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

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..

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..

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.: 443-572-5074 E-mail: SMURKUTE@SHA.STATE.MD.US Introduce yourself

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

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)

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

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

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

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

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

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”)

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

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

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

Concrete Overlay Pictures US 301 US 50 Project Limits

Concrete Overlay Pictures PROJECT SITE MD 197 Project Detour

Concrete Overlay Pictures Existing Roadway before Milling

Concrete Overlay Pictures Existing Roadway before Milling

Concrete Overlay Pictures Existing Roadway before Milling

Concrete Overlay Pictures Existing Roadway before Milling

Concrete Overlay Pictures Existing Roadway before Milling

Concrete Overlay Pictures Milled Roadway

Concrete Overlay Pictures Milled Roadway

Concrete Overlay Pictures Pre-wetting the Surface for Good Bond

Concrete Overlay Pictures Concrete Pouring Operation

Concrete Overlay Pictures Concrete Pouring Operation

Concrete Overlay Pictures Concrete Pouring and Finishing

Concrete Overlay Pictures Saw Cutting Operation

Concrete Overlay Pictures Saw Cutting Operation

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

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

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 Diamond Grinding

Concrete Overlay Pictures Diamond Grinding

Concrete Overlay Pictures Diamond Grinding

Concrete Overlay Pictures Close-up of Diamond Grinding

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

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

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

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

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

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..

Questions and Answers