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Rubblization
Rehabilitationfor
Concrete Pavements
www.AsphaltAlliance.com
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Rubblization
Overview
• Effective rehab for PCC– Break PCC into small segments– Overlay with Hot Mix Asphalt Road-user-
friendly– Rubblize and pave in off-peak hours– High production rates
• Final Product
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Rubblization
What is rubblization?
• Fracturing:– Eliminates slab action– Destroys bond between concrete and
steel• Rubblized base responds as a tightly
keyed, interlocked high-density, unbound layer – Layer cannot crack; already fractured
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Rubblization
Why Rubblize?
• Fracturing PCC to segments less than 9” precludes reflection of:– Joints– Cracks– Faults
• Production Rates up to 1 lane-mile/day
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Rubblization
Purposes for OverlayingPCC Pavements
• Improve ride quality• Correct surface defects
– improve surface drainage– increase surface friction
• Delay/prevent structural deterioration• Strengthen pavement structure
(rehabilitation)
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Rubblization
Pavement Rehabilitation Design Factors
• Pavement type• Condition of existing pavement
– Drainage– Distress – Response to load
• Foundation strength/stiffness– Subbase– Subgrade
• Future traffic loading• Additional corrections (safety, capacity, etc)
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Rubblization
PCC
Reflection Cracking
• By far, the biggest problem in HMA overlays of PCC pavement
• Caused by movement at PCC joints and cracks
Load-induced movement
Joint ClosesJoint Closes
HMA
Slabs ContractSlabs Contract Joint OpensJoint OpensSlabs ExpandSlabs Expand
Reflection crack
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Rubblization
HMA
PCC
Larger Pieces = Larger Movement = Cracking
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Rubblization
HMA
PCC
Smaller Pieces = Smaller Movement = No Cracking
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Rubblization
Benefits
• Time savings– Choose work hours– High production rates
• Economic Savings– Reduce user delay costs– Reduce construction costs
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Rubblization
• Environmentally friendly– Reduce landfill– Reduce fuel consumption/air pollution
• Smoothness– Eliminate reflection cracking/faulting
Benefits (continued)
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Rubblization
Construction Procedure
• Install/replace existing edge drainage system as required
• Remove existing overlay (if present)• Remove existing HMA patches, replace
with aggregate base as required• Fracture the concrete pavement• Roll• Place HMA overlay (multiple lifts)
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Rubblization
Resonant Pavement Breaker
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Rubblization
Multi-Head Breaker (MHB)
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Rubblization
Rolling
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Rubblization
Particle Size• PCC fractured into 9
in.-minus pieces• Most pieces are 1- 4
in. diameter• Aggregate interlock
maintained beneath surface
• Rolling knits together surface particles
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Rubblization
When to Rubblize
Patching > 10%.Severe D-cracking.Severe ASR or ACR cracking.Dowel bar lockingSevere joint deteriorationPersistent faulting.
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Rubblization
Precaution
• Weak soils may make construction difficult.
• Option 1– Adjust breaking pattern (12 - 18”) in soft
areas.– Use normal seating rolling.– Resume smaller pattern after weak area.
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Rubblization
Precaution• Option 2
– Cease rubblization– Define weak area– Remove/replace problem material– Resume normal operations when past
weak area• Perform a good soils evaluation prior to
construction
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Rubblization
How Effective is Rubblization?
• Witczak and Rada, 1992– "Rubblization . . . is the preferred
rehabilitation method for all types of PCC pavements."
• Thompson, 1999– Rubblization is a "viable and cost-effective
rehabilitation option."
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Rubblization
How Effective is Rubblization?
• 26 States have specifications for Rubblization
• Arkansas– 100 miles of rubblization this year– 300 miles over a 3-year period
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Rubblization
Projects• I-440, Raleigh Beltway, North Carolina
–$21.5 million contract–3 1/2 mile project–AADT = 100,000+
• Awards–1993 Sheldon G. Hayes Award - NAPA–1993 Pinnacle Award - AGC–1995 NQI Achievement
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Rubblization
I-440, Raleigh Beltway, North Carolina
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Rubblization
•Rubblize existing concrete pavement
•Widen overall roadway
•Place Permeable Asphalt Treated Base under new lanes
•Overlay with Superpave
•FHWA Showcase October 1997
I-65, Alabama
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Rubblization
Projects As of July 1999
no projects 5 + projects 1-4 projects 10 + projects
20 + projects
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Rubblization
Rubblizing PerformanceAll Data
y = -1.3149x + 99.439R2 = 0.5419
50
60
70
80
90
100
0 5 10 15 20 25
Age
PCR
PCR =70 @ 22.4 years
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Rubblization
Comparisons
Alternatives:• Rubblize PCC, overlay with 10“ HMA• Remove PCC, replace with 12” Fast
Track PCC• Leveling course, 10” Fast Track PCC
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Rubblization
Comparisons
Alternative Est. Cost
Rubblize, 10" HMA $17-23/sy
10" unbonded PCC (FastTrack)
$26-36/sy
Remove, replace w/12" FastTrack PCC
$34-46/sy
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Rubblization
References
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Rubblization
Conclusions
•Rubblization is effective. Prevents reflective cracking.
•Rubblization can be done rapidly, minimizing delays.
•Researchers and agencies have concluded that rubblization is technically sound.