Ornulv (Arnie) Sonsteby, PE Penn State / FAA Airport Conference 2007 INSTALLATION OF IN-PAVEMENT LIGHTS IN CONCRETE PAVEMENT & IMPACT ON LIGHT PHOTOMETRICS Ornulv (Arnie) Sonsteby, PE & Doron Lean Penn State / FAA Airport Conference 2007

IPRF-03-1 Project Best Practices Guide for In-Pavement Lighting, PCC Pavement Estimated Completion: 2007 PI & Contact: Ornulv (Arnie) Sonsteby, P.E. email: osonsteby@burns-group.com Sponsored by: FAA, in Cooperative Agreement with Innovative Pavement Research Foundation (IPRF)

GUIDE CONTENT Coordination between disciplines Installation in new vs. existing PCC Products, methods, tolerances Boxouts / blockouts Deficiencies and corrective alternatives Strength and load transfer

Preparing Light Base & Jig

Light Base Installation “Anchor” function (preparation for paving) (b) “Strengthening” function (completed installation)

INSTALLATION ISSUES Coordination between disciplines Selecting: Methods & procedures lighting products Pavement materials Tolerances & verification

CCOORDINATION IN DESIGN Light location vs. pavement joints Materials and method QC/QA Tolerances and Consequences

PCC JOINT CONFLICTS Touch Down Zone Lights Lead-off / Lead-on TW CTL Lights TW CTL Lights at curves / intersections In-pavement RGL / Stop Bar Lights

MATERIALS & METHODS Light Base, Conduit, Pavement materials Installation procedures and “structure” -- in new or existing pavement Surface finish (“cookie cutter” vs. Core)

QC / QA The quality of installation depends on: Good design by engineer Good craftsmanship by installer Close coordination between disciplines Inspection / verification of compliance

Tolerances and Consequences Pavement vs. Base tolerances Light Base: Location, Height, Azimuth, Level When to modify, when to replace

** Paving elevation tolerance -- + ½” Light Tolerances Location: Per AC. Depends on type and function of light. Height: Fixture edge even with pavement, (low side): +0”, -1/16. Azimuth: Within ± ½ degree. Level: With horizon. No tolerance specified. ** Paving elevation tolerance -- + ½”

Level Tolerance? Pavement has longitudinal grade & cross slope (up to 1.5% major R/Ws) No tolerance in AC. Engineer may establish tolerance (varies) Tolerance applied in wrong direction worsens condition Consider 

Level !! TRANSVERSE SLOPE LONGITUDINAL GRADE Ht D Ht D Deg Grade for 12” for 6” Ht D Ht D 1/2 0.9% 0.1” 0.05” 1 1.75% 0.2” 0.1” O LONGITUDINAL GRADE

COORDINATION IN CONSTRUCTION Survey Materials and method QC/QA Tolerances and Consequences

Survey Coordinate survey activities Survey to: Locate light Install light base Verify before paving

Selecting Materials & Methods Submittals review for compliance Establish installation sequence and responsibilities Inspection --- more inspection Protect lights while completing paving

Conduit in pavement base layer Setting base “in space” Light base Conduit in pavement base layer Setting base “in space”

Setting bases in “fill-in” lane

RW Edge Light, Toe-In Installation in existing PCC Pavement

QC / QA Verify light location Verify height, azimuth & level while securing light base Check tolerances prior to paving Inspect surface finish Protect light while paving, grooving, sweeping, and marking

2’ from Joint Issue AC 150/5340-30 Modeling: (by Tigerbrain) R/W CTL: “The line of lights is offset a maximum of 2’ from the runway centerline to the edge of fixture.” T/W CTL: “Fixtures should be installed so that their nearest edge is approximately 2’ from any rigid pavement joint.” Modeling: (by Tigerbrain)

σ - bottom of 18” thick 20’x20’ slab B-777 (254K edge loading).

σ - top of 18” thick 20’x20’ slab B-727 (corner loading).

Joint Issue Comments Pavement Design is conservative (edge stress, no load transfer). Modeling (with no load transfer between slabs, no bonding to underlying layer): Dowels generally reduced max edge stress by ~ 20%. With 2 dowels omitted, max edge stress reduced by ~ 12%.

(Joint Issue Comments continued) Hence: Inside 2’, with 1 or 2 dowels omitted has minimal impact on slab-slab load transfer. Load transfer between light base and pavement – assessment suggests non-issue. Embedded steel can help control cracking close to joint. Alternative: Boxout

PCC Joints Light base 18” 7” Light near PCC joint

Details, details !! PCC Joint Cracks In-Pavement Light Conduit Kerf

T/W CTL Light Boxout at PCC joint

Normal joints Crack Doweled joint for Boxout Boxout at PCC joints !

Threshold Light Bar “boxout”

A few Related concerns

for full section of kerf ! KERFS PCC Joint Maintain existing pavement joints - for full section of kerf !

Conduit below !! Longitudinal crack center T/W slab T/W Centerline Light

Faulty sealing

Fate of out-of-tolerance light bases!

Doron