Airfield Pavement Rehabilitation

CONCRETE AIRPORT PAVEMENT WORKSHOP ATLANTA, GA NOVEMBER 5, 2009

Topics Covered

Joint/crack maintenance
Joint/crack resealing
Repair/restoration
Partial-depth repair
Full-depth repair
Surface issues
Diamond grinding /
grooving
Joint/Crack Maintenance

Joint/crack resealing:
Reduces potential for F.O.D. caused by surface spalling
Increases pavement life

Minor Serious
Sliver Spalling Compression Spalling

Up to 1/4-inch

Will not affect p

performance Will not p
provide reasonable
of new sealant surfaces for sealing
4
Joint/Crack Resealing

Sealant design
Environment
Life-cycle cost
Performance S l t Nozzle
Sealant N l

Joint type
Joint spacing

Backer Rod
Reservoir
Reservoir Design

Joint movement
L = C x L ( x T + )
L = expected slab length change
C = slab/subbase friction restraint factor
L = slab length
= concrete coefficient of thermal expansion
T = maximum temperature change
= concrete shrinkage coefficient
Overview - Temperature Effects

A 60F temperature variation results in the following

change in slab length:
10-ft slab: 0.042 in
40-ft slab: 0.170 in
This movement accounts for expansion of the PCC due to
temperature and contraction due to drying shrinkage
Sh
Shape Factor
F t
Liquid
q sealant
Width
1/4 to3/8 in.

Shape Factor =
Depth
Depth/Width

Sealant
Hot pour = 1.0
Silicone = 0.5
Backer rod
10
11
12
Blade for Slight Widening

1/2 in. mm
Blade
3/8 in.

Old Sealant Sawing out the old Sealant

13
Main Cleaning Steps

Water wash to remove slurryy

Lightly sandblast to remove remaining residue
Air blow to remove sand,
sand dirt and dust

14
Sandblasting the Joints

15
Cleanliness Test
17
Backer Rod Installation

Must be compatible
p with liquid
q sealant
Backer Rod is used to help define the shape
factor

19
Dual-wheel backer rod roller

Handle

Insertion Wheel

Reservoir Backer Rod

20
Installing Liquid Sealant

Dry reser
Dr reservoir
oir wall
all
Uniform sealing
1/4 to
t 3/8 in
i recess
Proper heating
t
temperature
t vital
it l
Inspection after
installation
Installing Compression Seals

Application of
lubricant/adhesive
Mechanically
compressed and
inserted
Resealing Cracks

More difficult to:

Shape
Clean
Seal
Do not expect uniform reservoir
Same cleaning steps
M use tape iinsteadd off bbacker
May k rodd

27
Crack Saw Equipment

Do not use large-diameter

g blade
May overheat
Mayy lose segments
g
May endanger operator
Use pivoting crack saw with small-diameter blade
8 inch crack saw blade
Flexible to help trace wander
Resealed Crack
Guide for Concrete Cracks

upp to 1/4 in Leave alone

1/4 to 1/2 in Route and Seal
3/8 to 3/4 in(S) Partial Depth Repair
3/4 to 1 1/2 in Route and Seal
3/4 to 1 1/2 in (S) Full Depth Repair
More than 1 1/2 in Full Depth
p Repair
p
Sealant Performance Factors

Sealant Performance Depends

p On:
Design Factors
Sealant Selection
Joint Preparation
Sealant installation
36
37
38
KEYS TO SUCCESS

MONITOR JOINT CLEANING PROCESS

CHECK JOINT CLEANLINESS
MEASURE DEPTH OF JOINT
CHECK SEALANT THICKNESS
CHECK RECESS DEPTH
OBSERVE BACKER ROD INSTALLATION
TEST SEALANT BOND
CHECK MATERIAL EXPIRATION DATES

39
Partial Depth Repairs

Repairs localized distress in the top 1/3 of the slab

Generallyy located at jjoints,, but can be pplaced anywhere
y
surface defects occur

.
. . .

41
Transverse Joint Spalling

42
Defining Repair Boundaries

50-150 mm min. 50-150 mm min.

Patch
Spall

50 mm ((min.)) - t/3 ((max.))

43
Finding Unsound Concrete

Sounding the pavement:

Hammer
Steel rod
Steel chain

DULL SHARP

Unsound-Delaminated Solid

44
Sounding the Pavement

45
Removing Bad Concrete

Sawing and chipping

Carbide milling
Transverse
Longitudinal
g

46
47
Chipping

Break to minimum depth

p of 2 in
30 lbs maximum hammer
15 lbs hammer preferable for control
Spade bits preferable to gouge bits
Do not expose dowels
Removal of Concrete with Jackhammer

49
Cleaning

Sound to check for weak spots before

cleaning
Chip out with 15 lb hammer if necessary
Sandblast bottom and sides
Sounding for weak spots

51
Sandblasting

52
Cleaning

Airblow to remove dust & debris

Direct away from patches
Use 90 lbs minimum air pressure
Oil & moisture filters required
Check with clean cloth
Backpack blowers acceptable
Blowing Compressed Air to Remove Debris

54
Compressible Insert

3 in min. Spall

Patch

Compressible insert

1 in
57
Joint Insert

Separates
p ppatch from adjacent
j lane
Reforms joint reservoir
Provides uniform sealing reservoir
Acceptable materials:
Styrofoam
S f
Asphalt-impregnated fiberboard
Fiberboard

58
If Insert Not Used

Point Bearing

Popout & Breakage

J i t Closure
Joint Cl Debonding
Expansion Expansion
61
Patch Materials

Normal Set PCC

High-Early Strength PCC
R id St
Rapid Strength
th Proprietary
P i t Materials
M t i l
Epoxy Resin Mortar or Epoxy Concrete
Material Selection

Depends on:

Time available before opening to traffic

Air temperature during construction
Funding
Desired service life
Size & depth of patches

63
64
KEYS TO SUCCESS

Limit use to top 1/3 to 1/2 of slab

Soundingg and Markingg of Area
Minimize Overcuts
Removal of old Concrete
Cleanliness of Hole
Material Expiration Dates
Depth of Joint Inserts
Curing Application
Full Depth Repairs

Repairs distresses greater than 1/3 the slab depth.

depth
Consists of removing and replacing at least a portion of
the existing slab to the bottom of the concrete.
concrete

. Completed Patch
.

Patch under
Construction
Design of Full-Depth Repairs

Considerations:
Patch Size
Load Transfer
Concrete Materials
Construction of Full-Depth
R
Repairs
i

Isolate deteriorated area

Remove old concrete
Repair sub-base (if necessary)
Provide load transfer
Place & finish new concrete
Cure concrete
Saw & seal perimeters
Full Depth Repairs

06m
0.6
Minimum repair 2 feet
Full depth cut at joints
Diamond blades
Tie to existing slab Tiebars

Joints
Sawing Boundaries

Use diamond bladed saws

Saw full
full-depth
depth through the joints so base
of blade reaches boundary
IIsolate
l t ttransverse, llongitudinal
it di l andd
shoulder
Provide pressure-relief cut within patch if
saws bind
75
 Carbide-Tooth Wheel Saw
Only for:
Pressure relief cuts
C t along
Cuts l asphalt
h lt shoulder
h ld
Pressure Relief Cuts

77
Removal

Liftout
Lift pin and chain
F klift
Forklifts
Torque claws
Lateral-pressure lifts
Breakup
Handheld pneumatic hammers
Drop hammers or hydraulic rams
 Liftout
Pin and Chain

Torque Claw

Lateral Pressure
Liftout Damage
84
Gang Drill Dowel Holes
(slab surface reference)
Gang Drill
(base reference)

86
87
Cleaning Holes (Air Blast)

88
 Dowel Bar Placement
for Full Depth Repairs

Existing slab
Thin circular disk Anchoring material

Hole dia. = d+a

Repair area
d = dowel diameter
Subbase a = 1/8 in for epoxy
a = iin for
f cementt groutt

Subgrade Soil
1 Inject Grout
to Back of Hole

Twist one turn

2 while pushing
in dowel

Place grout
3 retention disk to
hold in grout
KEYS TO SUCCESS

SIZING AND MARKING OF SLAB

DOWEL HOLE DEPTH AND CLEANLINESS
DOWEL ALIGNMENT AND LOCATION
DAMAGE FROM SLAB REMOVAL
SIZE OF OVERCUTS
CLEANLINESS OF REMOVAL AREA AND SEALANT
REMOVAL
KEYS TO SUCCESS

PROPER PLACING OF EPOXY IN DOWEL HOLE AND

DOWEL INSERTION
EPOXY EXPIRATION DATE
DOWEL BAR LUBRICATION
CHECK CONCRETE BATCH TICKETS
DOWELS IMMOBILE BEFORE PLACING CONCRETE
CURING COMPOUND APLICATION
Diamond Grinding

Removes
Remo es roughness
ro ghness
Removes polished
concrete surface
Removes rubber build-
up

98
Polishing / Rubber Build-Up

Numerous
rubber
bb removall
operations can
polish and/or
p
remove the
pavement
surface
102
 Basic Components
Hydraulic Cylinder Grinding Machine Frame

Trailing Bogies Leading Bogies

Subframe
Depth-Control
Depth Control Wheels
Grinding Head
103
Selecting Saw Blades

Choose blades with

appropriate:
Bond hardness
Diamond concentration
Optimize grinding head
cutting life
Even appearance off ffinal
surface
Setting up
Grinding Head

Select blade spacing

based on aggregate
gg g
hardness
Hard (close spacing)
Soft (wide spacing)
Do not line up blade
segments
avoids vibration
Aggregate Hardness

SOFT MEDIUM HARD

Limestone River Gravel Granite

Dolomite Trap Rock Flint
Coral Granite Chert
River Gravel Quartz
River Gravel
 Height
Land Area

Groove

Hard Soft
Range Aggregate
gg g Aggregate
gg g
Grooves 0.1-0.15 0.1-0.15 0.1-0.15
Land Area 0.06-0.13 0.08 0.1
H i ht
Height 0 06
0.06 0 06
0.06 0 06
0.06

Grooves/ft 50-60 53-60 50-54

Bond Hardness

Bond Bond
Too Low Too High

Segment

Diamonds Polish Before

Diamonds Break Free
Metal Segments
Night Grinding Restoration Work
R G i
Re-Grooving P
Pavementt
Surfaces
New grooves must match depth, width and
spacing of original grooves
A skilled operator and properly set equipment
are essential for accurate groove tie-in
Re-grooving takes more time and patience than
virgin grooving
Questions?

Wouter Gulden P.E.

Dir of Engineering and Training
Dir.

wgulden@pavementse.com
g @p
678 546-1825
404 431-5552 Cell