JOINTED PCC PAVEMENTS

Transcription

1 JOINTED PCC PAVEMENTS REINVENTING THE OLD APPROACH Hua Chen, P.E Rigid Pavements and Concrete Materials Branch Construction Division, TxDOT 2014 Short Course

2 Jointed PCC Pavements - Jointed Portland Cement Concrete Pavements Jointed Concrete Pavement (JCP) Jointed Plain Concrete Pavement (JPCP) In Texas, Concrete Pavement Contraction Design (CPCD) CPCD = JCP = JPCP 2

3 Table of Contents 1 Background Current Statewide CPCD Conditions CPCD Memo 2014 CPCD Standard Summary of Success

4 CPCD Under Construction CPCD After Concrete Paving Tie Bars Dowel Bars ACP Base CPCD Before Concrete Paving 4

5 National Level Usage of CPCD 5

6 Texas Usage of CPCD TxDOT has started to use CPCD since 1930 s. TxDOT has began to construct CRCP since 1950 s. 6

7 Oldest CPCD Sections in Service District County Highway Construction Pavement Thickness P_Age Year Type (in.) BMT-US59_ Beaumont Jefferson US CPCD 6 BMT-US90_ Beaumont Orange US CPCD 7.5 DAL-SH183_ Dallas Dallas and Tarrant SH CPCD 8 DAL-SL12_ Dallas Dallas SL CPCD 9 BMT-SH87_ Beaumont Jefferson SH CPCD 9 DAL-US Dallas Denton US CPCD 10 DAL-US Dallas DENTON US CPCD 10 DAL-US Dallas Denton US CPCD 10 DAL-US Dallas Denton US CPCD 10 DAL-US Dallas DENTON US CPCD 10 DAL-US Dallas DENTON US CPCD 10 BMT-US90_ Beaumont Jefferson US CPCD 11 DAL-IH Dallas Denton IH CPCD 10 BMT-IH10_ Beaumont Jefferson IH CPCD 9 BMT-SH347_ Beaumont Jefferson SH CPCD 10 DAL-IH Dallas Denton IH CPCD 10 BMT-SH124_ Beaumont Chambers SH CPCD 10 BMT-SH73_ Beaumont Jefferson SH CPCD 10 BMT-SH124_ Beaumont Chambers SH CPCD 10 BMT-US90_ Beaumont Jefferson US CPCD 10 Moon Won, P.E. 7

8 8

9 9

10 CPCD Lane Miles and Conditions In

11 CPCD Lane Miles In 1985 PES Percentage Mileage 1985 Report of Mileage Evaluated Total Mileage Percent ACP 35.53% 25,816 72, % CRC 55.07% 1,346 2, % JCP 21.83% 352 1, % Total 76, % 60% of Texas Concrete Pavement was CRCP 40% of Texas Concrete Pavement was CPCD 11

12 CPCD Condition In 1980 s 12

13 2000 Memo Selection of Concrete Pavement Type 13

14 CPCD Usage in Recent Years Pavement Type FY 05 FY 08 Letting Lane Miles FY 09 - FY 13 Letting Lane Mils Total CRCP 2,719 4,183 6,902 JCP ,902/13,572 =50.8% After construction, about 50% CRCP on our network is less than 10 yrs old. 208/ 3,727 =5.5% After construction, about 5.5% JCP on our network is less than 10 yrs old. The three longest Interstate highway in Texas are: IH10 (878.6 miles), IH20 (636 miles, and IH35 (503.9 miles) 14

15 CPCD Lane Mile History Pavement Type 1985 MainLane Mileage 1995 Lane Miles 2005 Lane Miles 2014 Lane Miles ACP 72, , , ,842.8 CRCP 2,444 6, , ,572.7 JCP 1,612 2, , ,727.6 Statewide 76, , , ,

16 2. Current Statewide CPCD Conditions Lane Miles Percent Pavement Type Flexible or Asphalt concrete Pavement (ACP) 179, , , , % Continuously Reinforced Concrete Pavement (CRCP) 13, , , , % Jointed Concrete Pavement (JCP) 3, , , , % STATEWIDE 196, , , , % of Texas Concrete Pavement is CRCP 22% of Texas Concrete Pavement is CPCD 16

17 CPCD Conditions PMIS FY 2010 to FY

18 CPCD Ride Scores PMIS FY 2010 to FY

19 Lessons Learned CPCD Sections were placed directly on subgrade CPCD Sections were constructed without dowel bars CPCD Sections were constructed without tied concrete shoulder Many CPCD sections are still under traffic beyond their design life. 19

20 Memo Criteria for Use of CPCD 20

21 3. Criteria for Use of CPCD For roadways with design traffic of 40 million Equivalent Single Axle Loads or less For frontage roads where CRCP is difficult to construct due to numerous leave-out sections For roadways controlled and maintained by another government entity For parking areas or roadways with crosswalks, adjacent parking, or sidewalks For railroad crossings, approaches to structures or to widen existing jointed pavement For intersections and approaches in flexible pavement roadways that are associated with vehicle braking and acceleration which could cause shoving and rutting of an asphalt pavement 21

22 Factors Where/When CPCD CRCP Heavy Truck Roadway Traffic Level Medium Truck Roadway Low Truck Roadway Construction Flexibility Under Traffic Frontage with Numerous Leave-outs Intersection/ Crossings Material Sources Use Local Coarse Aggregates with High COTE for Low/Medium Truck Roadway Support Condition Natural Subgrade with Higher Risk for Heaves On Embankment with Higher Risk for Void under Slab 22

23 Cost Information from Site Manager FY 09 to FY 13 Item Description Number of Projects Avg.Bid Price total SY CONC PVMT (CONT REINF-CRCP)(10") ,836,196 CONC PVMT (CONT REINF-CRCP)(8") ,809,999 CONC PVMT (CONT REINF-CRCP)(9") ,264,845 CONC PVMT (CONT REINF-CRCP)(13") ,909,985 CONC PVMT (CONT REINF-CRCP)(12") ,118,267 CONC PVMT (CONT REINF-CRCP)(11") ,153,226 CONC PVMT (CONT REINF-CRCP)(15") ,927,197 CONC PVMT (CONT REINF-CRCP)(6") ,764 CONC PVMT (CONT REINF-CRCP)(14") ,260,931 CONC PVMT (CONT REINF - CRCP)(7") ,442 CONC PVMT (CONC REINF - CRCP)(11.5") ,184 CONC PVMT (CONT REINF-CRCP)(10.5") ,727 CONC PVMT(CONT REINF-CRCP)(7.5") ,844 CONC PVMT (CONT REINF-CRCP)(9.5) ,518 CONC PAV (CONT REINF-CRCP)(8.5") ,284 CONC PAV (CONT REINF - CRCP) (6.5") ,982 Total Letting CRCP = ,445,391 23

24 Cost Information from Site Manager FY 09 to FY 13 Item Description Number of Projects Avg.Bid Price total SY CONC PVMT (JOINTED-CPCD)(9") ,984 CONC PVMT (JOINTED-CPCD)(8") ,680 CONC PVMT (JOINTED-CPCD)(10") ,249 CONC PVMT (JOINTED-CPCD)(12") ,774 CONC PVMT (JOINTED-CPCD)(13") ,632 CONC PVMT (JOINTED-CPCD)(11") ,649 CONC PVMT (JOINTED)(15IN) ,832 CONC PVMT (JOINTED-CPCD)(6") ,396 Total Letting CPCD = ,195 24

25 Estimated Cost Items CPCD w/same Coarse Aggregate CRCP w/ Same CoarseAggregate Unit Quantity Unit Cost Total Cost Quantity Unit Cost Total Cost Coarse Aggregate for Concrete ton 2,930 $30.05 $88,032 2,930 $30.05 $88,032 Concrete w/o Coarse Aggregate yd3 3,499 $45.00 $157,450 3,499 $45.00 $157,450 Total Concrete Cost yd3 $245,481 $245,481 Dowel Bar each 7,744 $11.25 $87,120 0 $0.00 $0 Sawcutting lane-feet 8,424 $4.96 $41,783 5,280 $4.96 $26,189 Joint Clean and Seal lane-feet 8,424 $1.97 $16,595 5,280 $1.97 $10,402 Steel Reinforcement (#5, #6, Tie ton 5.50 $1,400 $7, $1,400 $271,432 Labor, Equipment & Overhead yd2 14,080 $15.30 $215,424 14,080 $16.16 $227,533 Total Construction Cost $614,104 $781,037 Unit Construction Cost /yd2 $43.62 $ ft x 24 ft 9 in. Slab Project Worksheet 25

26 CPCD Statewide Standard Design concept and structural responses of CPCD and CRCP are quite different. In CPCD, concrete volume changes are allowed to a full extent, and accommodations are made to ensure good load transfer at discontinuities, i.e., transverse contraction joint. Slab Thickness Slab Size Dowel Bar Size Base Support 26

27 Thickness Design for CPCD AASHTO 1993 Pavement Design Procedure Design Criteria: Performance Period (30 years) Initial and Terminal Serviceability (Difference of 2.0) Design Reliability (95%) Concrete Properties: 28-day Concrete Modulus of Rupture (620 psi) 28-day Concrete Elastic Modulus (5,000,000 psi) Traffic: ADT and one-way total 18-kip ESALs are provided by the Transportation Planning and Programming (TPP) Division. Reliability 90% when ESALs <= 5 million 95% when ESALs > 5 million Load Transfer Coefficient J J = 2.6 for CRCP J = 2.9 for CPCD 27

28 Base Support for CPCD Field performance evaluations of concrete pavement have revealed that the soundness of the base is essential to the longterm performance of concrete pavement. If the base underneath the concrete slab does not provide good support, long-term pavement performance will be severely compromised regardless of the concrete slab thickness. TxDOT recognized this and requires one of the following base layer combinations for concrete slab support: 4 in. of asphaltic concrete pavement (ACP) or asphalt stabilized base (ASB) or a minimum 1 in. asphalt concrete bond breaker over 6 in. of a cement stabilized base. 28

29 CPCD-14 : Concrete Pavement Contraction Design Standard 29

30 CPCD-14: Slab Size Right size of CPCD slab will accommodate concrete volume changes and minimize any random cracks. Slab length to width ratio <1.5, as square as possible Regular slab length =15 ft. Regular slab width = Lane width (12 ft.) Max.15 ft. width 30

31 CPCD-14: Slab Size 31

32 CPCD-14: Dowel Bar Size 32

33 CPCD-14: Tied Concrete Shoulder 33

34 Website Address for Concrete Pavement Standards TxDOT website Select Business Scroll to Resources Select Statewide Standard CAD Files Click I accept Select Roadway Standards Scroll to the Pavements

35 5. Summary of Success Adequate Slab Thickness Uniform and Sufficient Base Support Project Specific Joints Layout Install Dowel Bars Timely Saw-cut at Dowel Bar Locations and at Longitudinal Joints Use Tied Concrete Shoulder 35

36 CRCP for Heavier Traffic Roadways Longitudinal Joint CRCP after Concrete Paving CRCP before Concrete Paving Transverse Steel Tie Bars Longitudinal Steel 4 ACP Base 36

37 Rigid Pavement and Concrete Materials Branch Construction Division, TxDOT Andy Naranjo, P.E. Branch Manager (512) Hua Chen, P.E. (512)