precast pavement, where is this technology going? annual meeting. december 5, 2014. peter smith, p....
TRANSCRIPT
ACPA Annual Meeting
December 5, 2014
Peter Smith, P. E.The Fort Miller Co., Inc.NPCA, PCI & Caltrans Precast Pavement Committees
Precast Pavement, Where is this Technology Going?
The Fort Miller Co., Inc.
Why We Need Precast Pavement
180,000 ADTCross Bronx Exp. 162,000 ADT
Brooklyn-Queens Exp.
145,000 ADTI-287, Tarrytown, NY
The Fort Miller Co., Inc.
What’s Under that Interstate Traffic Right Now
Failed Rapid Set Patches
Hollywood, CAHeavily Faulted Slabs
Pasadena, CAShattered Slabs
Pasadena, CA
The Fort Miller Co., Inc.
210 Freeway, Pasadena, CA
Why Precast Concrete Pavement?
• Precast slabs are more durable Cast in controlled conditions Testing (of installed pavement) show promise of 40+ years of
service• Precast slabs can be installed in very short work windows
Enables concrete pavement replacement in 5 hour night work windows
• Precast pavement + Premium pavement overnight!
The Fort Miller Co., Inc.
Falling Weight Deflectometer Heavy vehicle simulator
Indicators for Long LifeFull scale load testing in California
Test resultsshow
no cracks ordistress
143 Million ESALs (100 KN Load)
4.3 Million Cycles
Result - 38 year life expectancy
Precast Pavement Emulates Cast in Place
• Full Bedding Support • Load transfer Dowels• Grade Control• Slab Surface Geometry
The Fort Miller Co., Inc.
(If you can use slip-form pavers – don’t use precast!
Cumulative Super-Slab Installations(as of November, 2014)
The Fort Miller Co., Inc.
Super-Slab - Over 96 projects, 36.1 lane-miles in 15 States + ONT & QUE(19,000 Slabs +/- = 254,000 SY +/-)
0
2
4
6
8
10
12
14
16
18
NY NJ ON-CA UT CA IL WI GA VA MI QC-CA PA NV MN VT MO OR
17.16
4.80
3.03 2.832.28 2.06
1.06 0.88 0.68 0.54 0.490.09 0.06 0.04 0.04 0.03 0.02
Lane
Mile
s
Location
Lane Miles (Super-Slab only – Nov. 30, 2014)
California?
Places (“pinch points”) where Precast Pavement is being used
The Fort Miller Co., Inc.
Intermittent Repairs (CPR)
I- 90
Albany, NY(2004)
I-15 Salt Lake City, Utah
(2012)
I-676 Vine St Expressway
Philadelphia, PA
(2009)
I-95, New Rochelle, NY(2007 & 2014)
The Fort Miller Co., Inc.
This(3,000 SF Per Eight Hour Shift)
(Within + 3 mm)
In 2001 and 2002
While MaintainingThis
(135,000 Vehicles per Day)
Continuous -Tappan Zee Bridge Toll Plaza
The Fort Miller Co., Inc.
Mainline I-15, Ontario, CA(200,000 VPD)
Continuous - Mainline Placement
The Fort Miller Co., Inc.
Continuous - Ramps and Ramp-Termini – That Can’t be Shut Down
Chicago, Il Plan View Tarrytown
Tarrytown, NYBrooklyn, NY
The Fort Miller Co., Inc.
Intersections – Replacing Composite Pavement, – Rotterdam, NY - 2006
Undercuts
New & Old
Replaced in 17 Nights!
Complex Geometry
The Fort Miller Co., Inc.
Intersection Approaches – Replacing Full Depth Asphalt, Rockaway Blvd., Queens, NY – 2010
Farmers Blvd Guy R. Brewer Blvd.
Intersection approaches and entire width (in areas)
The Fort Miller Co., Inc.
Bridge Approach Slabs(Existing Bridges)
Binghamton, NY (2009)
NY State DOT
Cross Section at Abutment
The Fort Miller Co., Inc.
New Bridge and Approach Slab Total Replacement
• Bridge replaced over two weekends - April 2011
• Two-span (40.2’, 40.2’) continuous, 28.76° skew
• Precast Approach Slabs - tied to prefabricated bridge units
Skewed Approach Slabs
Bridge Units
The Fort Miller Co., Inc.
US 46 Over Broad St., Clifton, NJ
Bus Pads, Hollywood & Santa Monica Blvd., North Hollywood, CA
Grading Placing
Finished, Next DayLast Slab
The Fort Miller Co., Inc.
Brooklyn Bridge Approaches2010 – 2013
Looking Towards Manhattan
Grading
Looking Towards Brooklyn
Placing
The Fort Miller Co., Inc.
Alexander Hamilton BridgeWest Approach, 2011 – 2013
Lower Level
Placing, June 2012
Grading
The Fort Miller Co., Inc.
Contractor Gets One LaneTo Replace The Same Lane
Pavement Under Low-Clearance Interstate Bridges, Kalamazoo, MI
The Fort Miller Co., Inc.
Two Lanes CompletedInstallation
New Panels (before Grinding)
The Fort Miller Co., Inc.
Where is Precast Pavement Going?
• Some current users are planning more (and some larger} projects NYS DOT – Brooklyn Queens Expressway California will be installing approximately 72,563 CY (36.78 lane
miles) in District 7 alone in the next two years New Jersey continues to award “sizable” intermittent repair
projects• “New” states planning projects in 2015
Kansas Hawaii Indiana Ohio?
New Developments in Precast (Super-Slab) Pavement Technology
The Fort Miller Co., Inc.
• Instrumented pavement High-speed EZ Pass pavement Toll booth treadles Weigh-in-motion panels
• Removable and re-usable precast pavement For utility-intensive intersections and streets
• Provision for adding on to previously-placed precast pavement Enables incremental total replacement
• More frequent use of laser grading equipment Will increase production rates
Super-Dowel
The Fort Miller Co., Inc.
Enables
•Precast Pavement Add-ons
•Removable & Re-usable Precast Pavement
Patent Pending
Extracting Half Dowels Left BehindThe Fort Miller Co., Inc.
Cross SectionExtracting Half Dowel
Precast Pavement Add-ons (Using Super-Dowels)
Makes The Most of Our Existing Concrete Pavement Asset
The Fort Miller Co., Inc.
Cut dowels to remove existing pavement
Replace dowels & place new panel
Summary
The Fort Miller Co., Inc.
• Precast pavement is here to stay It does reduce delays in the “pinch point “ areas Relatively few problems – so far
• Prices are coming down as contractors become more familiar with it
• “Frequent users” are on the rise New York, California, New Jersey, Illinois, Wisconsin, Utah
• New applications are being developed Will enhance versality
Keys to Success(Still More to Learn)
Good engineering Open mindsReal partnering
The Fort Miller Co., Inc.
Peter SmithV. P. Market Development
C - (518) [email protected]
Thank You
The Fort Miller Co., Inc.
0 – 518-695-5000 www.fortmiller.comTed Jones
Manager - Super-SlabC - (518) 265-7476
Dan MoellmanSenior Product Engineer
C - (518) [email protected]