Guide provides a clear, concise, and cohesive presentation of cement-bound materials options for 10 specific engineering pavement applications. Applications include new concrete pavements, concrete overlays, pervious concrete, precast pavements, roller-compacted concrete, cement-modified soils. The use of 7 and 8 applies to all uses depending on quality of soil and need for stabiliaztion.
Guide provides a clear, concise, and cohesive presentation of cement-bound materials options for 10 specific engineering pavement applications. Applications include new concrete pavements, concrete overlays, pervious concrete, precast pavements, roller-compacted concrete, cement-modified soils. The use of 7 and 8 applies to all uses depending on quality of soil and need for stabiliaztion.
Guide provides a clear, concise, and cohesive presentation of cement-bound materials options for 10 specific engineering pavement applications. Applications include new concrete pavements, concrete overlays, pervious concrete, precast pavements, roller-compacted concrete, cement-modified soils. The use of 7 and 8 applies to all uses depending on quality of soil and need for stabiliaztion.
August 2011 Cement-Based Integrated Pavement Solutions Heavy Industrial Airports Highways Country Roads Arterials Commercial Interstates Light Industrial Residential 1 4 1 4 1 4 1 2 4 1 4 6 1 2 4 1 4 6 ** The use of 7 & 8 applies to all uses depending on quality of soil and need for stabiliaztion 1 2 3 1 2 4 7 Heavy Industrial Light Industrial Airports Commercial Residential Recreation LAND USE CEMENT-BASED INTEGRATED PAVEMENT SOLUTIONS 1 2 3 4 5 6 7 8 Conventional Overlays CRCP VIBRATORY COMPACTION Pervious Concrete Full-Depth Reclamation Cement- Treat- ed Base Cement- Modied Soils Roller- Com- pacted Con- crete EXTERNAL COMPACTION Concrete Recycling Full-Depth Repair Partial-Depth Repair Dowel Bar Retrot Slab Stabilization Diamond Grinding SUSTAINABLE PRACTICE - PRESERVATION OF THE SYSTEMS EQUITY This page illustrates the land-use applications for the cement-based integrated pavement solutions described in this guide. For more information on these applications, please see the table of contents to locate page numbers for each application. Technical Report Documentation Page 1. Report No. 2. Government Accession No. 3. Recipients Catalog No.
4. Title and Subtitle 5. Report Date Guide to Cement-Based Integrated Pavement Solutions August 2011 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report No. Sabrina Garber, Robert Otto Rasmussen, and Dale Harrington 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) Institute for Transportation Iowa State University 2711 South Loop Drive, Suite 4700 Ames, IA 50010-8664 11. Contract or Grant No. 12. Sponsoring Organization Name and Address 13. Type of Report and Period Covered Portland Cement Association 5420 Old Orchard Road Skokie, IL 60077 14. Sponsoring Agency Code 15. Supplementary Notes 16. Abstract This guide provides a clear, concise, and cohesive presentation of cement-bound materials options for 10 specific engineering pavement applications: new concrete pavements, concrete overlays, pervious concrete, precast pavements, roller-compacted concrete, cement-treated base, full-depth reclamation with cement, cement-modified soils, recycled concrete aggregates, and repair and restoration. Each application is presented as a method for meeting specific design and construction objectives that todays pavement practitioners must accomplish. The benefits, considerations, brief description, and summary of materials, design, and construction requirements, as well as a list of sustainable attributes, are provided for every solution. This guide is intended to be short, simple, and easy to understand. It was designed so that the most up-to-date and relevant information is easily extractable. It is not intended to be used as a design guide for any of the applications identified herein. Recommendations for additional information that can provide such details are given at the end of each solution discussion. The intended audience is practitioners, including engineers and managers who face decisions regarding what materials to specify in the pavement systems they design or manage. The audience also includes city and county engineers, along with the A/E firms that often represent them, and state DOT engineers at all levels who are seeking alternatives in this era of changing markets. 17. Key Words 18. Distribution Statement pavement solutions, portland cement concrete, overlays, pervious pavement, roller-compacted concrete, full-depth reclamation, cement-treated base, cement- modified soils, pavement repair, pavement restoration No restrictions. 19. Security Classification (of this report) 20. Security Classification (of this page) 21. No. of Pages 22. Price Unclassified. Unclassified. 92 Form DOT F 1700.7 (8-72) Reproduction of completed page authorized G u i d e
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iii Guide to Cement-Based Integrated Pavement Solutions Authors Sabrina Garber, The Transtec Group, Inc. Robert Otto Rasmussen, The Transtec Group, Inc. Contributing Author Dale Harrington, Snyder and Associates Editorial Staff Sabrina Shields-Cook, Managing Editor Carol Gostele, Copyeditor Mina Shin, Graphic Designer Technical Advisory Committee Wayne Adaska, Portland Cement Association Tom Cackler, National Concrete Pavement Technology Center Greg Dean, American Concrete Pavement Association, Southeast Chapter Gary Fick, Trinity Construction Management Services Jerry Reece, North Carolina Concrete Pavement Association Matt Singel, Cement Council of Texas Gordon Smith, Iowa Concrete Paving Association Leif Wathne, American Concrete Pavement Association August 2011 G u i d e
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iv About This Guide This Guide to Cement-Based Integrated Pavement Solu- tions is a product of the National Concrete Pavement Technology Center (National CP Tech Center) at Iowa State Universitys Institute for Transportation, with funding from the Portland Cement Association. It provides a clear, concise, and cohesive presentation of cement-bound materials options for specic engineer- ing pavement applications. Each application identied in this guide is presented as a method for meeting specic design and construction objectives that todays pavement practitioners must accomplish. Acknowledgments The authors and co-authors, the National CP Tech Center, and the Portland Cement Association are grateful to the knowledgeable and experienced profes- sionals, public and private, who contributed to the development of this guide. While the authors gener- ated the overall content, it was the technical advisory committees and technical reviewers careful reviews of drafts, thoughtful discussions, and suggestions for revisions and renements that make this guide a com- prehensive resource for practitioners. The National CP Tech Center and the Portland Cement Association appreciate the committees and reviewers invaluable assistance. Photo Credits The photographs on the cover and throughout this guide were provided by the following individuals and organizations: - American Concrete Pavement Association - American Concrete Pavement Association, Southeast Chapter - California Nevada Cement Association - Cement Council of Texas - Charger Enterprises - Chicago Department of Transportation - Illinois Tollway - Iowa Concrete Paving Association - John Kevern, University of Missouri-Kansas City - National Concrete Pavement Technology Center - Portland Cement Association - The Transtec Group, Inc. For More Information For technical assistance regarding cement-based concrete paving, contact the Portland Cement Association or the National CP Tech Center: Wayne Adaska, Director, Pavements Portland Cement Association 5420 Old Orchard Rd. Skokie, IL 60077 847-966-6200, info@cement.org, www.cement.org/ Tom Cackler, Director Sabrina Shields-Cook, Managing Editor National CP Tech Center Institute for Transportation, Iowa State University 2711 S. Loop Drive, Suite 4700 Ames, IA 50010-8664 515-294-7124, shieldsc@iastate.edu, www.cptechcenter.org/ Disclaimers Neither Iowa State University nor this documents authors, editors, designers, illustrators, distributors, or technical advisors make any representations or warranties, expressed or implied, as to the accuracy of information herein and disclaim liability for any inaccuracies. Iowa State University does not discriminate on the basis of race, color, age, religion, national origin, sexual orientation, gender identity, sex, marital status, disability, genetic testing, or status as a U.S. veteran. Inquiries can be directed to the Director of Equal Opportunity and Diversity, Iowa State University, 3680 Beardshear Hall, 515-294-7612. G u i d e
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v Contents About This Guide ............................................................................iv Acknowledgments .........................................................................iv Photo Credits ...................................................................................iv Contents .............................................................................................v List of Figures ................................................................................. vii List of Tables ......................................................................................x Preface ................................................................................................xi Important Defnitions ..................................................................xii Table of Solutions ........................................................................ xiv 1. New Concrete Pavements ....................................................1-1 Objectives ......................................................... 1-1 Solution ............................................................ 1-1 Benets ............................................................. 1-1 Considerations .................................................. 1-1 Typical Applications .......................................... 1-1 Description ....................................................... 1-1 Materials ........................................................... 1-3 Design .............................................................. 1-4 Construction ..................................................... 1-5 Sustainability .................................................... 1-7 For More Information ....................................... 1-7 2. Concrete Overlays ...................................................................2-1 Objectives ......................................................... 2-1 Solution ............................................................ 2-1 Benets ............................................................. 2-1 Considerations .................................................. 2-1 Typical Applications .......................................... 2-1 Description ....................................................... 2-1 Materials ........................................................... 2-2 Design .............................................................. 2-3 Construction ..................................................... 2-5 Sustainability .................................................... 2-6 For More Information ....................................... 2-7 3. Pervious Concrete ...................................................................3-1 Objectives ......................................................... 3-1 Solution ............................................................ 3-1 Benets ............................................................. 3-1 Considerations .................................................. 3-1 Typical Applications .......................................... 3-1 Description ....................................................... 3-2 Materials ........................................................... 3-3 Design .............................................................. 3-4 Construction ..................................................... 3-5 Sustainability .................................................... 3-6 For More Information ....................................... 3-6 4. Precast Pavements..................................................................4-1 Objectives ......................................................... 4-1 Solution ............................................................ 4-1 Benets ............................................................. 4-1 Considerations .................................................. 4-1 Typical Applications .......................................... 4-1 Description ....................................................... 4-1 Materials ........................................................... 4-2 Design .............................................................. 4-3 Construction ..................................................... 4-3 Sustainability .................................................... 4-5 For More Information ....................................... 4-5 5. Roller-Compacted Concrete ...............................................5-1 Objectives .......................................................... 5-1 Solution ............................................................. 5-1 Benets .............................................................. 5-1 Considerations .................................................. 5-1 Typical Applications ........................................... 5-1 Description ........................................................ 5-2 Materials ............................................................ 5-3 Design ............................................................... 5-3 Construction ..................................................... 5-5 Sustainability ..................................................... 5-6 For More Information ........................................ 5-7 G u i d e
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vi 6. Cement-Treated Base ............................................................6-1 Objectives ......................................................... 6-1 Solution ............................................................ 6-1 Benets ............................................................. 6-1 Considerations .................................................. 6-1 Typical Applications .......................................... 6-1 Description ....................................................... 6-1 Materials ........................................................... 6-2 Design .............................................................. 6-3 Construction ..................................................... 6-3 Sustainability .................................................... 6-5 For More Information ....................................... 6-5 7. Full-Depth Reclamation with Cement (FDR) .................7-1 Objectives ......................................................... 7-1 Solution ............................................................ 7-1 Benets ............................................................. 7-1 Considerations .................................................. 7-1 Typical Applications .......................................... 7-1 Description ....................................................... 7-1 Materials ........................................................... 7-2 Design .............................................................. 7-2 Construction ..................................................... 7-2 Sustainability .................................................... 7-3 For More Information ....................................... 7-3 8. Cement-Modifed Soils (CMS) .............................................8-1 Objectives ......................................................... 8-1 Solution ............................................................ 8-1 Benets ............................................................. 8-1 Considerations .................................................. 8-1 Typical Applications .......................................... 8-1 Description ....................................................... 8-1 Materials ........................................................... 8-2 Design .............................................................. 8-2 Construction ..................................................... 8-2 Sustainability .................................................... 8-3 For More Information ....................................... 8-3 9. Recycled Concrete Aggregates ..........................................9-1 Objectives ......................................................... 9-1 Solution ............................................................ 9-1 Benets ............................................................. 9-1 Considerations .................................................. 9-1 Typical Applications .......................................... 9-1 Description ....................................................... 9-1 Materials ........................................................... 9-2 Design ............................................................... 9-2 Construction ..................................................... 9-3 Sustainability ..................................................... 9-4 For More Information ....................................... 9-4 10. Repair and Restoration .................................................... 10-1 Description .................................................... 10-1 Full-Depth Repairs ........................................ 10-1 Partial-Depth Repairs ..................................... 10-2 Stitching ........................................................ 10-2 Slab Stabilization ........................................... 10-2 Slab Jacking ................................................... 10-3 Joint Resealing ............................................... 10-3 Dowel Bar Retrot ......................................... 10-3 Diamond Grooving and Grinding .................. 10-4 For More Information .................................... 10-5 G u i d e
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vii List of Figures Figure 1-1. Schematic of typical concrete pavement cross-section ..................................................................... 1-1 Figure 1-2. Schematic of the various types of new concrete pavements ............................................................. 1-2 Figure 1-3. Concrete mixture constituents ......................................................................................................... 1-3 Figure 1-4. Sawcutting JPCP.............................................................................................................................. 1-5 Figure 1-5. Concrete placed over dowel baskets ................................................................................................ 1-6 Figure 1-6. Dowel-bar inserter .......................................................................................................................... 1-6 Figure 1-7. JRCP reinforcement in place before paving ...................................................................................... 1-6 Figure 1-8. CRCP reinforcement placed before paving....................................................................................... 1-6 Figure 1-9. Burlap drag on fresh concrete .......................................................................................................... 1-7 Figure 1-10. Curing compound applied by spray nozzles on a cure cart ........................................................... 1-7 Figure 2-1. Unbonded overlay ........................................................................................................................... 2-2 Figure 2-2 Overlay applications ......................................................................................................................... 2-2 Figure 2-3. Typical cross-section of unbonded overlay ....................................................................................... 2-3 Figure 2-4. Unbonded concrete overlay construction over a nonwoven geotextile interlayer ............................. 2-5 Figure 2-5. Bonded overlay construction ........................................................................................................... 2-6 Figure 3-1. Miller Park in Fair Oaks, California ................................................................................................. 3-1 Figure 3-2. Imperial Beach Sports Park, California ............................................................................................ 3-1 Figure 3-3. Pervious concrete for alley in Chicago, Illinois ................................................................................ 3-2 Figure 3-4. Pervious concrete ............................................................................................................................ 3-2 Figure 3-5. Pervious concrete pavement parking lot .......................................................................................... 3-2 Figure 3-6. Fresh pervious concrete .................................................................................................................. 3-3 Figure 3-7. Pervious concrete pavement in the rain ........................................................................................... 3-4 Figure 3-8. Schematic of pervious full exltration pavement design .................................................................. 3-5 Figure 3-9. Schematic of pervious partial exltration pavement design ............................................................. 3-5 Figure 3-10. Schematic of pervious no exltration pavement design ................................................................. 3-5 Figure 3-11. Compacting the placed pervious concrete ..................................................................................... 3-5 Figure 3-12. Curing pervious concrete with plastic sheeting ............................................................................. 3-6 G u i d e
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viii Figure 4-1. Precast pavement system cross-section ............................................................................................ 4-1 Figure 4-2. Nighttime placement of precast panels in Virginia ........................................................................... 4-2 Figure 4-3. Precast pavement system in Indonesia ............................................................................................. 4-2 Figure 4-4. Concrete poured into form for precast panel ................................................................................... 4-4 Figure 4-5. Vibrators for consolidation of concrete around reinforcement in precast prestressed panel .............. 4-4 Figure 4-6. Placement of precast panel for precast JCP system ........................................................................... 4-4 Figure 4-7. Placement of a prestressed precast panel ......................................................................................... 4-4 Figure 5-1. Typical RCC versus PCC surface ...................................................................................................... 5-2 Figure 5-2. Pavement cross-section with RCC surface ....................................................................................... 5-2 Figure 5-3. Pavement cross-section with RCC base ............................................................................................ 5-2 Figure 5-4. RCC construction for commercial and heavy industrial applications ............................................... 5-2 Figure 5-5. Typical mix design constituents ....................................................................................................... 5-3 Figure 5-6. RCC material looks drier than conventional concrete ...................................................................... 5-3 Figure 5-7. Flexural beam testing ...................................................................................................................... 5-4 Figure 5-8. Typical RCC design relies on aggregate interlock at cracks ............................................................... 5-4 Figure 5-9. RCC delivered to jobsite .................................................................................................................. 5-5 Figure 5-10. Tilt-drum mixer ............................................................................................................................ 5-5 Figure 5-11. Ready-mix transit trucks dumping into haul trucks ....................................................................... 5-5 Figure 5-12. Mobile RCC pugmill mixing plant and mixing chamber ................................................................ 5-6 Figure 5-13. RCC placement ............................................................................................................................. 5-6 Figure 5-14. Compacting RCC using both vibratory and pneumatic-tired rollers .............................................. 5-6 Figure 5-15. RCC in-place density measurement ............................................................................................... 5-7 Figure 5-16. Curing RCC .................................................................................................................................. 5-7 Figure 6-1. Load distribution of CTB compared to unstabilized granular base ................................................... 6-2 Figure 6-2. Typical pavement cross-sections showing CTB layers....................................................................... 6-2 Figure 6-3. Completed CTB for new pavement construction in Oklahoma ........................................................ 6-2 Figure 6-4. Spreading dry cement on grade prior to mixing .............................................................................. 6-4 Figure 6-5. Applying cement slurry on grade prior to mixing (cement slurry is applied the same way for FDR and CMS applications) ......................................... 6-4 Figure 6-6. Constructing CTB using mixed-in-place method ............................................................................. 6-4 Figure 6-7. Placement of plant-mixed CTB on prepared subgrade ..................................................................... 6-4 Figure 7-1. Schematic of the mixing chamber of a reclaimer machine ............................................................... 7-2 Figure 7-2. Reclaimer pulverizing existing asphalt pavement and base material ................................................. 7-2 Figure 7-3. Dry cement placed on pulverized material ...................................................................................... 7-3 Figure 7-4. Applying cement slurry on grade prior to mixing (cement slurry is applied the same way for CTB applications) ......................................................... 7-3 Figure 7-5. Mixing the cement into the pulverized material ............................................................................... 7-3 G u i d e
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ix Figure 7-6. Equipment for compaction and nishing ........................................................................................ 7-3 Figure 8-1. Typical cross-section with CMS ....................................................................................................... 8-2 Figure 8-2. Cement slurry added to subgrade material (cement slurry is applied the same way for CTB and FDR applications) ......................................... 8-2 Figure 8-3. Pulvermizer used for in-place mixing of CMS ................................................................................. 8-3 Figure 8-4. Sheepsfoot roller used for compaction ............................................................................................. 8-3 Figure 9-1. Recycled concrete aggregates ........................................................................................................... 9-2 Figure 9-2. Example of equipment used to break existing concrete ................................................................... 9-3 Figure 9-3. Broken concrete pavement is removed for recycling ........................................................................ 9-3 Figure 9-4. Existing concrete recycled in-place and reused for base material on the Tri-State Tollway in Illinois ........................................................................ 9-3 Figure 10-1. Full-depth repair of a concrete pavement slab ............................................................................. 10-1 Figure 10-2. Partial-depth repair process at joint ............................................................................................. 10-2 Figure 10-3. Cross-section of concrete pavement showing stitching. ............................................................... 10-2 Figure 10-4. Drilling operation as part of slab stabilization .............................................................................. 10-3 Figure 10-5. Application of joint sealant .......................................................................................................... 10-4 Figure 10-6. Contiguous concrete slabs prepared for dowel bar retrotting ..................................................... 10-4 Figure 10-7. Diamond grinding concrete pavement for surface restoration ...................................................... 10-4 Figure 10-8. Longitudinal grooving of a concrete pavement to restore macrotexture ....................................... 10-5 G u i d e
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x List of Tables Table 1. Table of solutions ...................................................................................................................................xv Table 2-1. Current state-of-the-practice overlay design methodologies .............................................................. 2-3 Table 2-2. Joint pattern for bonded concrete overlays ........................................................................................ 2-4 Table 2-3. Joint pattern for unbonded concrete overlays of concrete pavements ................................................ 2-5 Table 2-4. Joint pattern for unbonded concrete overlays of HMA and composite pavements ............................. 2-5 Table 3-1. Typical values for material properties ................................................................................................ 3-3 Table 5-1. List of design methodologies ............................................................................................................. 5-4 Table 6-1. Typical CTB properties ...................................................................................................................... 6-3 G u i d e
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xi How is this guide unique? Portland cement is the fundamental ingredient in con- crete. When you think of cement, it may be automatic to think of concrete; when you think of cement and pavements, you probably think of cement in conven- tional concrete used for pavement surface layers. But did you know that cement can be used in other pave- ment layers and for other applications? In fact, cement can be used in many other applications for pavement systems. Pavement systems containing cement-bound layers have been used worldwide for over a century, with great success. Portland cement can be used in virtually every layer in a pavement system. Typical applica- tions include improving the quality of subgrade soils and stabilizing base materials. Integrating multiple cement-based layers into a pavement design may pro- vide a cost-effective method for achieving a stronger, more durable, sustainable pavement. For instance, using a cement-modied soil and cement-treated base as opposed to an unbound granular base placed on an unprepared subgrade can reduce the required thickness of the base material. In addition, a cement- treated base may decrease the thickness needed for the concrete or asphalt surface, resulting in less materials and overall reduced cost. In addition to being the key constituent of new con- crete pavement and concrete overlay surfaces, other unique surface applications of cement include roller- compacted concrete (RCC), precast pavements, and pervious concrete pavements. Cement is also used in numerous pavement repair techniques, as well as an array of pavement recycling and reclamation applications. A great deal of research and effort by many sources has gone into developing literature about the indi- vidual pavement applications using cement. With so many applications, engineers and other practitioners could benet from one publication that integrates and summarizes all cement-based pavement applications and helps them select and apply appropriate solutions for specic needs. This publication lls that need. The Guide to Cement-Based Integrated Pavement Solutions provides a clear, concise, and cohesive discussion of 10 cement-bound material options for specic engineering pavement applications, or solutions: new concrete pave- ments, concrete overlays, pervious concrete, precast pavements, roller-compacted concrete, cement-treated base, full-depth reclamation with cement, cement- modied soils, recycled concrete aggregates, and repair and restoration. Each application is presented as a method for meeting specic design and construction objectives that todays pavement practitioners must accomplish. The benets, considerations, brief descrip- tion, and summary of materials, design, and construc- tion requirements, as well as a list of sustainable attri- butes, are provided for every solution. This guide is intended to be short, simple, and easy to understand. It was designed so that the most up-to-date and relevant information is easily extractable. It is not intended to be used as a design guide for any of the applications identied herein. Recommendations for additional information that can provide such details are given at the end of each solution discussion. Who is this guide for? It was developed for practitioners, including engineers and managers who face decisions regarding what mate- rials to specify in the pavement systems they design or manage. The audience also includes city and county engineers, along with the A/E rms that often represent them, and state DOT engineers at all levels who are seeking alternatives in this era of changing markets. Preface G u i d e
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xii Important Definitions This symbol represents applications of highly traf- cked roadways that experience high volumes of heavy truck trafc such as major highways and interstates. This symbol represents applications for city streets and local roads that experience moderate levels of passenger vehicle trafc and maybe some heavy truck trafc. This symbol represents roadway shoulder applications. This symbol represents applications including com- mercial parking lots, driveways, and residential roadways. This symbol represents applications for general-pur- pose aviation and/or commercial or military aireld facilities. This symbol represents applications for facilities that experience high volumes of heavy truck trafc and/or storage facilities, such as shipping yards, where heavy containers are stored for long periods of time. Highways Commercial / Lightweight Airfields Heavy Industrial Streets & Local Roads Shoulders G u i d e
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xiii ASTM ASTM International, originally known as the Ameri- can Society for Testing and Materials, is an interna- tional standards setting organization. Base The pavement layer constructed immediately beneath a hot-mix asphalt (HMA) surface and sometimes beneath a concrete surface. Material requirements for this layer are more stringent than those for most sub- base and subgrade layers. Concrete An initially plastic (slumpable) mixture created by the combination of cement, coarse and ne aggregates, water, and various chemical admixtures that hardens to a solid material over time. Concrete pavement A pavement system in which the surface layer is concrete. Typical concrete pavement systems include a concrete surface over a subbase and subgrade layers. Fine aggregate Dened by ASTM C33 as sand with 95100 percent of the total material passing a No. 4 (4.75 mm) sieve. Fines Portion of the soil ner than a No. 200 (75 m) sieve. Flexible pavement A pavement system in which the surface layer is hot- mix asphalt (HMA). Typical exible pavement systems include an HMA surface over a base, subbase, and subgrade layers. Pavement system The combination of surface, base/subbase, and improved subgrade layers constructed for the purpose of supporting trafc. Portland cement A commercial product that, when combined with water, forms a paste that over time becomes a hard- ened solid. It is typically combined with ne aggre- gates to form mortar or a combination of ne and coarse aggregates to form concrete. Subbase The pavement layer constructed between the base and subgrade in a exible pavement system, or the layer often found beneath a concrete surface in a concrete pavement system. G u i d e
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xiv Table of Solutions Within an integrated pavement solutions system, numerous alternative paving materials and techniques are available. While their common link is the use of portland cement, there remain notable differences that must be recognized. To assist in the selection of the most appropriate solutions for a given project, Table 1 should be referenced. Within this table, the various solutions are shown in the left column, along with a brief description of each. To assist in the selection of the most appropriate solutions, the challenges that a user might be facing are in the adjacent columns. This cross-referencing is intended to help narrow the selection of the available solutions. Complementing the table are both the ben- ets and typical applications. These too are intended to rene the selection of possible solutions. G u i d e
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xv Table 1. Table of solutions Solution / Denition Objectives Benets Typical Applications New Concrete Pavements New concrete pavements include both jointed and continuously reinforced concrete pavements. Thicknesses can range from 6 to 15 inches, depending on trafc, environment, and soils. x Provide long life and reduced maintenance. x Improve the surface. x Provide high load-carrying capacity. x Expedite construction/renewal. x Reduce urban heat island effect. x Increase light reectance. x Provide a sustainable option. x Concrete pavements can withstand many environments. x Concrete pavements typically last much longer than their original design life. x Concrete pavement surfaces reect light and reduce the urban heat island effect. x Vehicle fuel consumption for the driving public is reduced on concrete surfaces. x Highways x Streets and Local Roads x Shoulders x Commercial/ Lightweight x Airelds x Heavy Industrial Concrete Overlays Overlays are a method of rehabilitating and/ or increasing the structural capacity of existing pavements. Bonded overlays are thin (2- to 6-in.) layers of concrete bonded directly to a sound underlying pavement in order to increase structural capacity. Unbonded overlays are used principally when the underlying pavement is in fair to poor condition and are thick (4 to 11 in.) enough to support the trafc loads but recognizing the structural capacity of the underlying pavement. x Extend pavement life. x Improve the surface. x Increase load-carrying capacity. x Expedite construction/renewal. x Reduce urban heat island effect. x Increase light reectance. x Provide a sustainable option. x Reconstruction costs are avoided. x Construction of an overlay is much faster than reconstruction. x Concrete pavement surfaces reect light and reduce the urban heat island effect. x Highways x Streets and Local Roads x Shoulders x Commercial/ Lightweight x Airelds x Heavy Industrial Pervious Concrete Pervious concrete is a paving material consisting of almost exclusively coarse aggregate, but with sufcient cement paste to bind the mixture into a strong but open (porous) material with exceptional drainage properties. x Satisfy EPA Storm Water Phase II regulations. x Earn LEED credits. x Improve safety. x Reduce tire-pavement noise. x Provide a sustainable option. x Pervious concrete is an EPA Best Management Practice. x Stormwater runoff and ash ooding is minimized. x Hydroplaning and splash and spray are minimized. x Noise from the tire-pavement interaction is reduced. x Pervious concrete surfaces reect light and help reduce the urban heat island effect. x Streets and Local Roads x Shoulders x Commercial/ Lightweight Precast Pavements Precast pavements are a technique for constructing or repairing a concrete pavement surface where casting and curing of panels are done in advance. Precast pavements are a highly durable nished pavement and not just a temporary x. They are a repair option for jointed concrete pavements (JCP) or reconstruction option for both JCP and HMA pavements. Rapid placement of the hardened panels can then be conducted within short trafc closure windows. x Provide long life. x Improve the surface. x Provide high load-carrying capacity. x Expedite construction/renewal. x Provide a sustainable option. x Construction can be completed during short (overnight or weekend) closures. x Lane closures and associated user delays during construction are minimized. x Precast pavements are a highly durable nished pavement and not just a temporary x. x Precast pavement surfaces reect light and help reduce the urban heat island effect. x Highways x Airelds x Heavy Industrial G u i d e
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xvi Table 1. Table of solutions (Continued) Solution / Denition Objectives Benets Typical Applications Roller-Compacted Concrete Roller-compacted concrete (RCC) is a stiff and strong concrete mixture that is typically placed with asphalt pavers as either a surface or a support layer. Roller-compacted concrete surfaces can be used for low-speed or industrial applications. Roller-compacted concrete layers can also serve as a support layer to a thin (1.5- to 2-in.) HMA (or occasionally concrete) surface. x Provide low-cost option. x Provide high load-carrying capacity. x Expedite construction. x Allow early opening to trafc. x Provide a sustainable option. x Roller-compacted concrete provides a strong, dense, and durable material that can be quickly constructed. x Construction is fast with no forms or nishing. x No steel reinforcement and minimum labor make RCC economical. x For many applications, joint sawing is optional for aesthetic purposes resulting in additional cost savings. x Roller-compacted concrete pavement surfaces reect light and help reduce the urban heat island effect. x Highways x Streets and Local Roads x Shoulders x Airelds x Commercial/ Lightweight x Heavy Industrial Cement-Treated Base Cement-treated base (CTB) is a mixture of aggregate material and/or granular soils combined with engineered amounts of portland cement and water that hardens after compaction and curing to form a stronger, stiffer, and more durable paving material. Cement-treated base is used as a pavement base for exible pavements or a subbase for concrete pavements. x Provide a strong, uniform base/ subbase for current and future loading conditions using in-place or locally available marginal soils and granular material. x Reduce stresses on the subgrade. x Stabilize a variety of soils with a single stabilizer. x Reduce rutting and deections in a exible pavement surface. x Improve the structural capacity of the existing soil. x Provide a sustainable option. x A stiffer base reduces deections due to trafc loads, thereby extending pavement life. x Subgrade failures, pumping, rutting, joint faulting, and road roughness are reduced. x Base thickness is reduced compared to unbound granular base thicknesses. x Marginal aggregates, including recycled materials, can be used, thus reducing the need for virgin, high- quality aggregates. x Highways x Streets and Local Roads x Shoulders x Airelds x Commercial/ Lightweight x Heavy Industrial Full-Depth Reclamation Full-depth reclamation (FDR) is a technique in which hot-mixed asphalt (HMA) material from the existing pavement is removed, combined with portland cement, and used to create a new and improved base. The FDR base is then topped with a new HMA or concrete surface layer. x Provide a strong, uniform base/ subbase for current and future loading conditions using existing failed asphalt surface and base material. x Maintain existing grade with minimum material removal or addition. x Reduce or totally eliminate the need for virgin aggregates. x Reduce stresses on the subgrade. x Reduce rutting and deections in a exible pavement surface. x Improve the structural capacity of stabilized base over unstabilized base material. x Provide pavement reconstruction method that is fast and minimizes trafc disruption. x Provide a sustainable option. x The performance of the base layer is improved over an unbound granular base. x Little, if any, material is hauled off or onto the site, resulting in less truck trafc, lower emissions, and less damage to local roads. Work can be completed quickly compared to removal and replacement techniques. x Full-depth reclamation process is economical compared to removal and replacement and thick overlays. x Highways x Streets and Local Roads x Airelds x Commercial/ Lightweight x Heavy Industrial G u i d e
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xvii Solution / Denition Objectives Benets Typical Applications Cement-Modied Soils Cement-modied soils (CMS) are soils and/ or manufactured aggregates mixed with a small proportion of portland cement. Cement- modied soils exhibit reduced plasticity, minimized volumetric changes due to moisture changes, increased bearing strength, and improved stability. x Reduce the plasticity and high- volume change characteristics of clay soils due to moisture variations. x Improve stability of a poorly graded sandy soil. Improve the properties of a sandy soil containing a high- plasticity clay. x Provide a method to dry out a wet subgrade. x Provide a rm construction platform to work on. x Provide a sustainable option. x Cement-modied soils provide a weather- resistant work platform for construction operations. x Fatigue failures caused by repeated high deections are controlled. x There is a reduction in moisture sensitivity and subgrade seasonal load restrictions. x No mellowing period is needed as required by other stabilizing agents. x Highways x Streets and Local Roads x Shoulders x Airelds x Commercial/ Lightweight x Heavy Industrial Recycled Concrete Aggregates Recycled concrete aggregates (RCA) are aggregates produced from the recycling of existing concrete. Existing concrete is removed, processed into appropriate aggregate sizes, and reused in various pavement applications. x Recycle excavated concrete pavement. x Minimize construction cost. x Reduce dependence on good quality virgin aggregates, which may be hard to nd or expensive to bring in. x Provide a sustainable option. x Recycled concrete aggregates are versatile because they can be used in any pavement layer. x Material costs are reduced. x Construction time can be expedited with on-site recycling plants. x Pavement suffering from ASR or D-cracking can be recycled instead of discarded. x The need for old concrete disposal is reduced. x Highways x Streets and Local Roads x Shoulders x Airelds x Commercial/ Lightweight x Heavy Industrial Repair and Restoration Repair and restoration is a series of techniques including diamond grinding, dowel bar retrot, full and partial depth repairs, joint sealing, patching, and slab stabilization that extend the life of a concrete pavement. These techniques can often be used in lieu of resurfacing or reconstructing. x Extend life. x Improve the surface. x Expedite construction/renewal. x Repair and restoration xes distressed concrete pavement (Commentareas may not be isolated, i.e., diamond grinding an entire roadway). x These are options for low- cost concrete pavement life extensions. x Highways x Aireld x Streets and Local Roads Table 1. Table of solutions (Continued) G u i d e
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xviii G u i d e
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1-1 New Concrete Pavements Objectives - lrovioc long lilc +no rcoucco m+intcn+ncc - Improvc tnc surl+cc - lrovioc nign lo+o-c+rrying c+p+city - lxpcoitc construction/rcncw+l - lcoucc urb+n nc+t isl+no cllcct - Incrc+sc lignt rclcct+ncc - lrovioc + sust+in+blc option Solution - Construct + ncw concrctc p+vcmcnt Benets - Concrctc p+vcmcnts c+n witnst+no m+ny cnvironmcnts - Concrctc p+vcmcnts typic+lly l+st mucn longcr tn+n tncir origin+l ocsign lilc - Concrctc p+vcmcnt surl+ccs rclcct lignt +no rcoucc tnc urb+n nc+t isl+no cllcct - Vcniclc lucl consumption lor tnc oriving public is rcoucco on concrctc surl+ccs Considerations - lnc concrctc mixturc must bc ocsignco propcrly lor tnc cnvironmcnt - lropcr construction pr+cticcs +rc csscnti+l to long- tcrm pcrlorm+ncc Typical Applications Concrctc p+vcmcnt +pplic+tions incluoc nignw+ys (m+inlinc, snoulocrs, lront+gc ro+os), strccts +no loc+l ro+os, +s wcll +s nc+vy inoustri+l +pplic+tions, +irnclos (runw+ys, t+xiw+ys, ro+ow+ys, +prons, p+rking l+cili- tics), +no commcrci+l/ligntwcignt inoustri+l +pplic+- tions sucn +s orivcw+ys +no p+rking lots Highways Commercial / Lightweight Airfields Heavy Industrial Streets & Local Roads Shoulders Description A p+vcmcnt structurc is + combin+tion ol + surl+cc coursc +no b+sc/subb+sc courscs pl+cco on + prcp+rco subgr+oc A ncw concrctc p+vcmcnt is onc wncrc tnc surl+cc coursc is m+oc ol concrctc (ligurc 1-1) Prepared Subgrade Concrete Surface Subbase Prepared Subgrade Concrete Surface Subbase Figure 1-1. Schematic of typical concrete pavement cross-section 1 Guide to Cement-Based Integrated Pavement Solutions G u i d e
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P A V E M E N T S 1-2 Concrctc p+vcmcnts n+vc bccn built in tnc Lnitco St+tcs sincc tnc nrst concrctc strcct w+s built in lcllc- lont+inc, Onio, in 1S91 lnis p+vcmcnt is still in scr- vicc too+y Concrctc p+vcmcnts c+n bc vcry vcrs+tilc, tncy c+n bc ocsignco to n+nolc tnc lrcczing wintcrs ol \icnig+ns Lppcr lcninsul+ or tnc scorcning nc+t ol Ncw \cxico in tnc Soutnwcst Concrctc p+vcmcnts c+n bc + our+blc, cconomic+l, +no sust+in+blc solution lor m+ny +pplic+tions il propcr m+tcri+l mixturcs +rc usco +no tnc p+vcmcnt structurc is botn ocsignco +no constructco propcrly lncrc +rc oillcrcnt typcs ol concrctc p+vcmcnts built in tnc Lnitco St+tcs, nowcvcr, tnc two most com- mon oncs +rc jointco concrctc p+vcmcnts (]Cl) +no continuously rcinlorcco concrctc p+vcmcnts (ClCl) l+cn typc is suit+blc lor ncw construction, rcconstruc- tion, +no ovcrl+ys ol cxisting ro+os ]ointco concrctc p+vcmcnt c+n bc citncr pl+in (]lCl) or rcinlorcco (]lCl) lotn n+vc rcgul+rly sp+cco tr+nsvcrsc contr+ction joints witn oowcls lor lo+o tr+nslcr +no longituoin+l construction joints nclo togctncr witn tic b+rs Concrctc will cr+ck, joints +rc ocsignco to control wncrc tncsc cr+cks occur lnc ioc+ is to ocsign + joint sp+cing tn+t cnsurcs tn+t cr+cks occur unocr tnc joints instc+o ol r+noomly +cross tnc p+vcmcnt ]ointco rcinlorcco concrctc p+vcmcnt incluocs wirc mcsn +no/or oclormco stccl b+r rcin- lorccmcnt tnrougnout c+cn sl+b (tnc +rc+ bounoco by tr+nsvcrsc +no longituoin+l joints) lnc rcinlorccmcnt is intcnoco to nolo tignt +ny cr+cks tn+t m+y lorm witnin tnc sl+b Continuously rcinlorcco concrctc p+vcmcnts oo not rcuirc tr+nsvcrsc contr+ction joints, but oo incluoc tr+nsvcrsc +no longituoin+l construction joints Continuously rcinlorcco concrctc p+vcmcnts cont+in continuous longituoin+l +no tr+nsvcrsc rcinlorccmcnt tnrougn tnc cntirc p+vcmcnt (morc tn+n ]lCl) lcin- lorccmcnt in ClCl is ocsignco to control tr+nsvcrsc cr+ck wiotns, rcinlorccmcnt kccps cr+cks nclo tigntly togctncr +no is not ocsignco to nclp c+rry tr+lnc lo+os St+no+ro ClCl ocsigns +rc oltcn cnoscn by st+tcs (likc lcx+s, Virgini+, +no Illinois) to +ccommoo+tc nign tr+lnc +no nc+vy lo+os ligurc 1-2 illustr+tcs typic+l jointing +no rcinlorcc- mcnt lor ]lCl, ]lCl, +no ClCl ocsigns Concrctc p+vcmcnts +rc oltcn ocsignco spccinc+lly lor + givcn projcct, nowcvcr, somc +gcncics n+vc +ooptco st+no+ro v+lucs lor tnc gcomctric cn+r+ctcristics ol Figure 1-2. Schematic of the various types of new concrete pavements (from IMCP manual, Iowa State University, 2006) G u i d e
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P A V E M E N T S 1-3 p+vcmcnts +s wcll +s lor tnc m+tcri+ls spccinc+tions so tn+t ocsigns bccomc morc pr+ctic+l lnc cxccllcnt pcrlorm+ncc ol concrctc p+vcmcnts rclics on tnc usc ol suit+blc m+tcri+ls, +n +ocu+tc ocsign, +no souno construction pr+cticcs lotn struc- tur+l +no lunction+l pcrlorm+ncc is cnn+ncco wncn +ll ol tncsc +spccts +rc c+rclully iocntinco +no +ccountco lor lnc most inlucnti+l ocsign-rcl+tco v+ri+blcs lor structur+l pcrlorm+ncc (+t + givcn lcvcl ol tr+lnc) +rc sl+b tnickncss, joint sp+cing, rcinlorccmcnt, concrctc strcngtn, +no support conoitions lunction+l pcrlor- m+ncc ol tnc p+vcmcnt is oltcn rcl+tco to lc+turcs likc smootnncss, tcxturc, +no noisc lncsc +rc +llcctco-in p+rt-by tnc concrctc p+vcmcnt tcxturc +long witn tnc concrctc m+tcri+l usco +no, in p+rticul+r, its our+bility Materials \ixturcs lor concrctc p+vcmcnts typic+lly incorpor+tc tnc lollowing constitucnts + blcno ol co+rsc +no nnc +ggrcg+tcs, portl+no ccmcnt, w+tcr, +no somctimcs otncr ccmcntitious m+tcri+ls sucn +s ly +sn +no sl+g ccmcnt, +no/or cncmic+l +omixturcs (scc ligurc 1-3) lnc comp+tibility ol m+tcri+ls in concrctc p+vcmcnts is import+nt bcc+usc it will +llcct long-tcrm p+vcmcnt pcrlorm+ncc A blcno ol co+rsc +no nnc +ggrcg+tcs is typic+lly usco in concrctc p+ving mixturcs lnc +ggrcg+tcs +rc oltcn n+tur+l but c+n +lso bc m+nul+cturco Co+rsc +ggrcg+tcs m+y cvcn incluoc + pcrccnt+gc ol rccyclco +ggrcg+tcs A nnc +ggrcg+tc is ocnnco by ASl\ C33 +s n+ving 9 pcrccnt or morc m+tcri+l p+rticlcs p+ssing tnc =- (-7 mm) sicvc ASl\ C33 +lso proviocs guioclincs on typic+l +ggrcg+tc gr+o+tions lor concrctc \ost st+tcs n+vc st+no+ros +no spccinc+- tions tn+t iocntily ccrt+in gr+o+tion limits lor spccinc +pplic+tions +no lurtncr iocntily + limit lor rccyclco +ggrcg+tc contcnt Aggrcg+tcs strongly inlucncc con- crctcs lrcsn propcrtics (p+rticul+rly work+bility) +no long-tcrm our+bility A wcll-gr+oco blcno ol +ggrc- g+tcs will lurtncr cnsurc long-tcrm p+vcmcnt pcrlor- m+ncc Acnicving + wcll-gr+oco +ggrcg+tc supply c+n oltcn bc +tt+inco by +ooing +n intcrmcoi+tc (=S to 3/S in 23o to 9 mm]) +ggrcg+tc lortl+no ccmcnt givcs tnc m+tcri+l its strcngtn +no binos tnc +ggrcg+tcs togctncr lncrc +rc oillcrcnt typcs ol ccmcnt, but tnc most common lor p+ving incluoc lypcs I, II, I/II, +no III lypc I is commonly usco in norm+l concrctc mixturcs lypc II is simil+r to lypc I but givcs oll lcss nc+t +no is moocr+tcly sull+tc rcsis- t+nt It is common to usc + lypc I/II ccmcnt in p+ving +pplic+tions, wnicn mccts tnc rcuircmcnts +s botn + lypc I +no + lypc II lypc III ccmcnts g+in strcngtn Figure 1-3. Concrete mixture constituents (from IMCP Manual, Iowa State University, 2006) 915% Cement 1516% Water 2535% Fine aggregate 3045% Coarse aggregate Paste (cement + water) Mortar (paste + ne aggregate) Concrete (mortar + coarse aggregate) G u i d e
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P A V E M E N T S 1-4 uickly +no +rc oltcn usco in l+st-tr+ck p+ving or rcp+ir llcnoco ccmcnts sucn +s lypc Il (portl+no- pozzol+n ccmcnt) or lypc IS (portl+no bl+st-lurn+cc sl+g) ccmcnts incluoc otncr ccmcntitious m+tcri+ls +no +rc options lor usc in p+ving mixturcs It is common lor p+ving mixturcs to incluoc supplc- mcnt+ry ccmcntitious m+tcri+ls (SC\s) tn+t +rc +ooco to tnc mixturc by rcpl+cing + pcrccnt+gc (citncr m+ss or volumctric) ol tnc portl+no ccmcnt contcnt lncsc m+y incluoc inoustri+l byprooucts likc ly +sn or sl+g ccmcnt lnc proportions in wnicn tnc m+tcri+ls +rc usco usu+lly v+ry in cvcry ocsign +no +rc typic+lly sclcctco to b+l+ncc cost, strcngtn rcuircmcnts, work- +bility, +no our+bility \+tcr lor concrctc snoulo bc pot+blc (nt lor num+n consumption) Somc w+tcr rccyclco lrom rcturnco concrctc +no pl+nt w+sning c+n bc +cccpt+blc Spcci- nc+tions lor mixing w+tcr in concrctc mixturcs c+n bc louno in ASl\ C1o02 lypic+l w+tcr-to-ccmcntitious m+tcri+ls (w/cm) r+tios lor norm+l concrctc p+v- ing mixturcs r+ngc lrom 0-0 to 0- ligncr w/cm r+tios will rcsult in incrc+sco work+bility but +lso lowcr strcngtn +no occrc+sco long-tcrm p+vcmcnt pcrlorm+ncc Aomixturcs commonly usco in concrctc mixturcs incluoc +ir-cntr+ining +omixturcs, w+tcr-rcoucing +omixturcs, rct+rocrs, +no +ccclcr+tors Air-cntr+ining +omixturcs +rc usco to ocvclop +n +ir voio systcm tn+t is ncccss+ry lor concrctc our+bility, p+rticul+rly in lrcczc-tn+w cnvironmcnts \+tcr-rcoucing +omixturcs +rc usco to rcoucc w/cm r+tios wnilc improving work- +bility lct+rocrs occrc+sc sct timc +no +rc gcncr+lly usco in not wc+tncr pl+ccmcnts Accclcr+tors incrc+sc sct timcs lor colo wc+tncr concrcting lnc +mount ol +omixturc rcuirco lor c+cn ocpcnos on tnc +mount +no typc ol ccmcntitious m+tcri+l usco It is + gooo pr+cticc to lollow tnc m+nul+cturcrs rccommcno+- tions lor oos+gc Scvcr+l +omixturcs c+n bc usco in onc mixturc, but tri+l b+tcncs must bc run in orocr to cnsurc comp+tibility Il ocsignco propcrly lor tnc cnvironmcnt in wnicn tncy will bc pl+cco, concrctc p+vcmcnts will l+st + long timc V+rious Amcric+n Concrctc Institutc (ACI) intcrn+tion+l oocumcnts, tnc N+tion+l Concrctc l+vc- mcnt lccnnology Ccntcrs (Cl lccn Ccntcr) Integrated Materials and Construction Practices for Concrete Pave- ment (IMCP) Manual, +no tnc lortl+no Ccmcnt Asso- ci+tions (lCA) Design and Control of Concrete Mixtures provioc oct+ilco rccommcno+tions ol now to propor- tion + mixturc +no cnsurc gooo pcrlorm+ncc in + v+ri- cty ol cnvironmcnts In gcncr+l, comp+tiblc m+tcri+ls couplco witn low pcrmc+bility (ic, low w/cm r+tios +no tnc usc ol SC\s) +no + propcr +ir voio systcm will rcsult in gooo long-tcrm concrctc pcrlorm+ncc Design A concrctc p+vcmcnt ocsign incluocs c+lcul+ting + rcuirco p+vcmcnt tnickncss, octcrmining + joint l+yout, +no iocntilying tnc rcuirco stccl contcnt (il +pplic+blc) lnc most n+tion+lly +cccptco mctnoo lor concrctc p+vcmcnt ocsign is tnc American Association of State Highway and Transportation Ofcials (AASHTO) Design Guide (1993) A m+jor cllort is currcntly unocr- w+y to rcgion+lly c+libr+tc +no snilt to tnc ncw AASllO \ccn+nistic-lmpiric+l l+vcmcnt lcsign Guioc (\-l llG) Otncr ocsign tools sucn +s t+blcs lrom tnc ACI Com- mittcc 330 rcport Guide for the Design and Construction of Concrete Parking Lots, tnc Continuously Reinforced Concrete Pavement Design +no Construction Guidelines (l+smusscn, logcrs, +no lcrr+gut 2009), +no tnc Amcric+n Concrctc l+vcmcnt Associ+tions Strcctl+vc soltw+rc progr+m c+n bc usco to provioc s+tisl+ctory rcsults A concrctc p+vcmcnt nccos to bc tnick cnougn to witnst+no tnc strcss +no l+tiguc c+usco by tnc cnvi- ronmcnt in wnicn it is constructco +no tnc lo+os unocr wnicn it must pcrlorm ovcr +n +nticip+tco lilctimc Somc critic+l ocsign inputs lor c+lcul+ting tnickncss incluoc tnc cstim+tco tr+lnc lo+oing ouring tnc ocsign lilc, l+ilurc critcri+, concrctc strcngtn, +no stillncss +no or+in+gc cn+r+ctcriz+tion ol supporting l+ycrs lor ]Cl, tnc sp+cing ol contr+ction joints is ocsignco +t intcrv+ls sucn tn+t potcnti+l volumctric cn+ngcs ol tnc concrctc oo not rcsult in unintcnoco o+m+gc to tnc p+vcmcnt (ic, uncontrollco cr+cking) lnc lcocr+l lignw+y Aoministr+tions lign lcrlorm+ncc Concrctc l+ving (lIllllAV) soltw+rc c+n bc usco +s +n cllcctivc tool lor ocsigning propcr joint sp+cing G u i d e
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P A V E M E N T S 1-5 ]ointco pl+in concrctc p+vcmcnt tr+nsvcrsc contr+c- tion joints +rc typic+lly sp+cco +t 1 to 20 lt ( to o1 m) in orocr to control cr+cking lr+nsvcrsc contr+ction joints in ]lCl c+n bc sp+cco l+rtncr +p+rt (typic+lly +bout 30 to -0 lt 9 to 12 m]) bcc+usc ol tnc stccl contcnt Contr+ction joints +rc not rcuirco in ClCl Continuously rcinlorcco concrctc p+vcmcnt is ocsignco to n+vc r+noom tr+nsvcrsc cr+cks tn+t +rc nclo tigntly togctncr by tnc rcinlorcing stccl In +ll concrctc p+vcmcnts, longituoin+l construction joints +rc pl+cco bctwccn l+ncs +no tr+nsvcrsc construction joints +rc constructco +t tnc cno ol c+cn o+ys p+ving lcinlorccmcnt usco in concrctc p+vcmcnts incluocs oowcls, tic b+rs, +no continuous stccl b+rs tnrougnout tnc sl+b lowcls provioc lo+o tr+nslcr +no vcrtic+l support lor jointco p+vcmcnts +t tnc tr+nsvcrsc joints lic b+rs promotc +ggrcg+tc intcrlock +no +rc most oltcn usco +long longituoin+l joints \irc or oclormco stccl b+r rcinlorccmcnt in ]lCl kccps r+noom cr+cks nclo tigntly togctncr lcsigning tnc rcinlorccmcnt incluocs iocntilying tnc typc, sizc, +no sp+cing \ost st+tcs +lrc+oy n+vc st+no+ros +no spccinc+tions lor tnc ocsign ol p+vcmcnt rcinlorccmcnt lnc critic+l ocsign l+ctors lor rcinlorccmcnt incluoc p+vcmcnt tnickncss, concrctc m+tcri+l propcrtics, +no typc ol support A subb+sc is usu+lly +ovis+blc lor nc+vicr tr+lnckco p+vcmcnts A subb+sc in lignt outy p+vcmcnts (cg, rcsiocnti+l +no collcctor strccts +no p+rking lots) is not +lw+ys ncccss+ry +no ocpcnos on unocrlying soils, or+in+gc nccos, +no lo+os Construction lnc construction ol + concrctc p+vcmcnt involvcs obt+ining tnc m+tcri+ls, b+tcning +no mixing, pl+cing, tcxturing, +no curing l+tcning is tnc proccss ol mc+suring tnc constitucnts by m+ss or volumc +ccoroing to + mixturc ocsign +no introoucing tncm into + mixcr lnc sizc ol tnc b+tcn ocpcnos on tnc c+p+city ol tnc mixcr In most c+scs, citncr + st+tion+ry or + rc+oy-mix pl+nt is usco lor mixing p+ving concrctc, wnicn is tncn typic+lly tr+ns- portco to tnc job in oump trucks lor sliplorm p+ving lruck mixcrs c+n +lso tr+nsport p+ving concrctc but +rc usco morc oltcn lor nxco-lorm pl+ccmcnts \ncn pl+nning lor cuipmcnt, it is import+nt to consiocr tnc proouction c+p+city +no typic+l n+ul timcs lroj- ccts in congcstco +rc+s, wnicn oo not +llow lor on-sitc proouction, m+y rcuirc + mix ocsign tn+t pcrmits cxtcnoco n+uling +no pl+ccmcnt timcs Concrctc is pl+cco using sliplorm or nxco-lorm p+v- ing mctnoos, ocpcnoing upon tnc n+turc ol tnc proj- cct lnc concrctc mixturcs rcuirco by citncr pl+cc- mcnt mctnoo c+n v+ry signinc+ntly Sliplorm p+ving opcr+tions rcuirc + low-slump mixturc tn+t will not slougn +ltcr cxtrusion by tnc p+ving m+cninc, wnilc nxco-lorm p+ving opcr+tions rcly on + nigncr slump mixturc tn+t will low c+sily to nll tnc lorms Sliplorm p+ving is gcncr+lly lor pl+ccmcnts tn+t rcuirc nign proouction r+tcs, sucn +s m+inlinc p+ving lixco-lorm p+ving is +o+pt+blc to nc+rly +ny pl+ccmcnt circum- st+ncc, but bcc+usc it rcuircs sctting up sioc lorms to nolo tnc concrctc, it is gcncr+lly usco in irrcgul+r scctions wncrc sliplorm p+ving is not pr+ctic+l Contr+ction joints snoulo bc lormco or s+wcut +s soon +s possiblc +no +rc typic+lly s+wco to + ocptn ol onc-tniro tn+t ol tnc p+vcmcnt tnickncss ligurc 1-- ocpicts tnis proccss Contr+ctor cxpcricncc +no tools sucn +s tnc lcocr+l lignw+y Aoministr+tion lIlll- lAV computcr soltw+rc progr+m c+n nclp iocntily propcr s+wcut timcs b+sco on m+tcri+ls, ocsign, +no construction mctnoos ]oints snoulo bc sc+lco witn +n +ppropri+tc m+tcri+l, +ltnougn somc st+tcs +rc Figure 1-4. Sawcutting JPCP G u i d e
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P A V E M E N T S 1-6 cxpcrimcnting witn unsc+lco contr+ction joints loc+l pr+cticc snoulo govcrn +ccoroingly \ncn usco, oowcls c+n bc pl+cco in prcl+bric+tco oowcl b+skcts +no sccurco in pl+cc prior to p+ving ligurc 1- snows lrcsn concrctc pl+cco ovcr oowcl b+rs sccurco in oowcl b+r b+skcts Altcrn+tivcly, oowcls c+n bc inscrtco into tnc lrcsn concrctc ouring pl+ccmcnt using + oowcl-b+r inscrtcr (scc ligurc 1-o) lncrc +rc scvcr+l options lor pl+cing tic b+rs +s wcll A tic-b+r inscrtcr is commonly usco to pl+cc tic b+rs bctwccn l+ncs wncn two l+ncs +rc constructco +t tnc s+mc timc lor l+nc +ooitions, singlc-piccc tic b+rs c+n bc orillco +no inscrtco into tnc cxisting n+rocnco concrctc +no cpoxico into pl+cc lcnt tic b+rs c+n +lso bc inscrtco ouring p+ving +no pullco str+ignt +ltcr tnc p+vcmcnt n+s n+rocnco lin+lly, two-piccc tic b+rs c+n bc usco, wncrc onc-n+ll ol tnc tic b+r is inscrtco ouring pl+ccmcnt +no l+tcr tnc sccono n+ll is scrcwco into tnc nrst n+ll lcinlorcing stccl lor ]lCl +no ClCl is pl+cco bclorc p+ving bcgins +s sccn in ligurc 1-7 +no ligurc 1-S lcxturc is +pplico to tnc surl+cc ol tnc concrctc +ltcr pl+ccmcnt +no bclorc curing lnc purposc is to incrc+sc lriction +no improvc wct wc+tncr oriving conoitions lwo commonly usco wct tcxturc tccn- Figure 1-5. Concrete placed over dowel baskets Figure 1-6. Dowel-bar inserter Figure 1-7. JRCP reinforcement in place before paving Figure 1-8. CRCP reinforcement placed before paving G u i d e
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P A V E M E N T S 1-7 niucs incluoc tining +no or+g linco surl+ccs +rc +pplico using + stccl r+kc +no c+n bc +pplico longitu- oin+lly or in tnc tr+nsvcrsc oircction lr+g tcxturcs +rc +pplico by or+gging + piccc ol +rtinci+l turl or nc+vy burl+p on tnc surl+cc (scc ligurc 1-9) Aooition+l tcxturcs incluoc oi+mono grinoing +no grooving Il usco, grinoing +no grooving +rc oonc +ltcr curing +no oncc tnc p+vcmcnt is +blc to witnst+no tnc wcignt ol tnc m+cninc tn+t must bc usco lropcr curing mc+surcs prcvcnt r+pio w+tcr loss lrom tnc mixturc +no +llow morc tnorougn ccmcnt nyor+- tion It is csscnti+l to +pply curing +s c+rly +s possiblc +ltcr pl+cing concrctc +no to continuc until cnougn nyor+tion n+s t+kcn pl+cc +no tnc rcuirco n+rocnco propcrtics n+vc bccn +cnicvco A v+ricty ol curing mctnoos +no m+tcri+ls is +v+il+blc lor concrctc p+vc- mcnt, incluoing w+tcr spr+y or log, wct burl+p snccts, pl+stic snccts, +no insul+ting bl+nkcts \ost com- monly usco, nowcvcr, is tnc +pplic+tion ol + liuio mcmbr+nc-lorming compouno (scc ligurc 1-10) Sustainability - Concrctc p+vcmcnts n+vc longcvity - Inoustri+l by-prooucts (cg, ly +sn, sl+g ccmcnt, silic+ lumc) c+n bc usco in mixturc ocsign - Concrctc p+vcmcnt surl+ccs +rc nignly rclcctivc, m+king tncm morc visiblc +t nignt lcttcr visibility improvcs s+lcty lrigntcr strccts rcuirc lcss lignting, tncrclorc, cncrgy rcuircmcnts +rc rcoucco Figure 1-9. Burlap drag on fresh concrete Figure 1-10. Curing compound applied by spray nozzles on a cure cart - Concrctcs lignt surl+cc rcouccs tnc urb+n nc+t isl+no cllcct - Stuoics suggcst concrctc surl+ccs rcoucc vcniclc lucl consumption lor tnc oriving public For More Information Amcric+n Associ+tion ol St+tc lignw+y +no lr+ns- port+tion Olnci+ls 1993 American Association of State Highway and Transportation Ofcials (AASHTO) Design Guide. Amcric+n Concrctc Institutc 200S Guide for the Design and Construction of Concrete Parking Lots. ACI lcport 330l-0S Amcric+n Concrctc l+vcmcnt Associ+tion 2002 Concrete Pavement for General-Aviation, Business and Commuter Aircraft. Concrctc Inlorm+tion, IS202 Amcric+n Concrctc l+vcmcnt Associ+tion 200 StreetPave Computer Program. S\03 Amcric+n Concrctc l+vcmcnt Associ+tion 200o Design of Concrete Pavement for Streets and Roads. Con- crctc Inlorm+tion, ll237 lcocr+l lignw+y Aoministr+tion 1990 Concrete Pave- ment Joints. lccnnic+l Aovisory, l 0-030 lcocr+l lignw+y Aoministr+tion 2007 lIllllAV soltw+rc, wwwlIllllAVcom, wwwlnw+ootgov/ p+vcmcnt/pub_oct+ilsclm`io=oo0 G u i d e
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P A V E M E N T S 1-8 Nov+k, l +no l lilow 2009 A Sustainable Approach to Outdoor Lighting Utilizing Concrete Pavement. Sl393 lortl+no Ccmcnt Associ+tion 2011 Design and Con- trol of Concrete Mixtures. 1tn coition lortl+no Ccmcnt Associ+tion 2010 Integrated Paving SolutionsConcrete Pavements. nttp//wwwintcgr+tco- p+vingsolutionsorg/concrctcp+vcmcntsntml l+smusscn, l O, S I G+rbcr, G lick, l l lcrr+gut, +no l l \icg+no 200S How to Reduce Tire-Pavement Noise: Interim Better Practices for Constructing and Texturing Concrete Pavement Surfaces. loolco luno lll-(139) l+smusscn, logcrs, +no lcrr+gut 2009 Continuously Reinforced Concrete Pavement Design and Construction Guidelines. lr+lt, lcocr+l lignw+y Aoministr+tion +no Continuously lcinlorcco Concrctc Institutc, \+y l+ylor, G +no ] l+ttcn 200o Effects of Pavement Structure on Vehicle Fuel ConsumptionPhase III. lroj- cct --lV77, lccnnic+l lcport CSll-lVC-ll-0oS, NlC-CNlC, ]+nu+ry 27 l+ylor, l, S losm+tk+, G Voigt, ct +l 200o Integrated Materials and Construction Practices for Concrete Pave- ment: A State-of-the-Practice Manual. N+tion+l Concrctc l+vcmcnt lccnnology Ccntcr/Ccntcr lor lr+nsport+- tion lcsc+rcn +no louc+tion, Iow+ St+tc Lnivcrsity, lcccmbcr G u i d e
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2-1 Concrete Overlays Objectives - lxtcno p+vcmcnt lilc - Improvc tnc surl+cc - Incrc+sc lo+o-c+rrying c+p+city - lxpcoitc construction/rcncw+l - lcoucc urb+n nc+t isl+no cllcct - Incrc+sc lignt rclcct+ncc - lrovioc + sust+in+blc option Solution - Construct + concrctc ovcrl+y Benets - lcconstruction costs +rc +voioco - Construction ol +n ovcrl+y is mucn l+stcr tn+n rcconstruction - Concrctc p+vcmcnt surl+ccs rclcct lignt +no rcoucc tnc urb+n nc+t isl+no cllcct Considerations - lropcr +sscssmcnt ol cxisting p+vcmcnt conoitions is ncccss+ry to octcrminc lc+sibility - Any loss ol subgr+oc support or or+in+gc problcms must bc corrcctco Typical Applications Concrctc ovcrl+ys c+n bc usco lor tnc rcn+bilit+tion ol + v+ricty ol surl+ccs lowcvcr, v+rious l+ctors ncco to bc t+kcn into +ccount bclorc sclccting tnc +ppropri- +tc ovcrl+y systcm incluoing tnc cxisting p+vcmcnt conoition, ovcrl+y ocsign oct+ils, prc-ovcrl+y work, construction m+tcri+ls, +no luturc m+intcn+ncc +no rcn+bilit+tion Highways Commercial / Lightweight Airfields Heavy Industrial Streets & Local Roads Shoulders Description Concrctc ovcrl+ys +rc + our+blc +no cost-cllcctivc m+intcn+ncc +no rcn+bilit+tion +ltcrn+tivc wncn propcrly ocsignco +no constructco lcn+bilit+tion ol tnc cxisting p+vcmcnt is simplinco by tnc l+ct tn+t it oocs not ncco to bc rcmovco, +no uitc oltcn, lcw prc-ovcrl+y rcp+irs ncco to bc c+rrico out Ovcrl+ys prcscrvc p+vcmcnt scrvicc+bility lor scvcr+l occ+ocs bcyono tnc origin+l ocsign lilc Ovcrl+ys +rc constructco using convcntion+l concrctc p+ving proccourcs ]oint sp+cing, lo+o tr+nslcr ocsign, +no rcinlorccmcnt mctnoos +rc simil+r to ncw p+vc- mcnts In +ooition, typic+l concrctc mixturcs +rc usco, wnicn c+n bc +ojustco to +llow lor nigncr strcngtns or +n cxpcoitco construction proccss 2 Guide to Cement-Based Integrated Pavement Solutions G u i d e
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O V E R L A Y S 2-2 Concrctc ovcrl+ys +rc +blc to rcstorc tnc lunction ol + l+cility vcry cllcctivcly lnc construction ol + ncw surl+cc rcsults in subst+nti+lly improvco surl+cc cn+r- +ctcristics incluoing rioc+bility, improvco noisc lcvcls, +no incrc+sco lriction lclorc pl+ccmcnt ol +n ovcrl+y c+n occur, tnc cxisting p+vcmcnt must bc sulncicntly cv+lu+tco in orocr to cnsurc it is + gooo c+noio+tc lor ovcrl+y construction lncrc +rc two m+in typcs ol con- crctc ovcrl+ys bonoco +no unbonoco (scc ligurc 2-1) lotn ovcrl+y typcs c+n bc constructco ovcr concrctc, lcxiblc, +no compositc p+vcmcnts (scc ligurc 2-2) lonoco ovcrl+ys +rc rcl+tivcly tnin +no constructco oircctly on top ol cxisting p+vcmcnts lonoco ovcr- l+ys rcstorc tnc surl+cc +no +oo somc structur+l c+p+city to ro+ow+ys tn+t +rc somcwn+t to moocr+tcly oistrcssco Lnbonoco concrctc ovcrl+ys +rc typic+lly tnickcr tn+n bonoco ovcrl+ys +no rcuirc + scp+r+tion l+ycr (ic, bono brc+kcr) Lnbonoco ovcrl+ys rcstorc tnc struc- tur+l c+p+city ol cxisting p+vcmcnts tn+t +rc moocr- +tcly to signinc+ntly octcrior+tco Materials lnc typc ol projcct +no tnc construction scncoulc oict+tc tnc concrctc mixturc m+tcri+ls Convcntion+l mixturcs snoulo bc c+rclully sclcctco to +llow tnc rcsulting mixturc to bc ocnsc, rcl+tivcly impcrmc+blc, +no rcsist+nt to cnvironmcnt+l cllccts ovcr tnc lcngtn ol its scrvicc lilc \ost +gcncics spccily + 2S-o+y unconnnco comprcssivc strcngtn rcuircmcnt ol -,000 psi (2S \l+) lor tncir p+vcmcnts On tnc otncr Figure 2-1. Unbonded overlay Figure 2-2. Overlay applications Bonded Overlay Systems Unbonded Overlay Systems Bonded Concrete Overlays of Concrete Pavements previously called bonded overlays Bonded Concrete Overlays of Asphalt Pavements previously called ultra-thin whitetopping Bonded Concrete Overlays of Composite Pavements Unbonded Concrete Overlays of Concrete Pavements previously called unbonded overlays Unbonded Concrete Overlays of Asphalt Pavements previously called conventional whitetopping Unbonded Concrete Overlays of Composite Pavements In general, bonded overlays are used to add structural capacity and/or eliminate surface distress when the existing pavement is in good structural condition. Bonding is essential, so thorough surface preparation is necessary before resurfacing. In general, unbonded overlays are used to rehabilitate pavement with some structural deterioration. They are basically new pavements constructed on an existing, stable platform (the existing pavement). (Resurfacing/Minor Rehabilitation) (Minor/Major Rehabilitation) G u i d e
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O V E R L A Y S 2-3 n+no, somc st+tcs usc r+pio-strcngtn concrctc mix- turcs tn+t n+vc + nign ccmcntitious m+tcri+l contcnt, + low w+tcr-to-ccmcntitious m+tcri+ls (w/cm) r+tio, +no sm+llcr top sizc +ggrcg+tc lncsc typcs ol mixturcs c+n bc usco witn +ccclcr+ting +omixturcs to +llow lor l+stcr opcning timcs lypc I +no lypc II ccmcnts +rc norm+lly usco in con- crctc mixturcs lor concrctc ovcrl+ys lypc III ccmcnt c+n bc usco wncn nign c+rly strcngtn is ocsirco V+ri- ous +omixturcs +rc commonly introoucco +s wcll +no incluoc w+tcr rcouccrs, +ir cntr+inmcnt, +no SC\s Supplcmcnt+ry ccmcnting m+tcri+ls sucn +s ly +sn +no sl+g ccmcnt improvc tnc work+bility ol tnc con- crctc, incrc+sc our+bility +no long-tcrm strcngtn, +no cxtcno pl+ccmcnt timc ouring not wc+tncr A m+xi- mum w/cm r+tio ol 0- is common lor p+vcmcnts in + moist cnvironmcnt witn m+ny lrcczc-tn+w cyclcs, +ltnougn lowcr v+lucs +rc usco to minimizc orying snrink+gc Aggrcg+tcs usco in ovcrl+ys r+ngc lrom crusnco stoncs +no rivcr gr+vcls to rccyclco concrctc +ggrcg+tc +no snoulo posscss +ocu+tc strcngtn +no bc pnysic+lly +no cncmic+lly st+blc witnin tnc concrctc mixturc lnc m+ximum co+rsc +ggrcg+tc sizc snoulo bc usco in orocr to minimizc p+stc rcuircmcnts, rcoucc snrink- +gc, minimizc costs, +no improvc mccn+nic+l intcr- lock propcrtics +t joints +no cr+cks lnc scp+r+tion l+ycr in unbonoco ovcrl+ys is critic+l to tncir long-tcrm pcrlorm+ncc (scc ligurc 2-3) A 1-in (2 mm) tnick convcntion+l l\A surl+cc mix- turc is most commonly usco lowcvcr, tnc usc ol + nonwovcn gcotcxtilc intcrl+ycr n+s bccn snown to bc + promising +ltcrn+tivc lcsc+rcn +no projcct cxpcri- cncc n+s snown tn+t nonwovcn gcotcxtilcs provioc Figure 2-3. Typical cross-section of unbonded overlay Separation Layer Prepared/Untreated Subgrade Overlay Base/Subbase Existing Pavement Prepared/Untreated Subgrade Overlay Base/Subbase Existing Pavement unilorm, cl+stic support ol tnc concrctc sl+b, rcoucc pumping proccsscs, +no prcvcnt rclcctivc cr+cking Concrctc ovcrl+ys n+vc bccn snown to +oo 1 to 30 yc+rs ol scrvicc lilc to + ro+ow+y long-tcrm our+bility will rcsult lrom propcr m+tcri+ls sclcction, sulncicnt prc-ovcrl+y work, cllcctivc ocsign mctnoos, +no suc- ccsslul construction pr+cticcs l+vcmcnt m+n+gcmcnt +no prcscrv+tion +ctivitics sucn +s routinc +no prc- vcntivc m+intcn+ncc +no minor rcn+bilit+tion snoulo bc c+rclully consiocrco +s wcll in orocr to lurtncr incrc+sc tnc scrvicc lilc ol + concrctc ovcrl+y Design lnc ocsign ol +n ovcrl+y incluocs c+lcul+ting + tnick- ncss, cst+blisning + joint l+yout, +no octcrmining rcinlorccmcnt contcnt lncrc +rc scvcr+l st+tc-ol-tnc- pr+cticc ocsign mctnoos tn+t +rc listco in l+blc 2-1 In tnc c+sc ol +n unbonoco ovcrl+y, tnc ovcrl+y ocsign must incluoc +n intcrl+ycr Bonded Overlays lnc ocsign ol + bonoco concrctc ovcrl+y ocpcnos on tnc +ssumption tn+t tnc ovcrl+y +no cxisting p+vcmcnt will bc onc monolitnic structurc lor bonoco ovcrl+ys, typic+l tnickncsscs r+ngc lrom 2 to in (0 to 12 mm) lor nign-tr+lnc ro+os, + o in (10 mm) bonoco ovcrl+y or grc+tcr c+n bc constructco Table 2-1. Current state-of-the-practice overlay design methodologies
State-of-the-Practice Concrete Overlay Design Methods Bonded concrete overlay of concrete pavements s 1993 AASHTO Guide s M-E PDG Bonded concrete overlay of HMA and composite pavements s 1993 AASHTO Guide s M-E PDG s Modied ACPA method Unbonded concrete overlay of all types s 1993 AASHTO Guide s M-E PDG G u i d e
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O V E R L A Y S 2-4 lypic+l joint ocsign p+ttcrns +rc listco in l+blc 2-2 lccommcno+tions lor joint ocptn ocpcno on tnc typc ol joint +no cxisting p+vcmcnt, +s wcll +s tnc cuip- mcnt usco lor construction Ovcrl+y joint wiotns lor bonoco concrctc p+vcmcnts +rc cu+l to cxisting p+vcmcnt joints lor convcn- tion+l s+ws, tr+nsvcrsc joints in bonoco ovcrl+ys ol concrctc p+vcmcnts snoulo bc lull ocptn plus 00 in (13 mm) Simil+rly, longituoin+l joints +rc cut citncr lull ocptn or no lcss tn+n n+ll ol tnc p+vcmcnt tnick- ncss lr+nsvcrsc joints in bonoco ovcrl+ys ol l\A +no compositc p+vcmcnts constructco using + con- vcntion+l s+w snoulo bc cut to + ocptn ol onc-lourtn ol tnc p+vcmcnt tnickncss (l/-), longituoin+l joints snoulo bc s+wcut to + ocptn ol onc-tniro ol tnc p+vc- mcnt tnickncss (l/3) lcinlorccmcnt sucn +s tic b+rs, oowcl b+rs, +no otncr cmbcooco stccl prooucts +rc typic+lly not usco lor ovcrl+ys lcss tn+n o in (10 mm) tnick Continuously rcinlorcco bonoco ovcrl+ys n+vc bccn constructco by somc +gcncics, +no in tncsc c+scs stccl is pl+cco +t sulncicnt ocptn to provioc + minimum ol 3 in (7 mm) ol concrctc covcr lnc stccl c+n bc posi- tionco oircctly on top ol tnc olo p+vcmcnt, wnicn n+s tnc +ooco bcncnt ol cllcctivcly rcstr+ining concrctc volumc cn+ngcs +t tnc intcrl+cc Table 2-2. Joint pattern for bonded concrete overlays Joint Pattern for Bonded Overlays Bonded Overlay of JPCP Match joints with existing pavement joints. Bonded Overlay of CRCP Match longitudinal joints with existing pavement joints. Bonded Overlay of HMA and Composites Use small square patterns in the range of 3 to 8 ft. (0.9 to 2.4 m). Maximum dimensions of the square panels should be no greater than 1.5 times the thickness of the overlay. Avoid longitudinal joints in the wheel paths. Unbonded Overlays lnc ocsign ol +n unbonoco ovcrl+y is simil+r to ocsigning + ncw concrctc p+vcmcnt ovcr + st+bilizco subb+sc An unbonoco ovcrl+y ocsign +ssumcs tncrc is no bono bctwccn tnc bottom surl+cc ol tnc ovcrl+y +no tnc top surl+cc ol tnc cxisting p+vcmcnt lnc ocsign tnickncss ol +n unbonoco ovcrl+y typic+lly r+ngcs lrom o to 11 in (10 to 2S0 mm) but c+n bc +s tnin +s - in (100 mm) lor lowcr-volumc ro+os or wncn ovcrnc+o clc+r+ncc is +n issuc +no lo+oing is lignt Lnbonoco ovcrl+ys ol concrctc p+vcmcnts rcuirc +n intcrl+ycr +s + scp+r+tion l+ycr lnc ocsign ol tnc scp+- r+tion l+ycr is critic+l to tnc long-tcrm pcrlorm+ncc ol tnc ovcrl+y bcc+usc it nclps prcvcnt rclcctivc cr+cking +no +llows tnc ovcrl+y +no cxisting p+vcmcnt struc- turc to movc inocpcnocntly ol onc +notncr lr+in+gc must bc consiocrco ouring ocsign ol tnis intcrl+ycr lnc most common scp+r+tion l+ycr is + 1-in (2-mm) l\A surl+cc mixturc, nowcvcr, + nonwovcn gcotcx- tilc spccinc+lly m+nul+cturco lor usc +s +n intcrl+ycr bctwccn ccmcntitious l+ycrs n+s +lso bccn usco +s +n +ltcrn+tivc lnc tnickncss ol tnc l\A intcrl+ycr is somctimcs incrc+sco sligntly lor unbonoco ovcrl+ys ol ClCl An incrc+sc in intcrl+ycr tnickncss m+y +lso bc rcuirco il tnc cxisting p+vcmcnt cxpcricnccs l+rgcr ocgrccs ol l+ulting A gcotcxtilc is not + gooo +ltcrn+- tivc in sucn c+scs It snoulo bc notco tn+t wnilc unbonoco ovcrl+ys ol l\A or compositc p+vcmcnts oo not rcuirc +n intcrl+ycr, il + lull-ocptn concrctc p+tcn n+s bccn con- structco in tnc cxisting p+vcmcnt it must bc isol+tco Onc tccnniuc lor isol+ting tnc p+tcn is to +pply + ocbonoing +gcnt or m+tcri+l (cg, +spn+lt cmulsion co+ting) to tnc surl+cc ol tnc p+tcn bclorc tnc con- struction ol tnc ovcrl+y lor +n unbonoco ovcrl+y ol concrctc, m+ny st+tcs try to m+tcn tnc tr+nsvcrsc joints in tnc ovcrl+y witn tnosc in tnc cxisting p+vcmcnt lowcvcr, somc st+tcs intcntion+lly ocsign tr+nsvcrsc joints in tnc ovcrl+y +t +n ollsct lrom tnosc in tnc cxisting p+vcmcnt ]oint sp+cings +rc ocsignco b+sco on tnc tnickncss ol tnc ovcrl+y lypic+l joint p+ttcrns lor unbonoco ovcrl+ys +rc listco in l+blc 2-3 +no l+blc 2-- ]oint ocptns ocpcno on tnc typc ol s+w usco lor construction G u i d e
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O V E R L A Y S 2-5 Lnbonoco ovcrl+ys ol concrctc, l\A, or compositc p+vcmcnts snoulo incluoc tr+nsvcrsc joints tn+t, wncn cut witn convcntion+l s+ws, +rc constructco +t ocptns ol l/- to l/3 longituoin+l joints snoulo bc +t ocptns ol l/3 lowcls +rc usco in joints wncn tnc ovcrl+ys ocsign tnickncss is grc+tcr tn+n S in (200 mm) +no cxpcctco to c+rry nc+vy truck tr+lnc lic b+rs m+y bc +ppropri- +tc in opcn-oitcn (or snoulocr) scctions il tnc ocsign tnickncss is grc+tcr tn+n in (12 mm) lico snoul- ocrs +rc tnc +pprovco mctnoo lor provioing ovcrl+y cogc support lic b+rs +t connnco curb-+no-guttcr scctions snoulo bc consiocrco il tnc ovcrl+y ocsign tnickncss is grc+tcr tn+n o in (10 mm) Construction lnc construction ol +n ovcrl+y (scc ligurc 2--) is + proccss simil+r to convcntion+l concrctc p+vcmcnt Unbonded Overlays of Concrete Pavements Design Thickness Joint Pattern <5 in. (125 mm) Use square panels measuring 6 x 6 ft (1.8 x 1.8 m) panels 5 7 in. (125 175 mm) Maximum joint spacing in feet = 2 times thickness in inches > 7 in. (175 mm) Maximum joint spacing =15 ft. (4.6 m) Table 2-3. Joint pattern for unbonded concrete overlays of concrete pavements Unbonded Overlays of Concrete Pavements Design Thickness Joint Pattern <6 in. (150 mm) Maximum joint spacing in feet = 1.5 times thickness in inches 6 15 in. (150 380 mm) Maximum joint spacing in feet = 2 times thickness in inches > 15 in. (380 mm) Maximum joint spacing =15 ft. (4.6 m) Table 2-4. Joint pattern for unbonded concrete overlays of HMA and composite pavements +no incluocs concrctc proouction, prcp+r+tion ol tnc cxisting surl+cc, +no tnc pl+ccmcnt, curing, +no s+w- cutting ol ncw concrctc \nilc mixing +no pl+cing +rc tnc s+mc lor botn bonoco +no unbonoco ovcrl+ys, tncrc +rc subtlc oil- lcrcnccs in tnc otncr stcps ol tnc proccss b+sco on tnc typc ol ovcrl+y to bc constructco +no tnc typc ol cxisting p+vcmcnt Bonded Overlays lor bonoco ovcrl+ys ol +ny kino, rcp+irs ncco to bc m+oc to pl+cc tnc cxisting p+vcmcnt in gooo conoi- tion or +t lc+st in l+ir conoition lor cxisting concrctc p+vcmcnt, tn+t woulo incluoc rcp+iring wioc cr+cks +no subsurl+cc voios lor cxisting l\A +no compos- itc p+vcmcnts, rcp+irs incluoc +oorcssing potnolcs, moocr+tc to scvcrc +llig+tor cr+cking, +no loss ol subgr+oc support \ctnoos lor +oorcssing tnc vcrti- c+l movcmcnt ol concrctc in compositc p+vcmcnts +rc cxpl+inco in tnc N+tion+l Concrctc l+vcmcnt lccn- nology Ccntcrs Guide to Concrete Overlays Altcr rcp+ir, tnc surl+cc ol +n cxisting p+vcmcnt is prcp+rco +no clc+nco ol +ny loosc ocbris Surl+cc prcp+r+tion +no clc+ning promotcs + bono bctwccn tnc ovcrl+y +no cxisting p+vcmcnt lnc most com- mon mctnoo usco to prcp+rc + concrctc surl+cc is snotbl+sting lnc surl+cc is tncn clc+nco by swccping +no/or using comprcssco +ir \illing l\A +no/or compositc surl+ccs c+n +lso bc +n +ppropri+tc mctnoo ol rcp+ir, nowcvcr, too mucn milling (lor citncr rcp+ir or prcp+r+tion) will rcoucc structur+l c+p+city lnc Figure 2-4. Unbonded concrete overlay construction over a nonwoven geotextile interlayer G u i d e
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O V E R L A Y S 2-6 minimum rcm+ining l\A nccos to bc +t lc+st 3 in (7 mm), prclcr+bly - in (100 mm) \illing nccos to bc oonc to tnc top ol tnc nc+rcst l\A lilt linc to prcvcnt lr+cturing ol tnc l\A lot-mix +spn+lt +no compositc p+vcmcnts +rc tncn swcpt clc+n or blown witn comprcssco +ir ll+ccmcnt ol concrctc ovcr cxisting p+vcmcnts snoulo lollow st+no+ro convcntion+l concrctc p+ving pr+c- ticcs (scc ligurc 2-) ll+ccmcnt ovcr l\A or com- positc p+vcmcnts c+n bc +ccomplisnco using nxco- lorm or sliplorm construction tccnniucs \ncn l\A surl+cc tcmpcr+turcs +rc grc+tcr tn+n 120l (-9C), tnc surl+cc snoulo bc coolco by +pplying w+tcr in lront ol tnc p+vcr, nowcvcr, no st+noing w+tcr snoulo bc +llowco +t tnc timc ol p+ving Il tnc surl+cc c+n- not bc coolco sulncicntly, pl+ccmcnt m+y ncco to bc rcscncoulco lor +notncr p+rt ol tnc o+y Curing + bonoco ovcrl+y +no propcrly timco s+wcuts +rc critic+l l+ctors no m+ttcr wn+t typc ol cxisting p+vcmcnt lics bcnc+tn it lnc ncw concrctc l+ycr n+s + nign surl+cc-to-volumc r+tio tn+t m+kcs it vulncr+blc to r+pio moisturc loss Curing compounos snoulo bc +pplico +t twicc tnc r+tc typic+l lor convcntion+l con- crctc pr+cticcs +no snoulo co+t tnc surl+cc +no cogcs cvcnly ]oints must bc cut +s soon +s possiblc +no c+n bc constructco witn convcntion+l or c+rly-cntry s+ws It m+y bc ncccss+ry to n+vc multiplc s+ws on n+no in orocr to s+wcut joints l+st cnougn to prcvcnt uncon- trollco cr+cking ]oint sc+l+nts m+y not bc rcuirco Unbonded Overlays lclorc +n unbonoco ovcrl+y is constructco ovcr +ny cxisting p+vcmcnt typc (ic, concrctc, l\A, or com- positc), oistrcsscs tn+t c+usc + m+jor loss ol structur+l intcgrity will rcuirc rcp+ir lot-mix +spn+lt +no compositc p+vcmcnts m+y bc millco to corrcct surl+cc oclccts tn+t +rc 2 in (0 mm) or occpcr A minimum ol 3 to - in (7 to 100 mm) ol l\A must rcm+in in pl+cc +ltcr milling il tnc ovcrl+y ocsign tnickncss is o in (10 mm) or grc+tcr Il lcss tn+n o in (10 mm), +n ovcrl+y ol +t lc+st o in (10 mm) ol rcm+ining l\A is rccommcnoco, otncrwisc, + bonoco ovcrl+y snoulo bc ocsignco Altcr rcp+ir, il +ny +rc ncccss+ry, tnc surl+cc is swcpt or +ir blown Il tnc cxisting p+vcmcnt is concrctc, tnc surl+cc must bc voio ol +ny loosc ocbris bclorc tnc bono-brc+kcr intcrl+ycr is constructco lot-mix +spn+lt +no compositc surl+ccs c+n bc simply swcpt clc+n, sm+ll rcm+ining ocbris is not +n issuc likc bonoco ovcrl+ys, pl+ccmcnt ol unbonoco ovcr- l+ys ovcr cxisting concrctc snoulo lollow st+no+ro convcntion+l concrctc p+ving pr+cticcs ll+ccmcnt ovcr l\A or compositc p+vcmcnts c+n bc +ccom- plisnco using nxco-lorm or sliplorm construction tccnniucs lnc p+vcmcnt nccos to bc coolco prior to p+ving, wncn surl+cc tcmpcr+turcs +rc grc+tcr tn+n 120l (-9C) lowcl b+skcts must bc sccurco propcrly to tnc cxisting p+vcmcnt unlcss + oowcl b+r inscrtcr is usco Curing +no s+wcutting lollows tnc s+mc logic +s tn+t lor bonoco ovcrl+ys uick, tnorougn, cvcn +pplic+- tion ol curing +no propcrly timco s+w cuts +rc critic+l to long-tcrm pcrlorm+ncc Sustainability - Concrctc ovcrl+ys m+kc usc ol tnc cxisting p+vc- mcnt, climin+ting tnc ncco lor rcmov+l +no oispos+l - Concrctc ovcrl+ys c+n bc constructco +no opcnco to tr+lnc witnin + o+y, rcoucing uscr costs +no orivcr lrustr+tion - Concrctc ovcrl+ys posscss + low lilc-cyclc cost, witn long livcs +no minim+l m+intcn+ncc costs Figure 2-5. Bonded overlay construction G u i d e
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O V E R L A Y S 2-7 - Inoustri+l by-prooucts (cg, ly +sn, sl+g ccmcnt, silic+ lumc) c+n bc usco in mixturc ocsign - Concrctc p+vcmcnt surl+ccs +rc nignly rclcctivc, m+king tncm morc visiblc +t nignt lcttcr visibility improvcs s+lcty - Concrctcs lignt surl+cc rcouccs tnc urb+n nc+t isl+no cllcct For More Information Amcric+n Concrctc Institutc 200o Concrete Overlays for Pavement Rehabilitation lcport No ACI 3213l-0o l+rrington, l, ct +l 200S Guide to Concrete OverlaysSustainable Solutions for Resurfacing and Rehabilitating Existing Pavements. Sccono loition N+tion+l Concrctc l+vcmcnt lccnnology Ccntcr Scptcmbcr N+tion+l Concrctc l+vcmcnt lccnnology Ccntcr 2010 Guide for the Design of Concrete Overlays Using Existing Methodologies (lr+lt) l+ll lortl+no Ccmcnt Associ+tion 2010 Integrated Paving SolutionsConcrete Overlays nttp//wwwintcgr+tco- p+vingsolutionsorg/ConcrctcOvcrl+ysntml G u i d e
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3-1 Pervious Concrete Objectives - S+tisly llA Storm \+tcr ln+sc II rcgul+tions - l+rn llll crcoits - Improvc s+lcty - lcoucc tirc-p+vcmcnt noisc - lrovioc + sust+in+blc option Solution - Lsc pcrvious concrctc Benets - lcrvious concrctc is +n llA lcst \+n+gcmcnt lr+cticc - Stormw+tcr runoll +no l+sn loooing is minimizco - lyoropl+ning +no spl+sn +no spr+y +rc minimizco - Noisc lrom tnc tirc-p+vcmcnt intcr+ction is rcoucco - lcrvious concrctc surl+ccs rclcct lignt +no nclp rcoucc tnc urb+n nc+t isl+no cllcct Considerations - lcrvious concrctc m+y rcuirc pcriooic m+intcn+ncc to prcvcnt clogging - lcrvious concrctc m+y c+usc r+vcling +no +br+sion problcms on nigncr-spcco ro+ow+ys Typical Applications Commercial / Lightweight Streets & Local Roads Shoulders Org+niz+tions sucn +s tnc Grccn lignw+ys l+rtncr- snip +rc +ctivcly l+cilit+ting tnc rcocvclopmcnt ol m+ny inncr-city l+nosc+pcs in +n cllort to m+kc tncm morc sust+in+blc lcrvious concrctc p+vcmcnts +rc bccoming morc +ttr+ctivc +ltcrn+tivcs lor + v+ricty ol ncw construction +no urb+n rctront +pplic+tions ligurc 3-1 snows pcrvious concrctc inst+llco +t + p+rk to mcct Amcric+ns witn lis+bilitics Act (AlA) +cccssibility rcuircmcnts ligurc 3-2 snows pcrvious concrctc inst+llco +t + p+rk to minimizc impcrvious Figure 3-1. Miller Park in Fair Oaks, California Figure 3-2. Imperial Beach Sports Park, California 3 Guide to Cement-Based Integrated Pavement Solutions G u i d e
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C O N C R E T E 3-2 surl+cc runoll ligurc 3-3 snows + Cnic+go, Illinois, ncignbornooo +llcy constructco ol pcrvious concrctc to minimizc runoll lnc +bility to m+n+gc stormw+tcr runoll m+kcs pcrvious concrctc + common cnoicc lor +pplic+tions, incluoing city strccts +no loc+l ro+os, snoulocrs, pcocstri+n w+lkw+ys, +llcys, +no p+rking lots lcrvious p+vcmcnt c+n +lso bc usco +s + subb+sc lor convcntion+l concrctc, +t low-w+tcr crossings, +no lor rccrc+tion+l +rc+s sucn +s tcnnis courts +no grccnnouscs Figure 3-3. Pervious concrete for alley in Chicago, Illinois stor+gc +no rctcntion timc lor cgrcss +no pcrcol+tion ol w+tcr into tnc subgr+oc lnc mix ocsign is com- posco ol n+rrow spcci+lly gr+oco co+rsc +ggrcg+tc, ccmcnt, w+tcr, +no + sm+ll +mount ol nnc +ggrcg+tc lnc rcsult is + m+tcri+l witn intcrconncctco +ir voios ol bctwccn 1 to 2 pcrccnt, ocpcnoing on tnc mix ocsign \ncn comp+rco to convcntion+l concrctc p+vcmcnts, tnc cxposco +ggrcg+tc surl+cc ol pcrvi- ous concrctc c+n provioc cnn+ncco tr+ction lor botn pcocstri+ns +no vcniclcs lnc potcnti+l lor vcniclcs nyoropl+ning ouring wct wc+tncr conoitions is +lso rcoucco Il not curco propcrly, surl+cc p+rticlcs m+y bccomc loosc or r+vcl \itn propcr comp+ction +no curing, r+vcling c+n bc prcvcntco Figure 3-4. Pervious concrete Figure 3-5. Pervious concrete pavement parking lot Description lcrvious concrctc (scc ligurc 3--) is usco in + nignly pcrmc+blc p+vcmcnt tn+t c+pturcs r+inw+tcr +no +llows it to p+ss tnrougn tnc surl+cc +no pcrcol+tc into tnc unocrlying l+ycr lcrvious concrctc p+vcmcnts minimizc stormw+tcr runoll, l+sn loooing, +no st+noing w+tcr, tncy c+n rcoucc or cvcn climin+tc tnc ncco lor on-sitc noloing ponos or burico stormw+tcr rctcntion structurcs ligurc 3- snows + p+rking lot m+oc ol pcrvious concrctc lcrvious concrctc c+n bc pl+cco oircctly on + or+in- +blc +ggrcg+tc b+sc, +bovc s+no, or on soils witn sul- ncicnt or+in+gc propcrtics lcrvious concrctc m+y +lso bc pl+cco ovcr impcrmc+blc soils sucn +s cl+y, now- cvcr, provisions ncco to bc m+oc lor +ocu+tc w+tcr G u i d e
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C O N C R E T E 3-3 lcrvious concrctc p+vcmcnts c+n l+st lor morc tn+n 20 yc+rs witn nomin+l m+intcn+ncc lo cnsurc +ocu+tc or+in+gc, routinc m+intcn+ncc is typic+lly rcuirco lnc +mount ol routinc m+intcn+ncc ocpcnos on tnc r+tc ol soil lo+oing Swccping, v+cuuming, or powcr spr+ying c+n bc usco to mitig+tc clogging +no rcstorc pcrmc+bility lncsc p+vcmcnts n+vc bccn succcsslul in lrcczc-tn+w +no sull+tc cnvironmcnts wncn ocsignco +no constructco propcrly lnc +bility lor pcrvious concrctc p+vcmcnts to or+in w+tcr uickly minimizcs tnc s+tur+tion witnin tnc voios tn+t coulo otncrwisc lrcczc +no c+usc o+m+gc lcrvious concrctc is morc susccptiblc to sull+tc cnvironmcnts, nowcvcr, il kcpt isol+tco lrom sull+tc ricn soils or prooucco witn SC\s, pcrvious p+vcmcnts c+n pcrlorm s+tisl+ctorily Materials Scc l+blc 3-1 lor typic+l v+lucs ol m+tcri+l propcrtics lor pcrvious concrctc lcrvious concrctc uscs b+sic+lly tnc s+mc m+tcri+ls +s convcntion+l concrctc Onc cxccption is tn+t tnc nnc +ggrcg+tc contcnt is limitco +no tnc co+rsc +ggrcg+tc is kcpt to + n+rrow gr+o+tion (scc ligurc 3-o) Com- monly usco gr+o+tions ol co+rsc +ggrcg+tc incluoc ASl\ C33 No o7, No S, or No S9 Numbcr S9 is typic+lly usco in mixturcs lor p+rking lots +no pcocs- tri+n w+lkw+ys lounoco or +ngul+r (ic, crusnco) +ggrcg+tcs c+n bc usco lor pcrvious concrctc mixturcs \+ximum +ggrcg+tc sizc +no tnc typc ol +ggrcg+tc will +llcct tnc nn+l surl+cc tcxturc Figure 3-6. Fresh pervious concrete Table 3-1. Typical values for material properties Property Typical Values Unit Weight 70-80% of conventional concrete mixtures Density 100-125 lb/ft 3 (1600-2000 kg/m 3 ) this is dependent on mix design and construction procedures Percent Voids 15-25% Permeability 100 in./hr over 2000 in/hr (2.5-50 m/hr) Compressive Strength 2500 psi (17 MPa) but this can range from 500 4000 psi (3.5 28 MPa) lcrvious concrctc mixcs cont+in minim+l +mounts ol w+tcr, witn w+tcr-to-ccmcntitious m+tcri+ls (w/cm) r+tios +rouno 030, nowcvcr, r+tios +s nign +s 03- to 0-0 n+vc bccn usco succcsslully witn tnc propcr inclusion ol cncmic+l +omixturcs, sucn +s rct+rocrs lortl+no ccmcnts +no blcnoco ccmcnts m+y bc usco in pcrvious concrctc +pplic+tions In +ooition, SC\s sucn +s ly +sn, pozzol+ns, +no sl+g ccmcnt c+n bc usco to improvc m+tcri+l propcrtics sucn +s work+bil- ity +no strcngtn In lrcczc-tn+w cnvironmcnts, +ir- cntr+ining +omixturcs +rc rccommcnoco G u i d e
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C O N C R E T E 3-4 Design A pcrvious p+vcmcnt is ocsignco +s citncr +n +ctivc or + p+ssivc systcm An +ctivc systcm is ocsignco to n+nolc mucn morc r+inl+ll tn+n is cxpcctco to l+ll on just tnc p+vcmcnt itscll A p+ssivc systcm is + pcrvi- ous concrctc p+vcmcnt tn+t n+nolcs r+inl+ll tn+t l+lls oircctly on tnc p+vcmcnt surl+cc A p+ssivc mitig+- tion systcm c+n c+pturc mucn, il not +ll, ol tnc 'nrst lusn,` but it is not intcnoco to ollsct cxccss runoll lrom +oj+ccnt impcrvious surl+ccs An +ctivc mitig+- tion systcm is ocsignco to m+int+in runoll +t + sitc +t spccinc lcvcls lor citncr systcm (+ctivc or p+ssivc), + propcr tnickncss must bc ocsignco lcrvious p+vc- mcnt tnickncss is ocsignco b+sco on tnc c+lcul+tion ol nyorologic +no mccn+nic+l propcrtics incluoing tnc +mount ol cxpcctco r+inl+ll, p+vcmcnt cn+r+ctcr- istics, +no unocrlying soil propcrtics St+no+ro ocsign proccourcs incluoc ACI 22l, ACI 329l, or ACI 330l Scc ligurc 3-7 lor pcrvious concrctc subjcctco to r+inl+ll lcsigns lor pcrvious concrctc p+vcmcnt surl+ccs must consiocr pcrmc+bility +no stor+gc c+p+city Figure 3-7. Pervious concrete pavement in the rain lcsigncrs snoulo cnsurc tn+t pcrmc+bility is sulncicnt to +ccommoo+tc +ll r+in l+lling on tnc surl+cc ol or running onto pcrvious concrctc \nilc tnc pcrmc+bil- ity ol pcrvious concrctcs is + l+ctor in ocsign, tnc low r+tc tnrougn tnc subb+sc +no subgr+oc m+y bc morc rcstrictivc +no control tnc +mount ol w+tcr lc+ving tnc systcm lnc tot+l stor+gc c+p+city ol tnc pcrvious concrctc systcm incluocs tnc c+p+city ol tnc pcrvious concrctc p+vcmcnt, tnc c+p+city ol +ny subb+sc usco, +no tnc +mount ol w+tcr tn+t lc+vcs tnc systcm by innltr+tion into tnc unocrlying soil In lrcczc-tn+w clim+tcs, pcrvious concrctc systcms snoulo not bc ocsignco to storc w+tcr in tnc concrctc itscll bcc+usc ol tnc cxp+nsivc n+turc ol w+tcr wncn it lrcczcs lor typic+l ocsigns, tnc stor+gc c+p+city +no innltr+tion r+tc ol tnc subb+sc +no subgr+ocs +rc signinc+nt lypic+l ocsign tnickncsscs incluoc - to o-in (12- to 10-mm) tnick pcrvious concrctc witn + or+in+blc +ggrcg+tc b+sc gcncr+lly o- to 12-in (10- to 300- mm) tnick lnc b+sc l+ycr snoulo +llow + pcrcol+tion r+tc ol 0 in/nr (13 mm/nr) il no ovcrlow piping is G u i d e
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C O N C R E T E 3-5 inst+llco In lrcczc-tn+w cnvironmcnts, + minimum ol 12 in (300 mm) ol + or+in+blc +ggrcg+tc b+sc, sucn +s 1-in (2-mm) crusnco stonc, is typic+lly constructco A tnickcr p+vcmcnt systcm m+y ncco to bc usco il nc+vicr lo+os +no nigncr tr+lnc +rc +nticip+tco, or il tnc pcrcol+tion r+tc ol tnc b+sc l+ycr is in+ocu+tc ligurc 3-S, ligurc 3-9, +no ligurc 3-10 snow typic+l scncm+tics ol pcrvious p+vcmcnt ocsigns lull cxnl- tr+tion ocsigns +rc only usco wncrc tnc n+tur+l soil n+s + nign innltr+tion r+tc or gooo l+tcr+l pcrmc+bility l+rti+l cxnltr+tion ocsigns +rc tnc most common +no typic+lly usco to control tnc w+tcr u+lity volumc No cxnltr+tion ocsigns +rc usco wncrc problcm soils +rc + conccrn or wncrc it is not ocsir+blc to introoucc w+tcr into +oj+ccnt loc+tions Figure 3-8. Schematic of pervious full exltration pavement design Precast Pavement Drainable Base Untreated Subgrade Pervious Pavement Drainable Base Untreated Subgrade Friction Reducing Medium Figure 3-9. Schematic of pervious partial exltration pavement design Figure 3-10. Schematic of pervious no exltration pavement design Precast Pavement Drainable Base Untreated Subgrade Pervious Pavement Drainable Base Untreated Subgrade Tile Drain w/ Up-Turned Elbow Friction Reducing Medium Precast Pavement Drainable Base Untreated Subgrade Pervious Pavement Drainable Base Untreated Subgrade Friction Reducing Medium Tile Drain Construction lnc construction ol pcrvious concrctc p+vcmcnt incluocs proouction ol concrctc, pl+ccmcnt, comp+c- tion, +no curing lcrvious concrctc proouction rcuircs tigntcr con- trol ol mixturc proportioning It is +lso import+nt to m+int+in +ggrcg+tc moisturc +t s+tur+tco surl+cc ory moisturc contcnt ouring proouction \+tcr +bsorbco by tnc mixturc lrom +ggrcg+tcs tn+t +rc too ory will rcsult in + mix tn+t is too ory lor pl+ccmcnt +no com- p+ction loo mucn w+tcr in +ggrcg+tcs will incrc+sc w/ cm +no occrc+sc strcngtn +no our+bility A low slump +no stillcr consistcncy m+y oiscn+rgc slowcr lrom tr+nsit mixcrs tn+n convcntion+l concrctc \+tcr rcouccrs +no viscosity-mooinco +omixturcs c+n bc usco to incrc+sc low+bility +no m+int+in st+bility ol tnc concrctc ouring oiscn+rgc +no pl+ccmcnt Lnit wcignt or bulk ocnsity tcsts provioc tnc bcst routinc tcst to monitor u+lity, +s wcll +s scvcn-o+y corcs to cv+lu+tc tnickncss +no strcngtn Convcntion+l lormwork is typic+lly usco to pl+cc pcrvious concrctc, +no pl+ccmcnt snoulo bc continu- ous witn sprc+oing +no strikc oll +ctivitics pcrlormco in + r+pio m+nncr Comp+ction +no nnisning is gcncr+lly +ccomplisnco by + wcigntco rollcr-scrcco tn+t spins +s it is pullco +cross tnc lrcsn concrctc lnc spinning tubc proviocs somc surl+cc comp+ction +no crc+tcs + smootn unilorm surl+cc (ligurc 3-11) lccommcnoco joint sp+cings ol 20 lt (o m) n+vc bccn suggcstco, +ltnougn somc inst+ll+tions n+vc n+o joint sp+cings ol - lt (13 m) or morc witnout Figure 3-11. Compacting the placed pervious concrete G u i d e
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C O N C R E T E 3-6 uncontrollco cr+cking lcc+usc sctting timc +no snrink+gc +rc +ccclcr+tco in pcrvious concrctc con- struction, joints +rc usu+lly toolco into tnc concrctc soon +ltcr consolio+tion witn + rolling joint tool lnc opcn structurc +no rcl+tivcly rougn surl+cc ol pcrvious concrctc cxposc morc surl+cc +rc+ ol tnc ccmcnt p+stc to cv+por+tion, m+king curing cxtrcmcly import+nt Curing lor pcrvious sl+bs +no p+vcmcnts bcgins bclorc tnc concrctc is pl+cco-tnc subgr+oc must bc moistcnco to prcvcnt it lrom +bsorbing moisturc lrom tnc concrctc Altcr pl+ccmcnt, log mist- ing lollowco by pl+stic snccting is tnc rccommcnoco curing proccourc, +no snccting snoulo rcm+in in pl+cc until tnc concrctc +cnicvcs +ocu+tc strcngtn to support tnc tr+lnc lo+o witnout o+m+ging tnc surl+cc (scc ligurc 3-12) Curing snoulo bc st+rtco +s soon +s pr+ctic+lly possiblc +ltcr pl+cing, comp+cting, +no jointing Sustainability - lc+t +no lignt is rclcctco ouc to its ligntcr color +no lowcr ocnsity, occrc+sing tnc imp+ct ol nc+t isl+no cllccts Figure 3-12. Curing pervious concrete with plastic sheeting - lcrvious concrctc rcouccs runoll +no tnus nclps prcvcnt pollution ol n+tur+l booics ol w+tcr - lnc ncco lor on-sitc noloing ponos or cxpcnsivc irrig+tion systcms is rcoucco or climin+tco, rcsulting in occrc+sco costs +no morc usc+blc l+no sp+cc - S+lcty is improvco bcc+usc tnc potcnti+l lor nyoro- pl+ning is rcoucco sincc w+tcr is +blc to csc+pc lrom tnc surl+cc - Noisc is rcoucco, improving tr+vcling cxpcricncc For More Information Amcric+n Concrctc l+vcmcnt Associ+tion 200o Stormwater Management with Pervious Concrete Pave- ment. Concrctc Inlorm+tion, IS33-l Amcric+n Concrctc l+vcmcnt Associ+tion 2007 Green Highways Concrctc l+vcmcnt lcsc+rcn +no lccnnology Spcci+l lcport, Sl3Sl Amcric+n Concrctc Institutc 2010 Pervious Concrete. ACI Committcc 22, 22l Grccn lignw+ys l+rtncrsnip wwwgrccnnignw+y- sp+rtncrsniporg N+tion+l lc+oy \ixco Concrctc Associ+tion Pervious Concrete. wwwpcrviousp+vcmcntorg Obl+, l 2007 lcrvious concrctc lor sust+in+blc ocvclopmcnt In Recent Advances in Concrete Technol- ogy. \+snington, l C lortl+no Ccmcnt Associ+tion 2010 Integrated Paving SolutionsPervious Concrete nttp//wwwintcgr+tco- p+vingsolutionsorg/pcrviousconcrctcntml lcnnis, l l, \ lcming, +no l ] Akcrs 200- Pervi- ous Concrete Pavements. ll30202 Skokic, Illinois lortl+no Ccmcnt Associ+tion, Silvcr Spring, \+ryl+no N+tion+l lc+oy \ixco Concrctc Associ+tion G u i d e
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4-1 Precast Pavements Objectives - lrovioc long lilc - Improvc tnc surl+cc - lrovioc nign lo+o-c+rrying c+p+city - lxpcoitc construction/rcncw+l - lrovioc + sust+in+blc option Solution - Lsc prcc+st concrctc p+vcmcnt systcms Benets - Construction c+n bc complctco ouring snort (ovcr- nignt or wcckcno) closurcs - l+nc closurcs +no +ssoci+tco uscr ocl+ys ouring construction +rc minimizco - lrcc+st p+vcmcnts +rc + nignly our+blc nnisnco p+vcmcnt +no not just + tcmpor+ry nx - lrcc+st p+vcmcnt surl+ccs rclcct lignt +no nclp rcoucc tnc urb+n nc+t isl+no cllcct Considerations - Initi+l costs +rc gcncr+lly nigncr tn+n convcntion+l lCC p+vcmcnt - lnc lc+rning curvc lor proouction, pl+ccmcnt, +no tcsting c+n bc stccp Typical Applications lrcc+st concrctc p+vcmcnts +rc typic+lly usco lor nignw+y, +irnclo, +no nc+vy inoustri+l +pplic+tions Highways Airfields Heavy Industrial Description lrcc+st p+vcmcnts +rc constructco using prcl+bric+tco concrctc sl+bs inst+llco ovcr + prcp+rco subb+sc or cxisting p+vcmcnt (scc ligurc --1) lrcc+st p+ncls +rc l+bric+tco oll sitc +t cst+blisnco prcc+st concrctc l+cilitics prior to construction, tr+nsportco to tnc jobsitc, +no tncn inst+llco on sitc +no opcnco to tr+l- nc lrcc+st p+vcmcnts n+vc bccn usco prim+rily lor rcconstruction +no rcp+ir ol ]Cl-but n+vc +lso bccn usco lor ncw construction-+no n+vc tnc potcnti+l to bc usco lor rcconstruction ol l\A p+vcmcnts lrcc+st p+vcmcnt systcms c+n +lso bc usco +s +n unbonoco ovcrl+y, + cost-cllcctivc solution to +oo structur+l c+p+city +no cxtcno tnc lilc ol +n cxisting ro+ow+y lnc bcncnts ol prcc+st p+vcmcnt +rc prim+rily rc+lizco tnrougn rcconstruction ol cxisting l+cilitics
Prepared Subgrade Precast Pavement Subbase Prepared Subgrade Precast Pavement Subbase Prepared Subgrade Precast Pavement Subbase Friction Reducing Medium Figure 4-1. Precast pavement system cross-section 4 Guide to Cement-Based Integrated Pavement Solutions G u i d e
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P A V E M E N T S 4-2 ouring snort closurcs, +s snown in ligurc --2 our- ing tnc nignttimc rcconstruction ol Intcrst+tc oo in Virgini+ lrcc+st p+vcmcnt n+s +lso bccn usco suc- ccsslully lor ncw construction ol nignw+ys, likc tn+t snown in ligurc --3 in Inooncsi+ lor tnis projcct, up to 0o milcs (10 km) ol prcc+st p+vcmcnt w+s pl+cco o+ily lcp+ir or rcconstruction ol ]Cl +no l\A p+vcmcnts using prcc+st p+vcmcnt systcms c+n bc +ccomplisnco uickly, ouring snort ovcrnignt or wcckcno closurcs, tnus rcoucing uscr ocl+y +no +ssoci+tco costs lrcc+st p+ncls c+n bc usco lor isol+tco lull-ocptn rcp+irs, sucn +s joint rcpl+ccmcnts, lor singlc or multiplc consccu- tivc sl+b rcpl+ccmcnts, or lor tot+l rcconstruction ol +n cntirc scction lncrc +rc two prim+ry typcs ol prcc+st p+vcmcnt systcms usco in tnc Lnitco St+tcs to o+tc lnc nrst Figure 4-2. Nighttime placement of precast panels in Virginia Figure 4-3. Precast pavement system in Indonesia typc ol systcm uscs prcstrcssco concrctc p+ncls tn+t +rc prctcnsionco in onc oircction ouring l+bric+tion +no posttcnsionco togctncr in tnc otncr oircction +ltcr pl+ccmcnt on sitc lnc otncr typc ol systcm is + jointco systcm, wnicn rcplic+tcs convcntion+l ]Cl using prcc+st p+ncls lor tnc prcstrcssco systcm, lo+o tr+nslcr bctwccn p+ncls is provioco by posttcnsion- ing, oowcls +rc usco lor tnc jointco systcm lccioing on wnicn systcm to usc will ocpcno prim+rily on tnc typc ol +pplic+tion but +lso on issucs sucn +s cost +no contr+ctor cxpcrtisc Lnlcss tncy +rc to bc usco +s + tcmpor+ry p+tcn, prcc+st p+vcmcnts +rc ocsignco to pcrlorm cu+l to or bcttcr tn+n ncw concrctc p+vcmcnt \nilc tnc rioc u+lity ol tnc surl+cc +s inst+llco is +cccpt+blc lor opcning to tr+lnc, oi+mono grinoing c+n bc usco to cnsurc tnc nn+l rioing surl+cc mccts tnc stringcnt rcuircmcnts lor nign-spcco ro+ow+ys Materials lrcc+st concrctc n+s bccn provcn + our+blc nign- pcrlorm+ncc proouct lor briogc +no commcrci+l builoing construction lnc concrctc mixturcs usco +rc simil+r to tnosc utilizco lor otncr prcc+st clcmcnts +no +rc not rcstrictco to 'p+ving` mixturcs lowcvcr, consiocr+tion must bc givcn to p+vcmcnt-spccinc rcuircmcnts, sucn +s rcuircmcnts lor skio rcsist+ncc +no our+bility in potcnti+lly +ggrcssivc cnvironmcnts lign strcngtn, low pcrmc+bility concrctc mixturcs witn + low w/cm r+tio +no unilorm +ggrcg+tc gr+o+- tion +rc usco routincly by prcc+st l+bric+tion pl+nts +no will gcncr+lly bc suit+blc lor p+vcmcnt p+ncls +s wcll Strcngtn rcuircmcnts +rc typic+lly not oilncult to +cnicvc ouc to tnc ncco lor r+pio proouction ol prcc+st p+ncls by turning ovcr tnc c+sting bcos cvcry o+y or cvcry otncr o+y lypic+l prcc+st p+vcmcnt mixturcs +rc ocsignco lor +vcr+gc 2S-o+y comprcs- sivc strcngtns bctwccn -,000 +no o,000 psi (2S--1 \l+), +no nigncr strcngtns usu+lly +cnicvco lor prcstrcssco prcc+st p+ncls, strcngtns ol 3,000 to -,000 psi (21-2S \l+) +rc typic+lly rcuirco lor rclc+sc ol prctcnsioning low pcrmc+bility prcvcnts cnloriocs +no otncr corrosivc +gcnts lrom pcnctr+ting tnc con- crctc +no rc+cning tnc rcinlorccmcnt +no prcstrcssing G u i d e
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P A V E M E N T S 4-3 stccl in tnc p+ncls Aggrcg+tcs must mcct spccinco skio- +no +br+sion-rcsist+ncc rcuircmcnts typic+l lor p+vcmcnts Design lor prcstrcssco prcc+st p+vcmcnt systcms, tnc prcmisc lor ocsign is to nrst c+lcul+tc tnc tnickncss tn+t woulo bc rcuirco lor convcntion+l concrctc p+vcmcnt, tncn to rcoucc tn+t tnickncss, +s mucn +s pr+ctic+l, by +ojusting tnc prcstrcss lcvcls sucn tn+t strcsscs in tnc prcc+st p+vcmcnt will bc cuiv+lcnt to tnc convcn- tion+l concrctc p+vcmcnt Aooition+l prcstrcss c+n bc +ooco to lurtncr incrc+sc tnc ocsign lilc ol tnc p+vc- mcnt lrcc+st p+ncls +rc typic+lly + minimum ol S in (200 mm) tnick, but tncy c+n bc +ojustco +s ncccss+ry to m+tcn tnc tnickncss +no cross-scction ol tnc cxist- ing p+vcmcnt ]ointco prcc+st p+vcmcnt systcms +rc typic+lly ocsignco to rcplic+tc convcntion+l ]Cl lor rcp+ir or rcconstruction projccts, tnc prcc+st p+ncls +rc ocsignco to m+tcn tnc tnickncss ol tnc sl+b bcing rcmovco minus 1/--1/2 in (o-13 mm) to +ccommo- o+tc irrcgul+ritics in tnc b+sc bcnc+tn tnc p+vcmcnt sl+b bcing rcmovco lor ncw construction, tnc p+ncls +rc ocsignco to m+tcn tnc tnickncss tn+t woulo bc spccinco lor + convcntion+l concrctc p+vcmcnt ocsign b+sco on projcct conoitions lor prcstrcssco systcms, tncrc +rc two typcs ol joints (1) tnc intcrmcoi+tc joints bctwccn tnc inoiviou+l p+ncls, +no (2) tnc cxp+nsion joints +t tnc cnos ol c+cn posttcnsionco scction ol prcc+st p+ncls lnc intcrmcoi+tc joints +rc 'nonworking` joints tn+t +rc posttcnsionco togctncr +no sc+lco witn cpoxy +pplico to tnc +butting l+ccs ol tnc prcc+st p+ncls ouring construction lnc cxp+nsion joints +rc ocsignco to +ccommoo+tc or '+bsorb` movcmcnt ouc to cxp+n- sion +no contr+ction ol tnc posttcnsionco sl+bs lor jointco systcms, oowclco joints +rc usco simil+r to convcntion+l ]Cl lowcvcr, it snoulo bc notco tn+t tncrc is not +ny signinc+nt contribution to lo+o tr+nslcr lrom +ggrcg+tc intcrlock, +s is tnc c+sc lor convcntion+l ]Cl Grout or mort+r is typic+lly usco to cnsurc lull bcooing ol tnc oowcl b+rs in tnc prcc+st p+ncls +ltcr inst+ll+tion +no to nll tnc joint bctwccn tnc p+ncls lrcstrcssco p+ncls +rc typic+lly ocsignco witn minim+l nonprcstrcssco rcinlorccmcnt lnis is bcc+usc prc- strcssing nclps to minimizc or cvcn climin+tc cr+ck- ing tnrougn so-c+llco 'cl+sto-pl+stic` bcn+vior, wnicn nclps kccp +ny cr+cks tn+t oo lorm tigntly closco ]ointco prcc+st p+ncls +rc typic+lly nc+vily rcinlorcco witn two m+ts ol milo stccl rcinlorccmcnt to prcvcnt +ny cr+cks tn+t m+y lorm ouring n+noling or lrom wiocning ovcr tnc lilc ol tnc p+vcmcnt Subb+sc l+ycrs, il incluoco in tnc prcc+st p+vcmcnt ocsign, snoulo bc ocsignco to provioc unilorm sup- port lypic+l b+sc m+tcri+ls incluoc l\A, crusnco stonc, stonc oust, +no lc+n concrctc Construction lrcc+st p+vcmcnt construction cncomp+sscs prcl+bri- c+tion ol tnc concrctc p+ncls +no subscucnt pl+cc- mcnt +t tnc jobsitc lnc prcl+bric+tion proccss incluocs sctting up tnc lorms to vcry strict tolcr+nccs, sccuring rcinlorccmcnt, prcstrcssing, +no +ooing otncr cmbcomcnts witnin tnc lorms Ncxt in tnc prcl+bric+tion proccss is pl+c- ing concrctc into tnc lorms (ligurc --- +no ligurc --), scrccoing, tcxturing, +no curing tnc concrctc lin+lly, rcmoving tnc p+ncls lrom tnc lorms, complct- ing +ny +ooition+l stcps rcuirco bclorc pl+ccmcnt, +no stockpiling tnc p+ncls lor snipmcnt to tnc projcct concluocs tnc proccss A prim+ry bcncnt ol prcl+bric+tion is tnc nign ocgrcc ol u+lity control tn+t cxists in prcc+st concrctc l+cili- tics +long witn tnc controllco cnvironmcnt unocr wnicn tnc p+ncls c+n bc prooucco lnis nclps to cnsurc unilormity ol m+tcri+ls, workm+nsnip, +no +ocu+tc curing lor tnc prcc+st p+ncls Gooo con- struction pr+cticcs rccommcno tn+t +n cst+blisnco prcl+bric+tion l+cility bc usco, +s opposco to + tcmpo- r+ry pl+nt sct up nc+r tnc jobsitc lclivcry ol tnc prcc+st p+ncls to tnc sitc is + criti- c+l +spcct ol tnc inst+ll+tion proccss, +no c+rc must bc t+kcn to cnsurc tn+t tnc p+ncls +rc not o+m+gco in +ny w+y ouring n+noling or snipping ligurc --o +no ligurc --7 snow typic+l pl+ccmcnt mctnoos lor prcc+st p+vcmcnt systcms lrovioing + l+t, unilorm, +no st+blc pl+tlorm lor tnc prcc+st p+ncls to rcst on G u i d e
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P A V E M E N T S 4-4 Figure 4-4. Concrete poured into form for precast panel Figure 4-5. Vibrators for consolidation of concrete around reinforcement in precast prestressed panel is import+nt, rcg+rolcss ol tnc subb+sc m+tcri+l usco lor prcstrcssco prcc+st systcms, somc lorm ol lriction- rcoucing m+tcri+l is nccoco bctwccn tnc prcc+st p+vcmcnt +no unocrlying subb+sc m+tcri+l to rcoucc lriction+l rcstr+int strcsscs tn+t c+n +ccumul+tc ouring posttcnsioning +no o+ily cxp+nsion +no contr+ction cyclcs lo nclp cnsurc lull support bcnc+tn tnc p+ncls, grout or urctn+nc lo+m is typic+lly injcctco bcnc+tn tnc sl+bs +ltcr inst+ll+tion to nll +ny voios tn+t m+y cxist lnc construction proccss v+rics witn c+cn job, but b+sco on tnc typc ol prcc+st p+vcmcnt systcm usco, common stcps incluoc tnc lollowing - S+wcutting +no rcmoving cxisting p+vcmcnt (rcp+ir/ rcconstruction) or cnsuring tnc subb+sc is propcrly prcp+rco (ncw construction) Figure 4-6. Placement of precast panel for precast JCP system Figure 4-7. Placement of a prestressed precast panel G u i d e
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P A V E M E N T S 4-5 - S+wcutting +no j+ckn+mmcring oowcl slots or orill- ing +no cpoxying oowcls (jointco systcms) - lin+l lcvcling +no gr+oc +ojustmcnt ol tnc subb+sc - Inst+ll+tion ol tnc prcc+st p+ncl(s) - Applying tcmpor+ry posttcnsioning to pull +oj+ccnt p+ncls togctncr (prcstrcssco systcm) - Applying nn+l posttcnsioning +ltcr + lull scction ol p+ncls n+vc bccn inst+llco (prcstrcssco systcm) - l+cknlling ol tnc oowcl slots (jointco systcms) +no posttcnsioning blockouts (prcstrcssco systcm) - Grouting ol posttcnsioning tcnoons (prcstrcssco systcm) - Grouting or lo+m injcction bcnc+tn tnc p+ncls - lilling joints +rouno tnc pcrimctcr ol tnc p+ncls (jointco systcms) - Sc+ling joints - li+mono grinoing lor smootnncss (+s ncccss+ry) Sustainability - \+tcri+l us+gc is optimizco tnrougn minimizing tnc tnickncss ol tnc prcc+st p+ncls - Construction w+stc is rcoucco bcc+usc tnc cx+ct +mount ol ncccss+ry componcnts is oclivcrco to tnc sitc-tncrc is no +ooition+l 'inciocnt+l` tnickncss to tnc sl+b - lncrc is signinc+nt uscr cost s+vings incluo- ing lucl consumption +no lost work timc ouc to ocl+ys - Any sp+rc componcnts/p+ncls c+n bc rccyclco, +no tncir m+tcri+ls usco +g+in in +notncr proouct - \ixturcs lor prcc+st systcms usc loc+lly ocrivco m+tcri+ls +no c+n incorpor+tc rccyclco SC\s likc ly +sn +no sl+g ccmcnt For More Information lucn, N 2007 Precast Concrete Panel Systems for Full-Depth Pavement Repairs: Field Trials. lcport No ll\A-Il-07-019, lcocr+l lignw+y Aoministr+tion, lcbru+ry lcocr+l lignw+y Aoministr+tion 2009 Precast Prestressed Concrete Pavement for Reconstruction and Rehabilitation of Existing Pavements. lccn lricl, ll\A- Il-09-00S, wwwlnw+ootgov/p+vcmcnt/pub_oct+ils clm`io=o32 \crritt, l l, l l \cCullougn, N l lurns, +no A l Scninolcr 2000 The Feasibility of Using Precast Concrete Panels to Expedite Highway Pavement Construc- tion. lcport No ll\A/lX-01/117-1, Ccntcr lor lr+nsport+tion lcsc+rcn, lcbru+ry \crritt, l l, l l \cCullougn, +no N l lurns 2002 Construction and Preliminary Monitoring of the Georgetown, Texas Precast Prestressed Concrete Pave- ment. lcsc+rcn lcport 117-01-I\l, Ccntcr lor lr+nsport+tion lcsc+rcn, Lnivcrsity ol lcx+s +t Austin, lcccmbcr \crritt, l l, A ] \iron, l l logcrs, +no l O l+smusscn 2007 Construction ol tnc Iow+ lignw+y o0 lrcc+st lrcstrcssco Concrctc l+vcmcnt lriogc Appro+cn Sl+b lcmonstr+tion lrojcct Iow+ lignw+y lcsc+rcn lo+ro (Illl) lrojcct ll-10S, lnc lr+nstcc Group, ]uly N+ntung, l, ] lirm+nsj+n, l Suw+rto, +no A l+ry+ 2010 lcsign +no construction ol prcc+st prcstrcssco concrctc p+vcmcnt in Inooncsi+ In lrocccoings, 2010 b International Congress and PCI Annual Convention/ Bridge Conference, 21 \+y-2 ]unc, \+snington, lC lortl+no Ccmcnt Associ+tion 2010 Precast/Prestressed Concrete. wwwccmcntorg/builoings/prcc+st_spl+sn, (1 ]unc 2010) l+y+bji, S +no l l+ll, l 2010 Precast Concrete Panels for Repair and Rehabilitation of Jointed Concrete Pavements. lcport No ll\A-Il-09-003, lcocr+l lignw+y Aoministr+tion, April lnc lr+nstcc Group 2010 lrcc+st l+vcmcnt lnc lr+nstcc Group, wwwprcc+stp+vcmcntcom (1 ]unc 2010) G u i d e
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5-1 Roller-Compacted Concrete Objectives - lrovioc + low-cost p+vcmcnt option - lrovioc + strong, our+blc p+vcmcnt tn+t will sup- port nc+vy lo+os - \inimizc tr+lnc oisruption +no provioc lor rcuirco c+rly-opcning to tr+lnc - \iocn + l+nc or +oo + snoulocr in + cost-cllcctivc m+nncr - lrovioc + sust+in+blc option Solution - Construct witn rollcr-comp+ctco concrctc (lCC) Benets - lollcr-comp+ctco concrctc proviocs + strong, ocnsc, +no our+blc m+tcri+l tn+t c+n bc uickly constructco - Construction is l+st, witn no lorms or nnisning - No stccl rcinlorccmcnt +no minimum l+bor m+kc lCC cconomic+l - lor m+ny +pplic+tions, joint s+wing is option+l lor +cstnctic purposcs rcsulting in +ooition+l cost s+vings - lollcr-comp+ctco concrctc p+vcmcnt surl+ccs rclcct lignt +no nclp rcoucc tnc urb+n nc+t isl+no cllcct Considerations - A mixcr witn +ocu+tc cncrgy is rcuirco to mix lCC - lypic+lly, +n +spn+lt-typc p+vcr is usco lor pl+ccmcnt - Surl+cc typic+lly is not +s smootn or consistcnt in +ppc+r+ncc +s convcntion+l concrctc - lor nigncr tr+lnc spccos, tnc surl+cc m+y ncco to bc oi+mono grouno or toppco witn + concrctc or l\A ovcrl+y Typical Applications lollcr-comp+ctco concrctc p+vcmcnt +pplic+tions incluoc strccts +no loc+l ro+os, nignw+ys +no snoul- ocrs, +irnclos, nc+vy inoustri+l, +no commcrci+l/ lignt inoustri+l lollcr-comp+ctco concrctc is +n ioc+l c+noio+tc in situ+tions wncrc surl+cc smootnncss +no +ppc+r+ncc +rc sccono+ry to nign our+bility, low m+intcn+ncc, c+rly tr+lncking, +no low initi+l cost lollcr-comp+ctco concrctc witn + surl+cc trc+tmcnt sucn +s oi+mono grinoing or +n ovcrl+y c+n bc usco lor p+vcmcnts tn+t cxpcricncc nign-spcco tr+lnc, incluoing nignw+ys In sucn +pplic+tions, lCC +cts +s + b+sc or subb+sc Highways Commercial / Lightweight Airfields Heavy Industrial Streets & Local Roads Shoulders 5 Guide to Cement-Based Integrated Pavement Solutions G u i d e
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5-2 R O L L E R - C O M P A C T E D
C O N C R E T E Description lollcr-comp+ctco concrctc n+s + simil+r strcngtn to convcntion+l concrctc, yct it c+n bc morc cconomi- c+l l+vcmcnts witn lCC c+n rcsist rutting +no sp+n solt loc+lizco subgr+ocs lncy will not oclorm unocr nc+vy, conccntr+tco wnccl lo+os, will rcsist octcrior+- tion lrom lucl or nyor+ulic lucl spills, +no will rcm+in rigio unocr nign tcmpcr+turcs lnc comprcssivc strcngtn ol lCC is comp+r+blc to tn+t ol convcntion+l concrctc, r+nging lrom -,000 to o,000 psi (2S to -1 \l+), witn lcxur+l strcngtn r+nging in v+lucs lrom 00 to 1,000 psi (3- to o9 \l+) lnc strcngtn m+kcs it +blc to witnst+no nign conccntr+tco lo+os +no imp+cts lrom nc+vy inoustri+l, milit+ry, +no mining +pplic+tions, +s wcll +s support lignt vcniclc tr+lnc snortly +ltcr pl+ccmcnt lollcr-comp+ctco concrctc c+n bc usco +s + p+vcmcnt surl+cc l+ycr lor low-spcco ro+os +no inoustri+l l+cili- tics wncrc surl+cc smootnncss +no +ppc+r+ncc +rc not + m+jor conccrn +s comp+rco to nign our+bility, low m+intcn+ncc, +no low initi+l cost (scc ligurc -1) li+mono-grouno lCC n+o bccn usco succcsslully on urb+n +rtcri+ls witnout +ny +ooition+l surl+cc trc+t- mcnt lollcr-comp+ctco concrctc c+n +lso bc + b+sc or subb+sc lor nignw+ys +no otncr nign-spcco tr+lnc ro+ow+ys (scc ligurc -2 +no ligurc -3) lollcr-comp+ctco concrctc combincs v+rious +spccts ol convcntion+l concrctc p+vcmcnt m+tcri+ls pr+cticcs witn somc construction pr+cticcs typic+l ol lcx- iblc p+vcmcnts It n+s tnc s+mc b+sic ingrcoicnts +s convcntion+l concrctc ccmcnt, w+tcr, +no +ggrcg+tcs (sucn +s gr+vcl or crusnco stonc), but it is typic+lly Figure 5-1. Typical RCC versus PCC surface Figure 5-2. Pavement cross-section with RCC surface
Prepared Subgrade Subbase RCC Prepared Subgrade Subbase RCC Figure 5-3. Pavement cross-section with RCC base
Prepared Subgrade RCC Pavement Surface Prepared Subgrade RCC Pavement Surface pl+cco witn +spn+lt-typc p+ving cuipmcnt +no comp+ctco by vibr+tory stccl orum rollcrs to + spccinc ocnsity (scc ligurc --) Lnlikc convcntion+l concrctc, lCC is + 'oricr` mix +no still cnougn to bc comp+ctco by vibr+tory rollcrs Sincc tnc p+stc contcnt in lCC is lowcr, lcss concrctc snrink+gc +no rcoucco cr+cking lrom snrink+gc- rcl+tco strcsscs rcsult In +ooition, non-+ir-cntr+inco lCC p+vcmcnts c+n provioc rcli+blc +no our+blc pcr- lorm+ncc in lrcczc-tn+w cnvironmcnts +s long +s tnc mix is propcrly proportionco witn +ocu+tc ccmcnt contcnt +no souno +ggrcg+tcs lnc concrctc must +lso bc tnorougnly mixco, +ocu+tcly comp+ctco, +no propcrly curco Figure 5-4. RCC construction for commercial and heavy industrial applications RCC Pavement PCC Pavement G u i d e
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C O N C R E T E Materials lnc go+l in sclccting tnc +ppropri+tc u+ntity ol m+tc- ri+ls lor lCC is to proportion tnc mix so tn+t tncrc is cnougn p+stc to covcr tnc +ggrcg+tcs +no nll tnc voios (scc ligurc -) lrim+ry oillcrcnccs in proportions bctwccn lCC p+vcmcnt mixturcs +no convcntion+l concrctc p+vcmcnt mixturcs +rc tnc lollowing - lollcr-comp+ctco concrctc is gcncr+lly not +ir cntr+inco - lollcr-comp+ctco concrctc typic+lly n+s + lowcr w+tcr contcnt - lollcr-comp+ctco concrctc typic+lly n+s + lowcr p+stc contcnt - lollcr-comp+ctco concrctc gcncr+lly rcuircs + l+rgcr nnc +ggrcg+tc contcnt in orocr to prooucc + combinco +ggrcg+tc tn+t is wcll gr+oco +no st+blc unocr tnc +ction ol + vibr+tory rollcr - lollcr-comp+ctco concrctc usu+lly n+s + nomin+l m+ximum sizc ol +ggrcg+tc not grc+tcr tn+n 3/- in (19 mm) in orocr to minimizc scgrcg+tion +no pro- oucc + rcl+tivcly smootn surl+cc tcxturc Aggrcg+tc sclcction is vcry import+nt N+tur+l or m+n- ul+cturco +ggrcg+tcs c+n bc usco \incr+l +ggrcg+tcs constitutc up to S pcrccnt ol tnc volumc ol lCC +no pl+y +n inlucnti+l rolc in +cnicving tnc rcuirco work+bility, spccinco ocnsity in tnc nclo unocr vibr+- tory comp+ction, comprcssivc +no lcxur+l strcngtns, tncrm+l propcrtics, long-tcrm pcrlorm+ncc, +no our+bility Aggrcg+tc nncs +rc typic+lly in tnc r+ngc ol 2-S pcrccnt, p+ssing tnc =200 (7 m) sicvc Silts +no cl+ys, nowcvcr, snoulo bc +voioco Ccmcntitious m+tcri+ls usco in lCC p+vcmcnt mix- turcs incluoc portl+no ccmcnt or blcnoco nyor+ulic ccmcnt +no m+y incluoc pozzol+ns sucn +s ly +sn +no sl+g ccmcnt lypcs I +no II ccmcnts +rc commonly usco in lCC p+vcmcnts lypc III c+n bc usco wncn c+rly strcngtn g+in is rcuirco, +no lypc V c+n bc usco in +rc+s tn+t n+vc spccinc soil conoitions c+lling lor tnis typc ol ccmcnt lnc usc ol + blcnoco ccmcnt, pozzol+ns, or sl+g ccmcnt m+y nclp improvc work+bility, rcoucc tnc potcnti+l lor +lk+li-+ggrcg+tc rc+ction, cxtcno tnc com- p+ction timc, +no nclp in lrcczc-tn+w conoitions lnc usc ol ly +sn in lCC is +n cllcctivc mc+ns ol provio- ing +ooition+l nnc m+tcri+l nccoco to cnsurc +ocu+tc comp+ction, p+rticul+rly in tnosc lCC mixturcs tn+t cont+in st+no+ro gr+oco concrctc nnc +ggrcg+tc \+tcr contcnt snoulo bc just cnougn to cnsurc cvcn oistribution ol tnc p+stc but ory cnougn to support tnc vibr+tory rollcr (scc ligurc -o) Cncmic+l +omix- turcs c+n bc usco ligncr oos+gcs ol cncmic+l +omix- turcs tn+n in convcntion+l concrctc m+y bc rcuirco, +no m+tcri+l comp+tibility snoulo bc cst+blisnco tnrougn tri+l b+tcncs Design lollcr-comp+ctco concrctc p+vcmcnts l+ll into two m+in c+tcgorics (1) nc+vy-outy inoustri+l p+vcmcnts (cg, ports +no multimoo+l tcrmin+ls), +no Figure 5-6. RCC material looks drier than conventional concrete Figure 5-5. Typical mix design constituents RCC 50 45 40 35 30 25 20 15 10 5 0 Percent Total Weight Cement + Fly Ash Coarse Aggregate Fine Aggregate Water Conventional concrete G u i d e
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C O N C R E T E (2) p+vcmcnts c+rrying mixco-vcniclc tr+lnc (cg, trucks +no p+sscngcr vcniclcs) l+blc 7 snows + list ol ocsign mctnooologics lnickncss ocsign lor lCC p+vcmcnts cmploys tnc s+mc b+sic str+tcgy +s lor con- vcntion+l concrctc p+vcmcnts, nowcvcr, tncrc +rc no oowcls or stccl rcinlorccmcnt in lCC to +ccommoo+tc lo+o tr+nslcr lnc p+vcmcnt snoulo bc tnick cnougn to +llow lor lcxur+l strcsscs +no l+tiguc o+m+gc c+usco by wnccl lo+os witnin +llow+blc limits l+tiguc ouc to lcxur+l strcss is usco to c+lcul+tc tnc rcuirco p+vcmcnt tnickncss lnc minimum tnickncss ol +n lCC p+vcmcnt is typic+lly - in (100 mm) A singlc lilt snoulo bc no tnickcr tn+n 10 in (20 mm) l+sc +no subb+sc l+ycr rcuircmcnts +rc simil+r to tnosc rcuirco lor convcntion+l concrctc, nowcvcr, lCC c+n bc morc scnsitivc to tnc moisturc contcnt ol gr+nul+r subb+scs listoric+lly, lCC is constructco witnout joints \ncn lCC is +llowco to cr+ck n+tur+lly, +ggrcg+tc intcrlock usu+lly proviocs +ocu+tc lo+o tr+nslcr +cross tnc cr+cks Cr+cks typic+lly occur +t 20- to o0-lt (o1- to 1S3-m) intcrv+ls, ocpcnoing on tnc lCCs propcrtics +no p+vcmcnt tnickncss lnc prim+ry rc+son joints +rc usco in lCC p+vcmcnts is to initi+tc cr+ck loc+- tions or to improvc +cstnctics in p+rking lots, +cccss ro+os, or +rc+s ol cn+nnclizco tr+lnc +t spccos grc+tcr tn+n 30 mpn ligurc -7 snows lcxur+l bc+m tcsting \ncn joints +rc constructco in lCC, tncy +rc lcwcr in numbcr +no sp+cco l+rtncr +p+rt tn+n in convcntion+l concrctc p+vcmcnts lowcls or tic b+rs +rc not usco in lCC p+vcmcnts lor lo+o tr+nslcr tnc w+y tncy +rc usco in convcntion+l concrctc, tncrclorc, tnc ocsigncr nccos to consiocr tnc +bscncc ol lo+o tr+nslcr ocviccs in tnc ocsign ligurc -S snows + typic+l lCC ocsign cr+ck \ncrc conccntr+tco l+nc tr+lnc is not common, joints c+n bc s+wco in su+rc p+ttcrns using tnc tr+nsvcrsc sp+cing ol 1- to 20-lt (-o- to o1-m) intcrv+ls lor p+vcmcnts lcss tn+n S in (200 mm) tnick +no 3 to - timcs (in lcct) tnc p+vcmcnt tnickncss (in incncs) lor Figure 5-7. Flexural beam testing Figure 5-8. Typical RCC design relies on aggregate interlock at cracks Subbase RCC Subbase Crack Aggregate interlock RCC Table 5-1. List of design methodologies Property Heavy Industrial Applications Conventional Roadway Applications RCC-Pave Computer Software (PCA) 9 U.S. Army Corps of Engineers (USACE) 9 StreetPave (ACPA) 9 Guide for Design of Jointed Concrete Pavements for Streets and Local Roads (ACI 325.12R-02) 9 Guide for the Design and Construction of Concrete Parking Lots (ACI 330R-08) 9 G u i d e
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C O N C R E T E p+vcmcnts S in (200 mm) tnick or grc+tcr In +rc+s witn conccntr+tco l+nc lo+oing, tnc longituoin+l sp+c- ing snoulo bc 20 lt (o1 m) lor p+vcmcnts lcss tn+n S in (200 mm) tnick +no 2 timcs (in lcct) tnc p+vc- mcnt tnickncss (in incncs) lor p+vcmcnts S in (200 mm) tnick or grc+tcr Construction A continuous supply ol lrcsn lCC m+tcri+l to tnc p+vcmcnt pl+ccmcnt m+cnincry is ncccss+ry lor prooucing + u+lity proouct lncrclorc, tnc r+tc ol lCC proouction +no tr+nsport+tion c+p+bility snoulo m+tcn tnc spcco ol construction +t tnc sitc (scc ligurc -9) An lCC mixing l+cility must n+vc tnc clncicncy to cvcnly oispcrsc tnc rcl+tivcly sm+ll +mount ol w+tcr prcscnt in tnc still, ory mix Conscucntly, tnc rcl+- tivcly ory lCC rcuircs rigorous mixing cncrgics +no b+tcning timcs to provioc + unilorm mixturc, wnicn c+n rcoucc tnc pl+nts mixing c+p+city wncn comp+rco to convcntion+l concrctc lnc rignt mixing cuipmcnt is vit+l to cnsuring + continuous +no consistcnt u+lity supply to tnc p+vcr lncrc +rc two typcs ol mixcrs lor lCC b+tcn typc +no continuous mixcrs \ost concrctc b+tcn-typc mix- crs consist ol + tilt (ligurc -10) or nxco orum +no tr+nsit mixcrs (ory b+tcn rc+oy-mix trucks) (ligurc -11) lncsc mixcrs +rc typic+lly usco lor sm+llcr projccts bcc+usc ol tnc rcoucco mixing c+p+city +no longcr mixing timc Continuous mixcrs +rc typic+lly usco lor l+rgcr projccts bcc+usc tncy c+n prooucc lCC +t + l+stcr r+tc tn+n b+tcn mixcrs lypic+lly, lCC is blcnoco in continuous norizont+l sn+lt mixcrs sucn +s pugmills lign-output pugmills n+vc tnc mixing clncicncy nccoco to cvcnly oispcrsc tnc ccmcnt +no rcl+tivcly sm+ll +mount ol w+tcr usco in tnis oricr mix (scc ligurc -12) lollcr-comp+ctco concrctc is typi- c+lly oclivcrco in oump trucks, but tr+nsit mixcrs c+n somctimcs bc usco lor sm+ll projccts luring pl+ccmcnt, it is import+nt tn+t tnc subb+sc +no/or subgr+oc bc unilormly moist In gcncr+l, lCC p+vcmcnts +rc constructco using botn +spn+lt +no convcntion+l concrctc p+vcmcnt construction tccn- niucs lollcr-comp+ctco concrctc is typic+lly pl+cco witn +n +spn+lt-typc p+vcr \ncn conngurco witn + nign-ocnsity scrcco, rolling comp+ction is rcoucco, tnus minimizing v+ri+tions in surl+cc tolcr+ncc +no Figure 5-9. RCC delivered to jobsite Figure 5-11 Ready-mix transit trucks dumping into haul trucks Figure 5-10. Tilt-drum mixer improving surl+cc smootnncss A nign-ocnsity p+vcr is oltcn usco to +ccommoo+tc tnc rcl+tivcly l+rgc +mount ol m+tcri+l moving tnrougn tnc p+vcr lor p+vcmcnt tnickncsscs grc+tcr tn+n 10 in (20 mm), multiplc lilts +rc usco G u i d e
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C O N C R E T E Comp+ction is tnc most import+nt st+gc ol construc- tion, +s it pl+ys + l+rgc rolc in ocnsity, strcngtn, our+- bility, smootnncss, +no surl+cc tcxturc Sincc lCC mixturcs +rc rcl+tivcly ory +no still (zcro slump), + 10-ton (102-t) vibr+tory stccl orum +no rubbcr-tirco rollcrs +rc gcncr+lly usco ouring pl+ccmcnt opcr+tions (scc ligurcs -13 tnrougn -1o lor tnc lCC pl+cc- mcnt tnrougn curing proccss) \ncn using nign- ocnsity p+vcrs, nigncr comp+ction is +ccomplisnco prim+rily by tnc p+vcr +no p+ving scrccos lolling bcgins soon +ltcr pl+ccmcnt +no continucs until tnc ocnsity ol tnc p+vcmcnt mccts + minimum ol 9S pcr- ccnt ol tnc mooinco lroctor ocnsity lin+l comp+ction is gcncr+lly +cnicvco witnin onc nour ol mixing lropcr curing +no nyor+tion ol tnc lCC mixturc is critic+l to tnc long-tcrm our+bility ol tnc p+vcmcnt lcc+usc lCC n+s + low w+tcr contcnt +no cxnibits no blcco w+tcr, propcr curing tccnniucs +rc import+nt Figure 5-12. Mobile RCC pugmill mixing plant and mixing chamber to prcvcnt cv+por+tion +no prcm+turc orying ol tnc surl+cc l+ck ol +ocu+tc moisturc lor curing c+n rcsult in sc+ling, ousting, +no r+vcling ol tnc n+rocnco surl+cc lor most projccts, + wnitc concrctc curing compouno conlorming to ASl\ C309 (Spccinc+tion lor liuio \cmbr+nc-lorming Compounos lor Curing Con- crctc) is usco A w+tcr curc c+n +lso bc implcmcntco, wncrc tnc p+vcmcnt is spr+yco or irrig+tco to kccp it moist lowcvcr, moisturc curing ol lCC rcuircs + continuous +pplic+tion ol w+tcr lor tnc cntirc curing pcrioo Sustainability - long scrvicc lilc witn minim+l m+intcn+ncc, low initi+l costs, incorpor+tion ol by-proouct m+tcri- +ls, +no improvco s+lcty m+kc lCC + sust+in+blc option Figure 5-13. RCC placement Figure 5-14. Compacting RCC using both vibratory and pneumatic-tired rollers G u i d e
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C O N C R E T E Figure 5-15. RCC in-place density measurement - lollcr-comp+ctco concrctc surl+ccs rclcct nc+t, wnicn rcouccs tnc nc+t isl+no cllcct - lollcr-comp+ctco concrctc n+s + nign +lbcoo, m+k- ing lor bcttcr nignt visibility +no improvco s+lcty For More Information Ao+sk+, \ 200o Roller-Compacted Concrete (RCC) lcport No SN297, lortl+no Ccmcnt Associ+tion Ao+sk+, \ 200S Applications and Design of RCC Pave- ments lortl+no Ccmcnt Associ+tion Slioc prcscnt+- tion, nttp//wwwscccmcntorg/rccntm Amcric+n Concrctc Institutc 1999 State-of-the-Art Report on Roller-Compacted Concrete Pavements. lcport No ACI 3210l-99, l+rmington lills, \icnig+n G+utnicr, l +no ] \+rcn+no 200 Design and Construction of Roller Compacted Concrete Pavements in Quebec. Ccmcnt Associ+tion ol C+n+o+, Ott+w+, C+n+o+ l+rrington, l, l Aboo, \ Ao+sk+, +no C l+z+rcc 2010 Guide for Roller-Compacted Concrete Pavements. SN29S, lortl+no Ccmcnt Associ+tion +no N+tion+l Concrctc l+vcmcnt lccnnology Ccntcr, August liggott, l 1999 Roller-Compacted Concrete Pave- mentsA Study of the Long Term Performance. ll3oo Skokic, Illinois lortl+no Ccmcnt Associ+tion lortl+no Ccmcnt Associ+tion 2010 Integrated Pav- ing SolutionsRoller-Compacted Concrete. nttp//www intcgr+tcop+vingsolutionsorg/lCCntml Figure 5-16. Curing RCC - lnc +bility to usc somc nncs +llows lCC to incorpo- r+tc m+tcri+l tn+t woulo otncrwisc not bc +cccpt+blc lor convcntion+l concrctc G u i d e
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6-1 Cement-Treated Base Objectives - lrovioc + strong, unilorm b+sc/subb+sc lor cur- rcnt +no luturc lo+oing conoitions using in-pl+cc or loc+lly +v+il+blc m+rgin+l soils +no gr+nul+r m+tcri+l - lcoucc strcsscs on tnc subgr+oc - St+bilizc + v+ricty ol soils witn + singlc st+bilizcr - lcoucc rutting +no oclcctions in + lcxiblc p+vc- mcnt surl+cc - Improvc tnc structur+l c+p+city ol tnc cxisting soil - lrovioc + sust+in+blc option Solution - A ccmcnt-trc+tco b+sc (Cll) using cxisting soils or loc+lly +v+il+blc borrow m+tcri+l Benets - A stillcr b+sc rcouccs oclcctions ouc to tr+lnc lo+os, tncrcby cxtcnoing p+vcmcnt lilc - Subgr+oc l+ilurcs, pumping, rutting, joint l+ulting, +no ro+o rougnncss +rc rcoucco - l+sc tnickncss is rcoucco comp+rco to unbouno gr+nul+r b+sc tnickncsscs - \+rgin+l +ggrcg+tcs, incluoing rccyclco m+tcri+ls, c+n bc usco, tnus rcoucing tnc ncco lor virgin, nign- u+lity +ggrcg+tcs Considerations - lnc potcnti+l lor rclcctivc cr+cking +no incrc+sco lriction bctwccn tnc Cll +no surl+cc ncco to bc consiocrco Typical Applications Ccmcnt-trc+tco b+sc proviocs + our+blc, long-l+sting b+sc in +ll typcs ol clim+tcs It is oltcn usco in nign- w+y, strcct +no loc+l ro+o, snoulocr, commcrci+l, +no nc+vy inoustri+l +pplic+tions Ccmcnt-trc+tco b+sc is +lso common in +irnclo +pplic+tions, p+rticul+rly l+rgc +irport runw+y +pplic+tions lnc lcocr+l Avi+tion Aoministr+tion rcuircs Cll lor runw+ys tn+t cxpcri- cncc nign volumcs ol nc+vy +ircr+lt tr+lnc Highways Commercial / Lightweight Airfields Heavy Industrial Streets & Local Roads Shoulders Description Ccmcnt-trc+tco b+sc consists ol n+tivc soils, gr+vcls, or m+nul+cturco +ggrcg+tcs blcnoco witn mc+surco +mounts ol portl+no ccmcnt +no w+tcr tn+t n+rocns +ltcr curing to lorm + our+blc p+ving m+tcri+l lnc vcrs+tility ol ccmcnt is critic+l to tnc succcss ol tnc st+biliz+tion opcr+tion, bcc+usc sitc conoitions c+n c+sily cn+ngc ouring + projcct +no tnc st+bilizcr nccos 6 Guide to Cement-Based Integrated Pavement Solutions G u i d e
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B A S E 6-2 to +o+pt to tnc cn+nging conoitions Ccmcnt is known +s + 'univcrs+l st+bilizcr` bcc+usc it works wcll ovcr + wioc r+ngc ol oillcrcnt soil typcs l+vcmcnts witn Cll will bc mucn strongcr tn+n +n unst+bilizco, gr+nul+r b+sc lnickncsscs lor Cll +rc lcss tn+n tnosc rcuirco lor unst+bilizco gr+nul+r b+scs c+rrying tnc s+mc tr+lnc Ccmcnt-trc+tco b+sc c+n oistributc lo+os ovcr + wiocr +rc+ (scc ligurc o-1), rcoucing tnc strcsscs on tnc subgr+oc It n+s + nign lo+o-c+rrying c+p+city, oocs not consolio+tc lurtncr unocr lo+o, rcouccs rutting in l\A p+vcmcnts, +no is rcsist+nt to lrcczc-tn+w octcrior+tion In + p+vcmcnt systcm, Cll is gcncr+lly constructco ovcr tnc subgr+oc (scc ligurc o-2) An l\A or con- crctc wc+ring surl+cc is pl+cco on tnc Cll to com- plctc tnc p+vcmcnt structurc lnc ocsign ol + concrctc surl+cc l+ycr must t+kc into +ccount incrc+sco lric- tion v+lucs bctwccn tnc l+ycrs In somc inst+nccs, +n intcrl+ycr is usco to rcoucc rcstr+int strcsscs +no tnc potcnti+l lor rclcctivc cr+cking Scc ligurc o-3 lor + complctco Cll scction ol ro+ow+y Materials Ccmcnt-trc+tco b+sc is + mixturc ol +ggrcg+tc m+tc- ri+l, portl+no ccmcnt, +no w+tcr lnc mixturc snoulo bc ocsignco b+sco on strcngtn +no rcsist+ncc to lrcczc-tn+w +no wct cnvironmcnts lnc +ggrcg+tc m+tcri+l usco in + Cll mixturc c+n bc + v+ricty ol m+tcri+ls or combin+tions tncrcol lncsc m+tcri+ls incluoc cxisting or borrowco stonc, gr+vcl, s+no, silt, +no c+licnc lccyclco concrctc +ggrcg+tcs (lCA) +no rccyclco +spn+lt p+vcmcnt c+n +lso bc incorpor+tco A wcll-gr+oco s+noy +no gr+vclly +ggrc- g+tc m+tcri+l blcno typic+lly rcuircs tnc lc+st +mount ol ccmcnt lor +ocu+tc n+rocning, wncrc+s +n +ggrc- g+tc m+tcri+l tn+t is cl+ssinco +s citncr + poorly gr+oco s+noy m+tcri+l ocncicnt in nncs or + silty +no/or cl+ycy m+tcri+l botn rcuirc morc ccmcnt lor n+rocn- ing \+ny st+tc spccinc+tions rcuirc tn+t +ggrcg+tcs usco in Cll mcct typic+l gr+o+tion +no Attcrbcrg limit rcuircmcnts Any portl+no ccmcnt typc c+n bc usco, but lypcs I +no II +rc tnc most common Ccmcnt contcnt ocpcnos on tnc typc ol +ggrcg+tc m+tcri+l usco, Figure 6-1. Load distribution of CTB compared to unstabilized granular base Figure 6-2. Typical pavement cross-sections showing CTB layers Prepared Subgrade Concrete Surface CTB Subbase Prepared Subgrade Concrete Surface CTB Subbase Prepared Subgrade Concrete Surface CTB Subbase
Prepared Subgrade HMA Surface CTB Subbase Prepared Subgrade HMA Surface CTB Base Friction Reducing Medium Figure 6-3. Completed CTB for new pavement construction in Oklahoma G u i d e
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B A S E 6-3 nowcvcr, it usu+lly r+ngcs lrom 3 to S pcrccnt lor most +pplic+tions In gcncr+l, + ccmcnt contcnt tn+t will provioc + scvcn-o+y unconnnco comprcssivc strcngtn ol bctwccn 300 +no -00 psi (21 +no 2S \l+) is s+tisl+ctory lor most Cll +pplic+tions lnc cnginccring propcrtics ol tnc Cll mixturc +rc ocpcnocnt on inoiviou+l constitucnt m+tcri+ls tn+t m+kc up tnc mixturc (ic, +ggrcg+tc m+tcri+l +no ccmcnt typc), curing conoitions, +no +gc Agc m+kcs + oillcrcncc bcc+usc ccmcnt will continuc to nyor+tc ovcr timc, wnicn will incrc+sc strcngtn Gcncr+l r+ngcs lor comprcssivc strcngtn, mooulus ol rupturc, mooulus ol cl+sticity, +no loissons r+tio +rc listco in l+blc o-1 Design A Cll scrvcs +s +n intcgr+l componcnt ol tnc p+vc- mcnt systcm It nccos to bc strong cnougn to witn- st+no tnc strcss +no l+tiguc c+usco by tnc cnviron- mcnt in wnicn it is constructco +no tnc lo+os unocr wnicn it must pcrlorm ovcr +n +nticip+tco lilctimc Somc critic+l ocsign inputs lor c+lcul+ting Cll tnick- ncss incluoc tnc cstim+tco tr+lnc lo+oing ouring tnc ocsign lilc, subgr+oc strcngtn, +no Cll strcngtn lnc most common +ppro+cn lor octcrmining Cll tnickncss is to lollow tnc Amcric+n Associ+tion ol St+tc lignw+y +no lr+nsport+tion Olnci+ls (AASllO) lcsign Guioc (1993) proccourc lor p+vcmcnt ocsign, wnicn uscs + structur+l l+ycr coclncicnt to moocl b+sc m+tcri+l A m+jor cllort is currcntly unocrw+y to rcgion+lly c+libr+tc +no snilt to tnc ncw AAS- llO \ccn+nistic-lmpiric+l l+vcmcnt lcsign Guioc (\-l llG) Anotncr +ppro+cn is to usc tnc lortl+no Ccmcnt Associ+tion proccourc givcn in tnc lCA pub- lic+tion Thickness Design for Soil-Cement Pavements. lnc +bility ol + p+vcmcnt b+sc to c+rry lo+os ocpcnos on tnc strcngtn ol tnc b+sc m+tcri+l +no tnc tnickncss ol tnc b+sc l+ycr Altnougn + tnin, strong b+sc c+n tncorctic+lly c+rry tnc s+mc lo+o +s + tnick, wc+kcr b+sc, tnc tnickcr, wc+kcr b+sc is usu+lly prclcrrco lnis is bcc+usc tnc tnin, strongcr b+sc is morc brittlc +no morc likcly to cr+ck, rcsulting in potcnti+l rclcc- tivc cr+cking in tnc surl+cc p+vcmcnt On m+jor nignw+ys, typic+l tnickncsscs r+ngc lrom o to 12 in (10 to 300 mm) Construction Construction incluocs initi+l prcp+r+tion, proccss- ing, comp+ction, nnisning, +no curing lnc lollowing p+r+gr+pns givc + bricl summ+ry ol Cll construction Initi+l prcp+r+tion incluocs tnc lollowing stcps (1) Sn+pc +rc+ to crown +no gr+oc, (2) Corrcct unst+blc subgr+oc +rc+s, (3) Il ncccss+ry, sc+rily, pulvcrizc, +no prcwct tnc soil (in gcncr+l, not mucn pulvcriz+tion is rcuirco lor Cll), +no (-) lcsn+pc crown +no gr+oc lroccssing is continuous +no +ccomplisnco in onc o+y lncrc +rc two mctnoos lor proccssing Cll mixco-in-pl+cc or ccntr+l-pl+nt-mixco lor Cll mixco-in-pl+cc, ccmcnt is pl+cco ory onto tnc surl+cc ol tnc in-pl+cc +ggrcg+tc using + mccn+ni- c+l sprc+ocr +tt+cnco to + oump truck or bulk ccmcnt truck lnc ccmcnt m+y +lso bc pl+cco on tnc surl+cc in slurry lorm lnc in-pl+cc +ggrcg+tc c+n bc citncr tnc cxisting m+tcri+l or borrowco m+tcri+l A singlc- sn+lt pulvcrmixcr combincs tnc +ggrcg+tc +no ccmcnt Il ncccss+ry, w+tcr is +pplico on tnc surl+cc or oircctly into tnc mixing cn+mbcr lnc singlc-sn+lt mixcr tncn mixcs tnc ccmcnt, w+tcr, +no +ggrcg+tc until + unilorm, tnorougnly mixco m+tcri+l is +cnicvco (scc ligurc o--, ligurc o-, +no ligurc o-o) lnc ccntr+l-pl+nt-mixco mctnoo rcuircs mixing ccmcnt, +ggrcg+tc m+tcri+l, +no w+tcr in + st+tion+ry pl+nt \ixing +t + ccntr+l pl+nt is gcncr+lly oonc by pugmills or rot+ry-orum mixcrs lot+ry-orum mix- crs work wcll lor mixing co+rsc, nonpl+stic +ggrcg+tc m+tcri+l lign-spcco rot+ry sn+lt pugmills work wcll lor co+rsc +ggrcg+tc m+tcri+l +no nonpl+stic nnc-gr+inco m+tcri+l likc s+nos +no silts lor pl+nts witn rot+ry-orum or b+tcn-typc pugmills, m+tcri+l is Table 6-1. Typical CTB properties Property 7-Day Value Compressive Strength 300 800 psi (2.1 5.5 MPa) Modulus of Rupture (Flexural Strength) 100 200 psi (0.7 1.4 MPa) Modulus of Elasticity 600,000 1,000.000 psi (4,100 6,900 MPa) Poissons Ratio 0.15 G u i d e
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B A S E 6-4 b+tcnco by wcignt, mixco, oumpco into n+ul trucks, +no oclivcrco to tnc sitc At pl+nts witn continuous- low-typc pugmills, tnc most common typc ol ccntr+l pl+nt, m+tcri+ls +rc inoiviou+lly mctcrco by wcignt or volumc +no lco into tnc mixcr by +n +ugcr scrcw, bclt, or rot+ry-v+nc lccocr Altcr mixing +t tnc pl+nt, tnc Cll m+tcri+l is oumpco into trucks, n+ulco to tnc sitc, +no sprc+o cvcnly ovcr tnc +rc+ (scc ligurc o-7) An +ggrcg+tc sprc+ocr is commonly usco to pl+cc tnc Cll mixturc ovcr tnc subgr+oc lnc Cll mixturc snoulo bc comp+ctco +t optimum moisturc to m+ximum ory ocnsity +s octcrminco by prclimin+ry l+bor+tory tcsting pcr AASllO l13- or ASl\ lS, or +s ocnnco by projcct spccinc+tions Vibr+tory-stccl rollcrs, snccpsloot rollcrs, or pncu- m+tic-tirc rollcrs +rc typic+lly usco, ocpcnoing on tnc typc ol +ggrcg+tc m+tcri+l usco in tnc Cll mixturc lnc nnisning opcr+tions lollow immcoi+tcly +ltcr +ocu+tc comp+ction is obt+inco lnc go+l ol tnc nn- isning proccss is to prooucc + nign-u+lity surl+cc tn+t n+s +ocu+tc comp+ction +no is voio ol +ny solt +rc+s or surl+cc comp+ction pl+ncs lnc stcps lor nnisning Cll +lso ocpcno on tnc typc ol +ggrcg+tc m+tcri+l usco in tnc Cll mixturc In gcncr+l, nnisning + Cll mixturc incluocs + combin+tion ol sn+ping, scr+tcning tnc surl+cc, +pplying + broom or+g, ligntly +pplying w+tcr, +no rolling witn + pncum+tic stccl rollcr Altcr nnisning, tnc Cll must bc +ocu+tcly curco, +llowing ccmcnt to nyor+tc +no tnc ccmcnt-+ggrcg+tc Figure 6-4. Spreading dry cement on grade prior to mixing Figure 6-5. Applying cement slurry on grade prior to mixing (cement slurry is applied the same way for FDR and CMS applications) Figure 6-6. Constructing CTB using mixed-in-place method Figure 6-7. Placement of plant-mixed CTB on prepared subgrade G u i d e
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B A S E 6-5 mixturc to n+rocn lnc ncwly constructco b+sc snoulo bc kcpt continuously moist (by ligntly w+tcring or misting) lor + 3- to 7-o+y pcrioo, or + moisturc-rct+in- ing covcr or curing compouno c+n bc pl+cco ovcr tnc Cll soon +ltcr complction Sustainability - In-situ or loc+l m+rgin+l +ggrcg+tcs c+n bc usco in Cll lnis will minimizc tnc ncco to n+ul in costly sclcct gr+nul+r +ggrcg+tcs - Ccmcnt-trc+tco b+sc m+y rcuirc tnc usc ol inous- tri+l by-prooucts sucn +s ly +sn - lccyclco +spn+lt p+vcmcnt mixco witn ccmcnt m+kcs +n cxccllcnt Cll - Ccmcnt-trc+tco b+sc proviocs + strongcr b+sc tn+n unbouno gr+nul+r m+tcri+l, tncrclorc, lor tnc s+mc lo+o-c+rrying c+p+city, lcss m+tcri+l is rcuirco - l+uling lcss m+tcri+l rcouccs tnc numbcr ol trucks +no possiblc o+m+gc to surrounoing ro+os, rcsult- ing in lucl s+vings, lowcr cmissions, +no prcm+turc luturc ro+ow+y m+intcn+ncc For More Information Amcric+n Associ+tion ol St+tc lignw+y +no lr+nspor- t+tion Olnci+ls (AASllO) 1993 American Association of State Highway and Transportation Ofcials Design Guide. Amcric+n Concrctc Institutc 2009 State-of-the-Art Report on Soil Cement lcport No ACI-2301l, l+rm- ington, lills, \icnig+n Amcric+n Concrctc Institutc Amcric+n Concrctc l+vcmcnt Associ+tion 2007 Sub- grades and Subbases for Concrete Pavements. ll20-l Gcorgc, l l 2002 Minimizing Cracking in Cement- Treated Materials for Improved Performance ll12301 Skokic, Illinois lortl+no Ccmcnt Associ+tion Gutnric, \ S, S Scbcst+, +no l Scullion 2002 Selecting Optimum Cement Contents for Stabilizing Aggre- gate Base Material. lccnnic+l lcport 7--920-2, lcx+s lr+nsport+tion Institutc l+lstco G l, l l lunr, +no \ S Ao+sk+ 200o Guide to Cement-Treated Base. ll23o Skokic, Illinois lortl+no Ccmcnt Associ+tion lortl+no Ccmcnt Associ+tion 2001 Thickness Design of Soil-Cement Pavements. ll0oS Skokic, Illinois lortl+no Ccmcnt Associ+tion lortl+no Ccmcnt Associ+tion 2010 Integrated Paving SolutionsCement-Treated Base. nttp//wwwintcgr+tco- p+vingsolutionsorg/ccmcnt-trc+tcob+scntml G u i d e
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7-1 Full-Depth Reclamation with Cement (FDR) Objectives - lrovioc + strong, unilorm b+sc/subb+sc lor currcnt +no luturc lo+oing conoitions using cxisting l+ilco +spn+lt surl+cc +no b+sc m+tcri+l - \+int+in cxisting gr+oc witn minimum m+tcri+l rcmov+l or +ooition - lcoucc or tot+lly climin+tc tnc ncco lor virgin +ggrcg+tcs - lcoucc strcsscs on tnc subgr+oc - lcoucc rutting +no oclcctions in + lcxiblc p+vc- mcnt surl+cc - Improvc tnc structur+l c+p+city ol st+bilizco b+sc ovcr unst+bilizco b+sc m+tcri+l - lrovioc p+vcmcnt rcconstruction mctnoo tn+t is l+st +no minimizcs tr+lnc oisruption - lrovioc + sust+in+blc option Solution - lull-ocptn rccl+m+tion witn ccmcnt to rccyclc +no rcusc tnc cxisting p+vcmcnt m+tcri+l ccyclc +no rcusc tnc cxisting p+vcmcnt m+tcri+l Benets - lnc pcrlorm+ncc ol tnc b+sc l+ycr is improvco ovcr +n unbouno gr+nul+r b+sc - littlc, il +ny, m+tcri+l is n+ulco oll or onto tnc sitc, rcsulting in lcss truck tr+lnc, lowcr cmissions, +no lcss o+m+gc to loc+l ro+os \ork c+n bc complctco uickly comp+rco to rcmov+l +no rcpl+ccmcnt tccnniucs - lull-ocptn rccl+m+tion proccss is cconomic+l comp+rco to rcmov+l +no rcpl+ccmcnt +no tnick ovcrl+ys Considerations - lnc potcnti+l lor rclcctivc cr+cking +no incrc+sco lriction bctwccn tnc lll +no surl+cc p+vcmcnt nccos to bc consiocrco - Lnocrgrouno utilitics ncco to bc consiocrco ouring tnc ocsign +no construction pn+sc Typical Applications lccyclco m+tcri+ls +no rccycling tccnniucs +rc usco in nignw+y, strcct +no loc+l ro+o, commcrci+l/ ligntwcignt inoustri+l, +irnclo, +no nc+vy inoustri+l +pplic+tions Description Highways Commercial / Lightweight Airfields Heavy Industrial Streets & Local Roads lull-ocptn rccl+m+tion witn ccmcnt is + tccnniuc in wnicn +n cxisting l\A p+vcmcnt +no b+sc m+tcri+l is rccl+imco (pulvcrizco +s ncccss+ry), combinco witn portl+no ccmcnt, +no tncn rccomp+ctco to crc+tc + ncw +no improvco b+sc lnc lll b+sc is tncn toppco witn + ncw l\A or concrctc surl+cc l+ycr 7 Guide to Cement-Based Integrated Pavement Solutions G u i d e
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( F D R ) 7-2 lull-ocptn rccl+m+tion is +ppropri+tc unocr tnc lol- lowing conoitions - lnc p+vcmcnt is o+m+gco +no c+nnot bc rcn+bili- t+tco witn simplc rcsurl+cing mctnoos - lnc cxisting p+vcmcnt oistrcss inoic+tcs tn+t + problcm likcly cxists in tnc surl+cc, b+sc, +no/or subgr+oc - lnc cxisting p+vcmcnt oistrcss woulo otncrwisc rcuirc lull-ocptn p+tcning ovcr morc tn+n 1-20 pcrccnt ol tnc surl+cc +rc+ - lnc p+vcmcnt structurc is in+ocu+tc lor tnc cur- rcnt or luturc tr+lnc Materials \+tcri+ls usco lor lll incluoc tnc cxisting l\A surl+cc tn+t n+s bccn pulvcrizco +no blcnoco witn tnc unocrlying b+sc, subb+sc, +no/or subgr+oc, ccmcnt, +no w+tcr l+bor+tory tcsting +no tri+l mixcs +llow sclccting tnc bcst proportions ol ccmcnt lor tnc job lnc +mount ol w+tcr +no ccmcnt rcuirco in tnc mix will ocpcno upon tnc projcct-spccinco strcngtn +no gr+o+tion ol tnc nn+l blcno obt+inco lrom pulvcrizing tnc l\A ouring construction +no mixing it witn tnc b+sc m+tcri+l lypic+l spccinc+tions lor pulvcrizing c+ll lor + minimum ol 100 pcrccnt p+ssing tnc 3-in (7-mm) sicvc, 9 pcrccnt p+ssing tnc 2-in (0-mm) sicvc, +no pcrccnt p+ssing tnc No - (-7-mm) sicvc In gcncr+l, + ccmcnt contcnt tn+t proviocs + scvcn-o+y unconnnco comprcssivc strcngtn bctwccn 300 to -00 psi (21 to 2S \l+) is s+tisl+ctory lor most lll +pplic+tions Design lull-ocptn rccl+m+tion ocsign is + proccss tn+t involvcs (1) octcrmining tnc typc ol cxisting p+vcmcnt l+ycrs +no tncir rcspcctivc tnickncsscs, +no (2) iocnti- lying wnicn m+tcri+l will bc combinco witn ccmcnt in orocr to crc+tc + st+blc b+sc lor + ncw p+vcmcnt struc- turc lnc tnickncss ocsign is simil+r to + Cll +no is c+lcul+tco b+sco on strcngtn ol tnc m+tcri+l, strcngtn +no stillncss cn+r+ctcriz+tions ol +ooition+l l+ycrs, +nticip+tco lo+os, +no pcrlorm+ncc rcuircmcnts (ic, lilc, scrvicc+bility, rcli+bility) lnc AASllO proccourc lor p+vcmcnt ocsign or lCA tnickncss ocsign procc- ourc c+n bc usco lypic+l tnickncss v+lucs lor lll r+ngc lrom o to 12 in (10 to 300 mm) Construction lull-ocptn rccl+m+tion rcuircs + rccl+imcr mixcr, gr+ocr, ccmcnt sprc+ocr, w+tcr truck, +no rollcr A rccl+imcr m+cninc typic+lly m+kcs +n initi+l p+ss ovcr tnc cxisting lcxiblc p+vcmcnt, pulvcrizing tnc l\A surl+cc +no blcnoing it witn tnc b+sc +no/or subgr+oc m+tcri+l (scc ligurc 7-1 +no ligurc 7-2) \+tcr m+y bc +ooco ouring tnis mixing st+gc to bring tnc m+tc- ri+l up to optimum moisturc contcnt lnc m+tcri+l is tncn gr+oco +ccoroingly Ncxt, ccmcnt is sprc+o citncr ory or in slurry lorm in + controllco m+nncr onto tnc surl+cc (scc ligurc 7-3 +no ligurc 7--) lnc rccl+imcr tncn mixcs tnc ccmcnt into tnc pulvcrizco m+tcri+l Figure 7-1. Schematic of the mixing chamber of a reclaimer machine Figure 7-2 Reclaimer pulverizing existing asphalt pavement and base material G u i d e
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( F D R ) 7-3 Figure 7-6. Equipment for compaction and nishing Figure 7-3. Dry cement placed on pulverized material Figure 7-4. Applying cement slurry on grade prior to mixing (cement slurry is applied the same way for CTB applications) Figure 7-5. Mixing the cement into the pulverized material \ixing continucs until tnc m+tcri+l is tnorougnly mixco lnis is lollowco by comp+ction, nn+l gr+oing, curing, +no surl+cing Smootn-wncclco rollcrs +rc usco lor comp+ction lnc lll snoulo bc curco lor lrom tnrcc to scvcn o+ys Surl+cc trc+tmcnts incluoc cnip sc+ls, l\A, or concrctc lnc wnolc proccss c+n bc pcrlormco unocr tr+lnc (scc ligurc 7-) ligurc 7-o snows tnc cuipmcnt usco lor comp+ction +no nnisning Sustainability - lxisting m+tcri+ls +rc rcusco, rcoucing tnc cxploit+- tion ol virgin m+tcri+l - l+m+gc is rcoucco to surrounoing ro+os lrom n+ul- ing cxisting b+sc m+tcri+ls out +no bringing virgin m+tcri+ls in - Costs rcl+tco to tnc proccssing, purcn+sing, +no tr+nsport+tion ol virgin +ggrcg+tcs +rc minimizco - lruck tr+lnc is rcoucco, rcsulting in lucl s+vings +no lowcr cmissions For More Information Aspn+lt lccycling e lccl+iming Associ+tion 2001 Basic Asphalt Recycling Manual. Ann+polis, \+ryl+no Aspn+lt lccycling e lccl+iming Associ+tion G u i d e
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( F D R ) 7-4 lrown, Asnlcy, +no V+nnoy 200o Ccmcnt st+biliz+- tion ol +ggrcg+tc b+sc m+tcri+l blcnoco witn rccl+imco +spn+lt p+vcmcnt \+stcrs tncsis, lcp+rtmcnt ol Civil +no lnvironmcnt+l lnginccring, lrign+m Young Lni- vcrsity, August luropc+n Concrctc l+vcmcnt Associ+tion 2010 lLlAVl-In Situ Pavement Recycling. wwwcup+vccu/ oocumcnts/+ctivity-+rc+s/in-situ-p+vcmcnt-rccycling xml`l+ng=cn lunr, l l, \ S Ao+sk+, +no G l l+lstco 200 Guide to Full-Depth Reclamation (FDR) with Cement. ll23-, lortl+no Ccmcnt Associ+tion lortl+no Ccmcnt Associ+tion 2001 Thickness Design for Soil-Cement Pavements. ll0oS Skokic, Illinois lortl+no Ccmcnt Associ+tion lortl+no Ccmcnt Associ+tion 2010 Integrated Paving SolutionsFull-Depth Reclamation with Cement. nttp// wwwintcgr+tcop+vingsolutionsorg/lllntml Syco, I \ 2007 Full-Depth Reclamation with Portland Cement: A Study of Long-Term Performance. Sl01o Skokic, Illinois lortl+no Ccmcnt Associ+tion G u i d e
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8-1 Cement-Modied Soils (CMS) Objectives - lcoucc tnc pl+sticity +no nign-volumc cn+ngc cn+r- +ctcristics ol cl+y soils ouc to moisturc v+ri+tions - Improvc st+bility ol + poorly gr+oco s+noy soil Improvc tnc propcrtics ol + s+noy soil cont+ining + nign-pl+sticity cl+y - lrovioc + mctnoo to ory out + wct subgr+oc - lrovioc + nrm construction pl+tlorm to work on - lrovioc + sust+in+blc option Solution - Aoo + sm+ll +mount ol ccmcnt to tnc soil to crc+tc + ccmcnt-mooinco soil Benets - Ccmcnt-mooinco soils provioc + wc+tncr-rcsist+nt work pl+tlorm lor construction opcr+tions - l+tiguc l+ilurcs c+usco by rcpc+tco nign oclcctions +rc controllco - lncrc is + rcouction in moisturc scnsitivity +no sub- gr+oc sc+son+l lo+o rcstrictions - No mcllowing pcrioo is nccoco +s rcuirco by otncr st+bilizing +gcnts Considerations - Ccmcnt-mooinco soils +rc not intcnoco to witn- st+no tnc s+mc Cll our+bility +no comprcssivc strcngtn rcuircmcnts Typical Applications Ccmcnt-mooinco gr+nul+r soils c+n bc usco +s + trc+tco subgr+oc +no working pl+tlorm bcnc+tn + b+sc or subb+sc Highways Commercial / Lightweight Airfields Heavy Industrial Streets & Local Roads Shoulders Description Ccmcnt-mooinco soils +rc soils +no/or m+nul+cturco +ggrcg+tcs mixco witn + sm+ll proportion ol portl+no ccmcnt ly combining sm+ll +mounts ol ccmcnt witn soils, pl+sticity is rcoucco, volumctric cn+ngcs ouc to moisturc contcnt +rc minimizco, bc+ring strcngtn is incrc+sco, +no st+bility is improvco As + rcsult, + wc+tncr-rcsist+nt work pl+tlorm lor construction opcr- +tions +no + strongcr, pcrm+ncnt p+vcmcnt l+ycr lor cnn+ncco support +no c+p+city c+n bc constructco 8 Guide to Cement-Based Integrated Pavement Solutions G u i d e
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( C M S ) 8-2 Ccmcnt-mooinco soils +rc norm+lly usco to improvc m+tcri+l propcrtics in tnc subgr+oc lncy c+n climi- n+tc tnc ncco lor cxtcnsivc rcmov+l +no rcpl+ccmcnt ol cxisting soils, s+ving consiocr+blc timc +no moncy lnc most common +pplic+tion ol C\S is +s +n option lor subgr+oc m+tcri+l wncn cxisting or +v+il+blc soils +rc ol poor u+lity (scc ligurc S-1) lnc prim+ry oillcrcncc bctwccn C\S +no Cll is tn+t Cll typic+lly cont+ins morc ccmcnt +no is rcuirco to mcct ccrt+in strcngtn v+lucs pcr spccinc+tions +no to scrvc +s + our+blc, lrcczc-tn+w rcsist+nt m+tcri+l Ccmcnt-mooinco soils typic+lly oo not n+vc to mcct tnc s+mc rcuircmcnts lor strcngtn +no our+bil- ity, instc+o, sm+ll +mounts ol ccmcnt +rc +ooco to mitig+tc cxp+nsion ouc to moisturc v+ri+tions +no improvc concsion c+usco by poor soils An +ooition+l bcncnt is +n improvcmcnt in strcngtn +no stillncss Figure 8-1. Typical cross-section with CMS Design lnc ocsign ol + C\S l+ycr locuscs on crc+ting + work- ing pl+tlorm lor tnc construction ol b+sc/subb+sc +no, subscucntly, tnc surl+cc l+ycr lnc C\S l+ycr, nowcvcr, oocs not contributc +pprcci+bly to tnc struc- tur+l c+p+city ol tnc p+vcmcnt Accoroing to most st+tc +no/or job-spccinc spccinc+tions, + C\S l+ycr is ocsignco to mcct ccrt+in Attcrbcrg limit rcuircmcnts +s octcrminco by propcr l+bor+tory tcsting mctnoos Ccmcnt-mooinco soils +rc typic+lly not ocsignco to mcct + comprcssivc strcngtn rcuircmcnt, but r+tncr ocsignco to mcct rcoucco pl+sticity rcuircmcnts +no incrc+sco Cll v+lucs lnc ocsign will v+ry, ocpcnoing on cxisting soil propcrtics A common tnickncss ol o in (10 mm) n+s bccn snown to provioc +n +ocu+tc working pl+tlorm lor construction ol b+sc or subb+sc l+ycrs Construction Ccmcnt-mooinco soils +rc prooucco in pl+cc using cxisting soils Ccmcnt-mooinco soils construction consists ol mixing tnc ccmcnt into tnc soil using mixco-in-pl+cc mctnoos lowcvcr, bcc+usc ol tnc concsivcncss ol tnc soil somc +ooition+l cllort m+y bc rcuirco lor tnc pulvcriz+tion +no mixing opcr+- tions \ct soils m+y rcuirc multiplc mixing p+sscs Il tnc soil is ory, prc-wctting +no +llowing tnc w+tcr to so+k in m+y l+cilit+tc pulvcriz+tion (scc ligurc S-2) In contr+st to norm+l Cll construction, tnc timc limit bctwccn mixing +no comp+cting is not +s stringcnt, Materials Ccmcnt-mooinco soils +rc princip+lly usco to mooily nnc-gr+inco soils sucn +s silts +no cl+ys +no gr+nu- l+r soils n+ving + nign pl+sticity +no/or nnc contcnt Ccmcnt contcnt lor c+cn is typic+lly b+sco on iocn- tilying tnc +ppropri+tc +mount ncccss+ry to mcct spccinc+tions \ost C\S involvcs nign pl+sticity soils sucn +s cl+ys Spccinc+tions will oltcn rcuirc cnougn ccmcnt contcnt to rcoucc tnc pl+sticity inocx (lI) to witnin + r+ngc ol 12 to 1 lypic+lly, + ccmcnt contcnt ol 3 to - pcrccnt will rcoucc tnc lI sulncicntly +no incrc+sc tnc C+lilorni+ bc+ring r+tio (Cll) +no rcsist+ncc v+l- ucs lnc ccmcnt-mooinco soil snoulo provioc + nrm louno+tion lor comp+ction ol tnc b+sc/subb+sc l+ycr +bovc it Figure 8-2. Cement slurry added to subgrade material (cement slurry is applied the same way for CTB and FDR applications) Base/ - Untreated Subgrade Pavement Surface Subbase Cement- Modied Soil G u i d e
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( C M S ) 8-3 +ltnougn +ll opcr+tions, incluoing comp+ction, snoulo bc complctco in tnc s+mc o+y In gcncr+l, in-pl+cc mixing +no construction scucncc lollows tncsc stcps - lor initi+l prcp+r+tion, sn+pc tnc +rc+ to crown +no gr+oc +no corrcct +ny solt or unsuit+blc +rc+s - Il ncccss+ry, prcwct ory soils to +io pulvcriz+tion or ory b+ck wct soils by +cr+tion witn oisc n+rrow or rot+ry mixcr witn its nooo opcn - listributc ccmcnt in ory lorm witn mccn+nic+l sprc+ocr or in slurry lorm lrom oistributor truck - \ix witn pulvcrmixcr, +ooing w+tcr il ncccss+ry, until + nomogcncous, lri+blc mixturc is obt+inco tn+t will mcct tnc spccinco pulvcriz+tion rcuirc- mcnts (scc ligurc S-3) - Comp+ct witn t+mping (snccpsloot) rollcr (scc ligurc S--) - Complctc surl+cc comp+ction witn + stccl orum, pncum+tic tirc, or otncr +ppropri+tc typc ol rollcr - \itn gr+ocr, sn+pc +rc+ to nn+l crown +no gr+oc - Sc+l surl+cc witn pncum+tic-tirc rollcr Lnlikc ccmcnt-trc+tco b+scs, C\S is oltcn not curco lowcvcr, curing witn + lignt w+tcr spr+y or bitumi- nous co+ting will provioc tnc m+ximum bcncnt lrom tnc ccmcnt Sustainability - C\S rcouccs w+stc by +llowing tnc usc ol cxisting m+tcri+l - In-situ m+rgin+l subgr+oc soils c+n bc improvco, minimizing tnc ncco to n+ul in costly sclcct gr+nul+r +ggrcg+tcs - C\S proviocs + strongcr morc st+blc subgr+oc, wnicn m+y rcoucc tnc u+ntity ol b+sc m+tcri+l nccoco For More Information ln+tt+cn+rj+, S +no ] ln+tty 2003 Comparative Performance of Portland Cement and Lime Stabilization of Moderate to High Plasticity Clay Soils. ll12 Skokic, Illinois lortl+no Ccmcnt Associ+tion l+lstco, G l, \ S Ao+sk+, +no \ l \cConncll 200S Guide to Cement-Modied Soil (CMS). ll2-2 Skokic Illinois lortl+no Ccmcnt Associ+tion lortl+no Ccmcnt Associ+tion 2010 Integrated Paving SolutionsCement-Modied Soil. nttp//wwwintcgr+t- cop+vingsolutionsorg/C\Sntml Scullion, l, S Scbcst+, ] l+rris, +no I Syco 200 Evaluating the Performance of Soil-Cement and Cement- Modied Soil for Pavements: A Laboratory Investigation. ll120 Skokic, Illinois lortl+no Ccmcnt Associ+tion Figure 8-3. Pulvermizer used for in-place mixing of CMS Figure 8-4. Sheepsfoot roller used for compaction G u i d e
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9-1 Recycled Concrete Aggregates Objectives - lccyclc cxc+v+tco concrctc p+vcmcnt - \inimizc construction cost - lcoucc ocpcnocncc on gooo u+lity virgin +ggrc- g+tcs, wnicn m+y bc n+ro to nno or cxpcnsivc to bring in - lrovioc + sust+in+blc option Solution - Lsc olo concrctc +s +ggrcg+tcs in ncw p+vcmcnt l+ycrs Benets - lccyclco concrctc +ggrcg+tcs (lCA) +rc vcrs+tilc bcc+usc tncy c+n bc usco in +ny p+vcmcnt l+ycr - \+tcri+l costs +rc rcoucco - Construction timc c+n bc cxpcoitco witn on-sitc rccycling pl+nts - l+vcmcnt sullcring lrom ASl or l-cr+cking c+n bc rccyclco instc+o ol oisc+roco - lnc ncco lor olo concrctc oispos+l is rcoucco Considerations - Il ASl or l-cr+cking cxists in rccyclco p+vcmcnt m+tcri+l, spcci+l +ttcntion must bc givcn to mixturc ocsign - lccyclco concrctc +ggrcg+tcs in l\A m+y incrc+sc binocr contcnt rcuircmcnts - Concrctc mixturc ocsigns will n+vc to bc +ojustco lor strcngtn - Aooition+l u+lity control mc+surcs m+y bc ncccs- s+ry to cnsurc concrctc work+bility Typical Applications lccyclco concrctc +ggrcg+tcs +rc usco in nignw+y, strcct +no loc+l ro+o, snoulocr, +irnclo, commcr- ci+l/ligntwcignt inoustri+l, +no nc+vy inoustri+l +pplic+tions Highways Commercial / Lightweight Airfields Heavy Industrial Streets & Local Roads Shoulders Description lccyclco concrctc +ggrcg+tcs +rc +ggrcg+tcs prooucco lrom tnc rccycling ol cxisting concrctc lxisting con- crctc is rcmovco, proccssco into +ppropri+tc +ggrcg+tc sizcs, +no rcusco in v+rious p+vcmcnt +pplic+tions lnc bcncnts ol using lCA in p+vcmcnts incluoc rcoucco m+tcri+l costs, minimizco usc ol ocplct- ing virgin +ggrcg+tc sourccs, +no occrc+sco l+nonll contcnt lccyclco concrctc +ggrcg+tcs +rc prim+rily usco in b+scs +no subb+scs Accoroing to + 200S lcocr+l lignw+y Aoministr+tion n+tion+l rcvicw, S- pcrccnt ol st+tcs +rc rccycling concrctc +ggrcg+tc \nilc most 9 Guide to Cement-Based Integrated Pavement Solutions G u i d e
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A G G R E G A T E S 9-2 st+tcs usc lCA +s + b+sc m+tcri+l, 22 pcrccnt usc lCA +s +ggrcg+tc lor ncw concrctc p+vcmcnts lccyclco concrctc +ggrcg+tcs +rc ioc+l lor tnc bottom lilt ol + two-lilt p+ving mixturc ocsign lwo-lilt p+v- ing is + construction tccnniuc tn+t involvcs pl+c- ing + concrctc surl+cc l+ycr in two consccutivc lilts lnc proccss is somctimcs rclcrrco to +s 'wct-on-wct` bcc+usc tnc top l+ycr is pl+cco immcoi+tcly +ltcr tnc bottom l+ycr, bclorc tnc bottom l+ycr n+rocns lnc +ov+nt+gc to tnis kino ol construction is tn+t gooo u+lity +ggrcg+tcs +rc only rcuirco in tnc top lilt, wncrc+s +ggrcg+tcs sucn +s lCA c+n tncn bc usco lor tnc lowcr lilt lnc u+lity ol lCA is vcry ocpcnocnt on tnc u+l- ity ol tnc m+tcri+l lrom wnicn it w+s proccssco Olo concrctc p+vcmcnt is brokcn oown in-pl+cc, rcmovco, +no crusnco to prooucc lCA lccyclco concrctc +ggrcg+tcs prooucco lrom +ll but tnc poorcst u+lity origin+l concrctc c+n bc cxpcctco to p+ss tnc s+mc tcsts rcuirco ol virgin convcntion+l +ggrcg+tcs Materials lccyclco concrctc +ggrcg+tcs (scc ligurc 9-1) pro- oucco lrom concrctc p+vcmcnt rccycling cont+ins botn tnc origin+l +ggrcg+tcs +no nyor+tco ccmcnt p+stc lccyclco concrctc +ggrcg+tcs c+n bc proccssco to cxnibit propcrtics tn+t mcct tnc s+mc gr+o+tion rcuircmcnts +s virgin +ggrcg+tcs usco lor simi- l+r +pplic+tions lccyclco concrctc +ggrcg+tcs m+y improvc c+rly strcngtn propcrtics in somc +pplic+- tions bcc+usc ol tnc continuco nyor+tion ol cxposco ccmcnt p+rticlcs in tnc lCA lncrc +rc somc m+tcri+l cn+r+ctcristics spccinc to lCA in somc +pplic+tions tn+t snoulo bc unocrstooo +no +ccountco lor in citncr ocsign or construction Concrctc p+vcmcnts cont+ining lCA c+n rcsult in incrc+sco porosity +no +bsorption, nigncr coclncicnt ol tncrm+l cxp+nsion +no snrink+gc, lowcr strcngtns, +no rcoucco spccinc gr+vity wncn comp+rco to tnc usc ol only virgin +ggrcg+tcs lnc cnlorioc contcnt ol rccyclco +ggrcg+tcs snoulo bc invcstig+tco il tnc m+tc- ri+l will bc usco in rcinlorcco concrctc lo +cnicvc tnc s+mc work+bility, slump, +no w/cm r+tio +s in convcn- tion+l concrctc, mixturcs incorpor+ting lCA typic+lly rcuirc nigncr p+stc contcnt +no/or grc+tcr +mounts ol w+tcr rcouccr In +n l\A surl+cc +no +spn+lt- st+bilizco b+sc +no/or subb+sc l+ycrs, lCA c+n nclp to improvc st+bility +no lriction but typic+lly rcuircs +n incrc+sc in binocr contcnt As +n +ggrcg+tc in Cll l+ycrs, lCA rcuircs no spcci+l consiocr+tion +no pcrlorms simil+r to virgin +ggrcg+tc lccyclco concrctc +ggrcg+tcs c+n bc morc susccptiblc to +br+sion lncrclorc, wncn usco +s +n +ggrcg+tc in unbouno b+sc +no/or subb+sc l+ycrs, tnc construction proccss snoulo bc +ojustco +s nccoco lor propcr n+noling l+vcmcnts sullcring lrom ASl or l-cr+cking c+n bc rccyclco, but spcci+l +ttcntion must bc givcn to concrctc mixturc ocsign Supplcmcnt+ry ccmcntitious m+tcri+ls tn+t mitig+tc ASl must bc incorpor+tco into concrctc mixturc ocsigns wncn ASl-oistrcssco lCA is usco l-cr+ckco lCA must bc proccssco to propcr +ggrcg+tc sizcs lor tnc prcvcntion ol lurtncr l-cr+ck- ing oistrcss \ncn ocsignco +no constructco +ppropri+tcly, p+vc- mcnts built witn rccyclco m+tcri+ls c+n bc our+blc lnc kcy is to ocsign + mixturc witn propcr m+tcri+l proportions lor tnc intcnoco +pplic+tion Design It is common to combinc lCA witn virgin +ggrcg+tc in mixturcs lor ncw concrctc or l\A surl+cc l+ycrs In concrctc surl+cc +pplic+tions, up to 30 pcrccnt ol n+tur+l crusnco co+rsc +ggrcg+tc c+n bc rcpl+cco witn co+rsc lCA witnout signinc+ntly +llccting +ny ol tnc Figure 9-1. Recycled concrete aggregates G u i d e
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A G G R E G A T E S 9-3 mccn+nic+l propcrtics ol tnc concrctc As rcpl+ccmcnt +mounts incrc+sc, orying snrink+gc +no crccp will incrc+sc +no tcnsilc strcngtn +no mooulus ol cl+stic- ity will occrc+sc, nowcvcr, comprcssivc strcngtn +no lrcczc-tn+w rcsist+ncc +rc not signinc+ntly +llcctco Spcci+l c+rc is ncccss+ry wncn using nnc lCA in concrctc mixturcs Only + m+ximum ol 10 to 20 pcrccnt nnc lCA n+s bccn snown to bc bcncnci+l lccyclco concrctc +ggrcg+tcs contcnt in l\A surl+cc l+ycrs is not limitco il tnc mixturc ocsign propcrtics +oncrc to +ll spccinco pcrlorm+ncc rcuircmcnts (cg, +br+sion) lccyclco concrctc +ggrcg+tcs contcnt lor b+sc +no subb+sc +pplic+tions is not +s strict In gcncr+l, + wcll- gr+oco lCA c+n rcsult in + vcry st+blc subb+sc, +no lCA contcnt in Cll snoulo bc sucn tn+t it still mccts +ll pcrlorm+ncc rcuircmcnts Construction lnc stcps rcuirco lor tnc lCA proouction proccss +rc crusning +no rcmoving cxisting p+vcmcnt m+tcri+l, rcmoving +ny rcinlorccmcnt +no/or otncr cont+mi- n+nts, +no proccssing tnc rccl+imco m+tcri+l oown to +ppropri+tc +ggrcg+tc sizcs In gcncr+l, cuipmcnt usco lor lCA proouction incluocs tnc lollowing - l+no-opcr+tco or vcniclc-mountco crusning ocviccs (cg, n+no-nclo tools, orop n+mmcrs/bl+ocs, imp+ct brc+kcrs/n+mmcrs, ctc) (scc ligurc 9-2) - A b+cknoc or bulloozcr witn + rnino norn +tt+cn- mcnt lor looscning tnc crusnco m+tcri+l lrom tnc l+ycr bcnc+tn it +no +ny rcinlorccmcnt - lront-cno lo+ocrs or oump trucks lor tr+nsporting (scc ligurc 9-3) - A rccycling pl+nt tn+t c+n bc st+tion+ry, port+blc, or mobilc ligurc 9-- snows cxisting concrctc rccyclco in-pl+cc +no rcusco lor b+sc m+tcri+l \ncn usco in ncw concrctc, it is rccommcnoco tn+t lCA bc prcwcttco +no closc to + s+tur+tco surl+cc ory Figure 9-2. Example of equipment used to break existing concrete Figure 9-3. Broken concrete pavement is removed for recycling Figure 9-4. Existing concrete recycled in-place and reused for base material on the Tri-State Tollway in Illinois G u i d e
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A G G R E G A T E S 9-4 conoition bclorc b+tcning Aooition+l u+lity control mc+surcs m+y bc ncccss+ry to cnsurc gooo moisturc control Concrctc +no l\A mixturcs cont+ining lCA c+n bc tr+nsportco, pl+cco, +no comp+ctco in tnc s+mc m+nncr +s convcntion+l mixturcs lnc construction ol Cll +no unbouno b+sc/subb+sc l+ycrs lollows typic+l st+no+ro proccourcs Il lCA is usco in wn+t is intcnoco to bc + or+in+blc b+sc or subb+sc l+ycr, it is +ovisco tn+t n+noling (ic, sn+p- ing) tnc m+tcri+l is kcpt to + minimum, tnc tcnocncy lor nnc p+rticul+tcs to brc+k oll lrom tnc surl+cc ol tnc lCA is incrc+sco, otncrwisc In + or+in+blc l+ycr, incrc+sco nncs occrc+sc tnc +bil- ity lor w+tcr to csc+pc out ol tnc l+ycr It is +lso rcc- ommcnoco tn+t lCA b+sc +no subb+sc or+in+gc l+ycrs +rc o+yligntco lor tnis rc+son lccyclco concrctc +ggrcg+tcs usco in unbouno b+sc +no/or subb+sc l+ycrs c+n cont+in vcry sm+ll pcrccnt- +gcs ol cont+min+nts (sucn +s l\A binocr) witnout +ovcrscly +llccting pcrlorm+ncc Sustainability - lxisting m+tcri+ls +rc rcusco, rcoucing tnc cxploi- t+tion ol virgin m+tcri+l +no minimizing l+nonll m+tcri+l - Costs rcl+tco to tnc proccssing, purcn+sing, +no tr+nsport+tion ol virgin +ggrcg+tcs +rc minimizco - In-pl+cc rccycling rcouccs truck tr+lnc +no lucl consumption, +no +lso rcouccs loc+l ro+o o+m+gc lrom n+ul trucks - Lsing lCA, p+rticul+rly in +pplic+tions tn+t cxposc it to tnc +tmospncrc (cg, cmb+nkmcnt nll, gr+vcl ro+os, +no r+ilro+o b+ll+st), rcsults in + proccss c+llco c+rbon scucstcring lnc proccss csscnti+lly rcc+pturcs CO 2 lrom tnc +tmospncrc For More Information Amcric+n Concrctc Institutc Committcc 2001 Removal and Reuse of Hardened Concrete. ACI-l-01 Amcric+n Concrctc l+vcmcnt Associ+tion 2009 Recy- cling Concrete Pavements. ll0-3l Amcric+n Concrctc l+vcmcnt Associ+tion 2010 Recy- cled Concrete Aggregates Can Be Used in Any Application in Which Virgin Aggregate Can Be Used, and Even Some It Typically Is Not. lS0-3-l Construction \+tcri+ls lccycling Associ+tion 200o- 2010 Economical Good Sense. wwwconcrctcrccycling org lcocr+l lignw+y Aoministr+tion 200S Recycled Con- crete Aggregate. N+tion+l lcvicw, nttp//wwwlnw+oot gov/p+vcmcnt/rccycling/rc+clm lcocr+l lignw+y Aoministr+tion 2010 Use of Recycled Concrete Pavement as Aggregate in Hydrau- lic-Cement Concrete Pavement lccnnic+l Aovisory, l 0-037, nttp//wwwlnw+ootgov/p+vcmcnt/ t0-037clm N+tion+l Concrctc l+vcmcnt lccnnology Ccntcr Resources on Two-Lift Concrete Paving. nttp//www cptccnccntcrorg/projccts/two-lilt-p+ving (+cccssco ]uly 2010) lortl+no Ccmcnt Associ+tion 2010 Integrated Paving SolutionsRecycled Concrete. nttp//wwwintcgr+tco- p+vingsolutionsorg/lccyclcoConcrctcntml lortl+no Ccmcnt Associ+tion Concrete Technology Materials: Aggregates, wwwccmcntorg/tccn/cct_+ggrc- g+tcs_rccyclco+sp l+ylor, l, S losm+tk+, G Voigt ct +l 200o Integrated Materials and Construction Practices for Concrete Pave- ment. N+tion+l Concrctc l+vcmcnt lccnnology Ccntcr, Iow+ St+tc Lnivcrsity G u i d e
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10-1 Repair and Restoration Description lnc rcp+ir +no rcstor+tion ol concrctc p+vcmcnts +rc t+sks conouctco to improvc + oistrcssco p+vcmcnt by rcstoring botn lunction +no structur+l c+p+city lnc v+rious tccnniucs tn+t l+ll into tnis c+tcgory c+n bc conouctco onc or morc timcs ouring tnc lilc ol tnc p+vcmcnt lnc typc ol rcp+ir ocpcnos on tnc conoition ol tnc p+vcmcnt +t tnc timc Quitc oltcn, prompt rcp+irs +rc morc cllcctivc +no lcss cxpcnsivc tn+n ocl+yco rcp+irs or rcn+bilit+tion lnc lollowing summ+rizcs somc ol tnc morc common rcp+irs +no rcn+bilit+tion tccnniucs usco on concrctc p+vcmcnts in orocr to cxtcno pcrlorm+ncc Full-Depth Repairs lull-ocptn rcp+irs +rc usco to +oorcss +n +rc+ ol m+jor oistrcss in + p+vcmcnt lnis coulo bc + loc+lizco cvcnt or cxtcnoco tnrougnout tnc p+vcmcnt scction A lull-ocptn rcp+ir c+n provioc gooo long-tcrm pcr- lorm+ncc (morc tn+n 10 to 1 yc+rs) il tnc u+lity ol tnc rcp+ir is gooo +no tnc rignt m+tcri+ls +rc usco In concrctc p+vcmcnts, lull-ocptn rcp+irs most oltcn consist ol c+st-in-pl+cc concrctc tn+t rcpl+ccs tnc lull ocptn ol tnc cxisting sl+b ligurc 10-1 snows tnc proccss lor lull-ocptn rcp+ir ol + ]lCl p+ncl (lrom top to bottom) iocntily c+noio+tc sl+bs, rcmovc cxisting p+vcmcnt, +no rcpl+cc witn ncw concrctc A simil+r tccnniuc is usco lor jointco p+vcmcnts, wncrc p+rt or +ll ol + sl+b p+ncl c+n bc rcpl+cco witn tnc joint rcinlorccmcnt bcing rcpl+cco +t tnc s+mc timc Figure10-1. Full-depth repair of a concrete pavement slab 10 Guide to Cement-Based Integrated Pavement Solutions G u i d e
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R E S T O R A T I O N 10-2 Partial-Depth Repairs A p+rti+l-ocptn rcp+ir consists ol tnc rcmov+l +no rcpl+ccmcnt ol sm+ll, sn+llow +rc+s ol octcrior+tco concrctc p+vcmcnt +t sp+llco or oistrcssco joints lor + p+rti+l-ocptn rcp+ir to bc pr+ctic+l, tnc oistrcss typi- c+lly n+o not cxtcnoco occpcr tn+n onc-tniro ol tnc ocptn ol tnc sl+b lowcvcr, ouc to tnc rcccnt +v+il- +bility ol joint milling m+cnincs +s + 'L` mill, p+rti+l ocptn rcp+irs n+vc cxtcnoco to l/2 lnc lo+o tr+nslcr ocviccs, il prcscnt, snoulo bc lully lunction+l ligurc 10-2 snows + p+vcmcnt snowing sp+lling Sp+lling c+n c+usc rioc +no noisc problcms lor tnc tr+vcling public, +no tnus p+rti+l-ocptn rcp+irs c+n rcmcoy lunction+l pcrlorm+ncc A p+rti+l-ocptn rcp+ir bcgins witn tnc rcmov+l ol oistrcssco concrctc by s+wing, cnip- ping, +no/or milling until souno concrctc is cxposco lcp+ir m+tcri+l is tncn +pplico +no tnc surl+cc tcxturc rcstorco lin+lly, curing snoulo bc conouctco pcr tnc rccommcno+tions spccinc lor tnc p+tcn m+tcri+l usco Stitching Stitcning is + rcp+ir mctnoo lor rcstoring lo+o tr+nslcr +t longituoin+l cr+cks (scc ligurc 10-3) lnis typc ol rcp+ir is +n option wncn sl+bs +rc not scvcrcly ois- trcssco lolcs +rc orillco +t + oi+gon+l lrom onc sioc ol tnc cr+ck to tnc otncr lnc +nglc ol tnc oi+gon+l snoulo bc consistcnt +no mc+surc bctwccn 3 +no - ocgrccs lpoxy lollowco by + tic b+r nll tnc nolc lnc tic b+r snoulo p+ss tnrougn tnc cr+ck +t mio-ocptn It is import+nt not to o+m+gc tnc surl+cc ol tnc concrctc wnilc pcrlorming tnis typc ol rcp+ir Surl+cc o+m- +gc c+n bc +voioco by cnoosing +ppropri+tc orilling cuipmcnt sucn +s + nyor+ulic-powcrco orill +no + bit tn+t is 037 in (10 mm) grc+tcr tn+n tnc oi+mctcr ol tnc tic b+r tn+t will bc inscrtco lnc sizc ol tnc tic b+r ocpcnos on sl+b tnickncss, +nglc ol nolc, +no nolcs oist+ncc lrom tnc cr+ck Figure10-2. Partial-depth repair process at joint Figure 10-3. Cross-section of concrete pavement showing stitching Slab Stabilization Sl+b st+biliz+tion is + rcp+ir tccnniuc lor concrctc p+vcmcnt in wnicn + low+blc m+tcri+l is inscrtco bcnc+tn tnc p+vcmcnt sl+bs in orocr to rcstorc tncir support luring tnc proccss, voios +rc nllco tn+t lic bctwccn tnc sl+b +no tnc supporting l+ycr lncsc +rc oltcn c+usco by w+tcr innltr+tion +no subscucnt G u i d e
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R E S T O R A T I O N 10-3 pumping ol nncs to tnc surl+cc Voios wc+kcn tnc structurc +no witnout rcp+ir c+n lc+o to brc+king up ol tnc sl+bs ouc to tr+lnc lo+os lnc m+tcri+l tn+t is inscrtco snoulo nll tnc voios but snoulo not lilt tnc sl+b Sl+b st+biliz+tion rcstorcs sl+b support, rcouccs p+vc- mcnt oclcctions, +no minimizcs tnc progrcssion ol lurtncr oistrcss lnc succcss ol tnc rcp+ir ocpcnos, in p+rt, on iocntilying tnc +rc+s witn loss ol support lurtncrmorc, tnc injcction ol m+tcri+l unocr tnc sl+b must bc pcrlormco in sucn + w+y tn+t tnc voio is +ocu+tcly nllco, wnicn cncour+gcs tnc usc ol +n cxpcricncco contr+ctor ligurc 10-- snows typic+l t+sks ouring + sl+b st+biliz+tion rcp+ir, wncrc nolcs +rc orillco into tnc concrctc sl+b, wnicn is tncn nllco witn grout m+tcri+l Slab Jacking Sl+b j+cking is + rcp+ir proccourc in wnicn + concrctc p+vcmcnt sl+b is r+isco by +pplying prcssurizco grout bcnc+tn tnc sl+b Sl+b j+cking is usco to nx loc+lizco spots ol scttlcmcnt oltcn louno nc+r nll +rc+s, culvcrts, +no briogc +ppro+cncs \ncn oonc propcrly, tnis tccnniuc c+n rcstorc tnc rioc u+lity ol + p+vcmcnt, +ltnougn it oocs not corrcct l+ultco joints lnc grout mixturc or polyurctn+nc usco in tnc rcp+ir snoulo bc ccrtinco lor tnis purposc lnc proccourc is simil+r to sl+b st+biliz+tion in tn+t tnc loc+tions snoulo nrst bc c+rclully iocntinco lolcs +rc orillco, +no + pumping scucncc is iocntinco to +cnicvc tnc ocsirco cllcct \+tcri+l is tncn injcctco-in scucncc-so tn+t tnc Figure 10-4. Drilling operation as part of slab stabilization sl+b is r+isco no morc tn+n 02 in (o mm) lnis pro- ccss continucs until tnc sl+b rc+cncs tnc ocsirco gr+oc Succcss in sl+b j+cking is morc likcly wncn pcrlormco on structur+lly souno p+vcmcnt witn loc+lizco ocprcs- sions A provcn proccss +no our+blc m+tcri+ls snoulo bc usco Joint Resealing ]oint rcsc+ling consists ol pl+cing + sc+ling m+tcri+l in +n cxisting joint or cr+ck to rcoucc moisturc innltr+- tion +no minimizc intrusion ol incomprcssiblcs \ncn cr+cks +no joints +rc not propcrly sc+lco, w+tcr c+n somctimcs innltr+tc +no s+tur+tc tnc lowcr l+ycrs ol tnc p+vcmcnt lnis, in turn, c+n c+usc v+rious p+vc- mcnt oistrcsscs Sc+ling m+tcri+l is typic+lly + liuio (not or colo) but c+n +lso bc +n cxp+nsion joint nllcr (prclormco) lnc joint ocsign typic+lly oict+tcs tnc typc ol sc+l+nt to bc usco lnc ocsirco propcrtics ol tnc sc+l+nt +rc our+bility to tr+lnc +no cnvironmcnt, cxtcnsibility tn+t +llows joint/cr+ck movcmcnt witnout rupturc, +no +oncsivcncss tn+t pcrmits +oncrcncc to tnc cr+ck or joint w+lls A joint rcsc+ling proccourc lollows nvc b+sic stcps olo sc+l+nt rcmov+l, joint rcl+cing, joint rcscrvoir clc+ning, b+ckcr roo inst+l- l+tion, +no ncw sc+l+nt inst+ll+tion lnc kcy l+ctors lor tnc succcss ol tnis rcp+ir +rc tnc propcr sclcction ol joints/cr+cks, sclcction ol sc+ling m+tcri+l, rcstor+- tion ol tnc joint rcscrvoir +no sn+pc l+ctor, rcscrvoir prcp+r+tion, +no propcr sc+l+nt +pplic+tion ligurc 10- snows tnc +pplic+tion ol joint sc+l+nt Dowel Bar Retrot lo+o tr+nslcr +cross tr+nsvcrsc joints n+s +lw+ys bccn + l+ctor contributing to tnc lilc ol + concrctc p+vc- mcnt Stccl oowcls +rc oltcn usco to cnsurc lo+o tr+nslcr lowcvcr, problcms c+n somctimcs +risc ovcr timc, incluoing corrosion +no nign bc+ring strcsscs tn+t c+n crooc tnc surrounoing concrctc On olocr concrctc p+vcmcnts, or tnosc tn+t wcrc ocsignco lor lowcr tr+lnc, lo+o tr+nslcr m+y bc provioco by +ggrc- g+tc intcrlock only Ovcr timc, tnc loss ol lo+o tr+nslcr c+n m+nilcst itscll into joint l+ulting +no sl+b cr+cking +no tnus snoulo bc rcmcoico lo+o tr+nslcr rcstor+tion is ocnnco +s tnc inst+ll+tion ol mccn+nic+l ocviccs in +n cxisting p+vcmcnt Along G u i d e
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R E S T O R A T I O N 10-4 tr+nsvcrsc joints, tnc lo+o tr+nslcr is usu+lly +ccom- plisnco by inst+lling oowcl b+rs lo ocnnc wnctncr or not lo+o tr+nslcr is +ocu+tc, + l+lling wcignt oclcc- tomctcr c+n bc usco to +sscss tnc lo+o tr+nslcr cln- cicncy A gooo c+noio+tc lor rcp+ir is + p+vcmcnt in gooo structur+l conoition but witn poor lo+o tr+nslcr (lcss tn+n 0 to o0 pcrccnt) l+vcmcnts witn l+ulting bctwccn 012 +no 0 in (3 +no 13 mm) +rc +lso gooo c+noio+tcs, +s +rc tnosc witn lcss tn+n 10 pcrccnt ol sl+bs witn multiplc cr+cks lowcl b+r rctront bcgins witn slotting, typic+lly by s+wing +no cnipping lnc joint is prcp+rco +no tnc oowcl b+r +lnxco to + joint inscrt lnc rcp+ir m+tcri+l is tncn pl+cco +no curco +s nccoco Quitc oltcn, oi+- mono grinoing c+n bc conouctco +ltcr +ll oowcl b+r rctronts +rc complctc ligurc 10-o oispl+ys + concrctc p+vcmcnt wncrc slots n+vc bccn cut +no clc+nco to rctront oowcl b+rs Notc tn+t rctrontting is oltcn oonc in tnc wnccl p+tns only Diamond Grooving and Grinding li+mono grooving +no grinoing +rc surl+cc trc+t- mcnts pcrlormco to improvc tnc lunction+l cn+r+c- tcristics ol + p+vcmcnt li+mono grinoing consists ol rcmoving + vcry tnin l+ycr ol tnc surl+cc using + sct ol closcly sp+cco oi+mono s+w bl+ocs lnc rcsult ol tnis tccnniuc incluocs improvcmcnts to smootnncss, lric- tion, +no noisc Grinoing is rccommcnoco wncn tnc p+vcmcnt is structur+lly souno, +no bclorc conouct- ing tnis rcp+ir tnc n+roncss ol tnc concrctc +ggrcg+tc snoulo bc octcrminco so tn+t tnc oi+mono bl+ocs +rc sclcctco, sizco, +no sp+cco +ccoroingly lnc ncco lor Figure 10-5. Application of joint sealant Figure 10-6. Contiguous concrete slabs prepared for dowel bar retrotting Figure 10-7 Diamond grinding concrete pavement for surface restoration G u i d e
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R E S T O R A T I O N 10-5 +ssoci+tco trc+tmcnts (cg, lo+o tr+nslcr rcstor+tion) snoulo +lso bc consiocrco prior to tnis trc+tmcnt lig- urc 10-7 oispl+ys tnc typic+l +ppc+r+ncc ol + concrctc p+vcmcnt tn+t n+s bccn oi+mono grouno li+mono grooving is usu+lly oonc to minimizc tnc nyoropl+ning cllcct in + p+vcmcnt Cn+nncls +rc groovco onto tnc surl+cc to +ccomplisn tnis go+l li+- mono s+w bl+ocs +rc usco to cut tncsc p+r+llcl groovcs in citncr longituoin+l (morc common) or tr+nsvcrsc p+ttcrns Otncr bcncnts ol tnis rcp+ir +rc improvco wct wc+tncr lriction +no tnc rcouction in spl+sn +no spr+y wncn tnc p+vcmcnt is wct C+noio+tc p+vcmcnts lor oi+mono grooving +rc oltcn b+sco on nistoric+l cr+sn r+tcs lnis surl+cc trc+t- mcnt is gcncr+lly pcrlormco +t loc+lizco +rc+s +no on p+vcmcnts tn+t +rc structur+lly souno lnc suc- ccss ol tnis rcp+ir ocpcnos on tnc sclcction ol propcr c+noio+tc projccts +no tnc propcr sclcction ol groovc oimcnsions ligurc 10-S illustr+tcs + concrctc p+vcmcnt wncrc oi+mono grooving is bcing pcrlormco In tnis c+sc, tnc grooving p+ttcrn is longituoin+l For More Information Amcric+n Concrctc l+vcmcnt Associ+tion 200S Con- crete Pavement Field Reference: Preservation and Repair. ll239l Skokic, Illinois Amcric+n Concrctc l+vcmcnt Associ+tion l+nous, l S, ] l C+blc ct +l 200o Laboratory Study of Structural Behavior of Alternative Dowel Bars (Proj. 7). lcsc+rcn projcct, N+tion+l Concrctc l+vcmcnt lccn- nology Ccntcr, Iow+ St+tc Lnivcrsity, April lcocr+l lignw+y Aoministr+tion 200S Concrete Pave- ment Preservation Workshop. lr+lt instructor guioc l+ylor, l C, S l losm+tk+, G l Voigt, ct +l 2007 Integrated Materials and Construction Practices for Con- crete Pavement: A State-of-the-Practice Manual. N+tion+l Concrctc l+vcmcnt lccnnology Ccntcr, Iow+ St+tc Lnivcrsity, Octobcr lcx+s lcp+rtmcnt ol lr+nsport+tion 200S Pave- ment Design Guide. lxlOl Construction livision Novcmbcr Figure 10-8. Longitudinal grooving of a concrete pavement to restore macrotexture National Concrete Pavement Technology Center Institute for Transportation Iowa State University 2711 South Loop Drive, Suite 4700 Ames, IA 50010-8664 515-294-5798 www.cptechcenter.org SR035