Pavement

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425 Concrete Technology
Accelerated Concrete Pavement Construction
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Concrete Technology
Concrete Pavements
ACCELERATED CONSTRUCTION
OF URBAN INTERSECTIONS
WITH PORTLAND CEMENT
CONCRETE PAVEMENT (PCCP)
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Pavements
Asphalt pavement has long been a popular road
construction material.
In areas where traffic becomes concentrated, such as
urban intersection, flexible pavement may be prone to
rutting over time.
In areas with seasonal extremes of both hot and cold
weather, such as found in the Tri Cities, Washington,
the ruts can quickly become severe.
Several of the flexible pavement intersections in
eastern region of Washington state had been suffering
from severe rutting caused by slow moving heavy
vehicles, exasperated by high temperatures during the
summer months.
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Portland Cement Concrete Pavements

The frequent maintenance required on some
asphalt concrete (AC) pavement sections has made
reconstruction with Portland Cement Concrete
Pavement (PCCP) a more feasible alternative.
In Eastern Washington, three major AC
intersections with severe rutting problems were
reconstructed with PCCP in autumn 2000.
The entire reconstruction of each intersection,
including demolition of the AC pavement and its
replacement with PCCP, took place over a period of
three days - starting on Thursday evening and
opening the intersection to the traffic on Sunday
afternoon.
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Professor Kamran M. Nemati

Winter Quarter 2007 1
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The Problem…
25,000 - 30,000 ADT (Average Daily Traffic) with 20

percent trucks
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Rutting in Asphalt Concrete Pavements
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Intersection Construction
Replace the existing structure with 12
inches PCCP over the existing crushed
stone base
Thursday evening to Monday morning
closures to construct the intersection
square area
Detour traffic over surrounding surface
streets and state/interstate highway

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Intersection Construction
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Planning
Prior to Design of this Project, Washington State
Department of Transportation (WSDOT)
communicated with contractors, and the city
about strategies for avoiding some of the
inconvenience caused by the previous Contracts.
City allowed full weekend closure, Friday evening
to Monday morning, of one intersection at a
time.
Contractors felt that the entire intersection with
the exception of the radii could be completed in
this timeframe.
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Planning
The contractor at a later meeting proposed

completing the entire intersection including
the radii, if a three day closure was
Possible.
City of Kennewick agreed to a three-day,
Thursday evening to Monday morning
closure.
Traffic issues were worked out between
the City of Kennewick and WSDOT.
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Traffic Detours
Truck traffic detoured approximately

13 miles on interstate and state
highways.
Car traffic detoured on local streets.
Flaggers placed at all key locations.
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Public Relations
Weekly meeting were held by the project
engineer to update the local media
WSDOT tried to make the closures as
painless as possible:
Fully signed the detour routes
On site changes/refinements to allow traffic
flow
Aggressive scheduling to ensure a minimum
timeline for the closure
Variable message signs, flyers, and media
notices
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Construction Staging
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Staging Concerns
Traffic Flow and Traffic Control

Access to Adjacent Business
Access for Construction & Material Delivery
Construction Time
Safe Construction Area for Employees &
Public
Mix Designs
Time to Cure & Opening to Traffic
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Traffic Control Requirements

SR-395 & Yelm, Clearwater, Kennewick Avenue:
Close one Intersection at a Time
Temporary Lane Closures Stages 1,2,3
Complete Closure Stage 4, Thursday at 7:00
PM to Monday 6:00 AM.
Late opening penalty of up to $2,400.00 per
hour.
2,500 psi for opening to traffic.
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Modification to Traffic Control Plan
Place Traffic in NB or SB lanes for several

days. Once the traffic flow is modified
leave them in in the same configuration.
Set up Temporary Signals
Worked on Two Intersections at Once
(Clearwater & Kennewick)
No Left Turns to Facilitate Construction
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Kennewick Intersection Staging
Monday AM to Thursday 7:00 PM

Complete Approach and Departure Legs
on Southbound Legs as Shown in Stage
1 and Stage 2
Set up Traffic Control for Closure
Move materials, (Tie Bars, Dowel
Baskets, Forms, etc), into position for
easy access
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Stage 1
Work Zone
Traffic Flow
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Stage 2
Work Zone
Traffic Flow
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Complete Interior Portion of Clearwater

Avenue over the weekend
Monday through Friday Completed
Northbound Approach and Departure Legs
at Kennewick & Clearwater Avenue
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Stage 3
Work Zone
Traffic Flow
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7:00 PM Thursday to 6:00 AM Monday
Close Kennewick Intersection 7:00 PM Thursday
Begin Milling at 8:00 PM
Start Finish Grading at 2:00 AM Friday Morning.
Set Forms 7:00 AM
Start Concrete Placement 11:00 AM
Complete Daily placement 11:00 PM Friday
Evening.
Begin Green Sawing 4 to 6 hours after start of
placement
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Saturday
Check Maturity Meter
7:00 AM Remove & Reset Forms, Place
Baskets
8:00 AM Begin Placing Concrete
Complete Concrete placement 4:00 PM
Start Cleanup.
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•Stage 4a
•Stage 4b
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Stage 4a
Stage 4b
Work Zone
Road Closure
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Sunday
Check Maturity Meter for Required
Strength
Clean and Seal Joints 7:00 AM to 2:00
PM
Set Up Traffic Control for opening
Place Traffic on Pavement 6:00 PM
Sunday
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•Intersection Complete
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Time for Completion

In 15 days approximately 3384 cubic yards
of concrete were placed at Kennewick
Avenue and Cleawater.
Kennewick Avenue and Clearwater were
built concurrently.
The concurrent construction saved a
considerable amount of time. Crews were
able to place concrete daily.
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Time Components
Construction Activity
17% (No 1% 8% (Excavation)

Activity)
5% (Grading)
Components
2% 1%
3%
of typical
1%
5% (Joint Seal)
27% (Form &
5% (Clean
Joints)
Place Concrete)
turn-around
14% (Cure) time for a
PCCP
11%
(Sawcutting)
intersection
Closing Roadway Excavation
Grading Conduit Repair
Form and Place Concrete Sawcutting
Cure
Joint Seal
Clean Joints
Clean Roadway
reconstruction
Prep Roadway for Opening to Traffic Delay
No Activity
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Keys to this Projects Success

Good Communication between WSDOT
project office and Acme.
Key decision makers on site or available at
all times.
Involvement in the scheduling from
subcontractors and suppliers.
Hourly schedule for Weekend closures with
clear milestones for daily production.
Quality Control personnel onsite during all
placements.
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Construction Schedule
Contractor's CPM Schedule

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Mix Design
Bonus/Penalty for Air Content & Strength

evaluated statistically
Mix design required 650 flex in 14 days with 28
day cylinders for pay
Ultimate 28 day field strengths required to
exceed, 28 day lab cured compressive strength
less 1000 psi, evaluated statistically.
2500 psi for opening to traffic in 12 to 16 hours
Maturity Meter curves for early opening.
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Mix Design
WSDOT One Day Mix
705 # Type III Cement
940 # 1 1/2” Rock
799 # 3/4” Rock
140 # 3/8” Pea Gravel
590 # Coarse Sand
481# Fine Sand
254 # Water
11 oz/cy AEA
30.3 oz/cy WRA
17.6 oz/cy Delvo (Set Retarder)
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Maturity Meter
Maturity vs. Compressive Strength

Maturity vs. Flexural Strength
Flexural & Compressive vs. Time
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Mix Design (Cont’d)
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Maturity Meter
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Closing
There are many different ways an agency
can stage an intersection. The method
presented is only one method that worked
very well on this project.
None of the techniques used to place the
concrete are highly specialized.
The mix design is very simple and easy to
use.
High penalties for late openings will
increase the initial cost of the intersections
to cover contractor risk.
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Rapid Intersection Reconstruction

Kennewick, Washington
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CM

Portland Cement Concrete Pavements

Professor Kamran M. Nemati

 25,000 - 30,000 ADT (Average Daily Traffic) with 20

Rutting in Asphalt Concrete Pavements

Professor Kamran M. Nemati

 The contractor at a later meeting proposed

Professor Kamran M. Nemati

 Truck traffic detoured approximately

Professor Kamran M. Nemati

 Traffic Flow and Traffic Control

Traffic Control Requirements

Modification to Traffic Control Plan

 Place Traffic in NB or SB lanes for several

Professor Kamran M. Nemati

Kennewick Intersection Staging

 Monday AM to Thursday 7:00 PM

Professor Kamran M. Nemati

Kennewick Intersection Staging

 Complete Interior Portion of Clearwater

Kennewick Intersection Staging

Professor Kamran M. Nemati

Kennewick Intersection Staging

Professor Kamran M. Nemati

Kennewick Intersection Staging

Time for Completion

Professor Kamran M. Nemati

17% (No 1% 8% (Excavation)

Keys to this Projects Success

Contractor's CPM Schedule

Professor Kamran M. Nemati

 Bonus/Penalty for Air Content & Strength

 Maturity vs. Compressive Strength

Professor Kamran M. Nemati

Mix Design (Cont’d)

Professor Kamran M. Nemati

Rapid Intersection Reconstruction

Professor Kamran M. Nemati

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25,000 - 30,000 ADT (Average Daily Traffic) with 20

The contractor at a later meeting proposed

Truck traffic detoured approximately

Traffic Flow and Traffic Control

Place Traffic in NB or SB lanes for several

Monday AM to Thursday 7:00 PM

Complete Interior Portion of Clearwater

Bonus/Penalty for Air Content & Strength

Maturity vs. Compressive Strength