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

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Presentation on theme: "Concrete Overlay (Whitetopping) in MD March 18, 2014 Office of Materials Technology – Pavement and Geotechnical Division."— Presentation transcript:

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

2 Overview Introduction Introduction History of Concrete Overlay in MD History of Concrete Overlay in MD Completed Projects in MD Completed Projects in MD Selection of US 50 at US 301 Selection of US 50 at US 301 Design of US 50 at US 301 Design of US 50 at US 301 Concrete Overlay Pictures Concrete Overlay Pictures Lessons Learned Lessons Learned

3 Overview (Cont.) Advantages of Concrete Overlay Advantages of Concrete Overlay Current Projects in Design Current Projects in Design Future of Concrete Overlay Projects in MD Future of Concrete Overlay Projects in MD Thank You Thank You Questions and Answers Questions and Answers

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

5 History of Concrete Overlay in MD Original Concrete Pavement and subsequently overlaid with Asphalt Original Concrete Pavement and subsequently overlaid with Asphalt Not a Long History of Concrete Overlay until 2006 Not a Long History of Concrete Overlay until 2006 Pilot Project – Anne Arundel County – MD 3 at Cronson Boulevard – 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) 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) 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) 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) 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 Input from the District and Shop – Urban Area Candidates Site Visit – MDSHA and ACPA Site Visit – MDSHA and ACPA

8 Selection of US 50 at US 301 Rating Criteria: 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 Two Top Priority Projects were Selected. First One for Design and Second One as a Backup Longer Sections instead of only Intersections Longer Sections instead of only Intersections

9 Time to wake up! ImportantStuff….

10 Design for US 50 at US 301 Coring or Boring Coring or Boring – Cores in Mainline and Shoulder – The 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 Base – Shoulder – 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 Base – Shoulder – 7” To 12” HMA over 4” Stone Base

11 Design for US 50 at US 301 (Cont.) Restrictions Restrictions – No Increase in Roadway Grade Software 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 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 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 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 MOT – Two Weekends for Each Ramp – MD 197 used for the Detour – MOT Plans – Included in IFB Other Other – Diamond Grinding to Provide Smooth Surface and Improve Friction

16 Concrete Overlay Pictures Project Limits US 50 US 301

17 Concrete Overlay Pictures Project Detour PROJECT SITE MD 197

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

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

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

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

41 Advantages 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 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 2 at MD 214 – Anne Arundel County MD 182 Bus Pads – Montgomery County MD 182 Bus Pads – Montgomery County I-68 Truck Climbing Lanes – Allegany 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 MD 210 – Prince George’s County Bus Stop Pads for HMA Pavement – Statewide Bus Stop Pads for HMA Pavement – Statewide

44 Thank You Everybody who helped us make this Project a Great Success Everybody who helped us make this Project a Great Success

45 Questions and Answers


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