concrete overlay (whitetopping) in md march 18, 2014 office of materials technology – pavement and...

Concrete Overlay (Whitetopping) Concrete Overlay (Whitetopping) in MDin MD

March 18, 2014March 18, 2014

Office of Materials Office of Materials Technology – Technology –

Pavement and Pavement and Geotechnical Geotechnical

Division Division

OverviewOverview• IntroductionIntroduction

• History of Concrete Overlay in MDHistory of Concrete Overlay in MD

• Completed Projects in MDCompleted Projects in MD

• Selection of US 50 at US 301Selection of US 50 at US 301

• Design of US 50 at US 301Design of US 50 at US 301

• Concrete Overlay PicturesConcrete Overlay Pictures

• Lessons Learned Lessons Learned

Overview (Cont.)Overview (Cont.)• Advantages of Concrete OverlayAdvantages of Concrete Overlay

• Current Projects in DesignCurrent Projects in Design

• Future of Concrete Overlay Projects in MDFuture of Concrete Overlay Projects in MD

• Thank YouThank You

• Questions and AnswersQuestions and Answers

IntroductionIntroduction

• Shekhar (Shake-Her) Murkute, PEShekhar (Shake-Her) Murkute, PE

• Joined MD State Highway (MDSHA) as a Team Leader in Joined MD State Highway (MDSHA) as a Team Leader in June 2012June 2012

• Worked in Private Industry for 14 years – 10+ years with Worked in Private Industry for 14 years – 10+ years with MDSHA as a ConsultantMDSHA as a Consultant

• Phone No.: 443-572-5074Phone No.: 443-572-5074

• E-mail: E-mail: [email protected]

mailto:[email protected]

History of Concrete Overlay in MDHistory of Concrete Overlay in MD• Original Concrete Pavement and subsequently overlaid Original Concrete Pavement and subsequently overlaid

with Asphaltwith Asphalt

• Not a Long History of Concrete Overlay until 2006Not a Long History of Concrete Overlay until 2006

• Pilot Project – Anne Arundel County – MD 3 at Cronson Pilot Project – Anne Arundel County – MD 3 at Cronson Boulevard – 2006Boulevard – 2006

Completed Projects in MDCompleted Projects in MD• MD 3 at Cronson Boulevard – 2006 (Grind 6” HMA and 6” Concrete Overlay)MD 3 at Cronson Boulevard – 2006 (Grind 6” HMA and 6” Concrete Overlay)

• Benfield Boulevard Park and Ride Lot – 2010 (Grind 3” HMA and 3” Concrete Benfield Boulevard Park and Ride Lot – 2010 (Grind 3” HMA and 3” Concrete Overlay)Overlay)

• US 40 near MD Portable Mix Concrete Plant – 2011 (Grind 6” HMA and 6” US 40 near MD Portable Mix Concrete Plant – 2011 (Grind 6” HMA and 6” Concrete Overlay)Concrete Overlay)

• MD 355 at MD 27 – 2012 (Grind 6” HMA and 6” Concrete Overlay)MD 355 at MD 27 – 2012 (Grind 6” HMA and 6” Concrete Overlay)

Selection of US 50 at US 301Selection of US 50 at US 301

• Input from the District and Shop – Urban Area CandidatesInput from the District and Shop – Urban Area Candidates

• Site Visit – MDSHA and ACPASite Visit – MDSHA and ACPA

Selection of US 50 at US 301Selection of US 50 at US 301• Rating Criteria:Rating Criteria:

– Traffic Volume including Truck PercentageTraffic Volume including Truck Percentage

– Urban or Rural AreaUrban or Rural Area

– Recurring Rutting/Shoving IssuesRecurring Rutting/Shoving Issues

– Availability of nearby Roads for DetourAvailability of nearby Roads for Detour

– Existing Pavement StructureExisting Pavement Structure

• Two Top Priority Projects were Selected. First One for Design and Second One as a BackupTwo Top Priority Projects were Selected. First One for Design and Second One as a Backup

• Longer Sections instead of only IntersectionsLonger Sections instead of only Intersections

Time to wake up!Time to wake up!

ImportantImportant

Stuff….Stuff….

Design for US 50 at US 301Design for US 50 at US 301• Coring or BoringCoring or Boring

– Cores in Mainline and ShoulderCores in Mainline and Shoulder– The Most Important Step before DesignThe Most Important Step before Design

• US 50 Ramps – Existing Pavement Structure US 50 Ramps – Existing Pavement Structure – Mainline – 10” To 13” HMA over 4” Stone BaseMainline – 10” To 13” HMA over 4” Stone Base– Shoulder – 7” To 12” HMA over 4” Stone BaseShoulder – 7” To 12” HMA over 4” Stone Base

• US 301 Ramps – Existing Pavement Structure US 301 Ramps – Existing Pavement Structure – Mainline – 10” To 13” HMA over 4” Stone BaseMainline – 10” To 13” HMA over 4” Stone Base– Shoulder – 7” To 12” HMA over 4” Stone BaseShoulder – 7” To 12” HMA over 4” Stone Base

Design for US 50 at US 301 (Cont.)Design for US 50 at US 301 (Cont.)• RestrictionsRestrictions

– No Increase in Roadway Grade No Increase in Roadway Grade

• Software Software

– Illinois DOT Illinois DOT

– From ACPA WebsiteFrom ACPA Website

– AASHTO 1993 (Not Reliable)AASHTO 1993 (Not Reliable)

– MEPDG (Do Not have Module for 6” Concrete Overlay)MEPDG (Do Not have Module for 6” Concrete Overlay)

– For Future – University of Pittsburgh – BCOA-MEFor Future – University of Pittsburgh – BCOA-ME

Design for US 50 at US 301 (Cont.)Design for US 50 at US 301 (Cont.)

• Design InputsDesign Inputs

– Traffic Data including Truck PercentageTraffic Data including Truck Percentage

– Existing Pavement StructureExisting Pavement Structure

– Resilient Modulus of the SubgradeResilient Modulus of the Subgrade

– Pavement Modulus of the Remaining Existing Pavement after MillingPavement Modulus of the Remaining Existing Pavement after Milling

– Milling Thickness (6”)Milling Thickness (6”)


• Design OutputDesign Output

– Thickness of Concrete OverlayThickness of Concrete Overlay

– 6” Concrete Overlay6” Concrete Overlay

– Typical 6’ X 6’ Joint Spacing Slabs without Dowel Bars Typical 6’ X 6’ Joint Spacing Slabs without Dowel Bars and with Saw Cutsand with Saw Cuts


• Mix DesignMix Design

– Special Concrete MixSpecial Concrete Mix

– Developed Special Provision for the Special Concrete MixDeveloped Special Provision for the Special Concrete Mix

– Fast Setting Concrete Mix with Admixtures And Macrofibers Fast Setting Concrete Mix with Admixtures And Macrofibers

– 2500 Psi In 24 Hours2500 Psi In 24 Hours


• MOTMOT

– Two Weekends for Each RampTwo Weekends for Each Ramp

– MD 197 used for the DetourMD 197 used for the Detour

– MOT Plans – Included in IFBMOT Plans – Included in IFB

• OtherOther

– Diamond Grinding to Provide Smooth Surface and Improve Friction Diamond Grinding to Provide Smooth Surface and Improve Friction

Concrete Overlay PicturesConcrete Overlay Pictures

Project LimitsProject Limits

US 50US 50

US 301US 301


Project DetourProject Detour

PROJECT SITE

MD 197


Existing Roadway before MillingExisting Roadway before Milling


Milled RoadwayMilled Roadway


Pre-wetting the Surface for Good Bond Pre-wetting the Surface for Good Bond


Concrete Pouring OperationConcrete Pouring Operation


Concrete Pouring and Finishing Concrete Pouring and Finishing


Saw Cutting OperationSaw Cutting Operation


Concrete Overlay with 6’ X 6’ SlabsConcrete Overlay with 6’ X 6’ Slabs


Diamond GrindingDiamond Grinding


Close-up of Diamond GrindingClose-up of Diamond Grinding

Lessons LearnedLessons Learned

• Large Number of Cores – Mainline and ShoulderLarge Number of Cores – Mainline and Shoulder

• Include Joint Layout in the Contract DocumentInclude Joint Layout in the Contract Document

• Detour or MOT Plans during the Planning/Design StageDetour or MOT Plans during the Planning/Design Stage

• Potential/Future Utilities within the Project LimitsPotential/Future Utilities within the Project Limits

Advantages of Concrete OverlayAdvantages of Concrete Overlay

• Greater Design Life (15 – 25 Years)Greater Design Life (15 – 25 Years)

• Additional Structural Strength without Increasing the GradeAdditional Structural Strength without Increasing the Grade

• For the Same Thickness, Concrete Overlay adds More Structural Strength as For the Same Thickness, Concrete Overlay adds More Structural Strength as Compared to the HMA OverlayCompared to the HMA Overlay

• Rutting/Shoving can be Eliminated Rutting/Shoving can be Eliminated

Advantages of Concrete OverlayAdvantages of Concrete Overlay

• Less Rehab or MOT Occurrences over the Design Life Less Rehab or MOT Occurrences over the Design Life

• Reduces MOT Cost and Inconvenience to the Commuters Reduces MOT Cost and Inconvenience to the Commuters over the Design Lifeover the Design Life

Current Projects in Design/ConstructionCurrent Projects in Design/Construction

• MD 2 at MD 214 – Anne Arundel County MD 2 at MD 214 – Anne Arundel County

• MD 182 Bus Pads – Montgomery CountyMD 182 Bus Pads – Montgomery County

• I-68 Truck Climbing Lanes – Allegany CountyI-68 Truck Climbing Lanes – Allegany County

Future of Concrete Overlay Future of Concrete Overlay Projects in MDProjects in MD

““Future is Bright”Future is Bright”

• MD 210 – Prince George’s CountyMD 210 – Prince George’s County

• Bus Stop Pads for HMA Pavement – StatewideBus Stop Pads for HMA Pavement – Statewide

Thank You Thank You

• Everybody who helped us make this Project a Great Everybody who helped us make this Project a Great SuccessSuccess

Questions and AnswersQuestions and Answers

concrete overlay (whitetopping) in md march 18, 2014 office of materials technology – pavement and...

Documents

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md history of concrete

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