rigid pavement repair pavement repair larry scofield international grooving and grinding association...
TRANSCRIPT
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1
Rigid Pavement Repair
Larry Scofield
International Grooving and Grinding Association
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PCCP Repair Techniques
• Full-depth repair
• Partial-depth repair
• Slab stabilization
• Retrofitting dowels
• Cross-stitching longitudinal cracks/joints
• Diamond grinding
• Joint & crack resealing
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Partial Depth
Patching
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Partial Depth Repairs
• Repairs deterioration in the top 1/3 of the slab.
• Generally located at joints, but can be placed anywhere
surface defects occur.
... .
.
.
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Size of Patches
• Minimum length 300 mm
• Minimum width 100 mm
• Go beyond problem by 75-100 mm
• Combine close patches (<0.6 m)
• Repair entire joint if more than 2 patches
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•50-150 mm min.•50-150 mm min.
•50 mm (min.) - t/3 (max.)
•t
•Patch•Spall
Patch Layout
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Patch Materials
• Normal Set PCC
• High-Early Strength PCC
• Rapid Strength Proprietary Materials
• Epoxy Resin Mortar or Epoxy Concrete
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Construction of Partial-Depth Patches
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Finding Unsound Concrete
• Hammer
• Steel rod
• Steel chain
•Sounding the pavement:
•DULL •SHARP
•Unsound-Delaminated •Solid
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•Sounding the Pavement
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Concrete Removal
• Sawing and chipping
• Carbide milling
– Transverse
– Longitudinal
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Sawing
• Vertical cut at perimeters
• Diamond blade
• Depth to 50 mm
• Overcut slightly
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Chipping
• Break to minimum depth of 35 mm
(1/3 slab thickness maximum)
• 13.5 kg maximum hammer
• 7 kg hammer preferable for control
• Spade bits preferable to gouge bits
• Do not expose dowels
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Removal of Concrete with Jackhammer
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Milling Machine
• Requirements:
– High kilowatt (horsepower) rating
– 300-450 mm milling head width
– Wheels preferable to tracks
• Transverse orientation
• Longitudinal orientation
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Removal of Material
•Transverse Milling (small head, moves along joint)
•Longitudinal Milling (wide head, pick up & move over)
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Transverse Orientation
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Longitudinal Orientation
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Repair Area
After
Longitudinal
Orientation
Milling
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Cleaning
• Sound to check for weak spots before
cleaning
– Chip out with 7 kg hammer if necessary
• Sandblast bottom and sides
• Waterblast acceptable alternative:
– 100 - 200 MPa pressure
– Waiting period to dry
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Chipping out weak spots
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Sandblasting
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Blowing Compressed Air to Remove Debris
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Joint Insert
• Separates patch from adjacent concrete
• Reforms joint reservoir
• Provides uniform sealing reservoir
• MUST get below patch material
• Acceptable materials:
– Styrofoam
– Asphalt-impregnated fiberboard
– Fiberboard
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Compressible Joint Insert
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•75 mm min.
•Patch
•Spall
•Compressible insert
•25 mm
Compressible Insert
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•Point Bearing
•Expansion •Expansion
•Joint Closure •Debonding
•Popout & Breakage
If Insert Not Used...
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• Checking patch cleanliness
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Application of Grout Bonding Agent
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Placing Patch Material
• Mix in small quantities
• Place from wheelbarrows or buggies soon
after bonding grout
• Slightly overfill the patch area
• Use small spud vibrators (<25 mm)
– Hold at 15-30 degrees
– Do not drag!!
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Placing Patch Material
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Finishing & Texturing
• Match surrounding elevation
• Work tool from center toward edges
• Texture similar to surrounding pavement
• Seal saw-cut runouts with grout or liquid
epoxy
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Applying Curing Compound
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Joint Sealing
• Resealing joints will help prevent further
damage
• Saw & air blast all joint faces before sealing
• Seal according to agency specifications
(silicone, hot pour, etc.)
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Opening to Traffic
• 2 methods:
– Specified minimum strength
– Specified minimum time after completing
placement
• Time method acceptable
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Summary
• Limit use to top 1/3 of slab
• Avoid “point bearing”: Use a compressible
insert in joints & cracks
• Cure properly
• Reseal Joints
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Full Depth
Patching
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• Purpose
– Restore structure
– Restore ride
• Used for:
– Joint deterioration
– Transverse cracking
– Longitudinal cracking
– Broken slabs & corner breaks
Full-Depth Repair
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Uses of Full-Depth Repair
•Joint Deterioration–Spalling (also below surface)
–Cracking
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Uses of Full-Depth Repair
• Corner
Breaks
•Multiple Cracks
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Sizing a Patch
• Go beyond deterioration
• Remember to check for below-surface
spalling
• Minimum length 2 meters
• Adjust as necessary
• Combine closely spaced patches
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Field Adjustments to Patch Size
• Falls within 2 m of transverse joint
– Then extend to include joint
• Falls on or very near a doweled joint
– Then extend beyond joint 0.3 m to remove
the dowels
• Falls on a crack
– Then extend beyond crack by 0.15 m
•If Patch Boundary:
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Combine Patches!!
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Load Transfer
• 38mm dowels
• At least 175mm of embedment on either
side
• Minimum of 4 dowels in each wheelpath
• Corrosion resistance necessary if deicing
chemicals will be used
•Jointed Pavements:
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Load Transfer
•Jointed Pavements:
•Top View
•Side View
•Optional
•Dowels
•Remove loose material and fill any depressions with concrete
•Patch
•300 mm typ.
•300 mm c-c
•typ. spacing
•d/2
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Patch Materials
• ASTM C 150 Types I, II, or III portland cement
(CAN/CSA A5-M88)
• Target slump: 50 - 100 mm
• Entrained air: 4.5 - 7.5%
• Accelerators common for early strength gain
– CaCl2 accelerator may cause early set time (within 30
minutes)
– workability decreases with accelerators
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Defining Repair Limits
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Sawing Boundaries
• Use diamond bladed saws
• Saw full-depth through the joints so base
of blade reaches boundary (except
where aggregate interlock needed)
• Isolate transverse, longitudinal and
shoulder
• Provide pressure-relief cut within patch if
saws bind
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Sawing Boundaries
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Removal• Liftout
– Lift pin and chain
– Forklifts
– Torque claws
– Lateral-pressure lifts
• Breakup
– Handheld pneumatic hammers (small
projects)
– Drop hammers or hydraulic rams (large
projects)
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Liftout
•Pin and
Chain
•Torque
Claw
•Lateral
Pressure
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Liftout Damage
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Vibratory Plate Compactor
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Drilling Dowel Holes
• Use gang-mounted drill rig
– Consistent holes
– Alignment jig
– Improved productivity
• Slab reference preferable
• Hydraulic or pneumatic drills O.K.
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Drilling Dowel Holes
• Adjust location of hole for:
– Cracks
– Embedded steel
– Major spalling
• Size hole diameter for grout
– Cement-based use DOWEL DIA. + 5 mm
– Epoxy use DOWEL DIA. + 2 mm
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Self-Propelled Subbase Reference
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Self-Propelled Slab Reference
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Boom-Mounted Slab Reference
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•3
•2
•1 •Inject Grout
to Back of Hole
•Twist one turn
while pushing
in dowel
•Place grout
retention disk to
hold in grout
•Installing Dowels
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Injecting Grout
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Grout Retention Disk
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Troweling of Grout around Bar
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Placement of Bond-Breaking Board
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Placing Concrete
• Distribute evenly
• Avoid excessive shoveling
• Vibrate uniformly
– Use vertical penetrations of vibrator
– Do not drag!!
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Concrete Placement
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Finishing
• Vibratory screeds or 3m straight edges
• For short repairs (<3m), pull finishing tool
along transverse boundary
• For longer repairs, finish the concrete
longitudinally using vibratory screed
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•Straight Edge•Vibrating Screed
•<3 m •>3 m
•Finishing
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•Finishing
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•Texturing
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Curing
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Joint Sealing
• Form or saw joint sealant reservoirs at all
patch boundaries
• Sealed joints reduce spalling
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Opening to Traffic
• 3 methods:
– Specified minimum strength
– Specified minimum time after completing
placement (5 or 10 hour patches)
– Maturity method (mix specific)
• Strength method preferred
• Variations in air temperature influence
strength development
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Slab
Stabilization/
Jacking
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Slab Stabilization / Slab Jacking
Insertion point
�Pressure insertion of flowable material beneath the PCC slab
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Slab Stabilization vs. Slab Jacking
• Slab Stabilization:
– Pressure insertion of a flowable material to restore
support beneath PCC slabs
– Fills existing voids but does not lift slab
• Slab Jacking:
– The lifting or raising of a PCC slab by pressure
inserting a grout beneath the slab
– Levels depressed slabs and restores rideability (but
not for correcting faulted joints)
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Slab Stabilization
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Identifying Loss of Support
• Visual distress survey
• Deflection testing
– Maximum deflections
– Void detection procedures
• Other methods
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ConstructionMaterial Injection
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ConstructionOperation
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Quality ControlMonitoring Slab Lift
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Slab Jacking
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Slab Jacking
• Address localized areas of settlement
– Fill areas
– Culverts
– Bridge approaches
• Materials:
– Cement grouts widely used at one time
– More recent use of polyurethane materials
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•Maximum
•depth of sag
•String line
•Beginning
•of sag
•10 ft
•Wooden
•separator
•blocks
•Nail to secure line
Stringline Method
•Fig. 4.6 on p. 4.11
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Stringline Method
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Grouting Hole and Plug
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Completed Project
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Dowel Bar
Retrofit
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Load Transfer Restoration
• Placement of load transfer devices across joints
or cracks of existing pavements
• Candidate projects
– Poor load transfer (< 70 %)
– Pumping
– Faulting
– Corner breaks
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Purpose of Load Transfer Restoration
• Reestablish load-transfer
across joints or cracks
– Load-transfer is a slab’s
ability to transfer part of its
load to its neighboring slab
• Used in JRC and JPC
pavements to limit future
faulting Load Transfer = 100% (Good)
L= x
U= 0
Load Transfer = 0% (Poor)
L= x U= x
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Cutting the Slots
Diamond saw slot cutter
– Cuts multiple slots in a
single pass
– Cuts form the edges of
the slots
– Fins are removed later
– Can cut 3 or 6 slots in a
single pass
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Caution!
Modified milling machines are
NOT recommended!
Diamond sawing is the most reliable and proven method. Modified milling has been used experimentally with very limited success.
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•Milled slots may
cause patches to
fail and/or joints to
lock up.
• Modified milling
machines are
demolition tools,
not precision
cutting instruments.
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Questions