Options for Using Precast Concrete to Speed

Construction
A solution for repairing roadways with faster project schedules,
reduced congestion, and improved safety
Modular pavement technology uses precast concrete pavement (PCP) segments
that can be quickly installed on a prepared foundaton. PCP has applicaton both
in accelerated pavement reconstructon as a permanent surface over a wide
area, as well as for temporary segments to allow more fexibility in constructon
phasing. There are great potental benefts to using PCP systems: they can
speed up roadway reconstructon without sacrifcing quality; once installed, the
roadway can quickly be reopened; and trafc disrupton during constructon
can be signifcantly reduced through use of unique phasing opportunites. In
many cases, contractors have been able to repair the subgrade and return the
roadway to full service within one constructon shif.
Over the past 10 years, several transportaton agencies have recognized the
benefts of this technology and installed PCP systems in a variety of applicatons.
Because it is a relatvely recent technology, however, informaton on modular
pavement practces and PCP performance has not been well documented. In
additon, most PCP systems are proprietary, so state transportaton departments
have ofen found them difcult to specify.
The objectve of the research from the second Strategic Highway Research
Program (SHRP2) was to fll this gap in knowledge by developing guidelines
and tools for public agencies to use in the selecton, design, constructon,
installaton, and maintenance of PCP systems, and to provide the tools for cost/
beneft assessment in situatons where the technology may apply.
Modular Pavement Technology
The Solution
Because PCP systems are a recent technology, there was insufcient data on their
use over an extended period of tme, with gaps in knowledge regarding durability and performance at the joints and panels.
Additonally, unrealistc expectatons about PCPs as super pavements potentally could undermine the success of the
technology. To address these issues, SHRP2 investgated 16 PCP projects at locatons with a wide range of climates (from
Michigan to Texas) and assessed how the PCP systems were used (on ramps, toll plazas, at-grade roadways, and airports).
Field surveys included short, intermitent repairs as well as longer, contnuous applicatons.
Photo Credits: James Bryant, SHRP2
Precast concrete pavement
saves time and money
FOCUS AREA:
Renewal (R05)
Tools to match the right pavement
installaton optons to the project,
as well as specifcatons for design,
fabricaton, and installaton of
precast concrete pavement systems.
Save Lives
Shorter constructon
period means less
exposure to work
zone hazards for drivers and
constructon workers.
Save Money
Installaton
costs for PCP are
slightly higher than alternatve
CIP solutons, but can result in
signifcant savings because of
reduced installaton tme and
trafc maintenance costs.
Save Time
PCP enables rapid
installaton and
quality control, and roadways
can ofen remain partally open
during the installaton process for
reduced congeston and minimal
impact to users.
SHRP2s research found that modular pavement technology is stll evolving, but that over the 10 years it has been used,
well-designed and well-constructed PCP systems can provide high-quality, long-term service and are ofen a good choice
for rapid repair and rehabilitaton of existng pavements. These new guidelines provide transportaton agencies with
tools that can match the PCP installaton technology to the project, while providing clear specifcatons for PCP design,
fabricaton, and installaton, as well as model specifcatons.
The Benefts
PCP pavement provides the opportunity for signifcantly reducing trafc impacts of roadway reconstructon projects,
partcularly on heavily traveled routes. The technology has applicatons both in small segments to allow fexibility in
constructon phasing, as well as use for corridor-wide pavement reconstructon. This tool will support the contnued growth
and understanding of the use of PCP for roadway constructon. Some benefts are:
Shorter installaton tme means reduced trafc impacts.
Safety of drivers and constructon workers improves due to reducing the frequency and duraton of work zones.
Pavement is ready for trafc upon installatonno curing tme.
Slabs are cast in plants under ideal conditons for optmum quality.
Installaton can take place at night or under adverse weather conditons, extending the constructon season.
Durability can be similar to or beter than traditonal cast-in-place (CIP) solutons.
Who is using these modifed pavement technologies?
PCP systems are in place across the country. Here are just a few examples
Agency System Projects
Caltrans Precast, prestressed, and jointed PCP (Caltrans designed) I-680 (prestressed system)
I-15 (jointed system) and other locations
Illinois Tollway Jointed PCP for repairs
(Tollway designed and Fort Miller Co. systems)
Several projects in the Chicago area
Iowa Department of Transportation
(DOT)
Precast, prestressed, and jointed PCP for approach slabs Highway 60 near Sheldon, IA
Iowa 43 near Denver, IA
New Jersey DOT Jointed PCP for repairs (Fort Miller Co. systems) Several projects along I-95 and other primary
roadways
Utah DOT Utah DOT-designed Fort Miller Co. systems I-15 and other locations
Virginia DOT Precast, prestressed (Virginia DOT designed)
Jointed (Fort Miller Co. systems)
Fairfax County, VA; I-66 mainline (prestressed
system); I-66 ramp (jointed system)
How can you learn more?
For more informaton, email Sam Tyson at FHWA, sam.tyson@fwa.dot.gov, Keith Plate at AASHTO, kplate@aashto.org,
or James Bryant at TRB, jbryant@nas.gov. Additonal resources include a project overview on the TRB website at
htp://apps.trb.org/cmsfeed/trbnetprojectdisplay.asp?projectd=2169.
About SHRP 2 Implementation
The second Strategic Highway Research Program is a natonal partnership of key transportaton
organizatons: the Federal Highway Administraton, the American Associaton of State Highway
and Transportaton Ofcials, and the Transportaton Research Board. Together, these partners
conduct research and deploy products that will help the transportaton community enhance the
productvity, boost the efciency, increase the safety, and improve the reliability of the Natons
highway system.
Strategic Highway Research Program
U.S. Department of Transportaton | Federal Highway Administraton
American Associaton of State Highway and Transportaton Ofcials Transportaton Research Board
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