Concrete Pavement Overlays

Concrete Pavement Overlays
36th Annual Mid-Atlantic Quality Assurance Workshop

Charleston, WV February 12, 2003
Robert R. Long Jr.

Regional Director American Concrete Pavement Association Northeast Chapter
Family of Concrete Overlays

Concrete Overlays
Existing Pavement Concrete
Existing Pavement Asphalt
Bonded Concrete Overlay
Unbonded Concrete Overlay
Conventional Whitetopping Overlay
Ultra-Thin Whitetopping Overlay
Concrete Pavement Types

Jointed Plain
Undoweled Doweled
Jointed Reinforced Continuously Reinforced

Consists of a thin concrete layer (100 mm or less) on top of an existing concrete surface. Specific steps are taken to bond the new concrete overlay to the existing concrete.
. . .
.. . .
Bond = Strength
. .
History
First bonded PCC resurfacing
Warsaw Street in Toledo, Ohio in 1913. Used to correct construction deficiencies relating to a frozen pavement.
Typical applications have been:

to correct construction deficiencies to correct surface problems relating to wear or loss of skid resistance to repair damage caused by chemical spills.
In recent years, used to improve load-carrying capability where feasible to change the grade.
Advantages
Increase structural capacity.
More efficient than AC.
One in. of PCC ~ two in. of AC
Edge Stress (psi)
300 260 220 180 140 100 0 2 4 6 8

Overlay Thickness (in.)
Bonded PCC Overlay AC Overlay
Critical edge stresses are about 35% lower than an equivalent asphalt overlay.
Long service life

High PSI.
Lower user & engineering costs. Rut free
Applicability
Condition of underlying pavement dictates the feasibility...
But you must consider preoverlay repair.
Do NOT apply to
appreciably distressed pavements. pavements with high-severity "D" cracking or reactive aggregate problems.
Pre-Overlay Repair
Transverse Cracks Not all transverse cracks require repair. Address working cracks (faulting, pumping corner breaks)
Full-depth repair. Random crack control.
NOTE: Untreated cracks will eventually reflect through. Saw & seal the cracks
Placement of Crack Control Cages
Placed and Tacked Directly onto Pavement Surface 2 inches Cover
Milled
-OR-
Mounted on Chairs
Recessing Bars
Placement of Crack Control Cages
Pre-Overlay Repair
Joint Deterioration
Spalling, blow-ups, corner breaks.
Repair Full or Partial Depth
Lightly spalled joints may be milled to sound concrete.

Depressions less than 2 in. deep, fill with concrete during the overlay operation. Depressions more than 2 in. deep, fill with concrete prior to the overlay.
Bonding
Bonding between the two layers is principally a mechanical process
Depends primarily on the soundness and cleanliness of the underlying pavement.
Full Bond
Bond shear strength = 200 psi (min.)
Is grout required to enhance bonding?

Surface Preparation Cleanliness is key to long-term performance. Surface preparation procedures:
Shotblasting Milling

Shotblasting
Bonded Overlays
Milling
Bonded Overlays
Shotblasting Milling
Bonded Overlays
Surface Cleaning

Grout or No-grout?
600
Shear Strength (psi)
Corner
Center
Edge
Average
500 400 300 200 100 0 Milled/Grout Milled/None Shot blast/Grout Shot blast/None
Unpublished Research Data: University of Texas
Bonded Overlays
Curing
Critical because high ratio of surface area to volume of concrete. Apply ASAP
1 gallon/100 sq.ft.
Coat all exposed edges. Avoid extreme weather. Avoid contact with prepared surfaces.

Performance Good when:
Placed correctly and at the right time.
Poor when:
Placed on deteriorated pavements.
Loss of bond does not necessarily constitute failure.
Early Performance Studies

Gillette 1965
Included 10 overlays placed between 1954 - 1963.
Adequate performance can be expected regardless of the thickness of the resurfacing and the type of frequency of traffic
Gausman 1980
Overlays in seven states, built between 1973 -1975.
Overlays can be effectively bonded to clean pavements in good condition. Quality of surface preparation is critical Bond can be retained without bonding grout.
Other Performance Studies

Peshkin and Mueller - 1990
Study of 10 thin-bonded overlays constructed between 1976 1985. Thickness ranged from 2 5 in. All were jointed resurfacing of jointed original pavement.
Found mixed success.

Some projects failed in relatively few years Others carried more than the anticipated traffic and were performing well.

Consists of thick concrete layer (125 mm or greater) on top of an existing concrete. Uses a separation interlayer to separate new overlay and existing concrete.
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Unbonded Overlay
When to Use Unbonded Overlays

Little or no remaining structural life Extensive and severe durability distress Medium to very heavy truck traffic Very weak or wet subgrade Other obstacles to reconstruction
Unbonded Overlay
Benefits
Little pre-overlay repair needed Improved Structural Capacity.
Very Strong Base that can maintain traffic Reduced Faulting, Pumping, & Loss of Support
Can place on pavement in bad condition.

i.e. "D" cracked pavements, ASR, etc. No future reflective cracking.
Avoids reconstruction problems

Less construction time
What types of UBOLs and existing pavements are compatible?

Existing Pavement Type JPCP UBOL Type JRCP CRCP AC/PCC
JPCP
JRCP
CRCP
What types of UBOLs and existing pavements are compatible?

Existing Pavement Type JPCP UBOL Type JRCP CRCP AC/PCC
JPCP
JRCP
CRCP
Unbonded Overlay
Preoverlay Repair
Unbonded Overlays are less sensitive to underlying pavement condition than any other Overlay type
May be needed:
Repair/replace shattered or rocking slabs Repair punchouts in CRCP
Probably not needed:

Repair of other slab cracking Repair of joint spalling Load transfer restoration
Unbonded Overlay
Preoverlay Repair
Joint Deterioration
Remove Loose Material at Medium to High Severity Spalls (Cold Milling). Place Cold Patch if Thin Interlayer.
What about Fracturing the Existing Slab

If you can fracture an existing concrete slab and place an AC overlay
why cant you place an AC leveling course & an unbonded PCC overlay? A few UBOLs of rubblized PCC have been built
But is the extra expense of rubblizing justified?

Separation Interlayer:
Allows layers to act independently. Prevents distresses from reflecting into overlay. Materials that work:
Asphalt concrete Some surface treatments
Materials that do not:

Polyethylene Roofing paper Curing compound
Unbonded Overlays
Can also use existing AC overlay as interlayer

Key Overlay
Old Pavement Smooth Slip Plane
Overlay
Old Pavement Thick Interlayer (> 50 mm)

Whitewash
Prevent heat build-up by reflecting heat/energy Temperature reduction as much as 11C (20F) Typically lime slurry or curing compound
Unbonded Overlays
Jointing
Mismatch joints. Saw joints d/3.
3 FT.
3 FT.
Overlay joints should be mismatched from working cracks too

Performance Very Good Can be expected to perform for 20+ years.
Most failures are due to the use of inadequate separation layers.

Performance NCHRP Synthesis 99, 1983 NCHRP Synthesis 204, 1994 NCHRP Report 415, 1999
JPC Unbonded Overlay

14 12
UBOL Thickness (inches)
Thicknesses and Years Built No. Projects built = 105 No Projects taken out of service = 4 Avg age when taken out of service = 20.4 yr
10 8 6 4 2 0 0 20 40
Year Built
60
80
100
JRC Unbonded Overlay

12
Thicknesses and Years Built No. Projects built = 60 No Projects taken out of service = 13 Avg age when taken out of service = 22.8 yr
10
0 0 20 40
Year Built
60
80
100
CRC Unbonded Overlay

12 10
Thicknesses and Years Built No. Projects built = 31 No Projects taken out of service = 0 Avg age when taken out of service = NA
8 6 4 2 0 0 20 40
Year Built
60
80
100
Concrete Overlays of Asphalt (Whitetopping)

Consists of a thick concrete layer (100 mm or greater) placed directly on top of an asphalt concrete pavement. Behaves as a new pavement on a strong base.
Whitetopping
UTW
Whitetopping
Whitetopping: Well-established, proven pavement rehabilitation technique

Ultrathin Whitetopping: Newer technology Still under evaluation by some
Whitetopping - History
First Whitetopping
South 7th street in Terre Haute, Indiana - 1918 Existing flexible pavement was overlaid with 3 - 4 in. of reinforced concrete
During 40s and 50s Used to upgrade military & civil airports
Highway use
Started approx. 1960 Types have included JPCP, JRCP, CRCP, FRC
Whitetopping Use by State

1992
0 1 2-5
6 - 10 11 - 20 > 50
NCHRP Report 204 1992
Whitetopping by Pavement Type

85% of projects are jointed, plain concrete pavements (JPCP)
CRCP - 7.3% FRC - 4.5% JRCP - 3.2%
Number
160 140 120 100 80 60 40 20 0 JPCP JRCP CRCP FRC
Type of Overlay
Whitetopping - Advantages
Construction Can place on pavement in bad condition.
Little or no pre-overlay repair needed.
Avoid reconstruction problems.

Minimal rain delays. Maintain traffic on existing surface.
Whitetopping - Advantages
Structural
Improved structural capacity.
Reacts structurally as if on strong base course.
Maintains high level of serviceability. Concrete slabs bridge problems asphalt cannot. Reduced potential for pumping, faulting and loss of support.
Whitetopping Construction
Critical issue is uniform support
Subgrade / base failures need repair Need to evaluate drainage (esp. Inlays)
Address surface distortions

Direct application Profile milling Leveling course
Pre-overlay Preparation
Distress Rutting (< 2 in.) Rutting (> 2 in.) Shoving Raveling Trans. Cracking Block Cracking Alligator Cracking Long Cracking Bleeding Repair Performed None Milling or Leveling Milling? None None None None None None Sweep Surface Crack filler Other Factors Joint Sawing Depth Cost Comparison Drainage
Direct Application
Sweep surface and place Use when rutting < 50 mm On crowned roadways makes thickened edges Economical, practical.
Surface cross-section survey.

Determine cross-sectional area & overlay volume. Concrete overlay fills ruts.
Transverse Cracks
Key Overlay Old Pavement
Smooth Slip Plane

Overlay
Old Pavement
Profile Milling
Use when rutting > 50 mm Removes between 25 and 75 mm
Can shave off top of ruts
Used with inlays

Limited vertical clearances Single lane replacement
Leveling Course
Consider only where extreme rutting or distortion exists
Use when rutting > 50 mm Places between 25 and 50 mm of AC
Can just fill ruts
Requires more equipment, materials, time
Usually most expensive option
Whitewash Apply if surface > 110 degrees F. Prevents heat build-up or Excessive mix temperatures. Maintains hard paving surface.
Most critical for leveling course
Whitetopping Overlays
Jointing

Joint depth (D/3).

Adjust if vary over 1 inch of nominal thickness.
D D/3 + 1 inch
Performance Most projects are too new to provide data
Approximately 78 projects before 1982 Over 100 new projects between 1982 and 1992 Used to combat rutting in heavy truck corridors
Those that are old enough are providing excellent performance

Oldest in-service project built 1956
(Columbus AFB, Miss.)
Performance
US 1 - Daytona Beach, FL.

Built in 1987 19 test sections -150, 175, 200 mm thick 10 year design
After 14 years service - Excellent Condition

No sign of anticipated early deterioration High bonding between AC and PCC AC companion sections have been resurfaced twice
Inlay Whitetopping Performance

Performance
Have had good to poor performance Poor performance results from:

Poor drainage Bathtub sections Poor load transfer

Performance I-5 Portland, Oregon
Built between 1971 and 1975 330 mm thick CRCP Used in truck lanes
Excellent performance

Performance
I-70 Sherman Co., Kansas

Built in 1983 and 1985 200 mm thick - No dowels
After about 3 years of service

3 mm of faulting Some long. cracking, pumping, & corner breaks Absence of dowels and bathtub section contributed to distress development
Ultra-Thin Whitetopping
A concrete overlay, 2 to 4 inches thick with close joint spacing, bonded to the existing asphalt pavement.
May or may not contain fibers
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Performance Evaluation
Ten UTW projects in Tennessee & Georgia
Some of first projects in U.S.. Concrete of similar mixture proportions Relatively close proximity Roads of similar use (except one) Minimal traffic control during surveys
Pavement Condition Index (PCI)

Numerical Rating from 0 to 100 - 85-100 Excellent 70-84 Very Good 55-69 Good 40-55 Fair 25-39 Poor 10-24 Very Poor 0-9 Failed
UTW Condition Survey

Project Belvoir Ave - Chattanooga, TN Green Street - Athens, TN Highway 56 - McMinnville, TN Concord Road - Knoxville, TN Cusick Street (out), Maryville, TN Cusick Street (in), Maryville, TN Weigh Station (app.)- No. GA Weigh Station (leave)- No. GA Wesley Chapel - Dekalb Co., GA Marbut Rd. - Dekalb Co., GA Year Const. 1993 1994 1993 1992 1993 1993 1993 1993 1993 1993 PCI 1994 76 85 91 96 93 75 97 95 85 95 PCI 1995 76 83 86 94 89 71 97 93 82 91 PCI 1999 77 83 79 95 87 72 97 93 90 79
One Final Note

For concrete resurfacing, payment should be:
Cubic Yard Square Yard
NOTE: Divided payment is the most equitable and economic.
Any Questions ?

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What are the different types of concrete overlays discussed in the document?

What are the different types of concrete overlays discussed in the document?

What are some advantages of bonded concrete overlays compared to asphalt overlays?

What are some advantages of bonded concrete overlays compared to asphalt overlays?

Concrete Pavement Overlays

36th Annual Mid-Atlantic Quality Assurance Workshop

Robert R. Long Jr.

Family of Concrete Overlays

Existing Pavement Concrete

Existing Pavement Asphalt

Bonded Concrete Overlay

Unbonded Concrete Overlay

Conventional Whitetopping Overlay

Ultra-Thin Whitetopping Overlay

Concrete Pavement Types

Jointed Reinforced Continuously Reinforced

Bonded Concrete Overlay

Bonded Concrete Overlay

Typical applications have been:

300 260 220 180 140 100 0 2 4 6 8

Long service life

Lower user & engineering costs. Rut free

Placement of Crack Control Cages

Placed and Tacked Directly onto Pavement Surface 2 inches Cover

Placement of Crack Control Cages

Lightly spalled joints may be milled to sound concrete.

Is grout required to enhance bonding?

Bonded Concrete Overlay

Bonded Concrete Overlay

Bonded Concrete Overlay

Unpublished Research Data: University of Texas

Bonded Concrete Overlay

Loss of bond does not necessarily constitute failure.

Early Performance Studies

Other Performance Studies

Found mixed success.

Unbonded Concrete Overlay

When to Use Unbonded Overlays

Can place on pavement in bad condition.

Avoids reconstruction problems

What types of UBOLs and existing pavements are compatible?

What types of UBOLs and existing pavements are compatible?

Probably not needed:

What about Fracturing the Existing Slab

But is the extra expense of rubblizing justified?

Unbonded Concrete Overlay

Materials that do not:

Unbonded Concrete Overlay

Old Pavement Smooth Slip Plane

Old Pavement Thick Interlayer (> 50 mm)

Unbonded Concrete Overlay

Overlay joints should be mismatched from working cracks too

Unbonded Concrete Overlay

Unbonded Concrete Overlay

JPC Unbonded Overlay

JRC Unbonded Overlay

CRC Unbonded Overlay

Concrete Overlays of Asphalt (Whitetopping)

Whitetopping: Well-established, proven pavement rehabilitation technique

Whitetopping Use by State