1. Concrete Overlay (Whitetopping) in MD
Office of Materials Technology – Pavement and Geotechnical Division
March 18, 2014

2. Overview Introduction History of Concrete Overlay in MD
Completed Projects in MD
Selection of US 50 at US 301
Design of US 50 at US 301
Concrete Overlay Pictures
Lessons Learned
Overview of the Presentation. Informal presentation. Please feel free to ask any questions during or after the presentation. No fancy things..no letters or words coming from each corner of the screen to form a sentence. So you can look at the center and do not have to follow the flying letter to guess what the next sentence will be..it is less stressful that way..

3. Overview (Cont.) Advantages of Concrete Overlay
Current Projects in Design
Future of Concrete Overlay Projects in MD
Thank You
Questions and Answers
Overview of the Presentation. Informal presentation. Please feel free to ask any questions during or after the presentation. No fancy things..no letters or words coming from each corner of the screen to form a sentence. So you can look at the center and do not have to follow the flying letter to guess what the next sentence will be..it is less stressful that way..

4. Introduction Shekhar (Shake-Her) Murkute, PE
Joined MD State Highway (MDSHA) as a Team Leader in June 2012
Worked in Private Industry for 14 years – 10+ years with MDSHA as a Consultant
Phone No.:
Introduce yourself

5. History of Concrete Overlay in MD
Original Concrete Pavement and subsequently overlaid with Asphalt
Not a Long History of Concrete Overlay until 2006
Pilot Project – Anne Arundel County – MD 3 at Cronson Boulevard – 2006

6. Completed Projects in MD
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 Overlay)
US 40 near MD Portable Mix Concrete Plant – 2011 (Grind 6” HMA and 6” Concrete Overlay)
MD 355 at MD 27 – 2012 (Grind 6” HMA and 6” Concrete Overlay)

7. Selection of US 50 at US 301
Input from the District and Shop – Urban Area Candidates
Site Visit – MDSHA and ACPA

8. Selection of US 50 at US 301 Rating Criteria:
Traffic Volume including Truck Percentage
Urban or Rural Area
Recurring Rutting/Shoving Issues
Availability of nearby Roads for Detour
Existing Pavement Structure
Two Top Priority Projects were Selected. First One for Design and Second One as a Backup
Longer Sections instead of only Intersections

9. Important Stuff…. Time to wake up!
OK! It’s time to wake up. Let’s talk about the important stuff……

10. Design for US 50 at US 301 Coring or Boring
Cores in Mainline and Shoulder
The Most Important Step before Design
US 50 Ramps – Existing Pavement Structure
Mainline – 10” To 13” HMA over 4” Stone Base
Shoulder – 7” To 12” HMA over 4” Stone Base
US 301 Ramps – Existing Pavement Structure

11. Design for US 50 at US 301 (Cont.)
Restrictions
No Increase in Roadway Grade
Software
Illinois DOT
From ACPA Website
AASHTO 1993 (Not Reliable)
MEPDG (Do Not have Module for 6” Concrete Overlay)
For Future – University of Pittsburgh – BCOA-ME

12. Design for US 50 at US 301 (Cont.)
Design Inputs
Traffic Data including Truck Percentage
Existing Pavement Structure
Resilient Modulus of the Subgrade
Pavement Modulus of the Remaining Existing Pavement after Milling
Milling Thickness (6”)

13. Design for US 50 at US 301 (Cont.)
Design Output
Thickness of Concrete Overlay
6” Concrete Overlay
Typical 6’ X 6’ Joint Spacing Slabs without Dowel Bars and with Saw Cuts

14. Design for US 50 at US 301 (Cont.)
Mix Design
Special Concrete Mix
Developed Special Provision for the Special Concrete Mix
Fast Setting Concrete Mix with Admixtures And Macrofibers
2500 Psi In 24 Hours

15. Design for US 50 at US 301 (Cont.)
MOT
Two Weekends for Each Ramp
MD 197 used for the Detour
MOT Plans – Included in IFB
Other
Diamond Grinding to Provide Smooth Surface and Improve Friction

16. Concrete Overlay Pictures
US 301
US 50
Project Limits

17. Concrete Overlay Pictures
PROJECT SITE
MD 197
Project Detour

18. Concrete Overlay Pictures
Existing Roadway before Milling

19. Concrete Overlay Pictures
Existing Roadway before Milling

20. Concrete Overlay Pictures
Existing Roadway before Milling

21. Concrete Overlay Pictures
Existing Roadway before Milling

22. Concrete Overlay Pictures
Existing Roadway before Milling

23. Concrete Overlay Pictures
Milled Roadway

24. Concrete Overlay Pictures
Milled Roadway

25. Concrete Overlay Pictures
Pre-wetting the Surface for Good Bond

26. Concrete Overlay Pictures
Concrete Pouring Operation

27. Concrete Overlay Pictures
Concrete Pouring Operation

28. Concrete Overlay Pictures
Concrete Pouring and Finishing

29. Concrete Overlay Pictures
Saw Cutting Operation

30. Concrete Overlay Pictures
Saw Cutting Operation

31. Concrete Overlay Pictures
Concrete Overlay with 6’ X 6’ Slabs

32. Concrete Overlay Pictures
Concrete Overlay with 6’ X 6’ Slabs

33. Concrete Overlay Pictures
Concrete Overlay with 6’ X 6’ Slabs 33

34. Concrete Overlay Pictures
Concrete Overlay with 6’ X 6’ Slabs 34

35. Concrete Overlay Pictures
Diamond Grinding

36. Concrete Overlay Pictures
Diamond Grinding

37. Concrete Overlay Pictures
Diamond Grinding

38. Concrete Overlay Pictures
Close-up of Diamond Grinding

39. Lessons Learned Large Number of Cores – Mainline and Shoulder
Include Joint Layout in the Contract Document
Detour or MOT Plans during the Planning/Design Stage
Potential/Future Utilities within the Project Limits

40. Advantages of Concrete Overlay
Greater Design Life (15 – 25 Years)
Additional Structural Strength without Increasing the Grade
For the Same Thickness, Concrete Overlay adds More Structural Strength as Compared to the HMA Overlay
Rutting/Shoving can be Eliminated

41. Advantages of Concrete Overlay
Less Rehab or MOT Occurrences over the Design Life
Reduces MOT Cost and Inconvenience to the Commuters over the Design Life

42. Current Projects in Design/Construction
MD 2 at MD 214 – Anne Arundel County
MD 182 Bus Pads – Montgomery County
I-68 Truck Climbing Lanes – Allegany County

43. Future of Concrete Overlay Projects in MD
“Future is Bright”
MD 210 – Prince George’s County
Bus Stop Pads for HMA Pavement – Statewide

44. Thank You Everybody who helped us make this Project a Great Success
Overview of the Presentation. Informal presentation. Please feel free to ask any questions during or after the presentation. No fancy things..no letters or words coming from each corner of the screen to form a sentence. So you can look at the center and do not have to follow the flying letter to guess what the next sentence will be..it is less stressful that way..

45. Questions and Answers