Rapid. Slab System. System. The Case for Long Life. Using Super-Slab. Slab for. Repair and Replacement Of Concrete Pavements
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1 Using Super-Slab Slab for Rapid Repair and Replacement Of Concrete Pavements Virginia Concrete Conference March 11, 2005 Peter J. Smith, P.E. V. P. Market Development and Product Engineering The Fort Miller Co., Inc. 55 Hour Weekend Closures 8 Hour Night (or Daytime) Closures Night Closures Materials Currently used for Rapid Full Depth Repairs! Asphalt! Fast - but usually don t last long!! Rapid Set Concretes! Still requires cure time Precast Concrete Slabs- A Long-Considered Alternative! For Rapid Installation!! Get in (at night)! Get out (at dawn)! For Long Life! Stay out (for many years) The Case for Long Life The Super-Slab Slab System! High Performance Concrete! Stresses From Curing Minimized! Cast indoors and in a form! Ultimately Supported in Pre-Curled Position! Stainless Steel or Zinc Coated Dowels May be Used A Slab-on on-grade System (Super-Slab Slab is a Patented System) 1
2 Super-Slab Slab is:! Not a Competitor to Cast-in in-place! But a tool for rapid repair to keep pavement white! Not Re-invented Concrete Pavement! But an innovative combination of! High performance materials! Proven design details The System Consists of:! Precision Precast Slabs! Correct in Three Dimensions to + 4 mm! Techniques for Precision Grading! Correct in three dimensions - to + 3 mm! Interlocking Dowels and Tie Bars! Accessible From Top of the Slab! A Bedding Grout Distribution System to Insure Complete Support! Accessible From Top of the Slab Super-Slab Slab The Product Features: High Performance Concrete Embedded Dowels Embedded Tie Bars Matching Inverted Dovetail Slots Thickness as Required Length and Width as Required Channels Gaskets Dovetail Dowel Slots On The Bottom Bedding Grout Distribution System Channels and Gaskets Bedding Grout Port Dowel Grout Port Protects Grout From De-Icing Chemicals Two Types of Slabs (and Subgrade Surfaces)! Single Plane Three Dimensional Surfaces (General Case)! Single Plane Compute X, Y, Z of Every Corner of Every Slab Build Slabs and Subgrade Accordingly Set Slabs in Exact Locations!Warped Warped Plane Belt Parkway Jamacia, NY 2
3 Slab Design Geometric Design Slab Layout Vertical & Horizontal Curvature Superelevation Design Reinforcing Same as for Un-reinforced Pavement Design Thickness & Strength of Concrete Finish Load Transfer Devices Sub-Grade Joint Seals Reinforcing Options! None! Except for handling! Steel Reinforcing for Temperature and Shrinkage (ACI)! Fibers for Temperature and Shrinkage! Pre-stressing! Post Tensioning Precision Grading SuperGrading The process of grading fully-compacted bedding material to a surface accurate to + 3 mm Why SuperGrading?! Eliminates adjusting slabs after they are set! Simplifies and speeds up production! Slabs are set only once! Provides nearly complete subgrade support without grout! Allows early opening to traffic! Precise subgrade/slab contact completes bedding grout distribution system! Minimizes volume of bedding grout required SuperGrading Large Areas Supergrader Compact, Laser-Controlled (For Single or Warped Planes) SuperGrading Small Areas Hand Operated Grader (H.O.G.) Using adjacent concrete (or rails) for grade control (Under development) 3
4 Grouting Tie and Dowel Bars (2500 psi Before Opening to Traffic) Grout Distribution Channel Foam Gasket Bedding Grout (To fill any voids) (750 psi 24 hrs.) Grout Port Core Taken Through Transverse Dowel (Load transfer capacity verified by FWD tests) Grout Dowel Grout Inverted Dovetail Slot Proof Pumping Bedding Grout Continuous Full-Depth Replacement (During Off-Peak Hours) Rehabilitation of The Tappan Zee Toll Plaza Tarrytown, NY ( ) Precast Concrete Pavement Slabs-on on-grade 135,000 Vehicles per Day Project Particulars! 183,000 SF Pavement (4 Acres)! 135,000 Vehicles Per Day! Replace Pavement During Off-Peak Closures! Must be Open to All 13 Lanes of Traffic by 6:00 AM Each Day! $ 1300 per Minute Penalty After 6:00 AM 4
5 This (3,000 SF Per Eight Hour Shift) (Within + 3 mm) Traffic All Around (Taking 2-3 Lanes) While Maintaining This (135,000 Vehicles per Day) 3 D Supergrading Above 9A Ramp Tarrytown, NY All slabs warped All slabs trapezoidal (pie shaped) Traffic continuously maintained Intermittent Full-Depth Highway Repairs (Patching) (During Off-Peak Hours) Lincoln Tunnel The Port Authority of NY & NJ Friday Night - Saturday I-90 Albany, NY (2004) 105,000 Vehicles per Day Work Done 10:00 PM To 6:00 AM Contractor Value- Engineered Super-Slab Slab Over Rapid Set Concrete 5
6 Drilling For Dowels Two Bit Hydraulic Gang Drill Precision Grading Working on Rails (Notice Wheel Ruts) Setting Slabs 10 to 15 Slabs Per 8 hour Shift 5 to 7 Slabs Per 5 hour Shift Under Bridges Open to Traffic By 6:00 AM (Ungrouted Ungrouted) I-90 Albany, NY 378 Slabs in 47 Nights (48,000 SF +) Next Day (Ungrouted Ungrouted) In Half the Time Required for (Rapid Set) Cast-in in- Place Saw cutting M & P Traffic Removal Drill for Dowels Grading Grouting Dowels Setting Dowel & Bedding Grouting Hours A Typical Eight-Hour Night Operation Lessons Learned About Intermittent Patching! Make Standard Sized Slabs Cut (Accurate) Holes to Match! Faster to Leave Existing Subgrade Alone and Install Slightly Thinner Slabs! Existing Pavement Surface Difficult to Match! Because of wheel ruts and faulted slabs! Slabs Can be Opened to Traffic Without Grout for a Short Period of Time 6
7 So Far! 4.3 Lane Miles of Super-Slab Slab in Service! On 11 projects! 2.5 Miles in Service for Three Years! 85% Servicing over 100,000 VPD Summing it Up! It Works!! Contractors are skeptical! Until they do it! Pre-construction training a must!! For contractor s workmen, inspectors & owners! Development and Enforcement of specifications - challenging! You get what you inspect not what you expect!! Agencies need to discover how to! Justify it! Specify it Candidates for Super-Slab Slab Keys to Success (Still More to Learn)! Toll Plazas! Heavily Traveled Highways! Ramps! Pavement Under Bridges! Bridge Approach Slabs! Intersections! Airport Runways and Taxiways! Pedestrian Cross Walks! Structure Footings (Buildings, Bridges)! Joint Replacements! Weigh-in in-motion Stations - Good Engineering - Open Minds - Real Partnering The Fort Miller Co., Inc. P.O. Box 98 Schuylerville, NY Tel. (518) Fax. (518)
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