SR 600 (US 92) Concrete Slab Replacement Reconstruction Project with Precast Pre-Stressed. Florida Department of Transportation District Five

Transcription

1 SR 600 (US 92) Concrete Slab Replacement Reconstruction Project with Precast Pre-Stressed Florida Department of Transportation District Five

2 Project Overview Location SR 600 / US 92, Volusia County FPN: , Kepler Road (Start) FPN: , Tomoka River (End)

3 Overall Project Overview Rehab Project Only (4.5 miles), MP 2.7 to MP 7.2 Rehab and Reconstruction Project with Test Site (8.2 miles), MP 7.2 to MP 15.4 SR 600 / US RT 92 in Volusia County

4 Reconstruction Project Overview WB Raised Section: MP 9.2 to 11.1 (1.9 miles) Test Site : MP 9.42 to 9.57 (0.15 miles/793 ft) Test Site

5 Project History WB Lanes Constructed in 1940 s EB Lanes Constructed in 1970 s Shoulders Const. approx 1997 WB Lanes Flooded MP 9.0 to MP 10.5 (TBWMA to W. of Red John Dr) Test Section Located at MP 9.42 Numerous Individual Slab Failures

6 Show me the # s Clean/Seal Joints 364,603 LF Clean/Seal Random Cracks 3,804 LF Removal Existing Concrete Pavement 64,576 SY Plain Cement Pavement ,534 SY Concrete Pavement Slab Replacement 9,703 CY Grinding Concrete Pavement 299,503 SY Original Contract Amount $13,651, Original Contract Time 680 Days

7 Floodplain Zone A Elevation Not Determined

8 Drainage Investigations 25 Yr Flood Stage Elevations (MP 8.5 MP 12.3)

9 Existing Typical Section Crowned 12-18

10 Existing Typical Section MP 9.0 MP 10.5 WB Lanes Lower than EB 12 to 18

11 Pre-Construction Issues Lanes showing significant distress Never had true major rehabilitation (mostly localized slab replacements) WB Lanes experienced overtopping during significant storm events Ride quality deterioration

12 Causes of Pavement Distress Age (Loadings/67 yrs) Surface/Ground Water Fluctuations Weak Soils Slab Configuration (untied, 11ft x 20 ft) Joint Deficiencies (dowel corrosion, joint faulting, joint width, joint sealant) Differential Loading (slab length, edge stress/narrow lane, untied slabs, joint faulting/impact loading)

13 Typical Lane Pavement Distress

14 Pavement Rehabilitation Methods CONCRETE REHABILITATION Slab Replacements, Joint Reseal, Diamond Grind Finish NEW CONCRETE OVERLAY ON RAISED PROFILE Crushed Concrete Sub-base (recycled slabs) 2 Asphalt Overlay of the Crushed Concrete Sub Base Doweled Cast in Place Concrete Pavement NEW PRECAST POST-TENSIONED SLABS OVERLAY ON UNDISTURBED EXITING ROAD Undisturbed Existing Concrete Road Variable Asphaltic Overlay (platform) Precast Post-tensioned Concrete Pavement Diamond Grind finish

15 Pavement Rehabilitation Methods PPCS TEST on Raised Profile Area 793 ft of WB Lanes Build on top of existing slabs (undisturbed) 2 minimum asphalt layer (working platform, cross slope correction) Positive Drainage (non-erodible base, edge drain) Diamond Grind Finish

16 PPCS &Roadbed Draft Design

17 Key Design Considerations Roadbed or Road Foundation Model Fast Paced Construction Do Nothing to existing slabs regardless of condition Use Conventional Materials/Methods Widen with Minimal Effort but Maximum Benefits Upgrade Lane Widths Cross Slope Correction Non Erodible Base Model for Easy MOT & Construction Operations Stable Working Platform

18 Key Design Considerations For PPCS Components Minimize Field Assembly Difficulty Post Placement Poured Joints vrs Epoxy During Placement Stay within Asphalt Specs Tolerances Minimize Surface Irregularities External Bolsters Diamond Grinding Post Tension System Independent Operation

19 PPCS & Roadbed Final Design

20 Roadbed Components (Foundation)

21 Local Prestress Producer Dura-Stress, Inc. Leesburg, FL Florida Department of Transportation (FDOT) approved prestress plant (PCP )

22 Roles and Responsibilities Dura-Stress provides Quality Control (QC) FDOT in-house & consultants provide Quality Assurance (QA)

23 Plans & Shop Drawings Required concrete strength 5500 psi Reinforcing steel ASTM A615, Grade 60 Pre-stressing strand ASTM A416, Grade 270

24 Specified Tolerances Dimensions pre-pour and post-pour Range from 1/16 to ¼ (very tight)

25 Controlled Environment Indoor building

26 Forms Allowed wood face for smooth finish

27 Prestressing 31.0 kips per strand planned Measured and Recorded Bed Jack

28 Reinforcing Placement Inspected before concrete placement Chair Block

29 Post-Tension Ductwork Inspected before concrete placement Plastic Duct Block Wood (Keep Shape During Concrete Placement)

30 Concrete Production Dura-Stress provides concrete on-site FDOT Approved central mix batch plant (11-013) Use FDOT approved materials (i.e. cement, aggregates, etc.) FDOT inspects concrete batch plant quarterly Concrete transported short distance by Tucker built

31 Concrete Testing QC- every 50 CY or each day (plastic properties & strength) QA randomly test once for every four QC tests On-site Approved Laboratory (P11-013)

32 Concrete Placement Good slump & aggregate distribution

33 Concrete Finishing Meet tight tolerances

34 Concrete Finishing Medium broom finish Broom

35 Curing Blankets Ideal environment out of weather

36 Transfer to Storage Placed on flat bed truck in building

37 Storage

38 Loading & Shipping

39 Successes Partnering between producer, contractor, FDOT & FHWA Knowledgeable QC and QA staff at plant Using local approved producer Controlled environment for concrete and tight tolerances

40 Roadbed Components (Widening)

41 Roadbed Components (Working Surface)

42 Road Surface Components (PPCS)

43 Grouting of the PPCS

44 Full Width Construction

45 Box Culvert Cross Section

46 Box Culvert Replacement with Light Aggregate Fill

47 Slab Removal

48 Concrete Slab Removal

49 Drill for Dowel Bar Placement

50 Two Part Epoxy for Dowel Bars

51 Chairs for Larger Slab Replacements

52 6 Slab Ready for Concrete

53 Reinforced Concrete Slabs

54 Concrete Placement

55 Placing and Screeding of Slabs

56 Saw and Sealing of Expansion Joints

57 Final Component (Grinding)

58 Questions???