Concrete Overlays in Texas
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1 Concrete Overlays in Texas 90 th Annual Transportation Short Course October 12, 2016 Moon Won, P.E. Texas Tech University 1
2 Presentation Overview Concrete Pavement in Texas Overview of Concrete Overlays in Texas Performance of Concrete Overlays in Texas Current Efforts to Improve Concrete Overlays Summary 2
3 Lane Miles [mile] PCC Pavement in Texas 14,000 13,000 12,000 11,000 10,000 9,000 8,000 7,000 6,000 5,000 4,000 3,000 2,000 1,000 TxDOT PMIS 0 CRCP CPCD
4 General Concept in Current Overlay Type Selection Helga N. Torres., et al., Guide to the Design of Concrete Overlays Using Existing Methodologies, DTFH61-06-H (Work Plan 13), National Concrete Pavement Technology Center Institute for Transportation, Iowa State University,
5 Overview of Concrete Overlays in Texas Overlay Structures CPCD on CPCD CRCP on CRCP Thin PCP on CRCP CRCP on CPCD Overlay Thickness: 2-in to 12-in Interface Bonded Unbonded 5
6 Overview of Concrete Overlays in Texas Highway/Location Loop 610S/ Houston Loop 610N/ Houston Existing Pavement Overlay Type Overlay Construction Performance 8-in CRCP 2-in & 3-in BCO 1983 Satisfactory 8-in CRCP 4-in BCO 1986 Excellent IH 35/Denton 10-in CPCD 11-in CPCD 1988 Satisfactory IH 35E/Waxahachie 10-in CPCD 10-in CPCD 1990 Excellent IH 10/Beaumont 10-in CPCD 12-in CPCD 1994 Excellent IH 10/El Paso 8-in CRCP 6.5-in CRCP 1996 Mixed SH 146/Baytown 8-in CRCP 3-in BCO 1998 Early Failure US 281/Wichita Falls 8-in CRCP 4-in CRCP 2002 Excellent US 75/Sherman 10-in CPCD 7-in CRCP 2010 Mixed US 287/Bowie 8-in CRCP 4-in CRCP 2012 Premature Failure 6
7 Performance of Concrete Overlays in Texas Loop 610 South in Houston IH 35 in Denton IH 35 E in Waxahachie SH 146 in Baytown US 281 in Wichita Falls US 75 in Sherman US 287 in Bowie 7
8 1. S Loop 610 EB in Houston Harris County Completed in in & 3-in BCO 8-in existing CRCP Limits: From Doolittle Blvd to Calais Rd
9
10
11 2. IH 35 in Denton CSJ: Denton County Completed in in CPCD Overlay 220#/SY ACP Level Up 10-in existing CPCD IH 35 NB_Denton ,
12 1987 Typical Section (DAL-IH ) 11-in CPCD 6-in Roadbed Treatment Existing 10-in CPCD 1960 Typical Section (DAL-IH ) 10-in CPCD 6-in Roadbed Treatment (Type B)
13 13
14 03/23/ /20/
15 [mils] Load Transfer Efficiency Deflection Testing Average Deflection (D1) Average LTE Distance [ft]
16 Average Deflection [mils] 4.0 Statewide Average Deflection y = -3.61ln(x) R² = Slab Thickness [in] 16
17 3. IH 35E in Waxahachie Ellis County Completed in in CPCD Slab 1.4-in ACP 10-in existing CPCD
18 Pavement Structure (from LTPP database) 18
19
20 Load Transfer Efficiency 5 4 Deflection Testing Average Deflection (D1) Average LTE Distance [ft]
21
22 4. SH 146 in Baytown CSJ: XXX Harris County 3-in BCO (built in 1998) + 8-in existing CRCP 3-in BCO 8-in existing CRCP
23 23
24 24
25 5. US 281 in Wichita Falls CSJ: XXX Wichita County 4-in BCO (built in 2002) + 8-in existing CRCP (built in 1969, CSJ: ) 4-in BCO 8-in existing CRCP
26
27
28
29 29
30 Near the Construction Joint Deflection Data FWD
31 Near the Construction Joint Deflection Data FWD
32 Near the Construction Joint Deflection Data FWD
33 Near the Construction Joint Deflection Data FWD
34 Near the Construction Joint Deflection Data FWD
35 6. US 75 in Sherman From Travis Street in Sherman to FM 84
36 36
37 BCO 9,000 lbs [mils] CPCD 9,000 lbs [mils] Deflection (BCO vs CPCD) vs Distress CRCP (Mid Slab) CPCD (Joint-Mid Slab-Joint) Distress PCP CJ (J-45) J-31 J-76, 80, 86, 92, 93, 95, 96, 99, 101, 102, 104, 106, 107,110, 111, 112, 113, 114, 115, J Joint # Morning Section Afternoon Section 37
38 BCO Deflection of 9,000 Distress lbs [mils] [N] Distress Distribution Frequency [N] US75 - South Start at Exit U M D U M D U M D U M D A B B M D A A B A B U M D A B C C A A B C A B B C A B C D B C D A B C D U M D U M D U M D U M D U M D Joint Range Joint of # Joint # 38
39 J-110 J
40 7. US 287 in Bowie CSJ: XXX Montague County Overlaid with AC + 4-in BCO (built in Nov, 2012) + 8-in existing CRCP (built in 1972, CSJ ) Overlaid with AC 4-in BCO 8-in existing CRCP
41 Condition of Existing CRCP N W
42 ,000 lbs 35 FWD deflection Distance [ft] 42
43 Average Deflection [mils] Statewide Average Deflection y = -3.61ln(x) R² = Slab Thickness [in] 43
44 12/03/ /25/ /13/
45 STEP 1. D=2-in Coring STEP 2. Disk Attachment STEP 3. Testing Device Setup STEP 4. Loading and Pull-Out 45
46 Schematic of Pull-Off Test 46
![Bond Strength Test Results Test # Diameter of Core Specimen AREA Load Bond Strength GPS Coordinates D1 D2 D3 D4 AVE. D [in 2 ] [kn] [lb] [psi] [Mpa] N W #1 1.99 1.99 1.989 1.988 1.989 3.](/docs-images/90/102644864/images/47-1.jpg "11 FAILURE N 33 29 45.27 W 97 48 18.65 #2 1.977 1.977 1.967 1.97 1.973 3.06 2.35 528 173 1.2 #3 1.976 1.985 1.971 1.971 1.976 3.07 1.60 360 117 0.8 #4 1.957 1.969 1.983 1.966 1.969 3.04 2.")
47 Bond Strength Test Results Test # Diameter of Core Specimen AREA Load Bond Strength GPS Coordinates D1 D2 D3 D4 AVE. D [in 2 ] [kn] [lb] [psi] [Mpa] N W # FAILURE N W # # # # BASE BROKEN # FAILURE # # # # # # # # N W Failure [%] 14% Base Broken [%] 7% Analyzed Sample [%] 79% Average Bond Strength [psi] 186 Standard Deviation, SD [psi] 40 Coefficient of Variation, COV [%] 22% 186 psi 47
48 48
49 Current Efforts to Improve Concrete Overlays Research Project
50 General Concept in Current Overlay Type Selection Helga N. Torres., et al., Guide to the Design of Concrete Overlays Using Existing Methodologies, DTFH61-06-H (Work Plan 13), National Concrete Pavement Technology Center Institute for Transportation, Iowa State University,
51 Current Efforts to Improve Concrete Overlays Research Project Threshold values for BCO/UBCO Improved design procedures AASHTO UBCO too conservative Construction specifications 51
52 Summary TxDOT has many miles of PCC pavement that already exceeded or are approaching design lives. Concrete overlays could provide a cost-effective rehabilitation method. Overall, the performance of concrete overlays in Texas has been quite satisfactory, with some exceptions. Efforts are underway to further improve PCC overlay design/construction practices. 52
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