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Guide to Cement-Based

Integrated Pavement Solutions


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
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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
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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.
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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
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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
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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
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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
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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
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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
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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
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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
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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.
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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.
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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
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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
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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)
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xviii
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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
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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)
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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)
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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
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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
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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
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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
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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
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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
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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)
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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
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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
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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
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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
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- 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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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)
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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
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5-2
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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
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5-3
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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
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5-4
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(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
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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
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5-6
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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
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5-7
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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

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