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JOINTED PCC PAVEMENTS – REINVENTING THE OLD APPROACH Hua Chen, P.E Rigid Pavements and Concrete Materials Branch Construction Division, TxDOT 2014 Short Course

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Jointed PCC Pavements - Jointed Portland

Cement Concrete Pavements Jointed Concrete Pavement (JCP) Jointed Plain Concrete Pavement (JPCP) In Texas, Concrete Pavement Contraction

Design (CPCD)

CPCD = JCP = JPCP

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Table of Contents

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16-19

20-25

26-34

34-37

3-15 Background

Current Statewide CPCD Conditions

2014 CPCD Memo

2014 CPCD Standard

Summary of Success

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Dowel Bars

Tie Bars

ACP Base

CPCD Under Construction

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CPCD Before Concrete Paving

CPCD After Concrete Paving

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National Level Usage of CPCD

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Texas Usage of CPCD

TxDOT has started to use CPCD since 1930’s. TxDOT has began to construct CRCP since

1950’s.

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Oldest CPCD Sections in Service

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District County HighwayConstruction

YearP_Age

PavementType

Thickness(in.)

BMT-US59_0065-08-014 Beaumont Jefferson US 59 1938 76 CPCD 6BMT-US90_ 0028-11-024 Beaumont Orange US 90 1943 71 CPCD 7.5DAL-SH183_0094-02-006 Dallas Dallas and Tarrant SH 183 1944 70 CPCD 8DAL-SL12_ 0094-03-009 Dallas Dallas SL 12 1949 65 CPCD 9BMT-SH87_0306-03-023 Beaumont Jefferson SH 87 1951 63 CPCD 9DAL-US 77-0196-01-008 Dallas Denton US 77 1954 60 CPCD 10DAL-US77-0196-01-008 Dallas DENTON US 77 1954 60 CPCD 10DAL-US 77-0196-01-010 Dallas Denton US 77 1955 59 CPCD 10DAL-US 77-0196-01-012 Dallas Denton US 77 1955 59 CPCD 10DAL-US77-0196-01-010 Dallas DENTON US 77 1955 59 CPCD 10DAL-US77-0196-01-012 Dallas DENTON US 77 1955 59 CPCD 10BMT-US90_ 0028-13-014 Beaumont Jefferson US 90 1957 57 CPCD 11DAL-IH35-0195-02-016 Dallas Denton IH 35 1959 55 CPCD 10BMT-IH10_0028-13-018 Beaumont Jefferson IH 10 1960 54 CPCD 9BMT-SH347_0667-01-023 Beaumont Jefferson SH 347 1960 54 CPCD 10DAL-IH 35-0195-02-016 Dallas Denton IH 35 1960 54 CPCD 10BMT-SH124_0368-01-033 Beaumont Chambers SH 124 1962 52 CPCD 10BMT-SH73_0508-03-009 Beaumont Jefferson SH 73 1962 52 CPCD 10BMT-SH124_ 0368-01-033 Beaumont Chambers SH 124 1962 52 CPCD 10BMT-US90_ 0028-07-024 Beaumont Jefferson US 90 1964 50 CPCD 10

Moon Won, P.E.

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CPCD Lane Miles and Conditions In 1985

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CPCD Lane Miles In 1985

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PES1985 Report

Percentageof Mileage

MileageEvaluated Total Mileage Percent

ACP 35.53% 25,816 72,660 94.7%CRC 55.07% 1,346 2,444 3.2%JCP 21.83% 352 1,612 2.1%

Total 76,716 100.0%

• 60% of Texas Concrete Pavement was CRCP • 40% of Texas Concrete Pavement was CPCD

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CPCD Condition In 1980’s

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2000 Memo – Selection of Concrete Pavement Type

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CPCD Usage in Recent Years

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Pavement Type

FY 05 – FY 08 Letting Lane Miles

FY 09 - FY 13 Letting Lane Mils

Total

CRCP 2,719 4,183 6,902

JCP 106 102 208

• 6,902/13,572 =50.8% After construction, about 50% CRCP on our network is less than 10 yrs old. • 208/ 3,727 =5.5% After construction, about 5.5% JCP on our network is less than 10 yrs old. • The three longest Interstate highway in Texas are: IH10 (878.6 miles), IH20 (636 miles, and

IH35 (503.9 miles)

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CPCD Lane Mile History

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Pavement Type

1985 MainLane Mileage

1995 Lane Miles

2005 Lane Miles

2014 Lane Miles

ACP 72,660 168,156.7 177,071.9 179,842.8 CRCP 2,444 6,081.6 9,940.3 13,572.7 JCP 1,612 2,755.1 4,403.1 3,727.6 Statewide 76,716 176,993.4 191,415.3 197,143.1

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2. Current Statewide CPCD Conditions

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Lane Miles PercentPavement Type 2011 2012 2013 2014 2014

Flexible or Asphalt concrete Pavement (ACP) 179,318.3 179,485.9 179,599.9 179,842.8 91.2%

Continuously Reinforced Concrete Pavement (CRCP) 13,109.1 13,387.9 13,778.7 13,572.7 6.9%Jointed Concrete Pavement (JCP) 3,895.0 3,947.6 3,823.2 3,727.6 1.9%STATEWIDE 196,322.4 196,821.4 197,201.8 197,143.1

• 78% of Texas Concrete Pavement is CRCP • 22% of Texas Concrete Pavement is CPCD

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CPCD Conditions – PMIS FY 2010 to FY 2013

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CPCD Ride Scores – PMIS FY 2010 to FY 2013

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Lessons Learned

CPCD Sections were placed directly on subgrade

CPCD Sections were constructed without dowel bars

CPCD Sections were constructed without tied concrete shoulder

Many CPCD sections are still under traffic beyond their design life.

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3. 2014 Memo Criteria for Use of CPCD

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3. Criteria for Use of CPCD

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For roadways with design traffic of 40 million Equivalent Single Axle Loads or less

For frontage roads where CRCP is difficult to construct due to numerous leave-out sections

For roadways controlled and maintained by another government entity

For parking areas or roadways with crosswalks, adjacent parking, or sidewalks

For railroad crossings, approaches to structures or to widen existing jointed pavement

For intersections and approaches in flexible pavement roadways that are associated with vehicle

braking and acceleration which could cause shoving and rutting of an asphalt pavement

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Factors Where/When CPCD CRCP

Traffic Level

Heavy Truck Roadway ☺☺☺

Medium Truck Roadway ☺☺

☺☺☺

Low Truck Roadway ☺☺☺

☺

Construction Flexibility Under Traffic

Frontage with Numerous Leave-outs

☺☺☺

Intersection/ Crossings ☺☺☺

Material Sources

Use Local Coarse Aggregates with High COTE for Low/Medium Truck Roadway

☺☺☺

Support Condition

Natural Subgrade with Higher Risk for Heaves

☺☺☺

On Embankment with Higher Risk for Void under Slab

☺☺☺

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Cost Information from Site Manager FY 09 to FY 13

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Item Description Number of Projects Avg.Bid Price total SYCONC PVMT (CONT REINF-CRCP)(10") 151 53.4 5,836,196 CONC PVMT (CONT REINF-CRCP)(8") 139 56.5 2,809,999 CONC PVMT (CONT REINF-CRCP)(9") 87 49.3 4,264,845 CONC PVMT (CONT REINF-CRCP)(13") 62 58.6 5,909,985 CONC PVMT (CONT REINF-CRCP)(12") 46 52.4 2,118,267 CONC PVMT (CONT REINF-CRCP)(11") 36 46.8 2,153,226 CONC PVMT (CONT REINF-CRCP)(15") 23 53.2 3,927,197 CONC PVMT (CONT REINF-CRCP)(6") 22 67.3 29,764 CONC PVMT (CONT REINF-CRCP)(14") 15 59.3 1,260,931 CONC PVMT (CONT REINF - CRCP)(7") 8 42.7 431,442 CONC PVMT (CONC REINF - CRCP)(11.5") 4 48.8 348,184 CONC PVMT (CONT REINF-CRCP)(10.5") 4 59.1 101,727 CONC PVMT(CONT REINF-CRCP)(7.5") 3 48.6 173,844 CONC PVMT (CONT REINF-CRCP)(9.5) 1 38.3 67,518 CONC PAV (CONT REINF-CRCP)(8.5") 1 45.0 10,284 CONC PAV (CONT REINF - CRCP) (6.5") 1 55.0 1,982

Total Letting CRCP = 603 29,445,391

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Cost Information from Site Manager FY 09 to FY 13

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Item Description Number of Projects Avg.Bid Price total SYCONC PVMT (JOINTED-CPCD)(9") 17 58.3 140,984 CONC PVMT (JOINTED-CPCD)(8") 13 56.9 162,680 CONC PVMT (JOINTED-CPCD)(10") 13 63.0 101,249 CONC PVMT (JOINTED-CPCD)(12") 9 60.1 123,774 CONC PVMT (JOINTED-CPCD)(13") 6 88.8 47,632 CONC PVMT (JOINTED-CPCD)(11") 4 44.2 57,649 CONC PVMT (JOINTED)(15IN) 2 35.5 69,832 CONC PVMT (JOINTED-CPCD)(6") 1 35.0 17,396

Total Letting CPCD = 65 721,195

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Estimated Cost

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ItemsUnit Quantity Unit Cost Total Cost Quantity Unit Cost Total Cost

Coarse Aggregate for Concrete ton 2,930 $30.05 $88,032 2,930 $30.05 $88,032Concrete w/o Coarse Aggregate yd3 3,499 $45.00 $157,450 3,499 $45.00 $157,450Total Concrete Cost yd3 $245,481 $245,481

Dowel Bar each 7,744 $11.25 $87,120 0 $0.00 $0Sawcutting lane-feet 8,424 $4.96 $41,783 5,280 $4.96 $26,189Joint Clean and Seal lane-feet 8,424 $1.97 $16,595 5,280 $1.97 $10,402Steel Reinforcement (#5, #6, Tie ton 5.50 $1,400 $7,700 193.88 $1,400 $271,432

Labor, Equipment & Overhead yd2 14,080 $15.30 $215,424 14,080 $16.16 $227,533

Total Construction Cost $614,104 $781,037Unit Construction Cost /yd2 $43.62 $55.47

5280 ft x 24 ft 9 in. Slab 0-6681 Project Worksheet

CPCD w/same Coarse Aggregate CRCP w/ Same CoarseAggregate

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4. 2014 CPCD Statewide Standard

Design concept and structural responses of CPCD and CRCP are quite different. In CPCD, concrete volume changes are allowed to a full extent, and accommodations are made to ensure good load transfer at discontinuities, i.e., transverse contraction joint.

Slab Thickness

Slab Size

Dowel Bar Size

Base Support

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Thickness Design for CPCD

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AASHTO 1993 Pavement Design Procedure Design Criteria: Performance Period (30 years) Initial and Terminal Serviceability (Difference of 2.0) Design Reliability (95%) Concrete Properties: 28-day Concrete Modulus of Rupture (620 psi) 28-day Concrete Elastic Modulus (5,000,000 psi) Traffic: ADT and one-way total 18-kip ESALs are provided by the Transportation Planning and Programming (TPP) Division. Reliability 90% when ESALs <= 5 million 95% when ESALs > 5 million Load Transfer Coefficient J J = 2.6 for CRCP J = 2.9 for CPCD

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Base Support for CPCD

Field performance evaluations of concrete pavement have revealed that the soundness of the base is essential to the long-term performance of concrete pavement. If the base underneath the concrete slab does not provide good support, long-term pavement performance will be severely compromised regardless of the concrete slab thickness.

TxDOT recognized this and requires one of the following base layer combinations for concrete slab support:

4 in. of asphaltic concrete pavement (ACP) or asphalt stabilized base (ASB) or

a minimum 1 in. asphalt concrete bond breaker over 6 in. of a cement stabilized base.

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CPCD-14 : Concrete Pavement Contraction Design Standard

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CPCD-14: Slab Size

Right size of CPCD slab will accommodate concrete volume changes and minimize any random cracks.

Slab length to width ratio <1.5, as square as possible

Regular slab length =15 ft.

Regular slab width =

Lane width (12 ft.)

Max.15 ft . width

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CPCD-14: Slab Size

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CPCD-14: Dowel Bar Size

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CPCD-14: Tied Concrete Shoulder

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Website Address for Concrete Pavement Standards

http://www.txdot.gov/inside-txdot/division/design/cad.html

TxDOT website – www.txdot.gov – Select Business

– Scroll to Resources

• Select Statewide Standard CAD Files – Click “I accept”

– Select Roadway Standards

– Scroll to the Pavements

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5. Summary of Success

Adequate Slab Thickness Uniform and Sufficient Base Support Project Specific Joints Layout Install Dowel Bars Timely Saw-cut at Dowel Bar Locations

and at Longitudinal Joints Use Tied Concrete Shoulder

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CRCP for Heavier Traffic Roadways

Longitudinal Joint

Longitudinal Steel

Transverse Steel Tie Bars

4” ACP Base

CRCP after Concrete Paving

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CRCP before Concrete Paving

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Rigid Pavement and Concrete Materials Branch

Construction Division, TxDOT

Andy Naranjo, P.E. Branch Manager (512) 506-5858

Hua Chen, P.E. (512) 506-5846

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