Lessons Learned on Concrete Pavement Patching

Virginia Concrete ConferenceMarch 9, 2012

Thomas R. Tate, P.E.

Senior Pavement Engineer

Hampton Roads District Materials

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Project Development

• Determine needed patch types• How to set patch limits• Establish accurate(?) quantities• Include patch locations• Traffic control, lane closure considerations (MOT)

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Project Development

In the beginning:• Identify (see) need• Identify project limits• Pavement evaluation• Scoping meeting• Develop contract

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Project Development

Identify (See) Need• Low pavement rating (low CCI)• Rough pavement• Failing joint sealant• Visible distresses• Poor maintenance history• Customer complaints

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Project Development

Identify Project Limits• Original construction project limits• Change in pavement type• Change in pavement width• Limit by physical boundaries• Set limits by funding

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Project Development

Pavement Evaluation, Why?• Determine existing pavement thicknesses (mainline,

shoulders, concrete thickness/type, base thickness/type, subgrade condition, etc.)

• Determine cause of observed distresses• Determine structural capacity of existing pavement

layers• Condition of bases• Condition of subgrade• Material reactions?• Drainage issues?

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Project Development

Scoping Meeting

Bring all stake holders together• Funding (Maintenance or Construction)• Materials• Design• Construction• Traffic Engineering• Structure & Bridge• Operations• Others

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Project Development

Develop Contract• Determine needed patch types• How to set patch limits• Establish accurate(?) quantities• Include patch locations• Traffic control, lane closure considerations (MOT)

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Project Development

Determine Needed Patch Types

Patch Type JCP CRCP

Type I X

Type II X

Type III X

Type IV X

Anchor Slab X

Approach Slab X X

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Project Development

Patch Limits

Jointed Concrete Pavement (JCP) Types I & II• Minimum 6 ft long• Full lane width (12 ft)• Minimum 1 ft past/beyond distress (failed joint, pot

hole, failed crack, etc.)• Minimum 1 ft past/off existing joint• Minimum 10 ft between patches

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Project Development

Patch Limits

Continuously Reinforced Concrete Pavement (CRCP) Type IV

• Minimum 6 ft long• Full lane width (12 ft)• Minimum 1 ft past/beyond distress (punch out,

asphalt patch, cluster cracks, Y-cracks, etc.)• Minimum 1 ft past/off existing transverse crack• Minimum 10 ft between patches• Headers?

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Project Development

Accurate Quantities• Patching• Joint Sealing• Crack Sealing• Slab Jacking• Shoulder Rehab• Traffic Items (Guardrail, Pavement Markings, etc.)

Know Limits of Work!!!!

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Project Development

Accurate Quantities

Patching – Estimating Quantities• Shoulder survey (walk or in vehicle)• Video survey• Sample survey• Others?

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Project Development

Severity level 2 cluster cracking – patch.

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Project Development

Severity level 1 cluster cracking

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Project Development

Accurate Quantities

Patching• Work will be done one or more years after estimated• What is purpose of patching?• Will the concrete pavement be left exposed or will it

be overlaid?• Expect quantities to increase from time of estimate

until pavement is actually patched (how many more winters will pavement go through?)

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Project Development

Patch Locations• Near other patches• Near bridges or overpasses• Near or within interchanges• At pavement changes

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Project Development

Traffic Control/Lane Closure Considerations• Limitations of Operations (LOO)• Will a waiver of standard LOO be needed• Is there other work going on or planned in general

vicinity of project?• Operations (Tunnels, Bridges, TOC)

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Project Development

Special Provisions or Copied Notes for:• Concrete Patching• Concrete Grinding• Re-Sealing Joints• Sealing Joints or Cracks• Rideability• Asphalt Work• XJ-1 Joints

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Project Development

Questions?