S25_Overlay Low Volume Roads_LTC2013

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Dr. Michael Ayers, Global Pavement Consultants, Inc.

Building Concrete Overlays on Two Lane Roads

Under Traffic

U.S. 184 1/2 PCC UnbondedChickasaw / Fayette County, Iowa

Partnerships for Progress in Transportation

Louisiana Transportation Conference

February 17-20, 2013

Session 25


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Acknowledgements

Dr. James Cable, Cable Concrete Consultation.

The National Concrete Pavement Technology Center,

Iowa State University, Ames., Iowa. Federal Highway Administration.

Cement and Aggregates Association of Louisiana(CAAL)

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ProjectLocation


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US 18 Bid Information Bid date 10/19/2010

Late start date April 14, 2011 Work period 120 working days

Limitations No stringline at centerline

Project stages 6 (revised to 5 on site)

Number of bidders 6 Bid range - $8.48 million to $10.51 million

Prime contractor Manatts Inc.

Project length 18.97 miles

Project current traffic Chickasaw Co. - 1800 adt/22% trucks

Fayette Co. 3050 adt/13% trucks


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US 18 Construction Objectives

Demonstrate the ability to construct PCC overlayswhile maintaining traffic on two lane roads.

Identify design and construction features that shouldbe included in plans to:

Achieve overlay goals.

Encourage construction efficiency.

Reduce construction costs.


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Overlay Conditions

First single lane overlaypaving, under traffic in Iowa

Traffic control by pilot carand flaggers, 24/7


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Pre-Paving Project Staging

Stage I (Changes in Patching timing)

a. Patch (BOP to EOP), maintain traffic with pilot cars

b. Construct subdrains, culverts, foreslope flattening, ditchreshaping & erosion control (BOP to EOP)

Stage IIa. Use TBR/Signals to reconstruct/bridge approaches

b. Place shoulder strengthening, TBR/signals/ attenuators& flood lights at four bridges

c. Reconstruct bridge approaches, transition pavements at a time with HMA wedge ends


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Paving Project Staging

Stage III (Changes in Milling length)a. Maintain through traffic w/ lane closure (3.5 miles) &

pilot car

b. Mill existing HMA surface (18.9 miles)

Stage IVa. Pave overlay(EOP west to W-14), shoulder & open to

traffic

Stage V

a. Pave overlay (W-14 to BOP), shoulder & open to traffic


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Traffic Queue Length Patching & Milling(2mi. zone): 6 to 8 cars / trucks

average Paving (3.5 mi. zone): 15 cars / trucks average


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Miscellaneous Culvert Work


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Subdrain Installation

Two mile work zone 48,422 feet of tiling


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Full Depth Patches

651 ConcretePatches

Average 34 permile


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Full Depth PCC Patches

Average 30 per daywith sawing in PM

Equals about two lanemiles/day


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Full Depth PCC Patches

Average 30 per daywith sawing in PM

Equals about two lanemiles/day


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Longitudinal Joint Patching Prep.


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Longitudinal Joint Patch Repair


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Bridge Approach & Transitions


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End of Paving Temp. Transitions


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Overlay Survey & Concrete Yield*Milling limits set at 1/2 to 1 1/2 deep at centerline

* One mile test section topo to:- Identify section spacings (25 or 50 ft.)

- Number of survey shots/section (3, 5 or 9)

- Determine basis for value engineering proposal

* Test Section Results

Yield changed from 26% average overrun to average

of 6% after milling to new profile depth

Survey interval established at 50 ft.

Nine shot survey section for best yield fit

Nineteen miles surveyed 3D model established optimum profile model for use

by milling and paving machines


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Survey GPS / TotalStations

Survey existingsurface Develop database Create profile

Three wire level zcoordinates

GPS

x, y coordinates


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Milling of HMA Seven foot wide mill head

Cut ( to 1 ) at centerline

Based on profile grade

Centerline pass by total stations(25 to 30 ft. per minute)

Exterior pass by joint match (1/2 to 1mile per hour)


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Haul Road Selection


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Tie Bar Location & Installation


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Staging of PCC Overlay


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3.5 Mile Timeline for Opening to

Traffic

1.0 day- cut trench and lay tied steel(may include last safety edge)

2.5 day- Overlay Paving1.5 day- Curing1.0 day- Shouldering1.0 day- Painting and Signing

7.0 days- Open to traffic via Pilot Car.


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Traffic Shift


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Stringless Paving for PCC Overlay


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Stringless One Lane Paving Control


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PCC Overlay Paving


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Overlay Finishing Operations


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PCC Joint Development


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Finish Shouldering


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US 18 Overlay Conclusions

Single lane overlay construction under traffic wassuccessful

Multiple traffic work zones are necessary to optimizeconstruction forces and time

Staging preoverlay and overlay operations separatelywas beneficial.

Timely concrete delivery requires owner/contractorcooperation

Future improvements in the contract documents canreduce costs and increase construction efficiency.


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Michael E. Ayers

Global Pavement Consultants, Inc.

[email protected]

www.globalpavements.comPhone 217-621-3438

Documents

S25_Overlay Low Volume Roads_LTC2013