1. Jerry L. Larson IRMCA Indiana LTAP Basics of a Good Road
Concrete Pavement:
Selection of Concrete Materials
Jerry L. Larson
IRMCA
Indiana LTAP
Basics of a Good Road
INDIANA CHAPTER

2. Basic Components of a Concrete Pavement
Surface smoothness or rideability
Thickness Design
Longitudinal joint
Transverse joint
Surface Texture
Concrete materials
Dowel bars
Tiebars
Subgrade
Base

3. How Pavements Carry Loads
6600 LBS.
6600 LBS.
Flexible Pavement
pressure < 0.2 MPa
pressure » 2.0 MPa
Concrete’s rigid panels spread the load over a large area
reducing pressure on the sub grade.

4. Conventional Concrete Pavement Types
Full Depth
New Construction
Reconstruction
Overlays
Thin Overlays

5. Concrete Design “Optimize”
Cost
Performance

6. Subbase vs. NO Subbase Heavy Traffic?? > 120 Trucks/day = subbase
Fine grain soils prone to erosion
Presence of moisture/water
Potential pumping
Presence of all or most above conditions suggests need for subbase

7. Successful Concrete Pavement Design Requires Selecting Appropriate Features
Subgrade modification
Drainage system
Subbase
Joint Spacing
18 ft
15 ft
Dowels
Thickness
8 in
10 in
12 in
Reinforcement
Joint Sealant
None
Hot pour
Silicone
Preformed
Surface Texture
Transverse tine
Burlap drag
Shoulder
Asphalt
Concrete

8. Maximum top size coarse aggregate 0.75 - 1.0 in.
Concrete Mix Design
INDOT
Class C
Fast Track
INDOT
Class A
Material
(per cubic yard)
Cement (Type I)
564 lbs.
Cement (Type III)
708 lbs.
(658 lbs.)
Fly Ash
(50 lbs.)
Coarse Aggregate *
1750 lbs.
1425 lbs.
Fine Aggregate
1250 lbs.
1350 lbs.
Mix designs very greatly between various parts of the country. However the primary differences between a standard pavement design and a high early or fast track mix design is generally the amount of cement used and the admixture dosages and combinations. Often an accelerating admixture in added at the plant to increase the heat of hydration thereby increase the concrete set times and allow for quicker opening to traffic. If a type III cement is available they are used as well.
Water:Cement Ratio
0.45 max.
0.42
Water Reducer
yes
yes
Air Entrainer **
yes
yes *
Maximum top size coarse aggregate in. **
Air content 6% + 1.5%

9. Durability = Performance
Quality Materials
Aggregate – AP Approved, uniform gradation
Minimum Cement Content
Approved Admixtures
Proper Mix Design – Control to Design
Moisture/Water Control
Air Entrainment – 6% + 1.5%
Proper Curing – Liquid membrane manufacturer’s suggested rate

10. Panel Design
Plan
12 – 20 FT
Profile or

11. Jointing Spacing based on thickness > 12” thick - saw 1/3 the depth
6” thick – 12’ joint spacing
> 12” thick – 18’ joint spacing
> 12” thick - saw 1/3 the depth
If not specifying dowels – can skew joints 1’ in 12’ across pavement
High volume traffic – seal joints with silicone or neoprene
Low volume traffic – seal joints with hot pour rubberized asphalt

12. Dowels or NO Dowels
The slabs ability to share its load with its neighboring slab
Dowels
High Traffic Volumes
(Pavements > 8 in.)
Aggregate Interlock
Low Traffic Volumes
(Pavements < 7 in.) L
= x U
= 0
Poor Load Transfer
Good Load Transfer L
= x U

13. Surface Texture
Tineing

14. Surface Texture
Light Broom

15. Surface Texture
Drag Finish

16. Construction - Reconstruction

17. Construction - Reconstruction

18. Overlays Expected Performance Condition of existing sub-grade/pavement
UTW (2” – 4”) – 15 to 20 years
Thicker overlays (4” – 6”) 20 to 25 years
Condition of existing sub-grade/pavement
Clearance issues – if none, can build on top of old PCCP or HMA pavement

19. Concrete Resurfacing Applications
Concrete overlays for concrete pavements:
Bonded Concrete Overlays
Unbonded Concrete Overlays
Concrete overlays for asphalt pavements:
Conventional Whitetopping
Ultra-Thin Whitetopping

20. Unbonded Overlay
Consists of thick concrete layer (4” or greater) on top of existing concrete pavement.
Uses a “separation interlayer” to separate new overlay and existing concrete. . . . . . .. . . .. .

21. Unbonded Overlays Separation Interlayer: “Key” Overlay Old Pavement
Smooth Slip Plane
Interlayer (1 in)

22. I-69 UNBONDED PCC OVERLAY
PCCP over old Concrete Pavement

23. Conventional Whitetopping
Consists of thick concrete layer (4 in or greater) on top of an existing asphalt pavement.
Behaves as a new pavement on a strong base.

24. Typical Whitetopping Thickness
Depends on expected traffic load.
City streets, county roads, and small airports
4 to 7 in.
Primary roads and interstate highways
7 to 11 in.
Large airports
8 to 18 in.

25. Harding Street - Indianapolis
Built in 1985
6” Overlay on old HMA pavement
8” thick on stone where widened
Skewed Joints

26. PCCP over old Chip & seal road
121st St., Fishers

27. PCCP over 2 lane HMA street
Allisonville Road
PCCP over 2 lane HMA street

28. Allisonville Road Cross Section

29. UTW Schematic Thin Slabs (2 to 4 inches) Short Square Slabs
Existing HMA Pavement
Short Square Slabs
(2 to 6 ft.)
Milled Surface
As we saw in the introductory session, this is a schematic of the UTW application. The existing HMA pavement is milled to enhance bond.

30. Market & Columbia Streets - Warsaw
3.5” PCCP over HMA, Gravel, & Brick

31. Demonstration in 2002
Typical mill and fill job in older cities…you never know just what you're going to find under the surface.

32. Photo by Indiana Public Works.com Magazine

33. Joints were established at 5’ intervals based on slab thickness

34. Warsaw Whitetop
July 2005
October 2002

35. Concrete Roads and Streets

37. Concrete Intersections & Roundabouts
US 31 & SR 32
US 6 & US 421
Gray Rd. & 96th St.
Pontiac Ave. & Wayne Trace, Ft. Wayne
96th St. approaching Keystone Ave.

38. Pervious Concrete

39. Summary KNOW YOUR OPTIONS

40. Indiana Ready Mixed Concrete Association
Questions?
Contact:
Jerry L. Larson
(317)
Indiana Ready Mixed Concrete Association
(317)
INDIANA CHAPTER