SHRP2 Renewal – PCC
Implementation Update
Stephen J. Cooper
SHRP2 Renewal Pavements Engineer
What we will cover:
• SHRP2 Implementation Assistance
Program - Background & Update
• Implementation Update Highlights PCC Pavement Products:
 R21 New Composite Pavement
Systems
 R06E Tools to Improve PCC Pavement
Smoothness During Construction
 R05 Precast Concrete Pavement
 R23 Pavement Renewal Solutions
• FHWA’s PCC QA Workshop Update
2
SHRP2
Implementation Assistance
Program – Background &
Update
3
What is SHRP2?
• The Second Strategic Highway Research Program (SHRP2):
a large scale research program designed to make significant
advances in some of the most challenging areas in the
highway industry
• A nine-year, $232 million research program due to be
completed March 15, 2015
• TRB: managed over 100 research contracts, involving more
than 300 research contractors
• FHWA and AASHTO: underway with implementation
activities for the highest priority products emanating from the
research
4
Snapshot - Renewal
• All 24 products are being advanced at this time
• Products in 4 key categories:
– Pavements
– Structures
– Project Delivery
– Utilities and Railroads
• $40.2 million budget for implementation to be used over a 4-6 year
time period
• Completed implementation plans for 19 products
• 15 Renewal products featured in Rounds 1-4 of Implementation
Assistance
• Anticipated 9 Renewal products tentatively featured in Rounds 5, 6
& 7 (including several repeats)
5
SHRP2 Implementation
Assistance Program (IAP)
• Available to help State DOTs, MPOs, local agencies,
and other interested organizations deploy SHRP2
Solutions
• 24 SHRP2 Solutions have been included in Rounds 1-4
Round Launch Date
Round
Launch Date
1
February 2013
4
May 2014
2
August 2013
5
January 2015
3
January 2014
6
29 May 2015 –
26 June 2015
•6 Round 7 (Last Round) anticipated in January 2017
Pavement Renewal Products
IAP Rounds 1-4
Pavements
IAP Round
Selections
Guidelines for the Preservation of High-Traffic-Volume Roadways (R26)
1
13 DOTs & DC
Precast Concrete Pavement (R05)
3
4 DOTs,
1 Toll Authority
New Composite Pavement Systems (R21)
4
2 DOTs
Pavement Renewal Solutions (R23)
2
9 DOTs
Technologies to Enhance Quality Control on Asphalt Pavements (R06C)
4
11 DOTs
1 FLH
Tools to Improve PCC Pavement Smoothness During Const. (R06E)
4
5 DOTs
1, 2, 4
9 DOTs
1 FLH
1, 4
11 DOTs
2
4 DOTs
Project Delivery
Managing Risk in Rapid Renewal Projects (R09)
Project Management Strategies for Complex
Projects (R10)
Performance Specifications for Rapid Renewal (R07)
7
Implementation Assistance - Proposed
Renewal Products
Round 5
3D Utility Location Data Repository (R01A)
Performance Specs for Rapid Renewal (R07)
Railroad-DOT Mitigation Strategies (R16)
Round 6
Identifying & Managing Utility Conflicts (R15B)
Utility Locating Technologies (R01B)
Precast Concrete (R05) - Funding contingent
New Composite Pavement Systems (R21)
Pav. Pres. for high-vol-traffic Roadways (R26) – Funding contingent
Round 7
Service Life Design for Bridges (R19A)
Service Limit State Design for Bridges (R19B) – Funding contingent
Nondestructive Testing for Concrete Bridge Decks (R06A) – Funding contingent
Techniques to Fingerprint Construction Materials (R06B)
Advanced Methods to Identify Pavement Delamination (R06D)
NDT for Concrete Tunnel Linings (R06G) – Funding contingent
Utility Bundle (R01A, R1B, R15B)
SHRP2 Renewal
Implementation Update
Highlights – PCC Products
9
Strategic Highway Research Program
2 (SHRP2) Project R21
• Research study, 2007-2011
• Goal: Develop guidelines for design and
construction of composite pavements
(both PCC/PCC and HMA/PCC)
• Activities:
– Review of European practices
– Analytical evaluations of pavement
systems
– Field demonstrations
R21
SHRP2 Project R21 Implementation
• Goal: Support and promote
adoption of composite
pavement systems
– PCC/PCC
– HMA/PCC
• Contractor:
– Applied Pavement Technology
• Contracting Period
– 2014 to 2017
What Is Two-Lift Concrete Paving?
• Placement of two distinct concrete paving
layers to form a monolithic pavement
structure
Placement of
Top Lift
Durable Aggregate,
Effective Surface Texture
Recycled or Marginal
Quality Aggregate
Placement of
Bottom Lift
2 – 3 in Wet-on(typ)
Wet
6 – 8 in
(typ)
Monolithic Pavement
Structure
Applicability of
Composite Pavements (cont.)
Arizona, Netherlands
Surface long term durability,
low noise, or rapid renewal
conditions are desired
13
Operation Overview: MnRoad
(courtesy Derek Tompkins)
ReadyMix Truck
First
Paver
Belt
Placer
Second
Paver
Two-Lift Paving:
New and Innovative?
• No! Most early concrete
pavements (1900-1920) built
using two-lift paving practices
• Technique used in 1940s1970s (steel placement for
JRCP designs)
• Process re-emerged again in
early 1990s
1906 concrete
pavement,
Calumet, MI
(courtesy
Tom Van Dam)
Why The Re-Emergence?
• European Experience
– 1990 Scan Tour
– 2006 Scan Tour
(high-priority
(courtesy Shiraz Tayabji)
implementation item)
• Diminishing sources of
high quality aggregate
• Availability of marginal and recycled
materials
• Growing interest in being “sustainable”
Some Quick Comparisons
Item
I-70 KS
(2008)
Lift
1.5 in / 12 in
Thickness
Mn/Road
(2010)
IL Tollway
(2013)
I-65, TN
(2014)
3 in / 6 in
3 in / 9 in
3 in / 10 in
Bottom
Lift Agg
Local agg
(limestone)
RCA
Surface
Agg
Rhyolite
Crushed
Granite
Surface
Texture
Dowels
Various (incl Exp. Agg
EAS)
Surf (EAS)
Baskets
Baskets
Fractionated Conv agg
RAP
(limestone)
Crushed
Stone
Surface agg
(Limestone)
Long. tining Trans. tining
Baskets
Baskets
What About Costs?
• Initial costs expected to be higher
• Recent cost data:
– Austria: Costs not significantly higher
– Kansas 2008:
• Conv. $33/yd2 vs. 2-lift: $41/yd2
– Estimate based on MnRoad experience:
• Conv: $20.38/yd2 vs. 2-lift: $19.94/yd2
– Illinois Tollway:
• 12-inch Conv. (2006-2009): $56.37/yd2
• 12-inch 2-lift (2013/2014): $44.41/yd2
PCC/PCC Composite Pavements and
Costs Contractor Assessment
• 2-layer Composite Paving process is a viable and
competitive alternative to Conventional Paving, if:
– Good quality class aggregates aren’t readily available
 Long haul times drive the price of the aggregate too high
– Recycled concrete could be produced on or near the site
 Haul times would have to be cut to minimal levels
 Must produce recycled at about 50% the cost of good quality aggregate
– You were capable of producing and paving at an equal rate to
conventional paving
• Lower life-cycle costs
– Rapid renewal, lower maintenance and rehabilitation, long life
19
Operation Overview: Nashville,
Tennessee I-65N
End Dump
Belt Placer
ReadyMix Truck
Second
Paver
First Paver
Highlights:
Concern with polishing of course aggregate
13” conventional vs 3”/10” composite pavement on shoulder
Results – TN offering option in future contracts
SHRP2 R21 Opportunities
• Presently 2 agencies (TN and TX) participating at Lead
Adopter Agencies (incentive funding provided up to
$300k).
• Training & Technical Assistance available for up to 5
agencies.
• Will be included again in Round 6.
– Would provide financial assistance for up to 3 agencies to pilot
composite pavement projects (incentive between $160k and
$500k).
– Application around Jun-Jul 2015; Selection around Aug 2015
• If Interested, contact myself or APTech (Kurt Smith at
ksmith@appliedpavement.com)
Real-Time Smoothness
Measurements on PCC
• Background 2010 and 2011
• SHRP2 R06E
• Evaluation of GOMACO GSI and Ames Engineering RTP
• Georgia, Arkansas, Texas, Michigan and New York
GSI
RTP
R06E
Real-Time Smoothness Measurements
on PCC Pavements
BENEFITS:
 SHRP2 Solution provides real-time
information for process control of
smoothness
 Allows for immediate adjustments to
equipment and operations
 Minimizes pavement grinding and
remediation
 Better quality control
 Potentially better long-term performance
R06E
PRODUCTS:
 Model Specifications
 Guidelines
 Documentation of profiler performance
and recommendations
Non-Destructive Testing Tools
Real-Time Smoothness
• Conclusions from R06E, RTS is applicable for:
• Evaluating concrete pavement smoothness in real time
• Quality control
• Process improvements as a result of timely feedback
• Understanding how construction artifacts (stringline, padline,
basket rebound, …) can affect smoothness
RTS is not:
• A replacement for conventional profiling for acceptance
• A replacement for better practices to construct smoother
pavements
Rough Trackline
25
Rough Trackline:
Profile and Leg Motion
0.6
0.6
Profile from Dipstick
0.4
Leg height from sensor
0.2
0.2
0
0.0
-0.2
-0.2
-0.4
-0.4
-0.6
508+50
508+75
509+00
509+25
-0.6
509+50
Station
26
Leg height (in)
Profile elevation (in)
0.4
NY Contractor Experience
• Cold Spring Construction (Akron, NY)
• Participated in the original SHRP2 evaluation of RTS
• Purchased two Ames Engineering “Real-Time Profilers
(RTP)
• Systematic approach to improving pavement
smoothness
NY – Contractor Experience
(continued)
• Finishing foreman now operates the powered work
bridge with 2 RTPs and directs the finishing crew based
on real-time feedback
2009 – 2013
NY - What Was Learned
• IRI reduced from mid 90’s to mid 60’s
• Comprehensive approach
• Lightweight Profiler
• Stringless Paving
• Real Time Profiler
– Optimize paving variables…finishing, settings,
speed, etc.
Real-Time Smoothness
• RTS Implementation Support Activities
• Objective: Routine use of RTS technology by agencies
and contractors who routinely construct PCC pavement.
Real-Time Smoothness
• CP Tech Center was awarded a 36 month contract in
Aug 14 to provide implementation support for RTS.
Peter Tylor
Dr. Rob Rasmussen
Gary Fick
• Lead Adopt States:
Alabama
Idaho
Indiana
Ohio
Pennsylvania
Real-Time Smoothness Opportunities
• RTS Implementation Support Activities
• Task 1: Equipment Loan Program (2015 and 2016)
• Full use of an RTS system for two weeks
• On-site technical support and training (Rasmussen
and Fick) for the full two weeks
• Budget allows for 8 equipment loans
• Projects with a minimum of 10 consecutive
mainline paving days (more is preferable)
• Contractor or agency should commit to providing
daily QA profiles during the equipment loan
• Contact gfick@trinity-cms.com if interested (3
equipment loans are still available)
Real-Time Smoothness Opportunities
• RTS Implementation Support Activities
• Task 2: Regional Showcase (Open House)
• One day classroom presentations with an
on-site RTS demonstration
• In conjunction with an equipment loan
project
• Travel expenses are covered for up to 10
agency participants
Real-Time Smoothness Opportunities
• RTS Implementation Support Activities
• Task 3: Workshops
• Four hour workshops (5) – contact gfick@trinity-cms.com
• Tentative agenda
– Importance of Pavement Smoothness
– Fundamentals of Pavement Smoothness Measurement
– Fundamentals of Ride Quality and Pavement Profile
Analysis
– Current Practices for Concrete Pavement IRI
Specifications
– Best Practices for Concrete Paving Operations
– Using RTS Technology to Improve Concrete Pavement
Smoothness
– Q & A and Discussion
Real-Time Smoothness Deliverables
RTS Implementation Support Activities
• Task 4: Documentation of Results/Case Studies
• Synthesis of contractors’ experience
• Case study – Comparing real-time measurements
to QA results
• Case study – Long-term performance of RTS
• Documentation of equipment loans and lessons
learned
• Task 5: Specification Refinement
• QC approach
• Process improvement
Precast Concrete Pavement – R05
Challenge
Congestion and traffic delays due to roadway repair and
rehabilitation are a major source of irritation for drivers.
Solution
• The SHRP2 PCP Solution offers a
series of guidelines and model
specifications to help agencies
effectively design, fabricate, and install
long-life PCP systems.
• Coupled with shorter constructionrelated closures and potential long-life
performance, PCP offers transportation
agencies many significant advantages.
R05
Reasons for Using Precast
Concrete Pavement (PCP)
• Rapid Renewal/Maintenance of Traffic
– Limited lane-closure times
– Work-zone safety
– Open to traffic immediately
• Long-Life Performance /Concrete Quality
– Off-site fabrication of panels (QA)
– High strength (forms cycled daily)
VDOT I-66 Mainline and RushHour Lanes
VDOT I-66 Exit Ramp/Outside
Lane
PCP Use by Highway
Agencies
PCP constructed during 2002-2013
PCP routinely used.
PCP Lead Adopters in SHRP2
Implementation Assistance Program
Implementation Assistance Program –
PCP Lead Adopters
• Hawaii DOT – Inlay/Asphalt on H-1.
• Illinois Tollway – Bridge Approaches.
• Kansas DOT – Fort Leavenworth/
Intersection at Main Entrance.
• Texas DOT – Industrial Intersection.
• Wisconsin DOT – Rehabilitation of
Beltline Highway/Madison.
SHRP2 R05 Opportunities
• FHWA pursuing additional funds for additional User
Incentive Agencies.
– If successful, will announce R05 again as part of
SHRP2 IA Program Round 6.
– Would provide financial assistance up to 5 highway
agencies to pilot precast concrete projects (up to
$100k).
– Application around Jun-Jul 2015; Selection around
Aug 2015
• If Interested, contact Sam Tyson with FHWA
(sam.tyson@dot.gov)
Pavement Deterioration Curve
Pavement Condition
R26
40% Drop in Quality
75% of Life
40% Drop in Quality
12%
R23
Terminal Serviceability
T0
Pavement Life
T1
20 years  30-50 years
R23 - Pavement Renewal Solutions
• Developed through the second Strategic Highway Research Program
(SHRP2)
• Product elements:
– Pavement Assessment Manual
– Best Practices (design and construction)
• Rigid Pavements
• Flexible Pavements
– Guide Specifications
– Traffic Considerations
– Life-Cycle Cost Analysis
– Life-Cycle Assessment
– Emerging Technologies
44
rePave Scoping Tool
(Interactive Program)
A web-based, user-friendly means of walking through the
decision making process (selection and design tables)
A user-friendly means of navigating a large amount of
information (required to produce long-life pavements)
45
For Link to rePave & Resources: www.pavementrenewal.org
Rigid Best Practices:
Strategies
• Introduction
• Rigid Renewal Strategies
– Unbonded Concrete Overlays of Concrete Pavements.
– Unbonded Concrete Overlays of HMA Pavements
– Bonded Concrete Overlays of Concrete Pavements
46
Rigid Best Practices:
Details
• Unbonded Concrete Overlays of Concrete Pavements
– Criteria for Long Life Potential
– Materials Considerations
• Cementitious Materials
• Aggregate
• Chemical Admixtures
– Separator Layers
– Other Materials
– Design Considerations
– Structural Design and Joint Design Considerations
47
FHWA’s PCC QA Workshop
Update
48
Quality in the Concrete Paving
Process
• Two-day workshop on the benefits of a Quality Assurance
Program
– Increase concrete pavements life at reduced cost
– Contactor benefits of improved Quality Control
– New technologies and tools for testing and inspection
•
Agency and Contractor Participation
– Class size 30 to encourage discussion
– DOT (QA/QC, Materials, Construction Staff etc.)
– Contractor staff (Superintendents, QC Managers etc.)
– FHWA Division Office Staff
Workshop Outline:
•
•
•
•
•
•
•
•
•
Workshop Introduction
Module 1: Quality Assurance Concepts
Module 2: Concrete Materials
Module 3: Concrete Properties and Testing
Module 4: QC and Agency Acceptance
Module 5: Pre-Paving and Mix Production
Module 6: Paving
Module 7: Utilizing Quality Concepts
Module 8: Quality in Field Practice
Workshop Materials
• Participant Workbook
• Testing Guide for Implementing Concrete Paving
Quality Control Procedures
• Flash Drive with additional references and tools
Module 8: State Field Data
• Collect field data for a two
week period
• Visit the state at least three
months prior to the QA
workshop
Past QA Workshops
ME
WA
NH
MT
ND
OR
ID
WY
NV
CA
(2)
AZ
(2)
CO
NM
WI
SD
NE
UT
VT
MN
KS
OK
TX
MI
(2)
NY
PA (2)
IL
IN OH
(2)
WV
VA
MO
KY
NC
TN
AR
SC
MS AL GA
LA
IA
FL
AK
Workshops already held
RI
NJ
DE
MD
Future Workshops in 2015
ME
WA
NH
MT
ND
OR
ID
WY
NV
CA
(2)
AZ
(2)
CO
NM
WI
SD
NE
UT
VT
MN
KS
OK
TX
MI
(2)
NY
PA (2)
IL
IN OH
(2)
WV
VA
MO
KY
NC
TN
AR
SC
MS AL GA
LA
IA
RI
NJ
DE
MD
FL
AK
Workshops already held
Future workshops in 2015
Benefits of the QA Workshop –
Examples
•
Strength Issues
Benefits of the QA Workshop Examples
 MIT SCAN T2
- Faster, economical, accurate and
nondestructive means of measuring
pavement thickness
Pavement Thickness
Average Thicknkess
Design Thickness
Pavement Thickness, Inches
15.0
14.5
14.0
13.5
13.0
12.5
12.0
1
2
3
4
5
6
Location ID
7
8
9
Benefits of the QA Workshop
 Demonstration and benefits of good QA/QC and construction
practices for both agency and contractors.
 Demonstration of field implementable and practical
technologies. Equipment loan also available.
 Several States have started implementing some of these
practices and new technologies in their specifications.
Examples include gradation monitoring, MIT Scan 2, MIT
SCAN T2, maturity etc.
 If interested, Contact Gary Crawford at
gary.crawford@dot.gov
Thank You
• Any Questions on SHRP2 Renewal
Pavement Product – Contact:
Steve Cooper
FHWA Office of Technical Services
Stephen.j.cooper@dot.gov
443-257-7145
58