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Concrete Pavement Overlay Design Jeffery Roesler, Ph.D., P.E. Professor Department of Civil & Env. Eng. University of Illinois Urbana-Champaign 25 June 2015 ISCP Concrete Pavement Seminar IDOT District 1 (Schaumburg, IL)

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Page 1: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Concrete PavementOverlay DesignJeffery Roesler, Ph.D., P.E. ProfessorDepartment of Civil & Env. Eng.University of Illinois Urbana-Champaign

25 June 2015ISCP Concrete Pavement SeminarIDOT District 1 (Schaumburg, IL)

Page 2: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Concrete Overlay Overview Overlay Design Objectives Overlay Design Guides Inputs & critical variables Bonded Concrete Overlays

Concrete-Asphalt

Unbonded Concrete Overlays Whitetopping & Composites

Performance of Illinois O/L References for O/L design Summary of Overlay Design

Page 3: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Concrete Overlay Design: Objectives Achieve desired concrete pavement overlay

service life given: Existing pavement condition Expected traffic Layer and material properties Interface condition Slab geometry Climatic conditions

SCinitial SCOverlay

SCeffective

SCfuture traffic

Load Applications

Page 4: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

- 76

Page 5: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Guide on Existing Overlay Design Methods

Not a design procedure Background on

recommended overlay design methods 18 pages

Detailed design examples 35 pages

StreetPave12 released after this guide

http://www.cptechcenter.org/technical-library/documents/Overlays_Design_Guide_508.pdf

Page 6: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

How to start design of concrete O/L? Roadway site evaluation Existing pavement structure New pavement performance objectives Select candidate Overlay Options Collect input data & choose design features

Support layers, Slab size, etc.

Use appropriate overlay design methods Optimize design Write construction specs to reflect design objectives

Page 7: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Concrete Overlays: General Types

Whitetopping (unbonded) Bonded Concrete Overlay Asphalt (BCOA)

Bonded Concrete to Concrete Unbonded Concrete w/ Separation Layer

Page 8: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Concrete Overlay Guide, Third EditionContents

Overview of Overlays Overlay types and uses Evaluations & Selections Six Overlay Summaries Design Section Misc. Design Details Overlay Materials Section Work Zones under Traffic Overlay Construction Accelerated Construction Specification

Considerations Repairs of Overlays

http://www.cptechcenter.org/technical-library/documents/Overlays_3rd_edition.pdf

Page 9: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Concrete Overlays Categories

Concrete Overlays

Bonded Concrete Resurfacing of Concrete Pavements

Bonded Concrete Resurfacing of Asphalt Pavements

Bonded Concrete Resurfacing of Composite Pavements

Bonded Overlay Group

UnbondedConcrete Resurfacing of Concrete Pavements

Unbonded Concrete Resurfacing of Asphalt Pavements

Unbonded Concrete Resurfacing of Composite Pavements

Unbonded Overlay Group

Thinner Thicker

Bond is integral to design Old pavement is base layer

Page 10: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Thinner Concrete Pavement Options

Bonded Concrete Resurfacing of Asphalt Pavements

Bonded Concrete Resurfacing of Composite Pavements

Bonded Overlay Systems

Unbonded Concrete Resurfacing of Concrete Pavements

Unbonded Concrete Resurfacing of Asphalt Pavements

Thinner Concrete Pavement or Short Slabs

Unbonded Systems

ACPA BCOA or BCOA MEh=3 to 6 in.L=4 to 6 ft

Thin Concrete

Inlay -Preservation

h=2 to 3.5 inchL=4 to 6 ftEmerging

Colorado Method6in. x 6ft x 6ft

Opti-Paveh=2.5 to 9 in.L=4 to 9 ft

Page 11: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Which Overlay Design Method(s)?Concrete Overlay Type Design MethodsUnbonded on Asphalt, Composite, or Concrete

AASHTO ME, ACPA StreetPave 12, AASHTO 93, OptiPave 2.0

Bonded on Asphalt or Composite

ACPA BCOA, ACPA StreetPave 12,BCOA ME, CO 6x6x6, IDOT Chpt 53

Bonded on Concrete AASHTO ME, ACPA StreetPave 12, AASHTO 93

Page 12: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

• Slab thickness• Concrete Strength, CTE, Modulus, fibers (?)• Concrete-Asphalt Interface• Support layers (surface, base/subbase, soil) • Joint Spacing• Edge Support• Load Transfer• Subgrade Support • Traffic & Design Life• Climate

What are main Concrete Overlays Design Inputs?

Hamilton County, IL

Page 13: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Pre-overlay Repair & Reflective Crack Control Sub-drainage Structural vs Functional Overlays Recycling Existing Pavement (PCC & AC) Existing PCC Slab Durability PCC Overlay Reinforcement PCC Overlays Bonding / Separation Layers Overlay Design Reliability Level Pavement Widening Traffic Disruptions and User Delay Costs

Other Important Considerations in Overlay Design

Page 14: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

BCOA vs. “Whitetopping” Whitetopping (h > 6 in.)

More conventional slab sizes (6ft to 15ft)

30+ years experience

Ignores interface bond (unbonded)

Bonded Concrete Overlay Asphalt (h ≤ 6 in.) 20+ years experience (1991)

Smaller slab sizes (≤ 6ft)

Concrete/AC bond is essential

Ultra-Thin Whitetopping (UTW)

Page 15: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Composite Behavior Mechanics

Unbonded“Whitetopping”

Neutral AxisPCC

Bit.

BondedBonded Concrete Overlay Asphalt

PCC

Bit.

Riley

Page 16: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Concrete Overlay Solutions:Rehabilitation and Maintenance

Page 17: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Site Visit: Existing Pavement Condition

Page 18: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Why use smaller slab sizes?

1.2m 1.2m1.2m>2m

•Interface bond assumption (BCOA)-Reduce de-bonding of concrete and asphalt at early ages

•Short slab sizes reduce bending and curling stresses

Page 19: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Thickness Design for Concrete Overlays Highways/Roads AASHTO Pavement ME (2011) or MEPDG StreetPave 12 (ACPA) ACPA (Whitetopping/UTW) – 1998

Illinois DOT (2009) – new fatigue eqn. & fibers Chapter 53-4.08

BCOA Calculator (2012) – add climate database

BCOA ME (2012) – Univ. of Pittsburg AASHTO (1993)

Airports: Federal Aviation Administration (FAARFIELD)

Page 20: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

AASHTO Pavement MEor formerly known as MEPDG

Page 21: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

AASHTO Pavement ME - INPUTS!

Page 22: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Many OUTPUTS to Synthesize

Page 23: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Bonded Concrete Overlay Options

Thinner overlays (3 to 6 in) Constructed over concrete,

asphalt, and composite sections.

Existing pavement condition fair to good

Interface Bond is Critical!

Bonded Concrete

Resurfacing of

Concrete Pavements

Bonded Concrete

Resurfacing of

Asphalt Pavements

Bonded Concrete

Resurfacing of

Composite Pavements

Bonded Overlay Options

Page 24: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Bonded Concrete Overlay of AsphaltAASHTO 1993 Not applicableAASHTO Pavement ME (2011) Thickness 6 in. Slab length 10ftACPA (2012);IDOT (2009);Pitt BCOA ME (2013)Ultra-Thin Whitetopping Thickness 6 in. Slab length 6ft

Unbonded ConcreteOverlay of HMA

http://apps.acpa.org/apps/bcoa.aspx

Page 25: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

HMA

PCC

Base

40kN 40kN

EAC, AC

EPCCt

AC

Subgrade k-value

Bonded

hPCC

hAC

BCOA Critical Locations (Concrete and AC Layers)

t

Page 26: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Fibers Structural vs. non-structural (plastic shrinkage)

Structural Macro-Fibers

Micro-Fibers (non-structural)

012345

0 10 20 30 40CMOD (mm)

Load

(kN

)

Page 27: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

IDOT Concrete Thickness Calculation

Variable

Design Traffic Factor (BDE Manual, Figure 54-4C) TF 2.50

Modulus of Rupture (3-point bending, 14-day average) MOR 750 psi MORFRC Residual Strength Ratio 20%

Remaining Thickness of Asphalt h ac 3.0 in.Joint Spacing L 72 in. L

Elastic Modulus of Concrete E c 3,600,000 psi E c

Coefficient of Thermal Expansion CTE 5.50E-06 in./in./°F CTEElastic Modulus of Asphalt E AC 350,000 psi

Modulus of Subgrade Reaction k 100 pci

k

Thickness of Concrete h c 5.48in.

Solved

Note 1: The design MOR is the mean design strength, not the minimum 550 psi flexural strength (center-point loading) specified for opening to traffic. Also note that as MOR increases the risk of debonding increases and the effectiveness of synthetic fibers decreases.

PCC Inlay / Overlay Design Sheet, Required Thickness of PCC

5.50 x 10-6 in./in./°F

E AC

100,000 psi (poor)

350,000 psi (moderate)

3,600,000 psi

0% (w/o fiber reinforcement)

20% (w/ fiber reinforcement)

600,000 psi (good)

100 pci

Default InputsDefault Value

750 psi (Note 1)

48 in. or 72 in.

150150R

Compute Concrete Thickness

Help

150150R

http://www.dot.state.il.us/desenv/pdp.html

Page 28: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

IDOT Chapter 53-4.08 Tables

Page 29: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Asphalt Modulus (Eac)

0

1

2

3

4

5

6

1E+04 1E+05 1E+06 1E+07

ESALs

Conc

rete

Thi

ckne

ss h

c (in

)

Eac = 100,000psiEac = 350,000psiEac = 600,000psi

k = 100 pci

MOR = 650 psi

R150 = 0%

hac = 3 in

L = 4 ft

ΔT/h = -0.65 °F/in

35 % time

Page 30: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Effect of Asphalt thickness

0

1

2

3

4

5

6

1E+04 1E+05 1E+06 1E+07

ESALs

Conc

rete

Thi

ckne

ss h

c (in

)

hac = 3 inhac = 4 inhac = 5 inhac = 6in

k = 100 pci

MOR = 650 psi

R150 = 0%

Eac = 350,000 psi

L = 4 ft

ΔT/h = -0.65 °F/in

35 % time

Page 31: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

R150= Residual Strength Ratio Concept

0

1

2

3

4

5

6

1E+04 1E+05 1E+06 1E+07

ESALs

Conc

rete

Thi

ckne

ss h

c (in

)

R150,3 = 0%R150,3 = 15%R150,3 = 20%R150,3 = 25%

k = 100 pci

MOR = 650 psi

Eac = 350,000 psi

hac = 3 in

L = 4 ft

ΔT/h = -0.65 °F/in

35 % time

Page 32: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Effect of Slab Size (L)

0

1

2

3

4

5

6

7

8

1E+04 1E+05 1E+06 1E+07

ESALs

Conc

rete

Thi

ckne

ss h

c (in

)

L = 12 ftL = 6 ftL = 4 ft

k = 100 pci

MOR = 650 psi

R150 = 0%

Eac = 350,000 psi

hac = 3 in

ΔT/h = -0.65 °F/in

35 % time

Page 33: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

ACPA Bonded O/L of Asphalt

http://apps.acpa.org/applibrary/BCOA/ (2012)

Page 34: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform
Page 35: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

BCOA ME failure modes5 to 7 ft

Long. & DiagCrack

Positive ΔT Negative ΔT

< 4.5 ftCorner Break

Positive ΔT

10 x 12 ft12 x 12 ft12 x 15 ft

Trans. Crack

Vandenbossche (2013)

Page 36: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Surface Preparation Milling AC surface.

Remove rutting Restore profile Enhance bond

Minimum AC thickness remaining after milling: 6.5 cm

Surface cleaning Waterblast - preferred Sweeping

Page 37: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Guide to Concrete Overlays of Asphalt Parking Lots (2012)

www.rmc-foundation.org/images/Concrete_Overlay_Guide_11-14-12.pdf

Contents: Parking Lot Features Existing Pavement

Condition Concrete Overlay

Design Jointing Parking lot details Materials Construction Fibers

Page 38: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

PERFORMANCE OF UTW SECTIONS

Page 39: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform
Page 40: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Illinois Projects Visited (20)

Page 41: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

UTW Projects in Illinois (USA)

Intersection

Farm / Rural Road

State Highway

Parking Lot

Page 42: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Decatur, IL: Intersection of US 36 and Oakland Avenue (1998)

Major distresses Longitudinal, transverse or corner cracking in

33.8% of slabs Faulting throughout the project in joints and

cracks Three to five instances of partial slab blowups

due to slab migration

Slab migration Inside five rows of slabs had migrated into the

intersection from 2.5 to almost 15cm at the end of the project

Use of structural fibers likely could have locked the panels in and prevented this movement

2012

Page 43: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Kane County, IL: North Lorang Road (2004) 11cm thick concrete overlay of 7.5-9cm of HMA over

aggregate base 2.4 kg/m3 synthetic macro-fibers Square 1.5m x 1.5m panels Project built to serve a quarry: average of 30 trucks/day (peak

of 280/day)

2012

Page 44: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Mundelein, IL: Schank Avenue (2005) 10cm. concrete overlay of a composite pavement (5.7-16.5cm

HMA over 12-23.5cm PCC) Square 1.2m x 1.2m panels 2.4 kg/m3 synthetic macro-fibers High truck traffic volume (no data available, but comparable

to Lorang Road and more general traffic)

2012

Page 45: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Hamilton County, IL (Sept. 16, 2014)FRC UTW (4 in.)

Existing Asphalt Concrete (3 in.)

Cement Treated Soil (8 in)Natural Soil

Page 46: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Built in 2013

Built in 9/2014

Built in 9/2014

Page 47: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Overall Summary for BCOA Parking lots = 4ft x 4ft panels are fine w/ fibers Maintain 5.5 ft or 6 ft panel sizes w/ fibers More cracking/faulting on skewed joints Thinner saw blades No sealing except when joint in wheel path

No faulting or cracking on 4x4 ft or 6x6ft slab sizes with macrofibers (>2006)

FRC needs minimum revolutions at high torque in mixer

Page 48: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Bonded Concrete Overlay

Concrete Overlay hol

Existing Concrete Pavement

he

Excellent Interface Bond

Page 49: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Bonded Concrete O/L Design Methods

AASHTO Pavement ME (2011) Slab thickness based on following: Slab geometry, climate, structure, concrete

material and layer properties Complete interface bond hol = hf - heff

AASHTO 1993 Dol = Df - Deff

Page 50: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Unbonded Concrete Overlay Options Thicker concrete overlays

than bonded.

Constructed on existing concrete, asphalt, or composite pavements.

Bond is NOT considered in the design.

Slab sizes vary depending on type of design

Unbonded Concrete Resurfacing of Concrete Pavements

Unbonded Concrete Resurfacing of Asphalt Pavements

Unbonded Concrete Resurfacing of Composite Pavements

Unbonded Overlay Option

“Whitetopping”

Page 51: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Pavement evaluation establishes whether existing concrete and subbase can provide uniform support and, if not, what actions are necessary to obtain that uniformity.

Look for movement in the slab. Profile is a good check.

Unbonded Concrete Overlays of Existing Concrete Pavements

Page 52: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Unbonded Concrete O/L Design Methods

AASHTO Pavement ME (2011) or MEPDG Slab geometry, climatic factors, concrete

material and layer Assumes unbonded interface without friction

AASHTO (1993) D2

0L = D2f - (Deff)2

StreetPave 12

Page 53: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Separation Layer Good Performance.

Isolate overlay from existing pavement: Prevent reflection cracking. Prevent bonding/mechanical

interlocking. Provide level surface for overlay

construction. Interlayer material:

2.5 to 5cm dense-graded HMA. GEOTEXTILE (Missouri 2008)

Page 54: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

I-57/I-64 Alternatives (2010-2013)

HMA overlay of existing CRCP Rubblization with HMA JPCP and CRCP options

MEPDG & IDOT designs Milling options vs. rubblization Interlayer type Thickness options

Page 55: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Poor Section I-57/I-64 NB

Page 56: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

MEPDG CRCP Overlay: Inputs 20-year design life Mattoon-Charleston, IL Climate

ESALs 80x106

A-7-6 soil type k=200 psi/in

Tied concrete shoulder 40 to 80% LTE

CRCP Steel properties 3.5 inch depth; #6 bar; 0.7% steel content

Page 57: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

MEPDG CRCP Design: Results New CRCP = 11 inches HMA base unbonded = 4inches

Unbonded CRCP = 9 inches AC base interlayer = 2 inches CRCP (existing) = 8 inches

Unbonded CRCP = 10.5 inches HMA interlayer = 1 to 2 inches CRCP (rubblized) = 8 inches

Page 58: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

I-57 / I-64 Mt. Vernon (2011-2013) Mill existing HMA overlay Rubblize existing 8-inch CRCP Place 3-inch HMA interlayer 10.5-in. CRCP overlay w/ 0.7% steel

Page 59: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

2012 Unbonded CRCP Overlay (I-57)

Page 60: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Unbonded Concrete O/L of Asphalt Concrete

Dol = Df

Df = new concrete slab thickness

Existing Asphalt

Dol = Df

Subgrade

Base

Page 61: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Unbonded Bonded Concrete O/L of Asphalt

AASHTO Pavement ME (2011)-whitetopping Thickness > 6 inches Slab length > 10ftOptiPave 2.0 (2012) - TCPavements Short jointed slab systems Slab sizes < 10ft & thickness 2 in.AASHTO 1993 Existing asphalt treated as base layer

Page 62: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

(Thin) Unbonded Concrete O/L

Interlayer or thicker slab required relative to BCOA

Empirical designs to date in U.S.

TCPavements, Inc. (2007) – Chile, S.A. OptiPave 2.0 (2012) Only current design method for short jointed

unbonded concrete overlay

Page 63: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform
Page 64: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Final Day PavingOak Park, July 2001

• 10 cm “Fast-Track” Unbonded, Steel-Fiber Reinforced Concrete Inlay

• Mirafi 500N Woven Geotextile

Page 65: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Pavement Depth

Page 66: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Oak Park, IL: Marion Street (2001)

10 cm concrete over original concrete layer UNBONDED- woven geotextile placed between the layers at the time

of casting

2.0m x 1.5m panels 24 kg/m3 crimped steel fibers

2012

Page 67: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

I-72 Unbonded Overlay (2015)

6-inch PCC Asphalt

interlayer 8” CRCP 6ft x 6ft

panel sizes Fibers

Page 68: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

What is Flowable Fibrous Concrete (FFC)?

187

Flowable Fibrous Concrete

Ultra-Thin Whitetopping

Fiber-Reinforced

Concrete

Self-Consolidated Concrete

High Toughness/ Reduced Cracking

Ease of Placement

Cost-Effective Thin Pavement

HPFRSCC(ECC)

ConventionalPavingMixture

Page 69: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

Flowable Fibrous Concrete (FFC) for Thin Pavement Preservation Inlays

Lower speed applications Slab thickness < 8 cm 10-year service life Concrete wearing surface (Preservation) Asphalt-concrete bond essential Loads transmitted to substrate layers

Other sustainability enhancements: Reflectivity, skid, air pollutant reducer

Bordelon & Roesler (2010)

Page 70: Concrete Pavement Overlay Design · Overlay Design Reliability Level Pavement Widening ... Pavement evaluation establishes whether existing concrete and subbase can provide uniform

FFC Field Project (ATREL) Ensure Good Bond with Underlying HMA

Milled and cleaned surface Measured the FFC inlay bond with 10 cm diameter core, sheared off at greater

than 500 Nm torque (HMA overlays typically ~400 Nm)

Check Workability & Constructability of FFC Placed 5 cm thick inlay directly from truck Vibrated with screed and bull float finish

Joint Cracking Monitored Slabs sawcut at spacing 1.1 to 3.4 m (4 to 11 ft) Crack widths average from 0.4 to 1 mm wide after 20 days

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Field Demonstration 2in (5 cm)

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Concrete Overlay: Summary Existing pavement condition assessment Select new concrete pavement type Define interface assumption

Available structural design methods AASHTO Pavement ME (2011) IDOT BCOA (Chapter 53-4.08) ACPA (BCOA Calculator & StreetPave12) Pitt BCOA ME FAARFIELD- airfield

Construction details essential!!

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Questions?

141 fibers 131 fibersBordelon (2011)

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Acknowledgements Illinois Department of Transportation

Illinois Center for Transportation www.ict.illinois.edu

Randell RileyIL-ACPA

Amanda Bordelon Asst. Prof. @ University of Utah

National Concrete Pavement Technology Center Dale Harrington

American Concrete Pavement Association (ACPA) Rob Rodden

Daniel King (2012-2015) Research Assistant, UIUC

Dr. Julie Vandenbossche University of Pittsburg

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Annotated Bibliography Harrington, D. et al. (2012), Guidance for the Design of Concrete Overlays

Using Existing Methodologies, National Concrete Pavement Technology Center, Iowa State University, Ames, IA.

Roesler, J. R., Bordelon, A., Ioannides, A. M., Beyer, M., and Wang, D. (2008), Design and Concrete Material Requirements for Ultra-Thin Whitetopping, Final Report, Illinois Center for Transportation Series No. 08-016, University of Illinois, Urbana, IL, 181 pp.

Rasmussen, R., Rogers, R., Ferragut, T. (2009), Continuously Reinforced Concrete Pavements Design and Construction Guidelines, FHWA-CRSI.

Harrington, D. et al. (2014), Guide to Concrete Overlays Sustainable Solutions for Resurfacing and Rehabilitating Existing Pavements, National Concrete Pavement Technology Center, Iowa State University, Ames, IA.

Smith, K.D., H. Yu, D. Peshkin, (2002), Portland Cement Concrete Overlays: State of the Technology Synthesis, Federal Highway Administration, Washington, DC.

Vandenbossche (2011) Development of a Design Guide for Thin and Ultrathin Concrete Overlays of Existing Asphalt Pavements, TPF-5(165)