Rapid Pavement Construction Tools, Materials and Methods

Final Research Report

Rapid Pavement Construction Tools, Materials and Methods

by

Brett Ozolin Research Assistant

Stephen T. Muench Assistant Professor

Department of Civil and Environmental Engineering University of Washington

Engineering Professional Programs (UW EPP) 10303 Meridian Ave. N., Suite 301 Seattle, WA 98133-9483 UW Box 358725

Prepared for Washington State Transportation Commission

Department of Transportation and in cooperation with

U.S. Department of Transportation Federal Highway Administration

May 2007

1. REPORT NO.

TECHNICAL REPORT STANDARD TITLE PAGE

2. GOVERNMENT ACCESSION NO.

3. RECIPIENTS CATALOG NO

WA-RD 670.1

4. TITLE AND SUBTITLE

5. REPORT DATE

Rapid Pavement Construction Tools, Materials and Methods

May 2007

6. PERFORMING ORGANIZATION CODE

7. AUTHOR(S)

Brett Ozolin, Stephen T. Muench

9. PERFORMING ORGANIZATION NAME AND ADDRESS

Engineering Professional Programs (UW EPP) 10303 Meridian Ave. N., Suite 301 Seattle, WA 98133-9483 UW Box 358725

8. PERFORMING ORGANIZATION REPORT NO. 10. WORK UNIT NO. 11. CONTRACT OR GRANT NO.

12. CO-SPONSORING AGENCY NAME AND ADDRESS

13. TYPE OF REPORT AND PERIOD COVERED

Research Office Washington State Department of Transportation Transportation Building, MS 47372 Olympia, WA 98504-7372 Kim Willoughby, Project Manager, 360-705-7978

Final Research Report

14. SPONSORING AGENCY CODE

15. SUPPLEMENTARY NOTES

This study was conducted in cooperation with the U.S. Department of Transportation, Federal Highway Administration.

16. ABSTRACT

To address the need to deliver cost-effective projects while minimizing traffic impacts, the Washington State Department of Transportation (WSDOT) desires to improve their knowledge, awareness and retention of rapid pavement construction tools, materials and methods. This project discusses the implementation, use and experience of using the following items related to rapid pavement construction: CA4PRS (Construction Alternatives for Pavement Rehabilitation Strategies), portland cement concrete (PCC) pavement panel replacement, polymer concrete and traffic closure windows. CA4PRS is a Microsoft Access-based software program for predicting construction productivity for highway rehabilitation/reconstruction. It was tested in two case studies and has proved capable of providing meaningful scheduling and productivity inputs into early project planning. Panel replacement techniques and polymer concrete construction are reviewed (including contractor interviews) in an effort to document past successes and failures as well as key decision points when making future project decisions. Finally, a review of traffic closure windows for rapid construction is presented.

17. KEY WORDS

18. DISTRIBUTION STATEMENT

Rapid construction, portland cement concrete, polyester No restrictions. This document is available to the

concrete, panel replacement, traffic closure windows, public through the National Technical Information

construction, pavement

Service, Springfield, VA 22616

19. SECURITY CLASSIF. (of this report)

20. SECURITY CLASSIF. (of this page) 21. NO. .OF PAGES 22. PRICE

None

None

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Disclaimer

The contents of this report reflect the views of the authors, who are responsible for the facts and the accuracy of the data presented herein. The contents do not necessarily reflect the official views or policies of the Washington State Transportation Commission, Department of Transportation, or the Federal Highway Administration. This report does not constitute a standard, specification, or regulation.

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Contents

Contents ............................................................................................................................. iii Figures................................................................................................................................. v Tables............................................................................................................................... viii 1 Introduction................................................................................................................... 1 2 Construction Analysis for Pavement Rehabilitation Strategies ? CA4PRS ................. 4 3 Current WSDOT Estimation Practices ....................................................................... 15 4 Case Study 1 ............................................................................................................... 19 5 Case Study 2 ............................................................................................................. 113 6 Current CA4PRS Development Plans ...................................................................... 121 7 Case Study Conclusions and Recommendations ...................................................... 124 8 Rapid Concrete Panel Rehabilitation ........................................................................ 131 9 Polymer Concrete...................................................................................................... 150 10 Developing Construction Windows for Rapid Rehabilitation Projects .................... 175 11 List of References ..................................................................................................... 193 Appendix A: Bid tabs for the I-5 James to Olive Project ............................................... 199 Appendix B: WSDOT Plans Used to Identify Hand-Paving and Slipform Paving

Segments ................................................................................................................... 217 Appendix C: WSDOT Estimated Productivity Rates ..................................................... 222 Appendix D: Concrete Mix Quantities and Locations Used Per Construction Stage..... 223 Appendix E: Probabilistic and Deterministic CA4PRS Estimation Reports For The I-5

James to Olive Case Study Analyses 1, 2, 3 and 4 ................................................... 224 Appendix F: Truck Ticket Information Used to Derive a Weighted Paver Speed ......... 249

Slipform Truck Ticket Data Used for Deriving Weighted Paver Speed .................... 249 Hand Paving Truck Ticket Data Used for Deriving Weighted Paver Speed .............. 253 Appendix G: Preliminary Contractor Primavera Schedules ........................................... 256 Appendix H: Recorded Inspector Scheduling Information for Construction Stages 1, 2, 3 & 4 ............................................................................................................................ 260 Appendix I: Truck Ticket Data ....................................................................................... 265 Appendix J: Probabilistic Estimation.............................................................................. 270

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Appendix K: WSDOT Standard Plan A-6 ...................................................................... 298 Appendix L: Current WSDOT Polymer Bridges Overlays...................................... 300

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