Pavement Condition Index Distress Identification Manual for Jointed Portland Cement Concrete Pavements October 1991 First Edition Prepared by: Advanced Systems Applications Section Metropolitan Transportation Commission Published by: Metropolitan Transportation Commission Joseph P. Bort MetroCenter * 101 Eighth Street ¢ Oakland, CA 94607-4700 Telephone: 510.464.7700 ¢ TDD/TTY: 510.464.7769 * Fax: 510.464.7848Pavement Condition Index Distress Identification Manual for Jointed Portland Cement Concrete Pavements October 1991 _ First Edition Prepared by: Advanced Systems Applications Section Metropolitan Transportation Commission Published by: Metropolitan Transportation Commission Joseph P. Bort MetroCenter * 101 Eighth Street * Oakland, CA 94607-4700 Telephone: 510.464.7700 * TDD/TTY: 510.464.7769 * Fax: 510.464.7848Copyright @ 1991 by the Metropolitan Transportation Commission This publication may not be reproduced in whole or in part without the permission of the Metropolitan Transportation Commission, Joseph P. Bort MetroCenter, 101 - Eighth Street, Oakland, CA 94607-4700 This report was financed in part with federal funds made available from the U.S. Department of Transportation through the Federal Highway Administration, and may be reproduced by FHWA References 4. Metropolitan Transportation Commission, “Bay Area PMS User Guide,” The Metropolitan Transportation Commission, Oakland, CA 1986 2. Shahin, M. Y., and S.D. Kohn, “Pavement Maintenance Management for Roads and Parking Lots,” U.S. Army Corps of Engineering, Technical Report M-294, October 1981. 3. APWA, “APWA-COE PAVER Pavement Condition Index Field Manual, Concrete” American Public Works Association, 1983.Table of Contents Preface .. Inspection Procedures... 1 Corner Break... Divided (Shattered) Slab .... 2 3. Faulting .... 4 Linear Cracking (Longitudinal, Transverse and Diagonal Cracks)... 5 Patching and Utility Cuts . 6 Scaling/Map Cracking/Crazing ... 7 Spalling Helpful Hints .... Notes 39 Preface This manual is prepared to assist users of the Bay Area Pavement Management System (PMS) in identifying surface distress in a uniform and repeatable manner. The distresses included in this manual are used to calculate the Pavement Condition Index (PC!) for pavements with jointed portland cement concrete surfaces. It was prepared for the Metropolitan Transportation Commission (MTC) as part of their project to assist local agencies in implementing pavement management systems (PMS) (Ref. 1). It presents descriptions of the distress types to be inspected accompanied by photographs to aid the inspector in identifying the distress types and severity levels. This rating procedure was derived from the rating methods developed by Dr. M.Y. Shahin and his team at the U.S. Army Corps of Engineers Construction Engineering Research Laboratory (CERL) (Ref. 2) and adopted by the American Public Works Association (Ref. 3). This procedure uses only the distress types found to be significant in the San Francisco Bay Area. Austin Research Engineers, Inc., assisted in the development of the modifications to the original procedures. The Texas Transpor- tation Institute assisted with the final modifications and development.Inspection Procedures Pavement inspection is conducted on inspection units. An inspection unit is a small segment of a pavement or management section selected of convenient size which is then inspected in detail. The distress found in the inspection unit is used to calculate the PCI for the inspection unit inspected The PCI of the inspected inspection units in the section are then used to represent the condition of the entire section, An inspection unit can vary in size from ten to thirty slabs. For ease of inspection, inspection units should generally contain twenty slabs each, except for those at the end of the section. Slab joint spacing should be no larger than 30 ft (9 m). If the joint spacing is greater than 30 ft (9 m), the pave- ment should be inspected as if additional (imaginary) joints are located between the existing joints at an even interval such that the joint spacing is less than 30 ft (9 m). As an example, if the joint spacing is 50 ft by 12 ft (15.6 by 3.7 m), an additional imaginary joint would be assumed to be located at the midpoint of the length of each slab. No distress would be associated with the additional imaginary joint. The use of imaginary joints is illustrated in Figure 1 In this example, each actual slab would be inspected as two slabs. The distress in each half of the slab would be counted as if it were the distress for a single slab. No distress would be based on the center imaginary joint. For convenience of location and inspection, the inspection unit would contain 24 slabs. These 24 slabs are 12 actual slabs, each divided by a single imaginary joint. The inspector inspects the inspection unit by walking the inspection unit, or standing on the curb shoulder, and recording the type and severity of each distress present in each slab in the inspection unit. The type, severity and number of slabs affected must correspond to those defined in this Distress Identification Manual. Concrete distress quantities are based on the number of slabs which exhibit the distress. The inspector must check each slab in the inspection unit. The inspection method is designed to allow the calculation of a composite rating index called the Pavement Condition Index (PC!). The steps for determining the PCI of an inspection unit are shown in Figure 2. The PCI scale is shown in Figure 3. The distress types, severity levels, and methods of estimating quantities are keyed to the deduct curves presented in the Bay Area PMS User's Guide (1). These distress and severity level descriptions must be carefully followed since they were used in the development of the deduct curves. Failure to do so could invalidate the PCI calculated. The inspector is cautioned to record the quantity and severity of the distress types as they exist. The pavement management system (PMS) projects the condition into the future. Recording distress at a higher severity than actually present will invalidate the inspection results. The units inspected should be selected at random when more than two inspection units are to be inspected; when less than two inspection units are inspected, those selected should be "representa- tive of the condition of the section.” Selection of either the best, or worst, inspection units to inspect will bias the results.Figure 1. Illustration of Imaginary Joints i Jolelo!ieloie + | © | © | ej | ©!o!]o! o]e! © * Ololoiol| oi a L | bb} aye eae eo et * wmegrey ° nt * gran Figure 2. Computing the Pavement Condition Index Step 1 Inspect sample units. Determine distress Step 3 Adjust Total Deduct Value: TDV = a +b fs, severity levels and measure densit na Z af Step 4 Adjust Total Deduct Value Low-soverity. Transverse Crack Medium Corner Spailing Step 2 Determine deduct values. Loar y cracking /y, Step 5 Compute Pavement Condition Index PCI = 100 - CDV, for each sample unit inspectedFigure 3. Pavement Condition Index PCI 100 Rating Excellent |Very Good When a small area of pavement is found to be much worse than the majority of the pavement, it can be inspected and identified as a “special” inspection unit. This is used to identify areas of localized deterioration such as an area damaged by utility cuts, crossing of construction traffic, or other local- ized problems. A weighted average is used to calculate the PCI when special inspection units are inspected. A special inspection unit should only be used when two or more regular inspection units are also inspected The PCI values of individual inspection units are averaged to determine the PCI of the entire management section. For more information on the use of this manual, please contact MTC.1 Corner Break Description: Severity levels: How to Count: A corner break is a crack that intersects perpendicular joints at a distance less than or equal to one-half the slab length on both sides, measured from the corner of the slab. For example, a slab with dimensions of 12 by 20 ft. (3.7 by 6.1 m) that has a crack 10 ft (3 m) on the short side and 6 ft (2.3 m) on the long side is not consid- ered a comer break; it is a diagonal crack. However, a crack that intersects 4 ft. (1.2 m) on the short side and 8 ft (2.4 m) on the long is considered a corner break. A corner break differs from a corner spall in that the crack extends vertically through the entire slab thickness, while a corner spall intersects the vertical face of a joint at an angle. Load repetition combined with loss of support and curling stresses usually causes comer breaks. Comer breaks are considered a major structural distress L* Break is defined by a low-severity crack and the area between the break and the joints is not cracked or contains only one low severity crack. M* Break is defined by medium-severity crack and/or the area between the break and the joints, which contains a medium severity crack or more than one crack. H’ Break is defined by a high-severity crack and/or the area between the break and the joints, which contains a high severity crack, more than one medium severity crack, or the majority of the area is missing. Distressed slab is recorded as one slab if it 1. Contains a single corner break. 2. Contains more than one break of a particular severity. 3. Contains two or more breaks of different severities. For two or more breaks, the highest level of severity should be recorded. For example, a slab contain- ing both low- and medium-severity corner breaks should be counted as one slab with a medium corner break. Once the severity has been determined, the distress is recorded as occurring in one slab. If two or more corner breaks are present in a single slab, the highest severity present will be recorded. When three or more corner breaks occur, the slab will also be considered a divided slab. In Figure 4, slab 1 would be rated as. having a medium severity corner break and a low severity shattered slab. How- ever, slab 2 would be recorded as containing only a medium severity divided (shattered) slab, as described in divided slabs. * See linear cracking for a definition of low-, medium- and high-severity cracks.Figure 4. Illustration of Corner Breaks L = Low Severity M= Medium Severity Severity of Corner Breaks Present ‘A- Medium —D— High B-low E- Low C-Low — F— Medium Figure 7: Medium Severity Corner Break Figure 6: Medium Severity Corner Break12 2 Divided (Shattered) Slab Description: Cracks divide slabs into four or more pieces. Overloading and/or inadequate support normally cause this distress. Curling and warping stress may contribute to initial cracking, If all pieces or cracks are contained within a corner break, the distress is categorized as a corner break. Medium and high severity divided slabs are considered shattered slabs. Shattered slabs are considered major structural distresses. Severity levels: Severity of Number of Pieces Majority of Cracks* in Cracked Slab 4105 6to8 = More than 8 L L L M M M M H H M H H How to Count: Once the severity has been determined, the distress is recorded as occurring in the one slab. If the severity is medium or high, no other distress is counted for that slab. Figure 4 illustrates how to rate slabs with corner breaks. Slab 1 would be rated as both a low severity divided slab and having a medium severity corner break. Slab 2 would be rated as a medium severity divided (shattered) slab, and no other distress as would be recorded. Cracks within the corner break are not used to define the number of pieces to determine divided slab severity. Pieces less than one square foot (0.1 sq m) in size should not be counted * See linear cracking for definition of low-, medium- and high-severity cracks 133 Faulting Description: Severity Levels: 14 Faulting is the difference in elevation across a joint. Some of the common causes of faulting are: 1. Settlement because of soft foundation. 2. Pumping or eroding of material from under the slab due to repeated heavy loadings, 3. Curling of the slab edges due to temperature and moisture changes. 4. Poor construction. Most faulting is due to repeated loading, and faulting is considered a major foundation support problem. Severity levels are defined by the difference in elevation across a transverse joint. ‘Severity Level Difference _in_ Elevation L 3/8 to 1/2 inch (10 to 13 mm) M 1/2 to 1 inch (13 to 25 mm) H Greater than 1 inch (25 mm) 15How to Count: 16 Faulting across a joint is counted as occurring in one slab. Which slab the fault is counted as occurring in is arbitrary, since only the number is recorded. Only affected slabs are counted. If more than one severity occurs on a single joint, the highest is recorded. If more than one joint is affected, the number of joints with different severity levels present in the slabs are recorded. Figure 13 illustrates how to count faulting. Faults across a crack are not counted as distress but are considered when defining crack severity. Faults of patch joints are not counted because they are considered in defining patch severity. Faulting is not measured if the length of the fault is less than three feet. Faulting less than 3/8 inch (10 mm) is not counted. Figure 13. Illustration of Faulting L = Low Severity © © © M= Medium Severity H = High Severity Severity of Faulting Present : @® L © ™ Faulting Faulting Slab Present S@_ present 7 1-L, 1-H u u 8 1M OnRons 9 0 Oe Ore 10. 1-M 11. 1-M a 120 Oe 71 4 Linear Cracking (Longitudinal, Transverse and Diagonal Cracks) Description: These cracks, which divide the slab into two or three pieces, are usually caused by a combination of repeated traffic loading, thermal gradient curling, and shrinkage stresses. (Slabs divided into four or more pieces are counted as divided slabs). Low-severity cracks are often related to warping or shrinkage and are not consid- ered major structural distresses. Medium or high-severity cracks are usually working cracks caused by a combination of traffic loads and environmental factors and are considered major structural distresses. Severity Levels: L_—_ Unfilled crack with width less than 1 inch (25 mm), spalling (defined on page 31) less than 1 inch (25 mm) and faulting less than 3/8 inch (10 mm). Any filled crack in good condition, with faulting less than 3/8 inch (10 mm). M__ Unfilled crack with width or spalling greater than 1 inch but less than 3 inches (75 mm). Unfilled crack less than 3 inches (76 mm) wide with faulting greater than 3/8 inch (10 mm) but less than 1 inch (25 mm). Filled crack with faulting less than 1 inch (25 mm), but greater than 3/8 inch (10 mm). feH_ Unfilled crack with width or spalling greater than 3 inches (76 mm). Filled or unfilled crack with faulting greater than 1 inch (25 mm). How to Count: Once the severity has been identified, the distress is recorded as occurring in one slab. If more than one severity is present on a single crack, the highest is recorded. lf more than one crack is present, each with a different severity, each is recorded. If two medium-severity cracks are within one slab, the slab is counted as having one high-severity crack. Slabs divided into four or more pieces are counted as divided slabs. Figure 17 illustrates how to count linear cracking. * Spalling is defined in the distress Spalling. Figure 17. Illustration of Cracking L = Low Severity M= Medium Severity H = High Severity Types of Cracking and Severities Present Slab Type and Severity of Cracking 1 1 Low-severity Linear and 1 Low-severity Corner Crack 2 1 Low-severity Linear and 1 Medium-severity Linear Crack 3 1 High-severity Linear Crack 4 1 Medium-severity Shattered Slab a1Figure 19: Low Severity Linear Crack Figure 18: Low Severity Linear Crack Figure 20: Medium Severity Linear Crack Figure 21: Medium Severity Linear CrackFigure 22: High Severity Linear Crack Figure 23: High Severity Linear Crack 5 Patching and Utility Cuts Description: A patch is an area where the original pavement has been removed and replaced. A utility cut is a patch that has replaced the original pavement after the installation or maintenance of underground utilities. The severity levels of utility cuts are the same as those for regular patching. Patching material can be portland cement concrete, asphalt concrete, or other material : L_ Patch is in good condition and functioning well with little or no deterioration. M Patch is moderately deteriorated and/or moderate spalling* can be seen around the edges. Patch material can be dislodged with considerable effort, or patch has developed low or medium severity cracks. Low severity faulting has developed between the patch and the slab. H Patch is badly deteriorated. The extent of the deterioration warrants replace- ment of the patch. Patch is missing much of the material or has developed high severity cracking or more than two medium severity cracks. Medium or high severity faulting has developed between the slab and patch. * Spalling is defined in the distress type, Spalling. 25How to Count: If a single slab has one or more patches with the same severity level, itis counted as one slab containing that distress. If a single slab has patches with more than one severity level, each is counted. When an entire slab has been replaced, itis counted as a low severity patch, and all distress in the slab is recorded. Otherwise, distress within a patch is not recorded because it is used in defining the severity of the patch. Figure 24: Low Severity 26: Medium Severity Patch Figure 25: Low Severity Patch (Replaced Slab) FigureFigure 29: High Severity Patch 28 Figure 28: High Severity Patch 6 Scaling/Map Cracking/Crazing Description: Severity levels: How to Count: Map cracking or crazing refers to a network of shallow, fine, or hairline cracks which extend only through the upper surface of the concrete. The cracks tend to intersect at angles of 120 degrees. Map cracking or crazing is usually caused by concrete overfinishing and hot weather concrete construction. They may lead to surface scaling, which is the breakdown of the slab surface to a depth of approximately 1/4 to 1/2 in. (6 to 13 mm). Scaling may also be caused by deicing salts, improper construction, freeze-thaw cycles, and poor aggregate. L_ Crazing or map cracking exists and may cover most of the slab area; the sur- face is in good condition, with only minor scaling present. M_ Slab is scaled, but less than 15 percent of the slab is affected H__ Slab is scaled over more than 15 percent of its area. A scaled slab is counted as one slab, Low-severity crazing should only be counted if more than 15% of the slab is affected by crazing or map cracking, if the potential for scaling appears to be imminent, or a few small pieces have come out.7 Spalling Figure 30: Medium Severity Scaling Figure 31: High Severity Scaling Description: palling is the breakdown of the slab edges or corner within 2 feet (0.6m) of the joint. A spall usually does not extend vertically through the slab, but intersects the vertical face of the joint at an angle as illustrated in Figures 32 and 33. Spalling results from: 1. excessive compressive stresses, excessive deflection of the joint due to loss of support and traffic loading, or by infiltration of incompressible materials into the joint and thermal induced expansion: weak concrete at the joint caused by overworking: or water accumulation in the joint and freeze-thaw action. 3132 Severity Levels: Spall must be greater than 1 inch (25 mm) wide to be recorded Severity Width of Length of Level Spall Spall Spall Pieces L 1-4inch less than Tight - cannot be easily (25-100mm) 2 feet removed, or spall less than (0.6 m) two inches (50 mm) wide and the pieces are missing M 1-4inch greaterthan Loose - can be 2 feet removed and some OR pieces are missing greater than less than 4 inches 2 feet H greater greater than Missing - most than 4 inches 2 feet pieces have been removed How to Count: If one or more spalls with the same severity level are in one slab, the slab is counted as one slab with spalling. If more than one severity level occurs, it is counted as one slab with the higher severity level. Corner spalling having an area of less than 10 sq. inches (0.06 sq. m) is not counted. A frayed joint where the concrete has been worn away along the entire joint is rated as low severity. Figure 32. Illustration of Joint Spalling Joint Spall 38Figure 33. Illustration of Corner Spalling Figure 34: Low Severity Spalling Figure 35: Low Severity SpallingFigure 36: Medium Severity Spalling Figure 37: High Severity Spalling Helpful Hints Several questions frequently arise during inspection. Most are answered in the description of inspec- tion procedures or in the blocks on how to measure each distress type. However, they are also pro- vided here for convenience and further clarity. 1. All patched areas within the inspection unit are included in the rating. A replaced slab is counted as a patch. However, the distress in a replaced slab is also counted. 2. Ifa distress is found in a patched area, it is not recorded; however, the distress is considered in determining the severity level of the patch. 3. Faulting is only counted at joints. Faulting associated with cracks and patches are used in deter- mining the severity of those distress types. 4. Ia patch is placed in the middle of a severely damaged area, and the original distress is more severe than the patch, only the original distress is recorded. For example, if a small patch is placed in the center of a severely scaled slab, only the scaling is recorded. 5. The cracks forming corner breaks are normally at least one foot (0.3m) from the perpendicular joint and go through the slab vertically. Corner spalls do not go all the way through the slab and generally travel at about a 45 degree angle or less from the horizontal. 3738 6. Shattered slabs cover a majority of the pavement slab. Several pieces within a comer break affect the severity of the corner break; they do not form a shattered slab. 7. When a slab is counted as a medium or high severity shattered slab it is assumed that the slab should be replaced, and no other distress is recorded for that slab. 8. Aslab cannot contain linear cracking and be a shattered slab. The linear cracking is used to determine the number of pieces into which the slab is broken and is not counted separately when a shattered slab is counted. Notes 39