Case Studies - Concrete Overlays
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1 Case Studies - Concrete Overlays Lessons Learned - Concrete Overlays Purdue Road School March 6, 2013
2 Today s Topic 1. Overlays 2. New Full-depth 3. Pervious 4. Roller Compacted 5. Full Depth Patching 6. Partial Depth Patching 7. Diamond Grinding
3 What are we talking about?? Concrete overlays over old concrete Concrete overlays over old asphalt pavements Concrete overlays over old composite pavements
4 What Know or Have Learned Cost Competitive Long Lasting Versatile Traditional Construction Constructed Rapidly Sustainable Wide Spread Use Across Country
5 Competitive
6 Traditional Construction
7 Traditional Construction
8 Constructs Rapidly Single pass full depth
9 Constructs Rapidly Bremen Highway Joseph Co., IN Bonded Overlay 4 PCCP Inlay 24 wide 0.9 mi. Paved in 1 day
10 Sustainable Local Materials Recycled materials One-pass placement Longevity, fewer cycles Light reflective Mitigates Heat Island effect
11 Widely Used Across the Country
12 How do we know? Let s look at a few projects
13 Indiana s Concrete Overlays Local Streets/Roads Airports Interstate Highway State Highway
14 Indiana Overlays Local Roads Harding Street Indianapolis st Street Fishers Indianapolis Bus Lanes Allisonville Rd N. of 96 th th Street Brownsburg Market & Columbia Warsaw Rudisill/Broadway Inter. Fort Wayne Bremen Highway St. Joseph Co
15 Indiana Overlays Interstate and State Routes Interstate and State Routes I 69 North of SR I 65 North of SR West of SR I 70 at US 27 Richmond SR 161 Dubois Co
16 Indiana Overlays Airports Madison Airport Apron Grissom AR Fueling Apron Delphi Runway Elkhart Runway Jasper Co. Runway Columbus Runway
17 INDOT Research HPR-2064 Life & Cost Analysis of Three Rehabilitation Techniques on I-65 Between SR 2 & SR 114
18 I-65 Pavement Rehab Comparison LIFE AND COST COMPARISON OF THREE REHABILITATION TECHNIQUES ON I-65 BETWEEN SR-2 AND SR-114
19 3 Rehabilitation Techniques Crack and Seated Fiber modified HMA overlay on cracked and seated concrete miles Rubblized HMA overlay on the rubblized concrete miles Unbonded Concrete Overlay on 30mm intermediate HMA layer on the existing concrete miles
20 I-65 Rehab Options MP Concrete Overlay Built $239,800/center line mile MP HMA Overlay over Rubblized old Concrete Pavement Built $236,000/center line mile 2000 route & seal cracks - $17,200/cl mile 2010 Mill 2 & overlay $96,800/cl mile MP HMA Overlay over crack & seated old concrete pavement Built 1993 & $180,500/ center line mile 2000 route & seal cracks - $17,200/cl mile 2008 mill & overlay all HMA - $355,942/cl mile
21 I-65 Rehabilitation Options 7.5 HMA Overlay over crack & seated PCCP Built 1993 & 1994 Route & seal cracks Mill all HMA & overlay years service - $18,455/center line mile/year of service 2009 contract to mill 7.5 & overlay
22 I-65 Rehabilitation Options 13 HMA Overlay over Rubblized old PCCP Built 1994 Route & seal cracks 2000 Mill 2 & 2 HMA overlay July years service - $11,667/center line mile/year of service 2010 contract to mill 2 & overlay
23 I-65 Rehabilitation Options Concrete Overlay Still Like New condition 30 years service - $7993/center line mile/year of service No Rehab contracts to date route & seal 2014??
24 2004 Findings and Implementation Unbonded concrete overlay is a very effective rehabilitation technique for eliminating reflection cracks. Annual visual condition surveys suggest that concrete segment has better performance than the rubblized and cracking and seating segments. Life cycle cost analysis suggests that concrete segment is the most cost effective Unbonded concrete overlays are viable rehabilitation techniques which should be employed on appropriate highway sections.
25 Example Projects Bremen Highway Joseph Co., IN Bonded Overlay 4 PCCP Inlay over milled HMA Built: July 2007
26 Bremen Highway Alternate Bid Results Option Low Bid A. 4 HMA $217, B. 6 PCCP $309, C. 4 PCCP $244,300.25
27 Bremen Highway Mill 4 out & sweep surface Fill with 4 PCCP 24 Wide, single pass 0.8 mile long
28 Bremen Highway Standard Finishing & Texturing Saw Cut 4 x4 Panels
29 Bremen Highway Excellent Results
30 SR 161 (INDOT RS A) 6 PCCP Overlay 3.77 Miles long 71,000 SY
31 INDOT Specification 509 SR 161, Dubois County
32 What Have Learned - Contractor Don t be afraid of different practice Don t make too complicated Basic straight forward construction practices Traffic control plan on project was very manageable non-issue Profitable good work
33 What Have Learned Don t over engineer Cost competitive Don t need dowels Don t need tie bars Keep panels sized properly Joints single cut - unsealed Keep it simple
34 SR 161 Scarify/profile mill Pave one lane at time
35 SR 161 Maintain local traffic one way
36 SR 161 Bid Tab: $14.00/SY $2.33/sy/in ($42.36/Ton Equivalent)
37 Urban Arterial Allisonville Road th Street to Eller Road
38 Project Information Traffic: 26,360 vpd Existing 24 asphalt pavement Scope: widen to outside maintain traffic mill & overlay existing
39 Pavement Design PCCP plain, non-doweled with skewed joints overlay: 7 1/2 PCC widening: 10 1/2 PCC on 4 #53 aggregate base Lime treated subgrade HMA overlay: 5 HMA widening: 15 HMA Lime treated subgrade
40 Allisonville Road Cross Section
41 Allisonville Road 7 ½ PCCP Overlay of old asphalt with 10 ½ PCCP full depth widening Built: 1999
42 Airports Delphi Runway PCC Overlay of old HMA wide Delphi Municipal Airport
43 Design Concrete Overlay 5 Plain Concrete Pavement placed over existing asphalt runway Transverse joints 12-0 Longitudinal joints 10-0 All joints sawed, beveled and sealed Outside longitudinal joint and the 3 transverse joints at north and south ends of runway tied with ½ deformed bars spaced 3-0 c-c As constructed concrete overlay averaged 5.75
44 Project Bid Tabs Base: FDR w/ HMA Overaly $912,999.85
45 Project Bid Tabs Alternate: Concrete Overlay $715,935.58
46 Surface Preparation
47 Placement
48
49 Finishing
50 Curing
51
52 Sawing
53 Notice crack & broom finish
54 Concrete Overlays - Resources www. Information on over 275 PCCP overlays
55 DESIGN SPREADSHEET
56 What Have We Learned Cost Competitive Long Lasting Versatile Traditional Construction Constructed Rapidly Design & Tech Guidance Tools Available Wide Spread Use Across Country
57 Questions? Contacts for further information INDIANA CHAPTER
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