Concrete Pavement’s Ultra Thin Co c ete a e e t s U t aOverlay

Larry Scofield P ELarry Scofield, P.E.

IGGA

1

“Big Preservation”g

Funding, Funding, Funding 1. Decline in Buying Power2. Increase in Consumption (wear)3. Decline in Revenue Generation

Road Building/PreservationRoad Building/Preservation1993 to 2014

$34 595 $56 445$34,595 $56,44563%

Decrease in Buying Power 1993 to 2014

1993 Lets Build 100 Miles of

2014 Lets Build 67 Miles of Road

Road

Change in Consumption (Wear Out)Change in Consumption (Wear Out)1993 to 2014

Minnesota’s Consumption Increase

1993 L t D i 2014 L t D i 57 1993 Lets Drive 43 Billion VMT

2014 Lets Drive 57 Billion VMT (33%)

Increase in US Vehicle Miles Traveled and Miles of RoadwayTraveled and Miles of Roadway (1990-2012)

Standards in Vehicle Fuel Efficiency

Gas Tax

FHWA Performance MeasuresMeasure Surface Assessment

Population < 1 Million Population > 1 MillionAll

PavementIRI (in/mi)

Population Consideration

Good Fair Poor Good Fair Poor<95 95 - 170 >170 <95 95 - 220 >220

No Population ConsiderationsGood Fair Poor

Pavements

IRI (in/mi)

A h l Good Fair PoorAsphalt Jointed

PCCPCracking Percent <5 5 - 10 > 10

No Population ConsiderationsGood Fair Poor< 0.2 0.2-0.4 > 0.4

AsphaltRutting (in)

No Population ConsiderationsGood Fair Poor< 0.05 0.05-0.15 > 0.15

Faulting (in)Jointed

PCCP

No Population ConsiderationsGood Fair Poor

< 5 5 - 10 > 10Cracking Percent CRCP

Why Concrete Pavement PreservationBellefontaine, Ohio 1925Bellefontaine, Ohio 1925

2016= 125th Anniversary

2016 = 123rd Anniversary

M SlidMessage Slide

• Funding and the Transportation S t C iti l C t f thSystem are Critical Components of the National Economy

• Preservation is Not Only Important it is Absolutely NecessaryAbsolutely Necessary

• Times Have Changed

Grinding ConcreteConcrete

Commodity Price Increases2000

1600

1800

2000

Last Time Trust Fund Increased

1200

1400

1600

= 10

0)

Asphalt PPI

1000

1200

alue

(195

8

First National CPR

Conference Consumer CPI

DBR

600

800

Inde

x Va

Diamond Grinding

Conference

NGCS

Consumer CPI

200

400Grinding NGCS

Concrete PPI

0

Its Cost Effective and PredictablePredictable

$6.00

$5.00National CDG Cost for Projects > Than 7,000 SY

$

$4.00

s (s

q/yd

)

$2.00

$3.00

CD

G C

osts

$1.00

$0.001998 2000 2002 2004 2006 2008 2010 2012

Year

So Why Use Concrete yPavement’s Ultra Thin Overlay

• Existing Concrete Pavements: Little C ti f N R l RConsumption of Non Renewal Resources for Preservation

• Previously Overlaid Concrete Pavements: Ability to Replace Existing Thin HMAC Overlays (Buried Treasure)

Why Concrete’s Ultra ThinWhy Concrete s Ultra Thin Overlay

3 Million Tons of Aggregate to Use 2 in Overlayto Use 2 in Overlay

Exposed Concrete SurfacesExposed Concrete Surfaces

Impact of Blade SpacersWhat Texture Should Look LikeImpact of Blade Spacers Like

What is Diamond Grinding?What is Diamond Grinding?

R l f thi f l f h d dRemoval of thin surface layer of hardened PCC using closely spaced diamond saw blades;blades;

Results in smooth, level pavement surface;

Longitudinal texture with desirable friction and low noise characteristics;

Pavement Problems Addressed Faulting at joints and cracks

Built-in or construction roughness

Polished concrete surface—Friction Improvement

Unacceptable noise level

Permanent upward slab warping

Diamond Grinding Equipment

Diamond Grinding Equipment ProcessProcess

Finished Surface

Why Ultra Thin Overlay for PreWhy Ultra Thin Overlay for Pre-Overlaid Concrete Pavements–B i d TBuried Treasure

Urban Heat Island

So Why Consider this Now?y

How Do You Find Buried Treasure?Treasure?

National Treasure

ROADWAYROADWAY

Finding Buried TreasuresFinding Buried Treasures Identify Projects Nearing Rehab Based

on Distress Conditions that were Concrete Overlaid w/ACConcrete Overlaid w/AC

Identify Projects that were Overlaid for Functional Requirements (noise, ride, friction) or Repairablefriction) or Repairable…

– Bid Documents– PMS– Maintenance/Construction Personnel

Conduct Engineering Analysisg g y Review Historical Records Deflection Testing Ground Penetrating Radar

Steps to Recovering BuriedSteps to Recovering Buried TreasuresInvestigate the Project

Milling Off the OverlayMilling Off the Overlay

Repairing the Concrete

Diamond Grinding the Final SurfaceSurface

Digging it UP!MilliMilling

Overlay off Things to Notey Things to Note• Prevent Milling into the

ConcreteConcrete

• Often times variable depth of Overlaydepth of Overlay

• Carbide Tips can Damage TransverseDamage Transverse Joints

Protect the Joints During Milling

Repairing the Treasure!Repairing the Treasure!

Slab ReplacementSlab Replacement

Slab Jacking

Dowel Bar Retrofit

P t hiPatching

SealingSealing

Conventional Diamond GrindingGrinding

Newark N.J. Case Example

Concrete (23-60 yrs) Asphalt Overlay (7-8 yrs)( y ) 1931 – 1.4 Mile (Asbuilt)

1958 – 3.5 Mile (Asbuilt)

p y ( y ) 1993 Micro Surfacing

for Skid Improvement 1958 3.5 Mile (Asbuilt)

1970 – 1 Mile (Asbuilt) 2001 Micro Surfacing to Repair Previous Micro S f i D t i ti 9 Inches Thick

70,000 ADT

Surfacing Deterioration

2008 Buried Treasure (38 77 ld)

Dowels(38 – 77 yrs old)

R tPaper: Dan Frentress--National Conference onPreservation, Repair, and Rehabilitation of ConcretePavements

Route 21

Slab Jacking (N.J.)

Slab Replacement

Pre-cast Panel Installed Ready for Di d G i diDiamond Grinding

Partial Depth Patchesp

Conventional Diamond Grinding through AC and PCCPthrough AC and PCCP

Conventional Diamond GrindingGrinding

30 % Ride Improvement

Conventional Diamond GrindingL S t I AC--Low Spots In AC--

Joint ResealingJoint Resealing

Minnesota I-394 Buried Treasure ExampleTreasure Example

Courtesy Bernard Izevbekai--MnDOT

I-394 History• 1987: PCCP Constructed in

with Transverse Tining

• 1996: 2” AC Overlay for Noise1996: 2 AC Overlay for Noise

2004 1 ¾” Mill & Fill 5/8”• 2004: 1 ¾” Mill & Fill + 5/8” UTBWC

• 2015 Buried Treasure (30 yr old)

Courtesy Bernard Izevbekai--MnDOT

REPAIRS ON I-394REPAIRS ON I 394Anticipatedp

• 80% Full Depth Repairs• 20% Partial Depth Repairsp p

True Condition of Underlying Concrete

• 80% Partial Depth Repairs

After Removal of UTBWC Necessitated

• 80% Partial Depth Repairs• 20% Full Depth Repairs

AVINGSCalled “Buried Treasure”

AVINGSCourtesy Bernard Izevbekai--MnDOT

I-394 REMOVAL OF UTBWC

Courtesy Bernard Izevbekai--MnDOT

Removal of UTBWC

Courtesy Bernard Izevbekai--MnDOT

FULL DEPTH REPAIRS ON I-394

Courtesy Bernard Izevbekai--MnDOT

I-394 Project View

Note Transition PointT Ti d UTBWC Transverse Tined

Courtesy Bernard Izevbekai--MnDOT

I- 394 PAVEMENT SURFACES

Milled Surface

Conventional Diamond GrindDiamond Grind

Washington— SR522g

Concrete AsphaltConcreteConstruction

8” Plain Reinforced

Asphalt Numerous Overlays

Lane Widening with Full 8 Plain Reinforced Concrete Pavement

Previous Asphalt

Lane Widening with Full Depth Asphalt

Ride quality and appearance suffered due Previous Asphalt

widened lanes removed and replaced with

t th ti

appearance suffered due to multiple patches, overlays and aging asphalt lane additions soconcrete then entire

project diamond groundasphalt lane additions so Buried Treasure Approach Used in 2002

Washington SR 522

WA SR522– More Traditional Functional ad t o a u ct o aDistress Removal

Faulting

4/4/2017 International Grooving & Grinding Association 53

Q tiQuestions