Precast Concrete Pavement Technology (2012)

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TRANSPORTATION RESEARCH BOARD WASHINGTON, D.C. 2013 www.TRB.org RepoRt S2-R05-RR-1 The Second S T R A T E G I C H I G H W A Y R E S E A R C H P R O G R A M Precast Concrete Pavement Technology Shiraz Tayabji and dan ye Fugro Consultants, Inc. Columbia, Maryland neeraj buch Michigan State University East Lansing, Michigan

Subscriber Categories Construction Highways Pavements

SHRP 2 Reports Available by subscription and through the TRB online bookstore: www.TRB.org/bookstore Contact the TRB Business Office: 202-334-3213 More information about SHRP 2: www.TRB.org/SHRP2 SHRP 2 Report S2-R05-RR-1 ISBN: 978-0-309-12944-2 Library of Congress Control Number: 2013935791 © 2013 National Academy of Sciences. All rights reserved. Copyright Information Authors herein are responsible for the authenticity of their materials and for obtaining written permissions from publishers or persons who own the copy- right to any previously published or copyrighted material used herein. The second Strategic Highway Research Program grants permission to repro- duce material in this publication for classroom and not-for-profit purposes. Permission is given with the understanding that none of the material will be used to imply TRB, AASHTO, or FHWA endorsement of a particular prod- uct, method, or practice. It is expected that those reproducing material in this document for educational and not-for-profit purposes will give appropriate acknowledgment of the source of any reprinted or reproduced material. For other uses of the material, request permission from SHRP 2. Note: SHRP 2 report numbers convey the program, focus area, project number, and publication format. Report numbers ending in “w” are published as web documents only. Notice The project that is the subject of this report was a part of the second Strategic Highway Research Program, conducted by the Transportation Research Board with the approval of the Governing Board of the National Research Council. The members of the technical committee selected to monitor this project and to review this report were chosen for their special competencies and with regard for appropriate balance. The report was reviewed by the technical committee and accepted for publication according to procedures established and overseen by the Transportation Research Board and approved by the Governing Board of the National Research Council. The opinions and conclusions expressed or implied in this report are those of the researchers who performed the research and are not necessarily those of the Transportation Research Board, the National Research Council, or the program sponsors. The Transportation Research Board of the National Academies, the National Research Council, and the sponsors of the second Strategic Highway Research Program do not endorse products or manufacturers. Trade or manufacturers’ names appear herein solely because they are considered essential to the object of the report. The Second Strategic Highway Research Program America’s highway system is critical to meeting the mobility and economic needs of local communities, regions, and the nation. Developments in research and technology—such as advanced materials, communications technology, new data collection tech- nologies, and human factors science—offer a new opportunity to improve the safety and reliability of this important national resource. Breakthrough resolution of significant transportation problems, however, requires concentrated resources over a short time frame. Reflecting this need, the second Strategic Highway Research Program (SHRP 2) has an intense, large-scale focus, integrates multiple fields of research and technology, and is fundamentally different from the broad, mission-oriented, discipline-based research programs that have been the mainstay of the highway research industry for half a century. The need for SHRP 2 was identified in TRB Special Report 260: Strategic Highway Research: Saving Lives, Reducing Congestion, Improving Quality of Life, published in 2001 and based on a study sponsored by Congress through the Transportation Equity Act for the 21st Century (TEA-21). SHRP 2, modeled after the first Strategic Highway Research Program, is a focused, time- constrained, management-driven program designed to com- plement existing highway research programs. SHRP 2 focuses on applied research in four areas: Safety, to prevent or reduce the severity of highway crashes by understanding driver behavior; Renewal, to address the aging infrastructure through rapid design and construction methods that cause minimal disruptions and produce lasting facilities; Reliability, to reduce congestion through incident reduction, management, response, and mitigation; and Capacity, to integrate mobility, economic, environmental, and community needs in the planning and designing of new trans- portation capacity. SHRP 2 was authorized in August 2005 as part of the Safe, Accountable, Flexible, Efficient Transportation Equity Act: A Legacy for Users (SAFETEA-LU). The program is managed by the Transportation Research Board (TRB) on behalf of the National Research Council (NRC). SHRP 2 is conducted under a memo- randum of understanding among the American Association of State Highway and Transportation Officials (AASHTO), the Federal Highway Administration (FHWA), and the National Academy of Sciences, parent organization of TRB and NRC. The program provides for competitive, merit-based selection of research contractors; independent research project oversight; and dissemination of research results.

The National Academy of Sciences is a private, nonprofit, self-perpetuating society of distinguished scholars engaged in scientific and engineering research, dedicated to the furtherance of science and technology and to their use for the general welfare. On the authority of the charter granted to it by Congress in 1863, the Academy has a mandate that requires it to advise the federal government on scientific and technical matters. Dr. Ralph J. Cicerone is president of the National Academy of Sciences. The National Academy of Engineering was established in 1964, under the charter of the National Academy of Sciences, as a parallel organization of outstanding engineers. It is autonomous in its administration and in the selection of its members, sharing with the National Academy of Sciences the responsibility for advising the federal government. The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achieve- ments of engineers. Dr. Charles M. Vest is president of the National Academy of Engineering. The Institute of Medicine was established in 1970 by the National Academy of Sciences to secure the services of eminent members of appropriate professions in the examination of policy matters pertaining to the health of the public. The Institute acts under the responsibility given to the National Academy of Sciences by its congressional charter to be an adviser to the federal government and, on its own initiative, to identify issues of medical care, research, and education. Dr. Harvey V. Fineberg is president of the Institute of Medicine. The National Research Council was organized by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy’s purposes of furthering knowledge and advising the federal government. Functioning in accordance with general policies determined by the Academy, the Council has become the principal operating agency of both the National Academy of Sciences and the National Academy of Engineering in providing services to the government, the public, and the scientific and engineering communities. The Council is administered jointly by both Academies and the Institute of Medicine. Dr. Ralph J. Cicerone and Dr. Charles M. Vest are chair and vice chair, respectively, of the National Research Council. The Transportation Research Board is one of six major divisions of the National Research Council. The mission of the Transportation Research Board is to provide leadership in transportation innovation and progress through research and information exchange, conducted within a setting that is objective, interdisci- plinary, and multimodal. The Board’s varied activities annually engage about 7,000 engineers, scientists, and other transportation researchers and practitioners from the public and private sectors and academia, all of whom contribute their expertise in the public interest. The program is supported by state transportation departments, federal agencies including the component administrations of the U.S. Department of Transporta- tion, and other organizations and individuals interested in the development of transportation. www.TRB.org www.national-academies.org

SHRP 2 STAFF Ann M. Brach, Director Stephen J. Andrle, Deputy Director Neil J. Pedersen, Deputy Director, Implementation and Communications James Bryant, Senior Program Officer, Renewal Kenneth Campbell, Chief Program Officer, Safety JoAnn Coleman, Senior Program Assistant, Capacity and Reliability Eduardo Cusicanqui, Financial Officer Walter Diewald, Senior Program Officer, Safety Jerry DiMaggio, Implementation Coordinator Shantia Douglas, Senior Financial Assistant Charles Fay, Senior Program Officer, Safety Carol Ford, Senior Program Assistant, Renewal and Safety Elizabeth Forney, Assistant Editor Jo Allen Gause, Senior Program Officer, Capacity Rosalind Gomes, Accounting/Financial Assistant Abdelmename Hedhli, Visiting Professional AcknowledgmenTS This work was sponsored by the Federal Highway Administration in cooperation with the American Associa- tion of State Highway and Transportation Officials. It was conducted in the second Strategic Highway Research Program, which is administered by the Transportation Research Board of the National Academies. The project was managed by James Bryant, Senior Program Officer for SHRP 2 Renewal. The authors of this report gratefully acknowledge the technical support provided in the preparation of this report by the following: • Dennis Morian and Shervin Jahangirnejad, Quality Engineering Solutions, Inc., Conneaut Lake, Pennsylvania; • Ernest Barenberg, Consultant, Urbana, Illinois; • Raymond Rollings, Consultant, Beaufort, South Carolina; • Lambert Houben, Consultant, Delft University of Technology, Netherlands; • Marc Stet, Consultant, Netherlands; and • E. B. Lee, Consultant, Berkeley, California. A special thank you is extended to the many highway agencies and organizations and individuals who provided information on field projects and precast concrete pavement systems and who provided support for the precast concrete pavement field testing program. Specifically, a thank you is extended to the following: • Jonathan den Hartog, Kirsten Stahl, Tinu Mishra at Caltrans; • Jim Pappas at Delaware DOT; • Sam Tyson at Federal Highway Administration; • Peter Smith at Fort Miller Company; • Steve Gillen at Illinois Tollway; • Tommy Nantung at Indiana DOT; • Mark Dunn at Iowa DOT; • Tatsuo Nishizawa at Ishikawa National College of Technology, Japan; • John Donahue at Missouri DOT; • John Stanton and Andy Bennett at Michigan DOT; • Becca Lane at Ministry of Transport, Ontario, Canada; • Denis Thebeau at Ministry of Transport, Quebec, Canada; • Tom Burnham and Bernard Izevbekhai at Minnesota DOT; • Robert Sauber (retired) and Robert Blight at New Jersey DOT; • Michael Brinkman (retired) and Roy Reissig at New York DOT; • Tom Gemmiti at New York State Thruway; • Michael Griswold at Nevada DOT; • Scott Murrell at Port Authority of New York and New Jersey; • Tom Montalbine at Roman Stone Construction Company; • Dar Hao Chen at Texas DOT; • David Merritt at The Transtec Group; • Daniel Hsiao at Utah DOT; and • David Shiells at Virginia DOT. James Hedlund, Special Consultant, Safety Coordination Alyssa Hernandez, Reports Coordinator Ralph Hessian, Special Consultant, Capacity and Reliability Andy Horosko, Special Consultant, Safety Field Data Collection William Hyman, Senior Program Officer, Reliability Michael Marazzi, Senior Editorial Assistant Linda Mason, Communications Officer Reena Mathews, Senior Program Officer, Capacity and Reliability Matthew Miller, Program Officer, Capacity and Reliability Michael Miller, Senior Program Assistant, Capacity and Reliability David Plazak, Senior Program Officer, Capacity Onno Tool, Visiting Professional Dean Trackman, Managing Editor Connie Woldu, Administrative Coordinator Patrick Zelinski, Communications/Media Associate

The use of precast concrete pavement (PCP) technology has been steadily increasing over the last 10 years. While there are several precast concrete pavement systems, until recently, there was little guidance available for transportation agencies on the design, fabrication, and instal- lation of precast concrete pavements. This report provides guidance on the design, fabrication, construction, and maintenance of precast concrete pavement systems. The guidance in this report, as well as documentation of the performance of precast concrete pavements that are currently in service, will be of value for the transportation community as a whole. Precast concrete pavement systems have shown great potential for rapid rehabilitation and reconstruction of deteriorated pavement sections. Applications include, but are not limited to, isolated intermittent repairs, intersection and ramp rehabilitation, pavement replace- ment under overpasses, and construction of longer mainline pavement segments. The use of precast concrete pavement systems can speed up construction without sacrificing quality while minimizing lane closures and traffic disruption. Off-site fabrication has the potential to permit lighter, thinner, or more-durable pavement sections through more stringent qual- ity control and use of design details not feasible for in-place construction. Over the last 10 years, several transportation agencies—including Caltrans, Illinois Tollway Authority, New Jersey DOT, New York State DOT, and Utah DOT—have imple- mented PCP systems. Demonstration projects have been constructed in Delaware, Missouri, Michigan, and Hawaii. The systematic application of PCP technology in the United States is a recent occurrence; and information on the design, fabrication, installation, and in-service performance is not well documented. This report provides an assessment of the state of the practice for PCP technology and guidance on the design, fabrication, installation, and maintenance of PCPs. Specifically, it includes the following: 1. Guidelines for selection of precast concrete pavements a. The PCP use decision-making process; b. PCP System approval process; and c. Model specifications for PCP systems. 2. Guidelines for design of precast concrete pavements a. Technical considerations: design related; and b. Design of PCP. 3. Guidelines for fabrication and installation of precast concrete pavements a. Technical considerations: fabrication related; b. Technical considerations: installation related; c. Fabrication of PCP systems; d. Installation of PCP systems; and e. Repair of PCP systems. PCP technology is ready for use in the United States. With this report’s guidance, the transportation community will be able to move forward with implementation. F O R E W O R D James W. Bryant, Jr., PhD, PE, SHRP 2 Senior Program Officer, Renewal

C O n t E n t s 1 Executive Summary 4 cHAPTeR 1 Introduction 5 Report Content 6 cHAPTeR 2 Background 6 General 8 Precast Concrete Pavement Concepts 13 Historical Development of PCP in the United States 14 Developments Outside the United States 14 AASHTO Technology Implementation Guidelines 14 U.S.-Developed Precast Concrete Pavement Systems 17 Non-U.S.-Developed Precast Concrete Pavement Systems 21 North American Precast Concrete Pavement Use 21 Summary 22 cHAPTeR 3 Performance of Installed Precast Concrete Pavements 22 General 22 Caltrans Accelerated Precast Pavement Testing 23 Missouri Precast Pavement Instrumentation 23 Lessons Learned from Installed Projects 24 Field Testing Under the R05 Project 38 Summary 39 cHAPTeR 4 Technical Considerations: General 39 General 39 Proprietary PCP Components 39 Concrete Requirements 41 Panel Reinforcement 41 Panel Lifting and Shipping Requirements 43 Surface Characteristics 44 Nonplanar Panels 45 Production Rates 45 Preconstruction Meetings and Training 46 Maintenance of Traffic and Site Logistics 47 On-Site Contingency Management Plan 47 Summary 48 cHAPTeR 5 Technical Considerations: Jointing and Joint Load Transfer 48 General 48 Transverse Joint Spacing 48 Joint Load Transfer Analysis

49 Load Transfer Provisions for Jointed Systems 50 Design of the Load Transfer System 53 Joint Hardware Patching Materials 54 Tie Bar Provisions 54 Summary 55 cHAPTeR 6 Technical Considerations: Support Conditions 55 General Requirements 56 Bedding for Repair Application 56 Base and Bedding Support for Continuous Application 58 Interface Treatment for PPCP Systems 58 Granular Base Compaction Testing 59 Base and Bedding Issues 60 Summary 61 cHAPTeR 7 Technical Considerations: Prestressed Pavement 61 General 61 Prestressing Tendons 61 Prestressing Accessories 64 Posttensioning Methods 65 Prestress Losses for Posttensioned Systems 67 Pretensioning Considerations 67 Expansion Joint Systems 68 Load Transfer at Expansion Joints 68 Summary 69 cHAPTeR 8 Design of Precast Concrete Pavement Systems 69 General Concepts 71 Design for Intermittent Repair Applications 73 Structural Requirements for Continuous Applications 75 Continuous Application Design Criteria 76 Design of Nominally Reinforced Jointed Systems 78 Design of Individually Prestressed Panel Systems 78 Design of Prestressed Pavement Systems 87 Summary 88 cHAPTeR 9 Fabrication of Modular Rigid Pavement System Panels 88 General Considerations 88 Panel Formwork 88 Concrete Mixture 89 Panel Hardware Installation 90 Nonplanar Panels 91 Concrete Placement 92 Pretensioning 93 Formwork Stripping and Panel Finishing Details 93 Panel Storage and Curing 94 Quality Assurance and Quality Control Activities 95 Summary 97 cHAPTeR 10 Panel Installation for Intermittent Repairs 97 General 97 Overview of Panel Installation Process 98 Panel Installation Staging and Lane Closures

98 Removal of Distressed Concrete Slab 99 Base Preparation and Bedding Materials 100 Load Transfer Provisions 101 Panel Installation 102 Activities After Panel Installation 105 Quality Assurance and Quality Control Requirements 105 Summary 106 cHAPTeR 11 Installation of Continuous Jointed Precast Concrete Pavement Systems 106 General 106 Overview of Panel Installation Process 107 Installation Staging and Lane Closures 107 Removal of Distressed Concrete Slab 108 Base Preparation 109 Load Transfer Provisions 110 Panel Placement 111 Activities After Panel Installation 112 Quality Assurance and Quality Control Requirements 112 Summary 113 cHAPTeR 12 Installation of Continuous Precast Prestressed Concrete Pavement Systems 113 General 113 Overview of Panel Installation Process 114 Panel–Base Interface 115 Panel Placement 117 Finishing Activities 118 Surface Treatment 118 Opening to Traffic 118 Quality Assurance and Quality Control Considerations 119 Summary 120 cHAPTeR 13 Maintenance, Repair, and Rehabilitation of Rigid Modular Pavement Systems 120 General 121 MRR Considerations for Precast Concrete Pavements 122 Timing of PCP MRR 122 Summary 123 cHAPTeR 14 New Features and New Applications 123 General 124 Intermittent Repair of CRCP 126 Narrow-Mouth Dowel Bar Slots for Load Transfer 129 Incrementally Connected PCP Systems 131 Future PCP Refinements and New Applications 132 Summary 133 cHAPTeR 15 Modular Pavement Decision-Making Process 133 General Considerations 134 Agency Considerations 136 Project Suitability for PCP Application 137 Lane Closure Requirements 139 Pavement Structural Capacity Improvement and Vertical Clearance Requirement

139 Site Access for Heavy Construction Equipment 141 Contractor and Precaster Experience 142 Proximity of Certified Precast Concrete Plants 142 Preparatory Time Requirements 142 Summary 143 cHAPTeR 16 System Approval and Trial Installation 143 Introduction 144 PCP System Standard Drawings and Supplemental Information 146 Trial Installation 149 Summary 150 cHAPTeR 17 Summary and Recommendations 150 Summary 151 Recommendations 152 References 154 Appendix A List of U.S. and Canadian Precast Concrete Pavement Projects 158 Appendix B Precast Concrete Pavement Technology Implementation Plan 160 Appendix C Long-Term Performance Evaluation Plan Online version of this report: www.trb.org/Main/Blurbs/167788.aspx.

Cast-in-Place Concrete Pavement (Traditional Use) CIP cast-in-place CIP-PCP cast-in-place prestressed concrete pavement CRCP continuously reinforced concrete pavement JCP jointed concrete pavement JPCP jointed plain concrete pavement JRCP jointed reinforced concrete pavement Precast Concrete Pavement ICPCP incrementally connected precast concrete pavement ICPCP/P incrementally connected precast concrete pavement with prestressed panels ICPCP/R incrementally connected precast concrete pavement with reinforced panels JPrCP jointed precast concrete pavement JPrCP/P jointed precast concrete pavement with prestressed panels JPrCP/R jointed precast concrete pavement with reinforced panels PCP precast concrete pavement PCRP precast concrete repair panel PCRP/P precast concrete repair panel/prestressed PCRP/R precast concrete repair panel/reinforced PPCP precast prestressed concrete pavement (posttensioned) PTSection posttensioned section (a continuous slab section formed by post- tensioning a number of individual precast concrete panels) Other Terminology and Abbreviations AC asphalt concrete ASR alkali-silica reactivity ATB asphalt-treated base base the structural layer, granular or stabilized, immediately below the concrete slab of an existing pavement or below the precast panel for PCP applications; for PCP applications, a bedding layer may be used between the panel and the base bedding a thin granular layer or a thicker nongranular material layer used over the base to provide firm and uniform support under the precast con- crete panels; the nongranular bedding material may be rapid-setting cementitious grout or flowable fill, rapid-setting lean concrete, or high- density polyurethane foam CA4PRS construction analysis for pavement rehabilitation strategies CTB cement-treated base CTE coefficient of thermal expansion CTPB cement-treated permeable base L i s t O F t E R m s a n D a b b R E v i a t i O n s

DBR dowel bar retrofit ESAL equivalent single-axle loading FDBR full dowel bar retrofit FDR full-depth repair FRP fiber-reinforced polymer FWD falling weight deflectometer HVS heavy-vehicle simulator IRI international roughness index LCB lean concrete base LCCA life-cycle cost analysis LTE load transfer efficiency or load transfer effectiveness LTR load transfer restoration LWD lightweight deflectometer MOT maintenance of traffic MRR maintenance, repair, and rehabilitation NPCA National Precast Concrete Association PCI Precast/Prestressed Concrete Institute PDBR partial dowel bar retrofit PTI Posttensioning Institute QC/QA quality control and quality assurance RSFF rapid-setting flowable material RSLCB rapid-setting lean concrete base SCC self-consolidating concrete SFRC steel-fiber-reinforced concrete vpd vehicles per day