Rehabilitating Existing Pavements with Concrete Overlays Parking Lots

Transcription

1 Rehabilitating Existing Pavements with Concrete Overlays Parking Lots Guide to Concrete Overlays of Asphalt Parking Lots Jon Hansen Senior Vice President-Local Paving National Ready Mixed Concrete Assoc. Jan

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4 Old technology meets new methods Pinehurst Country Club-Denver CO 2015

5 Background of Concrete Overlays

6 The Blue Overlay Book

7 Many concrete overlay options F.K.A. Whitetopping (formally known as Whitetopping)

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9 How and Why Thinner Concrete Overlays Work Sawn Control Joints with Shorter Spacing Larger Joint Spacing-More Random Cracks Short joint spacing allows the slabs to deflect instead of bend. This reduces slab stresses to reasonable values.

10 How Bad Can They Be? Note Base Condition

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12 Concrete Over Brick

13 Environmental Hot Topics Before After

14 Concrete Parking Lots & Heat Island The Cameras Don t Lie Concrete Parking Garage Photos courtesy of the American Concrete Pavement Association

15 Economics

16 Material Cost- ENR 20 City Average

17 Why Contractor Outreach is Important

18 Why Contractor Outreach is Important

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20 Parking Lot Project Portfolio

21 Concrete Overlays: New life for existing parking lots without reconstruction

22 Project Profile Grimm Chevrolet Morton, IL Constructed: 2008 Scope of Work: 28 year old asphalt parking lot with one overlay and numerous patch and sealcoat 3 concrete overlay Design Factors: Asphalt alligator cracks with spot repair during it s life Car and light truck traffic Concrete: 4000 PSI No fibers Placement: Truss screed 4 x4 joint spacing early entry saw with narrow blade Full coverage white curing compound Spring 2009

23 Project Profile Armar Plaza Parking Lot Overlay Marion, IA Constructed: October 2009 Scope of Work: Existing 20+ year old asphalt parking lot 4 Inch concrete overlay 79,000 SF Design Factors: Deep asphalt ruts required thicker overlay Soft and broken surface layer asphalt Sand was used to fill and level rut area Concrete: 4000 PSI with cellulose fibers Placement: Truss screed placement Early entry saw cuts-thin blade 8 OC joint spacing typical July 2010 Update: Producer interview for info July 2011 Owner is very happy and has given reference for McGrath Auto Chevrolet dealer in Cedar Rapids, IA is considering same for his lot.

24 Project Profile Mile Miller Hyundai Peoria, IL Constructed: Summer 2010 Scope of Work: 25+ year old asphalt parking lot 3 concrete overlay Design Factors: Car parking and light truck traffic Concrete: 4000 PSI No Fiber Placement: Truss screed strip paving 6 x6 joint spacing-early entry saw Full coverage white curing compound 2010

25 Project Profile John Elway Chevrolet 5200 S. Broadway, Denver, CO Constructed: Phase 1 Oct 2011 Scope of Work: 3 concrete overlay on existing asphalt car dealership. Dealer has goal to be the greenest car dealer in Colorado and is using concrete overlays as part of that goal. Design Factors: Existing asphalt in typical condition in need of overlay. Minimal noticeable failures in base. Area behind building in dumpster area required total reconstruction due to drainage. Concrete: ACI 330 standard 4000 psi spec mix. Slump at placement 4-5 inch. No fibers. Placement: Placed by laser screed, straight edged, broom finish, full coverage white pigmented cure. Early entry saw cut joints 6 spacing max, T/3 depth, no joint sealant. Oct 24, 2011 Update: Oct 28, 2011 First phase (100,000 SF) of multi phase/multi location project. Contractor and subs refining their processes.

26 Project Profile John Elway Chevrolet 5200 S. Broadway, Denver, CO Constructed: Phase 1 Oct 2011 Scope of Work: 3 concrete overlay on existing asphalt car dealership. Dealer has goal to be the greenest car dealer in Colorado and is using concrete overlays as part of that goal. Design Factors: Existing asphalt in typical condition in need of overlay. Minimal noticeable failures in base. Area behind building in dumpster area required total reconstruction due to drainage. Concrete: ACI 330 standard 4000 psi spec mix. Slump at placement 4-5 inch. No fibers. Placement: Placed by laser screed, straight edged, broom finish, full coverage white pigmented cure. Early entry saw cut joints 6 spacing max, T/3 depth, no joint sealant. Oct 24, 2011 Update: Dec nd /final phase complete

27 Project Profile Russell Tyler Ruthton (RTR) High School Parking Lot Tyler, MN Constructed: Summer 2012 Scope of Work: 56,000 SF existing HMA 4 concrete overlay Design Factors: Car parking and light truck traffic Concrete: 4000 PSI Placement: Truss and roller screed strip paving

28 Hospital Group in Appleton, WI

29 Project Profile Ballwin Golf Course 333 Holloway Road, Ballwin, MO Constructed: October 2013 Scope of Work: 4 concrete overlay on existing asphalt parking lot. Design Factors: Existing asphalt in typical condition in need of overlay. Minimal noticeable failures in base. Area behind building in dumpster area required total reconstruction due to drainage. Concrete: ACI 330 standard 4000 psi spec mix with 1.5 lbs / cy of fibrillated fibers Placement: Placed by laser screed, straight edged, broom finish, full coverage white pigmented cure. Early entry saw cut joints 6 spacing max, T/3 depth, no joint sealant. 9/27/13 For More Information: Evan Bolesta Director of Marketing Concrete Council of St. Louis

30 Project Profile Ft. Zumwalt North Middle School and District Admin. Office O Fallon, Missouri Constructed: Summer, 2013 Scope of Work: 165,000 SF Design Factors: 4 Overlay 4 x4 Jointing BAX Engineering-Saint Louis Concrete: 4000 PSI Fibers Placement: Laser Guided Screed Contractor-VeeJay Concrete August 2013 Update: 2014 School district now programs a project every year For More Information: Concrete Council of St. Louis

31 Recent WY Project-Cam Plex Dave Gray-GCC

32 Apartment Complex in Joplin, MO Project photos by Jonah Weaver and Jay Taft

33 High School, Orange, CA Project photos by Bogh Engineering

34 A more viable option for parking lot owners is a technology called concrete overlay. New concrete is poured directly on top of an existing AC pavement. Concrete overlays offer significant long term cost savings for parking lot owners. Two key points include: * Concrete overlay lasts 20 years Alligator and Thermal Cracking, Potholes, Popouts, Raveling and Rutting from overuse normally associated with AC paving is eliminated. Concrete overlays are better suited for normal wear and tear from vehicles. Leaks from vehicles don t damage the surface. * Concrete overlay is a green solution. Concrete has a high solar reflectivity and absorbs less energy reducing heat. Urban Micro Heating is becoming a growing concern and Concrete parking lots can reducing the temperature around facilities thus lowering energy costs. It also creates a more luminous surface that reduces lighting requirements by as much as 50%. I would like to perform some field survey on the phase one of your parking lot improvements. This allows for feasibility determination early in the project (At no risk to the Owner). Listed below is a typical outline of our process. Also, below are before and after photos of a recent concrete overlay at Orange Lutheran High School, in Orange California.

35 Cantina Laredo Before After

36 Cantina Laredo In Between

37 New Pavement and Overlay-Same Lot

38 Pinehurst Country Club-Denver, CO

39 Pinehurst Country Club Parking Lot Rehabilitation

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41 Elements of Projects Master Plan Phases-As many as 5 Overlay on top of existing asphalt pavement Repair Sections before overlay Speed Control Swale Displaced Curb Tree root damage Full Depth Reconstruction

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43 Evaluation-Estimates of Scope of Work Concrete Overlay 80% Repair 10% Reconstruction 10% Other considerations for Pinehurst Project Lighting Permitting-Resurfacing/Reconstruction Storm Water Regulations Other code items now in place.-ada Our approach model..asphalt Industry

44 Typical Repair Areas

45 Other Enhancements Speed Control Swale Controls speed and directs water Curb Matching/Transition Details Milling Removal

46 Pinehurst Thickness Recommendations From Guide

47 Pinehurst Fall 2014

48 Pinehurst Fall 2014

49 Pinehurst Completed Spring 2015

50 Current Largest Overlay Parking Lot in U.S Northwest High School Cedar Hill, MO

51 Guide for Concrete Overlays of Asphalt Parking Lots

52 What is an overlay? Formally known as: Whitetopping Thin Whitetopping Thin Overlay

53 What is an overlay? Let s end the confusion.. Formally known as: Whitetopping Thin Whitetopping Thin Overlay Let s think about resurfacing with concrete

54 Points-To-Know Concrete overlays are a method to resurface existing asphalt paving-and then some: Renew the wear surface-black to white Increase the load carrying capacity of the pavement Improve lighting-reduce heat island Eliminate perpetual asphalt maintenance To give owners a choice Concrete overlays give support credit to the original asphalt construction for base and subgrade.

55 The Green Overlay Book

56 Part of a series

57 The guide is a technical document to be use by designers and contractors How to evaluate existing asphalt Determining overlay thickness based on 3 different zones. Car parking area Access roads Heavy duty truck Lanes Surface preparation Placement procedures and tools Joint layout guidelines Supplemental information for determining use fibers and dowels

58 Industry Team Lead Author-Dale Harrington, P.E., Principal Senior Engineer, Snyder and Associates, Inc. Co-Lead Author-Randell Riley, P.E., Illinois Chapter ACPA Contributing Technical Authors J. Dewayne Allen, Allen Engineering Jerry Holland, Structural Services, Inc. Nigel Parkes, PNA Construction Technologies Len Swederski, Swederski Concrete Construction Inc. Technical Advisory Committee J. Dewayne Allen, Allen Engineering Bryan Birdwell, Birdwell & Associates David Buzzelli, MCM Commercial Concrete, Inc. Tom Cackler, P.E., Director, CP Tech Ctr. John Cunningham, ICPA Dr. Norbert Delatte, Cleveland State University Sybil Ferrier, P.E. Construction Materials Testing Jon Hansen, NRMCA Jerry Holland, Structural Services, Inc. Nigel Parkes, PNA Construction Technologies Randell Riley, P.E., Illinois Chapter ACPA Gordon Smith, P.E., ICPA/IRMCA David Suchorski, Ash Grove Cement Company Len Swederski, Swederski Concrete Construction Lori Tiefenthaler, Lehigh Hanson

59 Zoned Parking Lot Design Areas Zone 3 Building Zone 2 Zone 1

60 Evaluation

61 Investigation

62 Thickness Determination Related to Region Midwest Region

63 Thickness Determination Related to Region East Coast Region

64 Thickness Determination Related to Region West Coast Region

65 Joint Lay Out

66 How To Details

67 More How To Details

68 Even More How To Details

69 Construction

70 Texturing and Curing

71 Sawing

72 Testing and Opening

73 Supplemental Information On. Fibers Plate and round dowels Strip paving or Block paving Surface prep-to mill or not to mill Clean and Dry Max Surface Temp-120 Joints-To seal or not to seal What works.and what to avoid

74 What one TAC member said on completion of the guide: The new document is a quantum leap for this field, for which I see spectacular potential in the coming years. I am planning on getting with my big clients and other commercial clients after it comes out to suggest they greatly increase their use of concrete overlays over their asphalt parking lots and specify the use of this document. Jerry Holland, P.E., F.ACI Vice-President & Director of Design Services Structural Services, Inc.

75 Guide to Concrete Overlays of Asphalt Parking Lots Free Download: Order Hard Copies:

76 Thanks to..

77 Rehabilitating Existing Pavements with Concrete Overlays Parking Lots Guide to Concrete Overlays of Asphalt Parking Lots Questions on overlays?

78 Questions on Concrete Overlay of Asphalt?

79 Questions?

80 NRMCA Design Assistance Program (DAP) for Parking Lots New, Overlays, Pervious, RCC Amanda H. Hult Director, Pavement Structures

81 What is DAP? Design Assistance Program-SLR and Parking Lot Teach by example Results in correct concrete design Does the heavy lifting for design engineers not familiar with concrete pavement design Provides a no or little cost second opinion Does not compete with local consultants

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83 What is on this site.. Who and How to submit project information Example of completed application Blank downloadable application Downloadable Parking Lot DAP Handout Information on JDAP (Jointing Plan Only)

84 What you will get back..

85 Sample Design

86 Thickness Recommendations

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88 CAD Jointing Plan

89 Jointing Plan Assistance Program-JPAP New offering just for contractors or designers

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