Construction ofConstruction of

Concrete PavementsConcrete PavementsJefferyJeffery RoeslerRoesler, Ph.D., P.E, P

h.D., P.E.
AssociAssocate Professoriate ProfessorDepartment of Civil and EngineeringDepartm
ent of Civil and Engineering
University of IllinoisUniversity of IllinoisPontificia Universidad CatPontificia
Universidad Catóólica de Chilelica de ChileDepartamento de IngenierDepartamento de
Ingenieríía y Gestia y Gestióón de la Construccin de la ConstruccióónnOctober 19, 2009Octob
r 19, 2009AcknowledgmentsAcknowledgments
..Dr. Dan Zollinger
Professor, Texas A&M
..NHI Training Course
..Gary Fick
Trinity Construction Management
Construction ofConstruction of
Concrete PavementsConcrete PavementsJefferyJeffery RoeslerRoesler, Ph.D., P.E, P
h.D., P.E.
AssociAssocate Professoriate ProfessorDepartment of Civil and EngineeringDepartm
ent of Civil and Engineering
University of IllinoisUniversity of IllinoisPontificia Universidad CatPontificia
Universidad Catóólica de Chilelica de ChileDepartamento de IngenierDepartamento de
Ingenieríía y Gestia y Gestióón de la Construccin de la ConstruccióónnOctober 19, 2009Octob
r 19, 2009AcknowledgmentsAcknowledgments
..Dr. Dan Zollinger
Professor, Texas A&M
..NHI Training Course
..Gary Fick
Trinity Construction Management
Types of Concrete PavementsTypes of Concrete Pavements
..Jointed Plain Concrete Pavements (JPCP)
..Continuously Reinforced Concrete Pavements (CRCP)
..Jointed Reinforced Concrete Pavements (JRCP) Pre-
stressed Concrete Pavements
..Interlocking Concrete Block Pavements (ICBP)
..Fiber Reinforced Concrete (FRC) Pavements
..Whitetopping and Ultrathin Whitetopping (UTW)
Types of Concrete PavementsTypes of Concrete Pavements
..Jointed Plain Concrete Pavements (JPCP)
..Continuously Reinforced Concrete Pavements (CRCP)
..Jointed Reinforced Concrete Pavements (JRCP) Pre-
stressed Concrete Pavements
..Interlocking Concrete Block Pavements (ICBP)
..Fiber Reinforced Concrete (FRC) Pavements
..Whitetopping and Ultrathin Whitetopping (UTW)
CONCRETE PAVEMENTSCONCRETE PAVEMENTS
..Typical Cross Section:
..Less stiff layer with depth
Subbase/ Base
Subgrade
Concrete
10cm Pervious Concrete/ OGDL
29cm PCCP
Limerock base
JOINTED PLAIN CONCRETE PAVEMENT
(JPCP) Portland Cement
Concrete
Subgrade
Joint with
Dowel Bar
Joint Spacing
3.5 to 6 m
Stabilized or
Granular Base
JOINTED PLAIN CONCRETE PAVEMENT
(JPCP) Portland Cement
Concrete
Subgrade
Joint with
Dowel Bar
Joint Spacing
3.5 to 6 m
Stabilized or
Granular Base
CONTINUOUSLY REINFORCED CONCRETE
PAVEMENT (CRCP)
Portland Cement
Concrete
Subgrade
Shrinkage Cracks,
1 to 2 m spacing
Stabilized Base
Continuous Steel Bars
throughout Length of
Pavement
Horizontal ConstructionHorizontal ConstructionPrimary Steps in ConcretePrimary S
teps in Concrete
Pavement ConstructionPavement Construction
..Preparing the soil & base layer
..Consistent concrete material
..Placing & finishing concrete
..Texturing surface
..Curing & temperature management
..Sawing and Sealing
..Opening to traffic
Horizontal ConstructionHorizontal ConstructionPrimary Steps in ConcretePrimary S
teps in Concrete
Pavement ConstructionPavement Construction
..Preparing the soil & base layer
..Consistent concrete material
..Placing & finishing concrete
..Texturing surface
..Curing & temperature management
..Sawing and Sealing
..Opening to traffic
Preparing the Support LayersPreparing the Support Layers
..Construction starts with the subgrade
(suelo)
..Uniformity
Soil type
Moisture content
Density
..Remove unsuitable materials
..Stabilize or treat poor soils
Preparation for PavingPreparation for Paving Construction staking alignment and e
levation
Setting string-line
Preparing the Support LayersPreparing the Support Layers
..Construction starts with the subgrade
(suelo)
..Uniformity
Soil type
Moisture content
Density
..Remove unsuitable materials
..Stabilize or treat poor soils
Preparation for PavingPreparation for Paving Construction staking alignment and e
levation
Setting string-line
Preparation for PavingPreparation for Paving
..Fine grading Laser Level
Critical for thickness control of every layer
Establishes a foundation for smoothness
Preparation for PavingPreparation for Paving
..Checking grade elevation and thickness
quality control
..Stretching a string across the grade
between the two longitudinal stringlines
Preparation for PavingPreparation for Paving
..Fine grading Laser Level
Critical for thickness control of every layer
Establishes a foundation for smoothness
Preparation for PavingPreparation for Paving
..Checking grade elevation and thickness
quality control
..Stretching a string across the grade
between the two longitudinal stringlines
Subbase OperationsSubbase Operations
..Granular materials (agregados)
Similar to subgrade preparation
Usually higher density requirement
..Cement-stabilized materials
Placed using slipform or asphalt equipment
Aggregate BaseAggregate BaseSubbase OperationsSubbase Operations
..Granular materials (agregados)
Similar to subgrade preparation
Usually higher density requirement
..Cement-stabilized materials
Placed using slipform or asphalt equipment
Aggregate BaseAggregate Base
GeosyntheticGeosyntheticReinforcementReinforcementAggregateAggregate SubbaseSubb
aseCompactionCompactionGeosyntheticGeosyntheticReinforcementReinforcementAggrega
teAggregate SubbaseSubbaseCompactionCompaction
Cement Treated BaseCement Treated Base
..Uniformity
..Compressive strength for the mix design
& measured by in-place density
Lean orLean or EconocreteEconocreteBaseBase
..Mixed, transported and placed the same as
concrete pavement
..No contraction joints typically
..7-day curing period
..Second application of wax curing compound as
a bond inhibitor
Cement Treated BaseCement Treated Base
..Uniformity
..Compressive strength for the mix design
& measured by in-place density
Lean orLean or EconocreteEconocreteBaseBase
..Mixed, transported and placed the same as
concrete pavement
..No contraction joints typically
..7-day curing period
..Second application of wax curing compound as
a bond inhibitor
Open Graded Base (319)Open Graded Base (319)
..Separator fabric is placed between soil layer
and open graded base
..Bituminous is placed with an asphalt paver and
screed compacted
..Cement treated is placed similar to CTB without
the roller (screed compacted)
Open Graded Base (319)Open Graded Base (319)
..Separator fabric is placed between soil layer
and open graded base
..Bituminous is placed with an asphalt paver and
screed compacted
..Cement treated is placed similar to CTB without
the roller (screed compacted)
Setting Dowel BasketsSetting Dowel Baskets
..Planned joint location
..Anchored firmly pins, clips and nails, etc.
..Alignment 3 planes (joint lockup will
cause cracking)
Setting Dowel BasketsSetting Dowel Baskets
..Planned joint location
..Anchored firmly pins, clips and nails, etc.
..Alignment 3 planes (joint lockup will
cause cracking)
FixedFixed--Form Paving OperationsForm Paving Operations
..Paving form is the mold
Holds concrete in place
Establishes grade and alignment
Serves as tracks for paving equipment
Typical Steel FormTypical Steel FormForm Lock
FixedFixed--Form Paving OperationsForm Paving Operations
..Paving form is the mold
Holds concrete in place
Establishes grade and alignment
Serves as tracks for paving equipment
Typical Steel FormTypical Steel FormForm Lock
Application AdvantagesApplication AdvantagesFixedFixed--Form PavingForm Paving
..Tight tolerances -side clearance
..Multiple changes of width
..Blockouts
..Intersections -quadrants open to traffic
Application AdvantagesApplication AdvantagesFixedFixed--Form PavingForm Paving
..Tight tolerances -side clearance
..Multiple changes of width
..Blockouts
..Intersections -quadrants open to traffic
Eliminate high and low areasEliminate high and low areasSecure to prevent moveme
ntSecure to prevent movementEliminate high and low areasEliminate high and low a
reasSecure to prevent movementSecure to prevent movement
MoistenMoisten SubbaseSubbase
..Subbase surface should be kept damp, but
without standing water
Surface temperature control
Transporting ConcreteTransporting Concrete
..Transit mix
..Agitator
MoistenMoisten SubbaseSubbase
..Subbase surface should be kept damp, but
without standing water
Surface temperature control
Transporting ConcreteTransporting Concrete
..Transit mix
..Agitator
Transporting ConcreteTransporting ConcreteDump Truck Dump Trailer
Live Bottom Trailer
Transporting ConcreteTransporting ConcreteDump Truck Dump Trailer
Live Bottom Trailer
Concrete Construction in ChinaConcrete Construction in China
Concrete Placer
Concrete PavementConcrete PavementPlacer / SpreaderPlacer / SpreaderConcrete Pla
cerConcrete PlacerConcrete PavementConcrete PavementPlacer / SpreaderPlacer / Sp
reader
Slipform Concrete PavingSlipform Concrete PavingTO EXTRUDE:
To shape a material by
forcing it through a mold.
PaverPaverSetupSetup
..Width fresh slab will expand after
extrusion
..Trueness cross-slope/crown
..Integral curb dimensions
..Vibrator spacing and operation
..Sensor operation -daily
Slipform Concrete PavingSlipform Concrete PavingTO EXTRUDE:
To shape a material by
forcing it through a mold.
PaverPaverSetupSetup
..Width fresh slab will expand after
extrusion
..Trueness cross-slope/crown
..Integral curb dimensions
..Vibrator spacing and operation
..Sensor operation -daily
SlipformSlipformPaverPaverComponentsComponentsIMCPManualSlipformSlipformPaverPav
er
..Vibrators
..Pan and Side form
SlipformSlipformPaverPaverComponentsComponentsIMCPManualSlipformSlipformPaverPav
er
..Vibrators
..Pan and Side form
Slipform Paving OperationsSlipform Paving Operations
..Establishing String Line and Elevation
..Paver Set Up
..Placement Steel
..Slipform Paving Process
SlipformSlipformPaverPaver
..Tractor
..Auger &
Strike-off
Slipform Paving OperationsSlipform Paving Operations
..Establishing String Line and Elevation
..Paver Set Up
..Placement Steel
..Slipform Paving Process
SlipformSlipformPaverPaver
..Tractor
..Auger &
Strike-off
Pavement slab constructionPavement slab constructionPavement slab constructionPa
vement slab constructionPavement slab constructionPavement slab constructionPave
ment slab constructionPavement slab construction
Global positioning system (GPS) controls will likely be
able to eliminate the need for a string line in the future
GPS Receiver GPS
Controller
and Laser
Height Gages
Laser
Sensor
Global positioning system (GPS) controls will likely beGlobal positioning system
(GPS) controls will likely be
able to eliminate the need for a string line in the futureable to eliminate the
need for a string line in the futureGPS Receiver GPS
Controller
and Laser
Height Gages
Laser
Sensor
High
Resolution
Laser
Vibrator Sphere of InfluenceVibrator Sphere of InfluenceDumping/SpreadingDumping
/Spreading
..Regardless of the method, the goal is to
maintain a consistent amount of concrete in
front of the paver
Vibrator Sphere of InfluenceVibrator Sphere of InfluenceDumping/SpreadingDumping
/Spreading
..Regardless of the method, the goal is to
maintain a consistent amount of concrete in
front of the paver
Paving Speed ~ 0.5 to 3m / min.Paving Speed ~ 0.5 to 3m / min. Paving Speed ~ 0.
5 to 3m / min.Paving Speed ~ 0.5 to 3m / min.
Discharging/placing PCCDischarging/placing PCCDowel bar inserter
Discharging/placing PCCDischarging/placing PCCDowel bar inserter
Discharging/placing PCCDischarging/placing PCCDowel bar inserter
Discharging/placing PCCDischarging/placing PCCDowel bar inserter
Discharging/placing PCCDischarging/placing PCCDowel bar inserter
Discharging/placing PCCDischarging/placing PCCTie bars
Discharging/placing PCCDischarging/placing PCCDowel bar inserter
Discharging/placing PCCDischarging/placing PCCTie bars
Crane Slab for Loading RailcarsCrane Slab for Loading RailcarsAirfield Concrete
PavementAirfield Concrete PavementCrane Slab for Loading RailcarsCrane Slab for
Loading RailcarsAirfield Concrete PavementAirfield Concrete Pavement
Edge SlumpEdge Slump
..Variability (non-uniform concrete) will result
in edge slump or edge failure
Edge SlumpEdge Slump
..Variability (non-uniform concrete) will result
in edge slump or edge failure
FinishingFinishing
..Burlap drag
..Mechanical
finishing
..
FinishingFinishing
..Burlap drag
..Mechanical
finishing
..
From Fine Aggregate
Particles
MicrotextureMicrotexture
Formed into
surface
MacrotextureMacrotexture(Grooves)(Grooves)
MicrotextureMicrotexture
..Burlap drag
..Turf drag
..Broom
Formed into
surface
MacrotextureMacrotexture(Grooves)(Grooves)
MicrotextureMicrotexture
..Burlap drag
..Turf drag
..Broom
MacrotextureMacrotexture
..Transverse tining
..Straight and clean tines
MacrotextureMacrotexture
..Transverse tining
..Straight and clean tines
Final TexturingFinal Texturing
..Transverse tining
..Longitudinal tining
Final TexturingFinal Texturing
..Transverse tining
..Longitudinal tining
Concrete Pavement (US Practices)Concrete Pavement (US Practices)
..Alternative Surface Textures
Grinding Exposed Aggregates
Curing CompoundCuring CompoundConcrete Pavement (US Practices)Concrete Pavement
(US Practices)
..Alternative Surface Textures
Grinding Exposed Aggregates
Curing CompoundCuring Compound
CuringCuring..Why?
..Plastic shrinkage
cracking
..Permeability
..When?
..Before the surface
can dry weather
will influence this
greatly
..How much?
COMPLETE
COVERAGE
CuringCuring..Why?
..Plastic shrinkage
cracking
..Permeability
..When?
..Before the surface
can dry weather
will influence this
greatly
..How much?
COMPLETE
COVERAGE
Joint Saw and Seal OperationsJoint Saw and Seal OperationsJoint Saw and Seal Ope
rationsJoint Saw and Seal Operations
Types of Pavement Joints
Transverse
Contraction
Construction
Expansion/Isolation
Longitudinal
Contraction
Construction
Types of Pavement Joints
Transverse
Contraction
Construction
Expansion/Isolation
Longitudinal
Contraction
Construction
Sawing JointsSawing Joints Why?
So it cracks where we want
it to
When?
Before it cracks, but after
raveling is minimized
Green saw at T/3 or early
entry is shallower (20 to
25mm)
Dimension sawing is
optional with 6mm joint
width
Sawing JointsSawing Joints Why?
So it cracks where we want
it to
When?
Before it cracks, but after
raveling is minimized
Green saw at T/3 or early
entry is shallower (20 to
25mm)
Dimension sawing is
optional with 6mm joint
width
SawsSawsWet Walk Behind Early Entry
Span Saw
SawsSawsWet Walk Behind Early Entry
Span Saw
Sawing WindowSawing WindowTime
Concrete SetToo
Early
Raveling
Too
Late
Random Cracking
Sawing JointsSawing JointsSawing JointsSawing Joints
Sealing JointsSealing Joints Backer rod
Silicone sealant
Longitudinal
construction joints
Sawing Window
.. Concrete mix characteristics
Cement type
Admixtures
Fast Track
.. Base Type
Aggregate, Stabilized, Open graded
.. Production schedule
- Early cut or conventional
.. Weather conditions
Ambient temperature, Wind, Humidity, Cloud
cover
Sawing WindowSawing Window
..Concrete mix characteristics
Cement type
Admixtures
Fast Track
..Base Type
Aggregate, Stabilized, Open graded
..Production schedule
-Early cut or conventional
..Weather conditions
Ambient temperature, Wind, Humidity, Cloud
cover
Two-Lift Concrete Pavement
.. New U.S. Trends
TwoTwo--Lift Concrete PavementLift Concrete Pavement
..New U.S. Trends
TwoTwo--Lift Concrete PavementLift Concrete Pavement
..New U.S. Trends
Continuously ReinforcedContinuously Reinforced
Concrete PavementConcrete PavementChair SetChair Set--upupContinuously Reinforce
dContinuously Reinforced
Concrete PavementConcrete PavementChair SetChair Set--upup
Steel LayoutSteel LayoutCRCP Chairs (Steel)CRCP Chairs (Steel)
Steel LayoutSteel LayoutCRCP Chairs (Steel)CRCP Chairs (Steel)
Steel TiesSteel TiesSteel TyingSteel TyingSteel TiesSteel TiesSteel TyingSteel T
ying
Bar SplicesBar SplicesSingle Layer SteelSingle Layer SteelBar SplicesBar Splices
Single Layer SteelSingle Layer Steel
Roller Compacted Concrete (RCC)Roller Compacted Concrete (RCC)Roller Compacted C
oncrete (RCC)Roller Compacted Concrete (RCC)