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Precast Prestressed Concrete PavementPrecast Prestressed Concrete Pavement
2009 PTI Technical Conference and Exhibition 2009 PTI Technical Conference and Exhibition May 3May 3--5, 20095, 2009
Portland, OregonPortland, Oregon
David K. Merritt, P.E.David K. Merritt, P.E.www.PrecastPavement.com
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 1 of 36
Overview
BackgroundBenefitsBenefitsBenefitsFHWA Demonstration ProjectsFHWA Demonstration ProjectsFHWA Demonstration ProjectsUpcoming Projects & Potential Future Upcoming Projects & Potential Future Upcoming Projects & Potential Future ApplicationsApplicationsApplications
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 2 of 36
PPCP Background
2000: FHWA Feasibility Study (University of Texas at Austin) 2002: FHWA Pilot Project in Georgetown, TX 2004: FHWA Demonstration Project in El Monte, California2006: FHWA Demonstration Project in Sikeston, Missouri2006: FHWA Demonstration Project in Sheldon, Iowa2009: FHWA Demonstration Projects in Bear, DE and Fairfax, VACurrently: FHWA providing design and construction support for additional Demonstration Projects
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 3 of 36
What is PPCP?
Precast Prestressed Concrete Pavement• “Standardized” full-depth precast panels• Keyed panel joints for vertical alignment during
assembly• Constructed over a prepared base (HMA, LCB,
Aggregate Base, etc.)
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 4 of 36
What is PPCP?
• 2-way prestressing• Combination of pretensioning/post-tensioning• 2-way post-tensioning• Bonded/grouted P-T system
Precast Prestressed Concrete Pavement
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 5 of 36
Typical PPCP Panel
Continuous Shear Key
Ducts for Post-tensioning
Pretensioning Strands
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 6 of 36
Typical PPCP Panel Layout
Prepared Base (HMA or LCB)
Base or Existing pavement
Joint Panel Base Panel(Multiple)
C.S. PanelBase Panel(Multiple)
Joint Panel
Polyethylene SheetDuct Holes
Traffic Flow
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 7 of 36
Typical PPCP Panel Layout
2” AC Leveling Course
Post-tensioning Post-tensioning
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 8 of 36
Typical PPCP Panel Layout
2” AC Leveling Course
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 9 of 36
Overview
BackgroundBackgroundBackgroundBenefitsFHWA Demonstration ProjectsFHWA Demonstration ProjectsFHWA Demonstration ProjectsUpcoming Projects & Potential Future Upcoming Projects & Potential Future Upcoming Projects & Potential Future ApplicationsApplicationsApplications
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 10 of 36
Why?
New techniques are needed for Expedited Pavement ConstructionNighttime or weekend construction
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 11 of 36
Why Precast Concrete?
Expedited construction technique for the commercial building and bridge industriesDurable, High-Performance solution
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 12 of 36
Benefits
Expedited Construction• Overnight or weekend “invisible” construction • Reduced user delay costs• Reduced disruption to local businesses• Reduced traffic control costs
Small Placements in Remote Areas• Does not require a local concrete plant• Does not require specialized equipment
Extended Construction Season
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 13 of 36
Benefits
Controlled Fabrication Conditions• Improved Durability and Performance
(consistent mix and mixture flexibility, adequate curing, adequate air entrainment, etc.)
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 14 of 36
Why Prestressed Precast Concrete?
Benefits
Why Not?
• Reduces/eliminates slab cracking (maintenance)• Reduced number of joints (maintenance/smoothness)• Reduced Slab Thickness (8” vs. 12”)
– Material savings– Allows for replacement of pavement in-kind
• Proven Long-Term Performance– 6” CIP post-tensioned pavement constructed in 1985 (near
West, Texas)– Virtually no maintenance in 22 years
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 15 of 36
Benefits
Why Prestressed Precast Concrete?• Ability to span voids/unsound support layers
• Move expansion joint further away from abutment (bridge approach slabs)
Approach Slab
AbutmentEmbankment
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 16 of 36
Overview
BackgroundBackgroundBackgroundBenefitsBenefitsBenefitsFHWA Demonstration ProjectsUpcoming Projects & Potential Future Upcoming Projects & Potential Future Upcoming Projects & Potential Future ApplicationsApplicationsApplications
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 17 of 36
Texas Demonstration Project (2002)2,300 ft of Interstate 35 frontage road pavement just north of Georgetown, Texas.Surface preparation: 2” HMA leveling course and single layer of polyethyleneFull-width (36 ft x 10 ft) AND Partial-width (16 ft + 20 ft x 10 m) panels8” thick 339 panels total Prestressing• Pretensioning: 6-0.5” strands/panel• Post-Tensioning: monostrand (0.6”) grouted tendons, 24” o.c.
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 18 of 36
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
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2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
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2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
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California Demonstration Project (2004)
Widening of Interstate 10 near El Monte, CANight constructionPrecast Panel Dimensions: 37 ft x 8 ft x 10”- 13.1”248 ft total project length (2 post-tensioned sections @ 124 ft)Panels installed over lean concrete basePrestress• Transverse Pretensioning: six 0.5” strands • Longitudinal (grouted) Post-tensioning: 0.6” strands @ 36” o.c. • Epoxy-coated (fine grit impregnated) strand for post-tensioning
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 22 of 36
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 23 of 36
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
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2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
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Missouri Demonstration Project (2006)Replacement of 40+ yr. old Interstate JRCP1,010 ft total length (4 sections @ 250 ft)• 2 lanes plus shoulders: 38 ft wide• Pavement crown incorporated into panels
Installed over permeable asphalt-stabilized basePrecast Panels: 10 ft x 38 ft x Variable thickness101 panels totalPrestress• Transverse Pretensioning: eight 0.5” strands • Longitudinal (grouted) Post-tensioning: 0.6” strands @ 24” o.c. • End-Stressing for post-tensioning
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 26 of 36
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
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2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
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Iowa Demonstration Project (2006)Precast Prestressed Bridge Approach Slabs• 77 ft at either end of a skewed bridge (16 panels)• Tied to an integral bridge abutment
2-way Post-Tensioning (no pretensioning)Partial-width panels (lane-by-lane construction)Installed over crushed limestone basePrecast Panels: 14 ft x 20 ft x 12 inPost-Tensioning (Longitudinal and Transverse)• 0.6” strands @ 24” o.c.• Grouted Tendons
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 29 of 36
Iowa Demonstration Project
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
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2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
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2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
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Other Projects:Red Dog Mine, Alaska (2002)
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 33 of 36
Overview
BackgroundBackgroundBackgroundBenefitsBenefitsBenefitsFHWA Demonstration ProjectsFHWA Demonstration ProjectsFHWA Demonstration ProjectsUpcoming Projects & Potential Future Applications
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 34 of 36
Upcoming Projects
I-5/Hwy 14 Interchange – Sylmar/Los Angeles, CA (Aug. 2009)• Ramp• Nighttime construction
Rte. 896 – Bear/Wilmington, DE (May 2009)• Arterial turn lanes• Nighttime construction
I-66 – Fairfax, VA (Summer/Fall 2009)• Interstate main lanes• Nighttime construction
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 35 of 36
Potential Future Applications
Potential FHWA Demonstration Projects1) Weigh-in-Motion Installations2) Intersections3) Unbonded Overlays4) Temporary Pavement/Crossovers5) Thinner pavement sections beneath bridgesOthers……FHWA is providing design and construction support for demonstration projects.
2009 PTI Technical Conference Precast Prestressed Concrete Pavement David K. Merritt, P.E.
© Copyright Post-Tensioning Institute all rights reserved. Page 36 of 36