Basics of Concrete Pavement Intersection Construction

1
Basics of Concrete Pavement Intersection
Construction
2
Cost Considerations

• Mix
• Day/Night Paving
• Number of Stages Required
• Amount of Concrete/Stage
• Add 5.00 - 300.00/SY

3
Production Rate Comparison
Fixed Form 12 Wide 70 120 CY/Hr Slip Form
Paver 24 Wide 10 depth 200CY-400CY/Hr
Reconstruction Mainline New Construction
2500-4000CY/Day
4
Construction Staging for Concrete Intersections
5
Traffic Flow Traffic Control

• Four Option
• Restricted Traffic Movement - Francis
  Division
• Partial Closures - Pines Broadway
• Complete Closures - Broadway and University
• Combination of the Above - SR 395 - Yelm,
  Clearwater, and Kennewick Avenue

6
Francis Division

• 32,000 ADT
• Four lanes required to remain open along
  Division. Two in each direction.
• Left turns from Division required to remain
  open.
• One lane required to remain open along Francis
  Avenue.
• Business were located on all four corners of
  the intersection. Access to businesses
  required.

7
Stage 1
8
Stage 2
9
Stage 3
10
Stage 4
11
Stage 5
12
Stage 6
13
Intersection Complete
14
Traffic Flow What The Contractor Noticed

• After the first week of reconstruction traffic
  volumes decreased 20 to 30 percent.
• Commuters used alternate routes.
• Access for material delivery was not a problem.
• Allowing left turns from Division to Francis
  caused long lines along Division.

15
Time For Completion

• The reconstruction took 35 working days of which
  18 were concrete placing days to complete
  3,047.3 cubic yard of concrete.

16
Partial Closure - Broadway Pines

• Original Intersection was to maintain traffic
  on all legs of the intersection.
• After evaluation of traffic control plan WSDOT
  allowed closure of Broadway. Therefore no left
  turns permitted.
• Broadway traffic used alternate routes.
• Pines traffic signals set on green for both
  north and south bound traffic. Traffic did not
  backup at intersection.
• Traffic along Pines was free flowing.

17
Stage 1 - Broadway Pines
18
Stage 2 - Broadway Pines
19
Stage 3 - Broadway Pines
20
Combination Closures

• SR-395 Yelm, Clearwater, Kennewick Avenue
• Lane Closures Stages 1,2, 4
• Complete Closure Stage 3, Thursday at 700 PM
  to Monday 600 AM.
• Late opening penalty of up to 2,400.00 per
  hour.

21
Time for Completion

• Kennewick Avenue and Clearwater were built
  concurrently. This saved a considerable amount
  of time. Crews always had a place to work.
• In 15 days approximately 3384 cubic yards were
  placed in the two intersections.

22
Kennewick Avenue Stage 1
23
Kennewick Avenue Stage 2
24
Kennewick Avenue Stage 3
25
Kennewick Avenue Stage 4
26
Time for Completion

• The reconstruction took 19 calendar days of
  which 9 of those days they placed concrete.
• A total of 1,681 cubic yard of concrete
  were placed.

27
Kennewick Avenue Thursday Evening
28
Kennewick Avenue Thursday Evening
29
Kennewick Avenue Thursday Evening
30
Kennewick Avenue Friday Morning
31
Kennewick Avenue Friday Morning
Photo Courtesy Tri-City Herald
32
Kennewick Avenue Friday Morning
33
Kennewick Avenue Friday Afternoon
34
Kennewick Avenue - Saturday Morning
35
Kennewick Avenue Saturday Afternoon
36
Kennewick Avenue Sunday Afternoon
37
Time Comparison
38
Reasons for Success

• WSDOT had several preliminary meetings with
  City of Kennewick to discuss impacts and City
  concerns.
• WSDOT invited businesses to preconstruction
  meeting.
• WSDOT met with contractors to discuss
  feasibility.
• WSDOT kept public informed via newspaper,
  radio, and television news broadcasts.
• WSDOT web page with up to date information.
• WSDOT gave flyers to businesses weekly.

39
Reasons for Success Continued

• WSDOT/Acme partnered on the modifications to the
  traffic control plan allowing continuous work
  operation with increased safety for employees.
• Clearwater Kennewick were constructed
  concurrently maximizing crew efficiency.
• Detailed schedule with known milestones.
• Meeting or beating schedule.
• Something going on all the time.
• Decision makers available to resolve issues.

40
Curing

• Use Standard Curing Techniques for PCCP

41
Curing

• Blankets to speed up curing in cooler
  temperatures.

42
Curing

• Using the 705 pound Type III WSDOT mix
  Strengths are achieved in 12 to 16 hours
  without using the blankets on a typical summer
  day.
• Ambient temperature has the largest effect on
  strength gain.
• It should be left up to the contractor whether
  to place blankets as needed to meet the opening
  to traffic schedule.
• The cost for blanketing all the concrete on the
  first Kennewick project totaled over 30,000.00.

43
Other Factors to Consider

• Maintain constant cross slope from center line
  to curb flow line.
• Maintain crowns on longitudinal joint lines.
• Maintain a constant joint spacing for ease of
  construction.
• Physically locate all utilities in the
  intersection.
• Allow time for sealing prior to traffic switch.
• The more work area available for construction
  the quicker construction can be accomplished.

44
Other Factors to Consider

• Requiring existing asphalt to be removed with a
  mill also reduces time by minimizing earthwork.
• If possible design PCCP section for no base
  rock. Installation of base gravels are costly
  in small areas and add a time to the process.

45
Types of Paving
Highways Airports
Slip Form
No Forms Required Wire used for line and
grade. Low Slump Concrete
46
Types of Paving
Intersections
Fixed Form
Normally Steel Forms Form Is Mold for
Paving Form Supports Finishing
Equipment Adaptable to Variable Conditions
47
Pre-Paving Meeting

• Assess
• Construction sequence/staging
• Order of Work
• Planned Sequence

48
Pre Paving Meeting (cont)

• Assess
• Daily Operations
• Start Time
• Hours of Operation
• Paving Methods
• Sampling and Testing
• Safety
• Sawing and Sealing Operations

49
Pre Paving Meeting (cont)

• Assess
• Concrete Delivery
• End Dumps
• 45 minute delivery time
• Load Limits
• Access Routes
• Safety

50
Pre Paving Meeting (cont)

• Assess
• Decision Making Process
• Whos in Charge
• Prime, Sub, WSDOT
• Surveying, Sampling Testing, Wire Adjustments
• Go No Go
• Final Acceptance
• Time Lines for Information

51
Basic Construction
Grading Forming Placing Curing Sawing Sealing
52
Preparing the Grade

• Construction always starts with the subgrade
• Uniformity
• Soil type
• Moisture content
• Density
• Remove pockets of unsuitable materials
• Stabilize unsuitable soils

53
Trim Grade and Compaction

• Trim after placement of forms
• Final rolling for compaction
• Final check form line
• Alignment
• Profile
• Depth

54
(No Transcript)
55
(No Transcript)
56
(No Transcript)
57
Fixed Form Paving Operations

• Paving form is the mold
• Holds concrete in place
• Establishes grade and alignment
• Serves as tracks for paving equipment

58
Typical Steel Form
Form Lock
59
Side Forms
Side form sections shall be straight, Free from
warps, bends, indentations, Or other defects
Commonly Steel Forms
60
(No Transcript)
61
Application AdvantagesFixed Form Paving

• Tight tolerances - side clearance
• Multiple changes of width
• Blockouts
• Intersections - quadrants open to traffic

62
3 minimum
63
(No Transcript)
64
(No Transcript)
65
(No Transcript)
66
(No Transcript)
67
Application AdvantagesFixed Form Paving

• Maintain quality during shortconcrete supply
• Critical staging for traffic control
• Small inexpensive equipment canplace concrete
• An adaptable system

68
(No Transcript)
69
Forming Curves

• Similar requirements to regular steel forms
• Depth equal pavement thickness
• Stake in place
• Ends must attach and be tight

70
(No Transcript)
71
(No Transcript)
72
Concrete ProductionandPlacement
Redi Mix Batch Plant Portable Batch Plant
73
(No Transcript)
74
Placement
75
(No Transcript)
76
(No Transcript)
77
(No Transcript)
78
(No Transcript)
79
(No Transcript)
80
EQUIPMENT
Concrete shall be spread, screeded, Shaped, and
consolidated, with one Or more self propelled
machines
81
(No Transcript)
82
(No Transcript)
83
(No Transcript)
84
(No Transcript)
85
(No Transcript)
86
(No Transcript)
87
(No Transcript)
88
Critical Factors Fixed Form Paving - Ride Quality

• Proper machine adjustments
• Steady machine progress
• Avoid excessive finishing
• Avoid excessive water on surface
• Straightedge check of slab

89
Pavement Steel

• Tie Bars
• Dowel Bars

90
Placing Dowel Bars
91
(No Transcript)
92
(No Transcript)
93
Keyways
94
(No Transcript)
95
(No Transcript)
96
Finishing Texturing Curing
97
Finishing
How Much Finishing How Many Finishers
98
(No Transcript)
99
(No Transcript)
100
(No Transcript)
101
(No Transcript)
102
No Water Added
?
103
(No Transcript)
104
(No Transcript)
105
Surface Smoothness
10 Straightedge
106
Texturing

• Transverse Tining
• Longitudinal Tining
• Astro Turf Drag
• Broom Finish

107
Microtexture
From Fine Aggregate Particles
Astro Turf Drag or Broom Finish
108
Macrotexture
Formed into surface
Transverse or Longitudinal Tining
109
(No Transcript)
110
(No Transcript)
111
(No Transcript)
112
Summary of Critical Factors

• Sound grade
• Monitored supply
• Consistent workability
• Controlled Density

113
Curing

• Uniform
• Timely
• Check yield
• 150 sq ft/gal

114
(No Transcript)
115
(No Transcript)
116
Saw and Seal Operations
117
(No Transcript)
118
Joints

• Formed Joints
• Longitudinal Transverse Construction
• Sawed Joints
• Longitudinal Transverse Contraction

119
(No Transcript)
120
Sawing Transverse Contraction Joints
121
(No Transcript)
122
(No Transcript)
123
(No Transcript)
124
(No Transcript)
125
(No Transcript)
126
(No Transcript)
127
Types of Saw Cuts

• Initial Saw Cut (Crack control)
• Widening Cut (Joint sealant reservoir)

128
(No Transcript)
129
(No Transcript)
130
Sawing Window

• Production schedule - Early cut or conventional
  Wet Saw

131
Temperature and the Sawing Window

• Begins with acceptable raveling
• Ends with significant concrete shrinkage that
  induces cracking

Contraction or Differential Shrinkage
Excessive Raveling
Saw
Unacceptable
Late Sawing
Acceptable
Time
132
Joint Sawing
Too Early Raveling
Too Late Random Cracking
Concrete Set
Time
133
Sawing Window

• Concrete mix characteristics
• Cement type
• Admixtures
• Fast Track

Job Site Operations
134
Sawing Window

• Base Type
• Aggregate
• Stabilized
• Open graded

Job Site Operations
135
Sawing Window

• Weather conditions
• Ambient temperature
• Wind
• Humidity
• Cloud cover
• Season

Job Site Operations
136
(No Transcript)
137
Sealant Materials

• Formed-in-place
• Backer rod
• Preformed

Joint Sealing
138
Formed-In-Place

• Hot applied
• Cold applied

Joint Sealing
139
Formed-In-Place Joint Preparation

• Flush residue (Widening cut)
• Abrasive Cleaning
• Air Cleaning

Joint Sealant Installation
140
Backer Rod Material

• Polyethylene foam (cold)
• Crosslinked polyethylene foam (hot or cold)

Joint Sealing
141
(No Transcript)
142
(No Transcript)
143
(No Transcript)
144
(No Transcript)
145
Joint Sealant Material

• Preformed
• Polychloroprene elastomeric compression sealant

Joint Sealing
146
Critical Factors in Sawing and Sealing

• Weather is a constant variable
• Layout/Marking of joints
• Timing of initial control sawing
• Saw depth

147
What Could Possibly Go Wrong?
148
(No Transcript)
149
(No Transcript)
150
(No Transcript)
151
Fast Track Paving
152
?
Questions