3. Lafarge Research Center (LCR)
www.lafarge.com
@LafargeGroup
Robert Rodden, P.E.
www.robertrodden.com
Infrastructure Solutions – Roads
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International Society for
Concrete Pavements (ISCP)
www.concretepavements.org
@ConcPaveSociety
Executive Director
6. ALL OF TODAY’S PRESENTATIONS
• Can be downloaded at any time at:
http://bit.ly/1PO7ixS
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7. Countries with the Largest Paved
Roadway Networks
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7Source: USA CIA’s World Factbook
KilometersofPavedRoadway
10. Why Joint Concrete Pavement?
• Historical Reason: control natural cracking
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40-80 ft
(12-24 m)
15-20 ft
(4.5-6 m)
Sawcut
@ 15 ft (4.5 m)
or less
11. Why Joint Concrete Pavement?
• Other reasons we joint concrete pavements:
Divide pavement into construction lanes or increments.
Accommodate slab movements.
Provide load transfer via placed dowels.
Provide uniform sealant reservoir.
To leverage joint spacing in design!
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12. Why Joint Concrete Pavement?
• Not for lane delineation!
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13. Types of Concrete Pavement
Steel Reinforcing, Joint Spacing, and Crack Spacing Differentiate Between the JPCP, JRCP, and CRCP
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Jointed
Plain
Concrete
Pavement
(JPCP)
Steel
0%
Joints
12-20 ft
(3.6-6 m)
Cracks
N/A
Jointed
Reinforced
Concrete
Pavement
(JRCP)
Steel
0.06-0.25%
Joints
40-100 ft
(12-30 m)
Cracks
15-20 ft
(4.5-6 m)
Continuously
Reinforced
Concrete
Pavement
(CRCP)
Steel
0.6-0.85%
Joints
N/A
Cracks
2-6 ft
(0.6-1.8 m)
14. Joint Layout
• Critical to crack control
• Typically decided by engineer and included in
project plans
– No knowledge of contractor, equipment, processes
– Hard to precisely place things like utilities
• Contractor may be allowed to develop plans
but, even if not, field adjustments can and
should be made
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15. The ACPA 10 Step Method
of Joint Layout for Intersections
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16. Field Adjustments are Necessary
• Adjust joints that are within 5 ft (1.5 m) of a utility!
• Must isolate utilities as shown on plans
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Contractor must also
consider impact of
moving joints!!!
17. Joint Layout
Design…
References:
• EB237 – Concrete Pavement Field
Reference: Pre-Paving
• IS006, Intersection Joint Layout
• IS061 – Design and Construction of
Joints for Concrete Streets
• R&T Update 6.03 – Concrete
Roundabouts
• TB010 – Design and Construction of
Joints for Concrete Highways
• TB017 – Airfield Joints, Jointing
Arrangements and Steel
• TB019 – Concrete Intersections: A
Guide for Design and Construction
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20. It Starts from the Ground Up
• Roadbed (subgrade and subbase) design and
construction are key to:
– Long-term performance
– Smoothness (initial and long-term)
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21. What is Good Support?
• Roadbeds for a concrete pavement structure
should:
– Be free from abrupt changes in character of the materials
(should be uniform and constructed of a material that will
provide requisite stability over the life of the pavement)
– Resist erosion
– Be engineered to control subgrade soil expansion/frost
heave
• Above all other concerns,
uniformity is of utmost
importance
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24. Unstabilized Subgrades
1. Grade to match roadway plans
2. Cross haul to avoid abrupt changes
3. Compact at optimum moisture content
4. Identify soft spots and fix
5. Protect from rain by “tight blading” and
finishing with smooth drum roller
6. Fine grade to plan elevations within
tolerances
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25. Stabilized Subgrades
1. Trim to match roadway plans but finish the
grade below the final grade elevation
2. Spread stabilized agent as evenly as possible
3. Mix, add water and
compact
4. Finish grade
5. Cure the subgrade
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26. Step 3 for Cement-Treated Soils
• Mix, add water, and compact (within 2 hours)
in one continuous operation
• Moisture content within 2% of optimum
• Min of 60% passing #4
(4.75 mm) sieve
• Special attention to
longitudinal overlap
• Strictly adhere to 2hr
working period
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27. Step 3 for Lime-Stabilized Soils
• Mix and add water simultaneously
• Moisture content of optimum to +5% of optimum
• Lightly compact and grade to drain excess water
• Let soil sit idle for 24 to 72 hours
• Re-mix, adding water as necessary to target
moisture content of optimum +3%; recompact
• Min of 60% passing #4 (4.75 mm)
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29. General Notes on Subbases
• Thick subbases (greater than 6 in. [150 mm]) are
typically not beneficial, and therefore are not
recommended
• The width of the subbase should accommodate the
paving equipment by extending approximately 3 ft (1
m) beyond the width of the pavement on each side
• Recommended
minimum thickness:
– Unstabilized: 4 in. (100 mm)
– CTB or LCB: 4 in. (100 mm)
– ATB: 2 in. (50 mm)
• Recycled materials are
commonly used
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30. Unstabilized Subbases
1. Mix a uniformly moist, homogeneous material
2. Place using preferred method
3. Compact to required density w/min effort
4. Trim to plan elevation and tolerances
5. Moisture content key
during construction
of subbase AND
immediately before
paving
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31. Cement-Treated Subbases (CTB)
1. Central-mix and place material or road-mix
2. Compact with rollers and trim to specified
grade
a) Must place and trim within 4 hrs of mixing!
3. Cure the subbase
4. If trimmed after
curing, curing
compound must
be reapplied
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32. Lean Concrete Subbases (LCB)
1. Central-mix the concrete
2. Place to plan elevation and tolerances
a) No additional finishing
b) No texturing
3. Cure (if necessary)
4. Joint (If necessary)
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35. Safety
• Ride quality is pointless if
someone is hurt
• Plan out truck routes
• Use of highway patrol
• Daily safety meetings
• Employees get bold
• Teach employees to
watch traffic
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36. Safety
• Pay attention to broom
handles, saws and
protrusions in traffic
• Watch for backing
trucks and make sure
alarms are functional
• Be aware of
surroundings
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37. FREE Safety Training!
• Available
around
the
clock,
365
days
per
year.
• No
cost
to
par;cipants.
• Cer;ficates
of
comple;on
may
count
toward
a
total
of
11.0
professional
development
hours
(PDHs).
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www.acpa.org/self-paced-online-courses/
39. Stringline Considerations
• Can be wire, cable, woven nylon,
polyethylene rope, or similar material
• Continuously check tension
• Clean and tight splices
• Stakes must be long enough
• Maximum stake spacing of 25 ft (7.6 m)
• See Staking Interval Calculator at
apps.acpa.org for recommendations on curves
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40. Stringline Considerations
(con’t)
• Place winches at ≤
1,000 ft (305 m)
• Beneficial to have
stringlines on both
sides of paving
• Some situations
require cantilever or
trusses for sensors to
reach stringline
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41. Setting the Stringline
1. Set reference hubs at proper interval and
place a stringline support stake outside of
each hub
2. Set stake arm to
the proper elevation
3. Install stringline
4. Tighten stringline
5. Check installation
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45. Notes on Setting
Reference Hubs
• Reference hubs are set using
a variety of methods
• Contractor determines offset
• Grade info on identifier next
to where hubs will be set
• Proper communication is KEY
to a successful operation!!
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46. Once Set, the Paver Does the Rest
Uniform Slope in a Superelevation into and though a Horizontal Curve
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47. Once Set, the Paver Does the Rest
Rooftop Slope in a Straight Section to Encourage Drainage to Each Edge of Pavement
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48. Once Set, the Paver Does the Rest
Transition from Rooftop Slope to Uniform Slope into a Horizontal Curve
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54. Placing Embedded Steel
Pre-Placed in Baskets
• Requires support system
• Requires placement ahead of
paving or at the same time as
paving is occurring
• Increased transport cost
• Increased labor in placement
Placed with Insertion
• No support system needed
• Dowels or tiebars are inserted after
concrete is placed
• Lower transport cost
• Decreased labor in placement
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… both methods can place dowel bars and tiebars
within typical specifications, though the concrete mixture
characteristics are more important with insertion.
59. Slipform Paver Equipment Setup
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Like extrusion processes but we pull the form.
60. Slipform Mold (Pan) Setup
• Preliminary leveling of paving machine’s frame
and then slipform mold
• Check joints in the pan
• Adjust center to
account for cross slope
• Check alignment
• Adjust edges for
edge slump
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70. Cement
• The “glue” that hold concrete together
• Increase cement content = increase strength,
but:
– Need more air entraining admixture for desired air
– Need more water, resulting in more drying shrinkage
– Increased risk of segregation with more paste
– More bleed water, increasing permeability
– Earlier sawing required
– Stiffer mixture
– Less fatigue capacity
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71. Cementitious Materials Content
• Use least amount of cementitious materials
necessary to meet strength and workability
– Typical minimum is about 500 lb/yd3 (300 kg/m3) for slipform
• Dosage typically reported as cement
replacement:
• SCMs may retard strength gain
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72. Water-Cementitious Mataerial Ratio
• Lower w/cm = higher strength
– Slipform paving - maximum: 0.45; typical = 0.40
– Fixed-form paving/hand pours - max: 0.50; typ = 0.45
• For w/cm below
about 0.40,
autogenous
shrinkage
becomes a
concern
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73. Aggregates
• 60-75% of mixture
• Provide volume stability!
• Coarse to fine ≈ 60/40
• Selection in critical
– All aggregate should be prequalified for durability to freeze-
thaw, ASR, alkali-carbonate, D-cracking
• Coarse agg is major driver in concrete CTE
• Agg hardness impacts sawing operations
• Cleanliness and surface moisture important
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77. Testing –
Temperature
• ASTM C1064
• EASY, just place thermometer in concrete
• Results help verify conformance to
requirements
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78. Testing –
Slump
• ASTM C143 / AASHTO T119
• Measures consistency;
NOT QUALITY!
• Typical values:
– Slipform: 0.5-1.5 in. (13-38 mm)
– Fixed form: 3-4 in. (75-100 mm)
• Slump is dependent on
mixture and also on time
of testing
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79. Testing –
Density (Unit Weight)
• ASTM C138 / AASHTO T121
• Measures known volume
• Typically 130 to 150 lb/ft3 (2,000 – 2,400 kg/m3)
• Indicates batch-to-batch variability
• Reduction in density may indicate:
– Higher air content, higher water content, lower cement content,
change in proportions of ingredients, or change in aggregate
specific gravity or moisture
• One of the most valuable tests for process control
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80. Testing –
Air Content
• ASTM C231 / AASHTO T152
• Target air depends on agg size
• Testing at plant or in front of paver doesn’t
account for air loss of up to 2% in paver
• Quality critical to durability
• AVA and petrography are
other means to measure
• Super Air Meter latest tool!
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Max Agg Size Target Air
3/8 in. (9.5 mm) 7 ½%
½ in. (13 mm) 7%
¾ in. (19 mm) 6%
1 in. (25 mm) 6%
1 ½ in. (38 mm) 5 ½%
81. Testing –
Air Content (continued)
• Affected in the field by:
– Cement
– SCMs
– Chemical admixtures
– Gradation of aggregates
– w/cm ratio
– Temperature
– Delays
– Placement/consolidation
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89. Specifications
• Address concrete materials durability and what
needs to be measured to control critical
elements of construction and design
• All specifications act to assign risk.
– Method specifications assign risk to the owner.
– End result specifications assign risk to the contractor.
• Alternative types of specifications and
contracting methods are being used on an
ever increasing number of projects:
– Performance based specifications, design/build,
warranties and others
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91. Quality Control (QC) versus
Quality Assurance (QA)
• QA is responsibility of
owner – ensure the end
product is of proper
quality and motivates QC
• QC is responsibility of
contractor – makes the
product of proper quality
and motivated by QA
and acceptance
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96. Coordination
• QC plan must be discussed at pre-paving meeting
• Communication between owner, project engineer,
inspector, plant manager, etc. is crucial to project
success!
• Hot/cold weather
contingencies
• Who conducts QA tests?
• Communicate necessary mix
adjustments based on QC
results!!!!!
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97. Test Specimens
• Hardened tests (e.g., strength, hardened air,
etc.) are more susceptible to ambient
conditions and handling than fresh tests (e.g.,
air content, unit weight, etc.)
• Cylinders typically preferred over beams
– Less sensitive to handling and curing of specimen
– Smaller and easier to transport
• Portable containers available to control
both moisture and temp in transport
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