast Paving Systems. • Design Guideline Specifications • Construction Guideline Specifications • Approval Guidelines for PCPS • Research Reports • Proven Agency Specifications

  27. Prequalification of PCPSGaining State DOT Approval Type of system employed Slab thickness Slab geometry Joint matching needs Load transfer Reinforcing steel Material handling Embedment Material Subgrade requirements Bedding requirements Pre & Post-tension requirements Surface texture Ride Quality Load Transfer Efficiency Slab installation procedures Prove the PCPS off-site, before the project begins

  28. Qualified precaster presence in area Contractor’s familiarity with PCPS construction process Planning and scheduling Quality assurance Contract plans Construction Considerations

  29. Contract Plans Locate PCPS use within project limits Detailed typical section of installed PCPS Detailed road geometry data Slab layout & shop drawings

  30. Should expand beyond initial costs LCCA - Reduced maintenance costs and user-delay cost MTO reports only 10% higher cost than high early strength Economies of scale and industry familiarity Cost Considerations

  31. PCPS Lessons Learned Before construction – Decision logic to select candidate projects During construction - Good planning, and mobilization critical for success Post construction PCPS perform very well M&R schedules and treatments different

  32. PCPS Summary Successful installations nationwide Proven long term performance Ideal for accelerated construction for projects with lane closure restrictions Specification and guidelines available for your use PCPS can be added to your PCC treatment toolbox

  33. Highways for LIFEAccelerating innovation for the American driving experience Gary L. Hoffman ghoffman@ara.com Timothy J. LaCoss Timothy.LaCoss@fhwa.dot.gov

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