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Construction and Rehabilitation of Concrete Pavements Under Traffic A Synthesis of Highway Practice Shreenath Rao Applied ReseARch AssociAtes, inc. Champaign, IL Deepak Raghunathan Applied ReseARch AssociAtes, inc. Champaign, IL 2018 Research sponsored by the American Association of State Highway and Transportation Officials in cooperation with the Federal Highway Administration Subscriber Categories Highwaysâ â¢â MaintenanceâandâPreservationâ â¢â Pavements N A T I O N A L C O O P E R A T I V E H I G H W A Y R E S E A R C H P R O G R A M NCHRP SYNTHESIS 530
Published reports of the NATIONAL COOPERATIVE HIGHWAY RESEARCH PROGRAM are available from Transportation Research Board Business Office 500 Fifth Street, NW Washington, DC 20001 and can be ordered through the Internet by going to http://www.national-academies.org and then searching for TRB Printed in the United States of America NCHRP SYNTHESIS 530 Project 20-05, Topic 48-16 ISSN 0547-5570 ISBN 978-0-309-39058-3 Library of Congress Control Number 2018952100 Â© 2018 National Academy of Sciences. All rights reserved. COPYRIGHT INFORMATION Authors herein are responsible for the authenticity of their materials and for obtaining written permissions from publishers or persons who own the copyright to any previously published or copyrighted material used herein. Cooperative Research Programs (CRP) grants permission to reproduce material in this publication for classroom and not-for-profit purposes. Permission is given with the understanding that none of the material will be used to imply TRB, AASHTO, FAA, FHWA, FMCSA, FRA, FTA, Office of the Assistant Secretary for Research and Technology, PHMSA, or TDC endorsement of a particular product, method, or practice. It is expected that those reproducing the material in this document for educational and not-for-profit uses will give appropriate acknowledgment of the source of any reprinted or reproduced material. For other uses of the material, request permission from CRP. Cover photo: Construction of concrete overlay of an existing asphalt pavement on SH 14 near Ault, CO, in 2015 with traffic in the adjacent lane. Cover photo credit: Courtesy Interstate Highway Construction (IHC) and ZoZo Group. NOTICE The report was reviewed by the technical panel and accepted for publication according to procedures established and overseen by the Transportation Research Board and approved by the National Academies of Sciences, Engineering, and Medicine. The opinions and conclusions expressed or implied in this report are those of the researchers who performed the research and are not necessarily those of the Transportation Research Board; the National Academies of Sciences, Engineering, and Medicine; or the program sponsors. The Transportation Research Board; the National Academies of Sciences, Engineering, and Medicine; and the sponsors of the National Cooperative Highway Research Program do not endorse products or manufacturers. Trade or manufacturersâ names appear herein solely because they are considered essential to the object of the report. NATIONAL COOPERATIVE HIGHWAY RESEARCH PROGRAM Systematic, well-designed research is the most effective way to solve many problems facing highway administrators and engineers. Often, highway problems are of local interest and can best be studied by highway departments individually or in cooperation with their state universities and others. However, the accelerating growth of highway transportation results in increasingly complex problems of wide inter- est to highway authorities. These problems are best studied through a coordinated program of cooperative research. Recognizing this need, the leadership of the American Association of State Highway and Transportation Officials (AASHTO) in 1962 ini- tiated an objective national highway research program using modern scientific techniquesâthe National Cooperative Highway Research Program (NCHRP). NCHRP is supported on a continuing basis by funds from participating member states of AASHTO and receives the full cooperation and support of the Federal Highway Administration, United States Department of Transportation. The Transportation Research Board (TRB) of the National Academies of Sciences, Engineering, and Medicine was requested by AASHTO to administer the research program because of TRBâs recognized objectivity and understanding of modern research practices. TRB is uniquely suited for this purpose for many reasons: TRB maintains an extensive com- mittee structure from which authorities on any highway transportation subject may be drawn; TRB possesses avenues of communications and cooperation with federal, state, and local governmental agencies, univer- sities, and industry; TRBâs relationship to the National Academies is an insurance of objectivity; and TRB maintains a full-time staff of special- ists in highway transportation matters to bring the findings of research directly to those in a position to use them. The program is developed on the basis of research needs identified by chief administrators and other staff of the highway and transportation departments, by committees of AASHTO, and by the Federal Highway Administration. Topics of the highest merit are selected by the AASHTO Special Committee on Research and Innovation (R&I), and each year R&Iâs recommendations are proposed to the AASHTO Board of Direc- tors and the National Academies. Research projects to address these top- ics are defined by NCHRP, and qualified research agencies are selected from submitted proposals. Administration and surveillance of research contracts are the responsibilities of the National Academies and TRB. The needs for highway research are many, and NCHRP can make significant contributions to solving highway transportation problems of mutual concern to many responsible groups. The program, however, is intended to complement, rather than to substitute for or duplicate, other highway research programs.
The National Academy of Sciences was established in 1863 by an Act of Congress, signed by President Lincoln, as a private, non- governmental institution to advise the nation on issues related to science and technology. Members are elected by their peers for outstanding contributions to research. Dr. Marcia McNutt is president. The National Academy of Engineering was established in 1964 under the charter of the National Academy of Sciences to bring the practices of engineering to advising the nation. Members are elected by their peers for extraordinary contributions to engineering. Dr. C. D. Mote, Jr., is president. The National Academy of Medicine (formerly the Institute of Medicine) was established in 1970 under the charter of the National Academy of Sciences to advise the nation on medical and health issues. Members are elected by their peers for distinguished contributions to medicine and health. Dr. Victor J. Dzau is president. The three Academies work together as the National Academies of Sciences, Engineering, and Medicine to provide independent, objective analysis and advice to the nation and conduct other activities to solve complex problems and inform public policy decisions. The National Academies also encourage education and research, recognize outstanding contributions to knowledge, and increase public understanding in matters of science, engineering, and medicine. Learn more about the National Academies of Sciences, Engineering, and Medicine at www.national-academies.org. The Transportation Research Board is one of seven major programs of the National Academies of Sciences, Engineering, and Medicine. The mission of the Transportation Research Board is to increase the benefits that transportation contributes to society by providing leadership in transportation innovation and progress through research and information exchange, conducted within a setting that is objective, interdisciplinary, and multimodal. The Boardâs varied committees, task forces, and panels annually engage about 7,000 engineers, scientists, and other transportation researchers and practitioners from the public and private sectors and academia, all of whom contribute their expertise in the public interest. The program is supported by state transportation departments, federal agencies including the component administrations of the U.S. Department of Transportation, and other organizations and individuals interested in the development of transportation. Learn more about the Transportation Research Board at www.TRB.org.
C O O P E R A T I V E R E S E A R C H P R O G R A M S CRP STAFF FOR NCHRP SYNTHESIS 530 Christopher J. Hedges, Director, Cooperative Research Programs Lori L. Sundstrom, Deputy Director, Cooperative Research Programs Crawford F. Jencks, Staff Officer Cheryl Keith, Senior Program Assistant Eileen P. Delaney, Director of Publications Natalie Barnes, Associate Director of Publications Doug English, Senior Editor NCHRP PROJECT 20-05 PANEL Brian A. Blanchard, Florida DOT, Tallahassee, FL (Chair) Stuart D. Anderson, Texas A&M University, College Station, TX Socorro Briseno, California DOT, Sacramento, CA David M. Jared, Georgia DOT, Forest Park, GA Cynthia L. Jones, Ohio DOT, Columbus, OH Malcolm T. Kerley, NXL, Richmond, VA John M. Mason, Jr., Auburn University, Auburn, AL Roger C. Olson, Minnesota DOT, Bloomington, MN (retired) Benjamin T. Orsbon, South Dakota DOT, Pierre, SD Randall R. Park, Utah DOT, Salt Lake City, UT Robert L. Sack, New York State DOT, Albany, NY Francine Shaw Whitson, FHWA, Washington, DC Joyce N. Taylor, Maine DOT, Augusta, ME Jack Jernigan, FHWA Liaison Stephen F. Maher, TRB Liaison TOPIC 48-16 PANEL Emanuel Banks, Arkansas DOT, Little Rock, AR Jeremy Daniel, Georgia DOT, Thomaston, GA Sabrina Garber, The Transtec Group Inc., Austin, TX Steven Gillen, Illinois Tollway, Downers Grove, IL Craig Landefeld, Ohio DOT, Columbus, OH Leo Mahserelli, California DOT, Sacramento, CA John M. Mason, Jr., Auburn University, Auburn, AL Richard B. Duval, FHWA Liaison Michael Praul, FHWA Liaison Nelson H. Gibson, TRB Liaison Amir N. Hanna, TRB Liaison
FOREWORD Highway administrators, engineers, and researchers often face problems for which information already exists, either in documented form or as undocumented experience and practice. This infor- mation may be fragmented, scattered, and unevaluated. As a consequence, full knowledge of what has been learned about a problem may not be brought to bear on its solution. Costly research findings may go unused, valuable experience may be overlooked, and due consideration may not be given to recommended practices for solving or alleviating the problem. There is information on nearly every subject of concern to highway administrators and engineers. Much of it derives from research or from the work of practitioners faced with problems in their day- to-day work. To provide a systematic means for assembling and evalu ating such useful information and to make it available to the entire highway community, the American Association of State High- way and Transportation Officialsâthrough the mechanism of the National Cooperative Highway Research Programâauthorized the Transportation Research Board to undertake a continuing study. This study, NCHRP Project 20-05, âSynthesis of Information Related to Highway Problems,â searches out and synthesizes useful knowledge from all available sources and prepares concise, documented reports on specific topics. Reports from this endeavor constitute an NCHRP report series, Synthesis of Highway Practice. This synthesis series reports on current knowledge and practice, in a compact format, without the detailed directions usually found in handbooks or design manuals. Each report in the series provides a compendium of the best knowledge available on those measures found to be the most successful in resolving specific problems. PREFACE ByâCrawfordâF.âJencks StaffâOfficer TransportationâResearchâBoard With advancements in materials, equipment, placement procedures, and project management techniques, the construction and rehabilitation of concrete pavements can be effectively accom- plished under traffic. Many projects have been constructed under varying levels of traffic, ranging from temporary closures to the maintenance of high traffic volumes adjacent to or through the projects. However, the current state of the practice in constructing or rehabilitating concrete pave- ments under traffic relies primarily on a few high-profile and well-documented projects. This study identified practices from projects representing a wider range of conditions and techniques. Information on existing practices and advancements in concrete pavement construction and rehabilitation was gathered through literature reviews and a survey of state transportation agen- cies, including that of the District of Columbia and the Illinois Tollway. Furthermore, sixteen case examples were reported to illustrate successful projects conducted under a variety of scenarios. Appendices A and B can be found at www.TRB.org by searching for âNCHRP Synthesis 530.â Shreenath Rao, Ph.D., P.E., the studyâs principal investigator, and Deepak Raghunathan, both from Applied Research Associates, Inc., collected and synthesized the information and wrote the report. The members of the topic panel are acknowledged on page iv. This synthesis is an immediately use- ful document that records the practices that were acceptable with the limitations of the knowledge available at the time of its preparation. As progress in research and practice continues, new knowledge will be added to that now at hand.
1â Summary 4 Chapter 1â Introduction 6 Chapter 2â âConsiderationsâandâStrategiesâforâConstructingâandâ RehabilitatingâConcreteâPavementsâUnderâTraffic 6 Work Zone Management 8 Maintenance of Traffic 13 Project Planning and Construction Staging 16 Materials and Design 19 Equipment and Operations 21 Project Management, Delivery, Procurement, and Payment 23 Communications and Outreach 25 Summary of Concrete Construction Under Traffic 29 Chapter 3â âAgencyâPerspectivesâandâPracticesâforâConstructingâ orâRehabilitatingâConcreteâPavementsâUnderâTraffic 29 Survey Participation 29 Concrete Pavement Construction 30 Concrete Pavement Rehabilitation/Restoration Techniques 31 Maintenance of Traffic 33 Materials and Design 35 Paving Equipment and Concrete Placement 36 Paving Operations 37 Project Management 37 Project Delivery 38 Project Procurement 40 Payment Methods 41 Project-Related Communications 42 Public Outreach 43 Motorist Information 44 Modification of Standard Practices for Constructing or Rehabilitating Concrete Pavements Under Traffic 47 Chapter 4â CaseâExamples 47 Unbonded Concrete Overlay of Asphalt on U.S. Highway 18 in Iowa 51 Replacement of Four Traffic Lanes Using Precast Concrete Panels on Interstate 66 in Virginia 54 Concrete Pavement Widening on Interstate 75 in Ohio 57 Reconstruction and Widening of Interstate 90 at the Illinois Tollway, Illinois 62 Bonded Concrete Overlay of Asphalt on Interstate 70, Missouri 63 Intersection Reconstruction Using Precast Panels on State Route 7, New York 64 Unbonded Concrete Overlay on Interstate 77, North Carolina C O N T E N T S
65 Bonded Concrete Overlay of Asphalt on U.S. Highway 2, North Dakota 66 Bonded Concrete Overlay of Asphalt on U.S. Highway 40/287, Colorado 67 Bonded Concrete Overlay of Asphalt on U.S. Highway 385, Colorado 68 Bonded Concrete Overlay of Asphalt on State Route 79, Missouri 69 Reconstruction and Widening of Interstate 15, Utah 70 Unbonded Overlay and Widening of Interstate 75, Michigan 71 Unbonded Concrete Overlay on Little Mack Avenue, St. Clair Shores, Michigan 72 Unbonded Concrete Overlay on Alma Drive, Plano, Texas 73 Roller-Compacted Concrete on State Route 684, Virginia 76 Chapter 5â ConclusionsâandâFurtherâResearch 78 Further Research 80â References 82â AbbreviationsâandâAcronyms 84â Appendices Note: Photographs, figures, and tables in this report may have been converted from color to grayscale for printing. The electronic version of the report (posted on the web at www.trb.org) retains the color versions.