Precast Concrete Pavement (PCP)

A Fast and Durable Strategy

New Delhi, January 2019

Mehdi Parvini, Ph.D., PE, PMP
Outline
• Introduction
• PCP Characteristics
• PCP Selection and Design
• PCP Construction Considerations
• PCP Operation
Introduction
Pavement Engineering Concerns
• Aging Highway Systems
• Traffic Congestion
• Heavier Truck Loads
• Work Zone Safety
• High Maintenance Cost
• Sustainability
Pavement Engineering Solution
• Long-Life Pavement
• Low Maintenance
• Safe and Sustainable
Pavement Construction under Traffic
• Conventional Concrete Pavement
• Long delays & long service life
• Rapid Setting Concrete Pavement
• Short delays & variable service life
• Precast Concrete Pavement
• Short delays & long service life
PCP Characteristics
PCP Definition
Precast Concrete Pavement systems are concrete panels
fabricated off-site, transported to the project site, installed
(connected and supported) on a prepared foundation
(existing or re-graded) foundation).
• Requires minimal field curing
• Rapid repair, rehabilitation and reconstruction of
asphalt and concrete

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PCP Benefits
• Short work zones – No on-site finishing and curing
• Reduced user delays – Immediately ready for traffic
• Improved safety/satisfaction – Workers and users
• No need for paver – Less mobilization cost
• Long-life performance – High-quality concrete
• Reduced maintenance – Strength and durability assured.
• Sustainability – Economic, social & environmental benefits

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PCP Facts
• PCP is relatively new – in use since 2001
• Long-Life pavement strategy
• Used primarily for rapid repair & rehabilitation
• Typically night‐time work & short work windows
• More expensive than conventional PCC
• Do not solve subgrade and drainage problems

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PCP Performance
• Good Performance
• Panels are fabricated in a plant
• Under controlled environment
• Quality concrete and reinforcement/prestressing
• Cured and gained strength

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PCP Applications
• Single Slab Replacement

• Multi Slab Replacement

• Lane Replacement

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PCP Types
• Jointed Type
• Precast Individual Slab Replacement (IPSR)
• Precast Jointed Concrete Pavement (PJCP)

• Post –Tensioned Type

• Precast Post-tensioned Concrete Pavement
(PPCP)
Jointed PCP Type (PJCP)

• Individual (repair)

• Continuous
(repair or reconstruction)
Post-tensioned PCP Type (PPCP)
Continuous (construction/reconstruction)

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Jointed PCP Systems
Generic or Patented Systems

• Connection
• Grading
• Support
Jointed PCP Systems (cont.)

California Generic System Illinois Tollway Generic System

California Rapid Roadway TM System Narrow Mouth Surface Slots

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Jointed PCP Systems (cont.)

Fort Miller Super-Slab TM Roman Stone TM

URETEK’s stitch-In-Time™ Kwik Slab TM

PCP Structure
• Jointed systems
• Nominally reinforced or pre-tensioned panels
• Post‐tensioned systems
• Reinforced and Post-tensioned panels

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PCP Selection and Design
PCP Selection Factors
• Repair vs. Replacement
• Type of Road
• Service life Expectation
• Support Condition
• Traffic Management
• Time Constraint
• Budget
PCP Design
•Performance Difference
• Post-tensioned vs. Jointed
• Pre-tensioned vs. Reinforced
• Load Transfer Method
• Support Method
•Life Cycle Cost
PCP Design (cont.)
•Curves
• Horizontal
• Vertical
•Super-elevation Transition
•Connection to existing
•Placement order
Jointed vs Post-tensioned PCP

PJCP PPCP
Thickness 10 to 14 in 8 to 10 in
(25 to 30 cm) (20 to 25 cm)
Joint Spacing 12 to 15 ft 150 to 250 ft
(3.6 to 4.5 m) (45 to 75 m)
Joint width 0.25 to 0.35 in 0.5 to 2 in
(6 to 9 mm) (12 to 50 mm)
Joint Load Transfer Dowel Bars Dowel Bars/Shear Key

Support Grout Grout

Base/Panel Finished base or Polyethylene sheet over

Interface bedding layer stabilized base

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Specifications and Plans
PPCP
PJCP
PRECAST JOINTED CONCRETE PAVEMENT
IPSR 40-8.01 GENERAL
40-8.01A Summary
Section 40-8 includes specifications for furnishing and installing
precast jointed concrete pavement (PJCP). Furnishing includes
pretensioning PJCP before shipping to the jobsite. Installing
includes grading PJCP in place, furnishing and installing dowel
bars at joints between PJCP and the existing pavement, and
sealing non-compliant joints.
Before submitting shop drawings, field verify the geometry
described.
For horizontal curves and transition to horizontal curves, PJCP
must match the superelevation and superelevation transition of
the roadway.
Install dowel bars at joints between PJCP and the existing
concrete in compliance with the requirement in either section
41-8 or “Dowel Bar Slots” of these special provisions.
40-8.01B Definitions
system: consists of features that are part of design,
construction, and performance of the precast pavement
product. These features are included, but are not limited to size
and thickness of panels and slabs, joints, elements cast in the
panels, load transfer method, techniques for providing grade
control for the panels, etc.
Concrete Pavement Office: Office of Concrete Pavements and
Pavement Foundations, Caltrans Pavement Program, Translab,
5900 Folsom Blvd., Sacramento, CA 95819
40-8.01CSubmittals
40-8.01C(1) General
…
 Letting
• Bidding – Bid Inquiries
• Contractor Qualification - Lowest Bid
• Value Analysis - System Approval
• Training – Pre-Construction
PCP Construction
PCP Construction Considerations
• Traffic considerations
• Traffic volume
• Lane closure time
• Alternate Routes
• Site considerations
• Base/subgrade support issues
• Drainage issues
• Constructability considerations
• Work window
• Work space
• Matching layout
• Transportation

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Traffic Management Impact
• Traffic Management dictates Work Window
• Work window drives production rate
• Production rate affects costs
Goal – Maximize production rate by effective traffic
management

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Construction Work Space
• At least an additional lane in addition to the repair lane
• At least one lane open to traffic (in most cases)
• Space for operation remove existing, base, grade, grout
• Space for trucks carrying panels
• Space for crane to lift panels

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PCP Quality
• Concrete durability – controlled quality at plant
• Load transfer at joints – mechanical
• Panel support element – good support necessary

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PCP Panel Fabrication

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PCP Panel Grading

Placement directly on prepared Placement using strong-back beams

base/bedding

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PCP Panel Grading (cont.)

Placement using polyurethane foam

Placement using levelling bolts

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PCP Production Rate
Typical (current) production rates/nighttime closure
• Repairs: 15 to 20 panels
• Continuous:
• 30 to 40 panels for jointed application (up to 600 ft)
• Up to 600 ft for post-tensioned system
• Higher rates with larger crews,
better planning & new systems
(record is 60 panels-900 ft)
PJCP Installation

Previous IPPCP
Section

Inactive Joint Active Joint Inactive Joint Inactive Joint Inactive Joint Active Joint Inactive Joint Inactive Joint
PPCP Installation
PPCP Installation (cont.)
PPCP Installation (cont.)
PPCP Installation (cont.)
Sample PJCP Operation
Fabrication
Cut Existing
Remove Existing
Compact Subgrade
Place Base
Grade Base
Place Panels
Slide Panels
Inject Bedding Grout
Fill Dowel Slots
Finished Product
 Questions?

Contact:
Mehdi Parvini
mehdi.parvini@dot.ca.gov
(510) 715-6587