Concrete0709 PDF
Concrete0709 PDF
Concrete0709 PDF
Rehabilitation Techniques
By
Robert W. Sauber
Supervising Engineer II
July 2009
Bureau of Materials
NJDOT
Business as usual will not
work !
Pavement Performance
Business as Usual
Will not Work !
Preventive Maintenance
Applying the right treatment… To the right pavement… At the right time…
PRICING COMPARISON
H.D.P. vs. Replacement
100
80
60
Percent
40
20
H.D.P. Replacement
TENSILE STRENGTH
H.D.P. vs. CONVENTIONAL GROUT
160
140
120
Tensile Strength
100
H.D.P.
80
Convential
60
40
20
0
0 1 2 3 4 5 6
Density, lbs./ft3
Hot--Pour Joint Sealants
Hot
Key Factors
Field control of heating
– 175-200°C (350-400°F)
– Double boiler
– Agitation
– Insulated hoses
Shape factor (filler/sealant)
Clean and dry sidewalls!!
Material selection, ASTM
6690 Type 2 or Type 4
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.
.
. . .
Transverse Joint Spalling
Removal of Concrete with Demolition Hammer
Repair Area after Sawing & Chipping
Compressible Joint Insert
Rt 21 TechCrete
p/d synthetic resin patch
Full Depth Slab Repair
Rt 295 South Jersey
The volume of heavy trucks is projected to
increase 3% each year over the next 20 years
Sawing Boundaries
Combine Patches!!
Liftout
Pin and Chain
Torque Claw
Lateral Pressure
Self--Propelled Slab Reference
Self
Injecting Epoxy Grout
Placement of Bond-
Bond-Breaking Board
Concrete Placement
Finishing
Texturing
Why Precast PCCP in NJ?
Precast concrete has quickly become the
preferred method for intermittent full depth slab
repair, contractors and RE’s like it.
Portland cement fast track mixtures require 6.5
hr cure, are temperature sensitive and
have questionable long term durability
Polymer concretes are too expensive
Some hydraulic cements perform well but
require calibrated mobile mixers and on site
strength testing
Why Precast PCCP in NJ?
Cast in place requires on site flexural beam test
that require agency staff and equipment
Some concrete plants don’t want to open at night
for only a few loads of concrete
Some towns prohibit concrete plants from
operating at night
Precast is more expensive than cast in place fast
track and cost competitive with proprietary
hydraulic cement mixtures
Precast has better quality control because slabs are
cast in a controlled environment
NJDOT’s Experience
with Precast PCCP
Route I-295 Burlington County (completed)
– $8.7 million total, *$2.4 M for slab repairs
– Award 9/1/06 Precast Qty 62,000 SF
Route 21 Essex & Passaic Co. (completed)
– $9 million total, $2.3 M for precast slabs
– Letting 1/31/08 Precast Qty 44,000 SF
Route I-280 Essex County (active)
– $21.6 million total, $2.6 M for precast slabs
– Award 6/5/08 Precast Qty 38,000 SF
NJDOT Precast PCCP
Groove
Hard Soft
Range Aggregate Aggregate
Grooves 2.25-3.75 mm 2.50-3.75 mm 2.50-3.75 mm
Land Area 1.50-3.25 mm 2.00 mm 2.50 mm
Height 1.50 mm 1.50 mm 1.50 mm
10.0
9.0
8.0
7.0
6.0
S N e ff
5.0
4.0
3.0
2.0
1.0
33.6 33.7 33.8 33.9 34.0 34.1 34.2 34.3 34.4 34.5
Milepost
Maximum Normalized Deflections for Route I-295 Northbound & Southbound Left Lanes After
Rubblization, After 3 in. Overlay, and After 14 in. Overlay
100.0
90.0
80.0
70.0
D 0 (m ils )
60.0
50.0
40.0
30.0
20.0
10.0
0.0
33.6 33.7 33.8 33.9 34.0 34.1 34.2 34.3 34.4 34.5
Milepost
NJDOT’s second project
Route I-78 Union & Essex Counties
Accelerated schedule with incentive
Union Paving awarded bonus for early
completion
Full depth reconstruction areas require
undercuts, cost overruns
Multi-Head Breaker used
Rutgers performed PSPA testing
Route I-
I-78 Essex & Union
Counties
Route I-
I-78 Essex & Union
Counties
Route I-
I-78 Essex & Union
I-78 MP 54 Sept ‘06
Rubblized and compacted PCCP
Cross section of rubblized PCCP
Portable Seismic Property
Analyzer (PSPA) for soils
Route I-
I-78 PSPA Test Results