- - -

Construction of the California

Precast Concrete Pavement

Demonstration Project PUBLICATION NO. FHWA IF 06 010 AUgUsT 2004

Notice

This document is disseminated under the sponsorship of the U.S. Department of Transportation in the interest of information exchange.The U.S. Government assumes no liability for the use of the information contained in this document.This report does not constitute a standard, specification, or regulation.

The U.S. Government does not endorse products or manufacturers.Trademarks or manufacturers names appear in this report only because they are considered essential to the objective of the document.

Quality Assurance Statement

The Federal Highway Administration (FHWA) provides high-quality information to serve Government, industry, and the public in a manner that promotes public understanding. Standards and policies are used to ensure and maximize the quality, objectivity, utility, and integrity of its information. FHWA periodically reviews quality issues and adjusts its programs and processes to ensure continuous quality improvement.

Technical Report Documentation Page 1. Report No.

FHWA-IF-06-010 2. Government Accession No. 3. Recipient's Catalog No.

4. Title and Subtitle Construction of the California Precast Concrete Pavement Demonstration Project

5. Report Date August 2004

6. Performing Organization Code

7. Author(s) David K. Merritt, B. Frank McCullough, Ned H. Burns, Robert Otto Rasmussen

8. Performing Organization Report No.

9. Performing Organization Name and Address The Transtec Group, Inc. 1012 East 38 1/2 St. Austin, Texas 78751

10. Work Unit No. (TRAIS)

11. Contract or Grant No. DTFH61-03-R-00105

12. Sponsoring Agency Name and Address U.S. Department of Transportation Federal Highway Administration 1200 New Jersey Avenue, SE, HIPT-20 Washington, DC 20590

13. Type of Report and Period Covered Final Report June 2003August 2004

14. Sponsoring Agency Code HIPT-20

15. Supplementary Notes Contracting Officer's Technical Representative: Sam Tyson, FHWA Office of Pavement Technology, 1200 New Jersey Avenue SE, HIPT-20 / E73-440, Washington, DC 20590, E-mail: sam.tyson@dot.gov, Phone: 202-366-1326

16. Abstract

This report documents the construction of a precast prestressed concrete pavement demonstration project on Interstate 10 in El Monte, California. This work was conducted under a new effort by the Federal Highway Administration to further evaluate and refine precast prestressed pavement technology through the construction of additional demonstration projects. All aspects of the California demonstration project are presented, including the design, panel fabrication, pavement construction, and instrumentation and monitoring. An evaluation of each of these aspects is also discussed. This project represents the first of three demonstration projects to be constructed under this effort.

17. Key Word precast pavement, prestressed pavement, concrete pavement, expedited construction

18. Distribution Statement No restrictions. This document is available to the public through the National Technical Information Service, Springfield, Virginia 22161.

19. Security Classif. (of this report) 20. Security Classif. (of this page) 21. No. of Pages 82

22. Price

Form DOT F 1700.7 (8-72) Reproduction of completed page authorized

i

ii

TABLE OF CONTENTS

CHAPTER 1. INTRODUCTION.......................................................................................1 Background......................................................................................................................1

FHWA Demonstration Projects .......................................................................................1

Benefits of Precast Concrete Pavement ...........................................................................1

Report Objectives.............................................................................................................2

CHAPTER 2. PRECAST CONCRETE PAVEMENT CONCEPT ................................5 Introduction......................................................................................................................5

Full-Depth Panels.......................................................................................................5

Prestressed Pavement.................................................................................................5

Panel Assembly................................................................................................................6 Base Panels ................................................................................................................7

Joint Panels ................................................................................................................7

Central Stressing Panels.............................................................................................8

Base Preparation ..............................................................................................................9 Post-Tensioning ...............................................................................................................9 Grouting ...........................................................................................................................10

Construction Process........................................................................................................11

CHAPTER 3. CALIFORNIA DEMONSTRATION PROJECT ....................................13 Project Scope ...................................................................................................................13

Location .....................................................................................................................13 Field Change ..............................................................................................................13

Project Layout..................................................................................................................14

Geometry....................................................................................................................14

Slab Width .................................................................................................................15

Slab Length ................................................................................................................16

Project Coordination ........................................................................................................16

CHAPTER 4. DESIGN........................................................................................................17 Design Considerations .....................................................................................................17

Traffic Loading ..........................................................................................................17

Temperature and Moisture Effects.............................................................................17

SlabSupport Interaction ...........................................................................................18

Prestress Losses .........................................................................................................18

Design Procedure .............................................................................................................18 Design for Fatigue............................................................................................................19

Equivalent Thickness .................................................................................................19

Support Structure and Prestress Requirements ..........................................................19

Fatigue Life Implications...........................................................................................21

Design for Environmental Effects ...................................................................................22

PSCP2 Design Program .............................................................................................22

PSCP2 Analysis .........................................................................................................23

Longitudinal Prestress Requirements ........................................................................25

Transverse Prestress Requirements............................................................................25

iii

Expansion Joint Limitations ......................................................................................26

CHAPTER 5. PANEL FABRICATION............................................................................29 Procedure .........................................................................................................................29

Tolerances ........................................................................................................................29

Panel Details ....................................................................................................................30

Keyways.....................................................................................................................30

Grout Channels ..........................................................................................................32

Base Panels ..........................................................................................................