Roadway Paving Operations

10/30/2014
Construction of Concrete Pavements

Roadway Paving
Operations
Robert Rodden, P.E.
www.robertrodden.com
1
10/30/2014
EB238
Available in ACPAs online bookstore:
http://www.acpa.org/publications-for-purchase/
2
3
Construction of Concrete Pavements 10/30/2014

Pre-Paving Considerations
Specifications

10/30/2014
Specifications
Address
concrete materials durability and
what needs to be measured to control critical
elements of construction and design

All specifications act to assign risk.
Method specifications assign risk to the owner.
End result specifications assign risk to the contractor.
Alternative
types of specifications and
contracting methods are being used on an
ever increasing number of projects:
Performance based specifications, design/build,
warranties and others
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Roadway Paving Operations
Quality Control

10/30/2014
Quality Control (QC) versus
Quality Assurance (QA)
QA
is responsibility of
owner ensure the end
product is of proper

quality and motivates QC
QC
is responsibility of
contractor makes the
product of proper quality
and motivated by QA
and acceptance
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Tests
Which
To Use
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Tests
Which
To Use
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Tests
Which
To Use

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Tests
Which
To Use

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10/30/2014
Coordination
QC plan must be discussed at pre-paving meeting
Communication between owner, project
engineer, inspector, plant manager, etc. is crucial

to project success!
Hot/cold weather
contingencies
Who conducts QA tests?
Communicate necessary mix
adjustments based on
QC results!!!!!
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10/30/2014
Test Specimens
Hardened tests (e.g., strength, hardened air,
etc.) are more susceptible to ambient
conditions and handling than fresh tests (e.g.,

air content, unit weight, etc.)
Cylinders typically preferred over beams
Less sensitive to handling and curing of specimen
Smaller and easier to transport
Portable
containers available to control
both moisture and temp in transport
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10/30/2014
Producing Concrete
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10/30/2014
The Loader Operator is KEY!
Manages stockpile
Prevents dirty or contaminated aggregates
Maintains uniform moisture content of aggregates if

major variations exist, they MUST notify batch plant
operator
Feeds hoppers
Checks supply
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10/30/2014
Mixing Concrete
A consistent concrete
mixture is the primary
objective

Two
primary mixing
methods:
Central mixed (e.g.,
portable batch plant)
Truck mixed (e.g., ready-
mixed)
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10/30/2014
Mixing Concrete
Mixingmethod impacts
order of operations

Truck Mixed
Central Mixed
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10/30/2014
Hauling/Delivery
Uniform delivery rate is a key to smooth paving.
This is not good:

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10/30/2014
End-Dump Truck
Agitating Truck
Side-Dump Truck
Ready-Mix Truck
Methods of Transport
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10/30/2014
Dump and Agitors
Generally have 30 mins to deliver and place
concrete

Agitator paddle in agitor can extend to 90 mins, as
can the use of retarding admixtures
Delivery time limit also depends on ambient temp
HAVE ENOUGH TRUCKS to deliver concrete to

match paving rate see ACPAs Rate of Delivery
Calculator at apps.acpa.org
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10/30/2014
Ready-Mix Trucks
Both for mixing and delivery
Most commonly used for streets and roads

Generally have 90 mins to deliver concrete
Min 70 revolutions and max of 300 typical
Slump meter estimates slump within in. (13 mm);
for QC only!
Contractor receives batch ticket upon delivery
One addition of water may be permitted requires
30 additional revolutions
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Placing Concrete

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Wetting the Grade
Application of water mitigates drying shrinkage
from dry subgrade/subbase support; whitewash
asphalt if hot

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10/30/2014
Access
If
adequate space, deliver concrete from a
haul road adjacent to paving operation

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10/30/2014
Access
Example of truss to stringline over haul road

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10/30/2014
Access
If
necessary, deliver in front of paver but ensure
that subbase is capable of carrying delivery traffic

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10/30/2014
Access
Must also work around pre-placed dowels

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Inappropriate Placement

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Fixed Form Paving
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10/30/2014
Fixed Form Paving Machines
Less complex equipment (e.g., vibratory screed and single
type finisher) good for complex areas
External (surface) vibration good to about 8 in. (200 mm)

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10/30/2014
Fixed Form Paving Machines
Larger
equipment (e.g., bridge deck finishers)
can place and consolidate in one pass

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10/30/2014
Fixed Form Paving Limitations
Fixed
form paving can be used on widths
upwards of 50 ft (15 m) but the owner and
contractor must recognize limitations of fixed

form paving machines
If
placement is large enough, contractor might
opt to use slipform; slipform also typically
produces desirable consolidation and ride
quality more efficiently than fixed form
methods
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10/30/2014
Fixed Form Paving
Spreading Mixture
Evenly deposit concrete on grade; pile too high and
it is difficult to strike off

Shovels are preferred hand moving tool; keep to min
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10/30/2014
Fixed Form Paving
Consolidation
Whennecessary, supplemental spud vibration
should precede placement screed; vertical
plunge of spud roughly every 1 ft (0.3 m) do

not drag spud mind the edges
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Dowel Bars
and Tiebars

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Header Joints

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10/30/2014
Fixed Form Paving
Thickness Verification
No brainer
forms set
thickness

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10/30/2014
Fixed Form Paving
Finishing
Can use roller screed, clary screed, laser
screed, bridge deck finisher, etc.

Depending on desired surface texture,
subsequent finishing may or may not be
necessary
If
necessary, final finishing same as slipform
paving, with a straightedge
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10/30/2014
Fixed Form Paving
Form Removal
After
texture, cure, etc., must remove forms
from fixed form paving remove before
sawcutting if

possible
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Slipform Paving

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10/30/2014
Slipform Paving
Placer/Spreader Ahead of Slipform

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Use Conveyor
Can Otherwise

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Slipform Paver Equipment Setup

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10/30/2014
Slipform Paving
Auger
Large horizontal screw that spreads concrete sideways
Keep concrete head not too big and not too small

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10/30/2014
Slipform Paving
Plow
Sometimes a plow is used instead of an auger

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Sideform
Slipform Paving

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10/30/2014
Slipform Paving
Vibrators
Consolidate and fluidize concrete inside form

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10/30/2014
Slipform Paving
Vibrators
Equipmentavailable to auto
monitor frequency to prevent
over/under vibration

VIBRATOR
TRAILS
from too
much
vibrational
energy
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10/30/2014
Slipform Paving
Dowel Bar Insertion (DBI)

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10/30/2014
Slipform Paving

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10/30/2014
Slipform Paving
Direct access in front of paver

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10/30/2014
Slipform Paving
Slipform Mold or Pan
Applies confining pressure to fluidized concrete
Pan builds cross slope and crown note edge slump

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10/30/2014
Slipform Paving
Tiebar Insertion

We will see the rocket launcher
in an upcoming video!
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A Two-Lift Paving Train

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10/30/2014
Avoid Stopping the Machine!!!
Delays in material
supply, equipment
breakdowns, or any

other stoppage will
increase pavement
roughness
Wecan now
measure real time
smoothness
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10/30/2014
Slipform Paving
Thickness Verification
Duringconstruction:
probe thickness;
depending on subbase

type, might require pre-
placement of metal
plates
Post construction: coring
or non-destructive
testing (NDT) method
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10/30/2014
Slipform Paving
Finishing
Ideally, no finishing is necessary after slipforming
If necessary, use straightedge to close/smooth surface

Overfinishing or adding water to surface during finishing
leads to a weak surface and potential scaling; fogging
of surface is acceptable to aid finishing
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Finishing
Slipform Paving

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10/30/2014
Texturing Methods
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Burlap Drag

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Broom Drag

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Astroturf Drag

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Tining
Transverse

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Tining
Longitudinal

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Exposed Aggregate

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Diamond Grooving

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Diamond Grinding

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10/30/2014
Videos of US Practice
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Curing

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10/30/2014
Definition of Curing
Maintenance of a satisfactory moisture
content and temperature in concrete
during some definite period immediately

following placing and finishing so that the
desired properties may develop.
+
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10/30/2014
Curing Objectives
Prevent (or replenish) the loss of moisture
Maintain a favorable temperature

for a predefined period of time. 75
10/30/2014
Curing Methods and Materials
Initial Cure
Evaporation Retarder
Misting or Fogging

Final Cure
Wet Coverings
Impervious Paper
Plastic Sheets
Steam or Electrical Heating
Membrane-Forming Compounds Common
Insulating Blankets Common
Linseed oil cure/seals
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GOOD Practice
Curing Compound:

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Curing Compound:
MARGINAL Practice

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POOR Practice
Curing Compound:

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10/30/2014
Blanket Insulation
Place after spraying curing compound
Further reduces loss of hydration heat

Lessen effects of:
Air temperature
Solar radiation
Thermal Resistance (R)
0.035 m2 oK/W
0.5 hr ft2 oF/Btu
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10/30/2014
When to Use Blankets
Ambient Air Opening Time, Hr
Temperature

8 16 24 36 48
<10oC (<50oF) Yes Yes Yes Yes No
10-18oC (50-65oF) Yes Yes Yes No No
18-27oC (65-80oF) Yes No No No No
>27oC (>80oF) No No No No No
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GOOD Practice
Blanket Curing
POOR Practice

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Jointing

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Identification
Dowel Location

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Forming Joints
Saw Cutting or

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10/30/2014
Saw Blades
Mostcommon are industrial
diamond (require water
cooling) or abrasive

(carborundum)
Mustmatch the saw blade
to the concrete; based
primarily on aggregate
hardness but also depends
on power output of saw
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10/30/2014
Order of Saw Cuts
Common practice to first
cut transverse joints to
alleviate internal stresses

However, best practice
to keep all sawing as
close to the paving
operation as possible
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Successful Crack
Control + Location

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10/30/2014
Check the Depth!
Too shallow = may not relieve TRANSVERSE
T/4 T/3
stresses adequately; random
cracking

Too
deep = additional effort
LONGITUDINAL
and expense, unnecessary
T/3 T/3
equipment wear, and reduce
aggregate interlock
Asblade diameter decreases,
the saw operator must adjust
saw to ensure proper depth
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10/30/2014
No Speeding!
Sawing speed controls cut depth;
hard aggregate might require a
slower speed

Speed typically controlled by saws
self-propelling mechanism
Saw operators that attempt to
speed up cutting may tend to push
a saw too fast, causing the blade to
ride up out of its full cut not cutting
to proper depth = risk for cracking!
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10/30/2014
Starting and Stopping a Cut
Cut
start and stop requires
special attention

Early-entrysaws may require the
saw cut stop about in. (13 mm)
short of the pavement edge to Down-Cut Saw
prevent blow out
Inwindy conditions, best to orient
direction of sawing with wind; the
slab face exposed to the wind
will dry quicker
Up-Cut Saw
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10/30/2014
Make Certain the
Joint is Clean!
Allsealed joints must be cleaned
immediately behind saw cutting
or joint widening and immediately

prior to sealing operations
Removes saw-cut slurry, soil, sand, etc.
Cleanliness
of both joint faces is
extremely important to
concrete/sealant bond
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10/30/2014
Its not Hard to Check
If
wiping a finger along the face picks up dirt or
dust, recleaning should be done before sealing!

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and is not Expensive to Fix!

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10/30/2014
Backer Rod (if used)
Minimizes
excess stress on
sealant material from
improper shape factor

Providessupport for the
tooling of the surface
Prevents self-leveling matl
from filling entire joint
Prevents
three-sided
adhesion
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10/30/2014
Sealing the Joint
Only apply when temps are above
min recommended by
manufacturer

Ensure joint faces clean and dry
before sealing
Fill joint from the bottom up to
prevent air from becoming trapped
under the sealant
Fill from beginning to end in one
smooth operation
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10/30/2014
Transverse Construction
Joints (Headers)
Built
at the end of a section of
pavement
Must be constructed at the end of a days run

Constructed due to significant paving delays
Either formed or sawed

Noway to account for in layout
planning
If
next to previously placed
pavement, best to match header
with existing transverse joint
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10/30/2014
Formed Header
Eithertwo-part form with
dowels or tiebars
protruding through form

or false-dowels
attached to form face
and dowels inserted
upon form removal;
consolidate concrete
well at form
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Formed Header

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10/30/2014
Sawed Header
Paving continued
through of header,
pavement sawed

back, dowel/tiebar
holes drilled, and
dowels/tiebars
installed
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Opening to Traffic
Requirements
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Strength Requirements
Required flexural strength for construction equipment:

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Strength
Requirements
Required flexural
strength for
public traffic:

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10/30/2014
Determining Strength
Flexural versus compressive
Flex is a sensitive test, especially at early ages
In most cases, comp is correlated to flex for mixture

Strength assessment methods
Opening strength cylinders
Field-cured
Maturity method
Estimate in-place strength via TTF
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10/30/2014
Concrete Mixture Considerations
If
opening strength cannot be met with
conventional mixture, can use high-early
strength mixture

Type III or HE high-early-strength cement
High cement content (675 - 850 lb/yd3 [400 - 500 kg/m3])
Lower w/cm to as low as 0.37
Use higher concrete mixing temp with heated water or
agg
Use accelerating admixtures
Use insulating curing practices
Etc.
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10/30/2014
Paving in
Inclement Weather
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10/30/2014
Cold Weather Paving
Potential problems:
Cement hydration slows, slowing
strength development

Surface cools faster, causing
differential stresses
Mitigation:
Dont pave on frozen subgrade
Dont use frozen aggregate lumps
Use higher cement content
Use accelerating admixture
Use blanket curing to contain heat of
hydration
Heat materials to raise temp of mixture
(see Concrete Temp app)
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10/30/2014
Hot Weather Paving
Potential problems:
Moisture loss during hauling and placing
Aggregate stockpiles dry out, affecting batch consistency

Subbase dries out and absorbs moisture from slab
Dark subbase heats bottom, causing differential stresses
Rapid evaporation = plastic shrinkage cracks
Difficult to entrain air at higher temps
Concrete sets more quickly, making finishing difficult
Sawing operations must proceed more rapidly
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10/30/2014
Hot Weather Paving
Mitigation:
Begin curing ASAP
Dont pave on hot day, if possible

Maintain uniform stockpiles
Use retarding admixtures
Use SCMs to lower cement content
Whiteswash dark colored subbases
Pave in morning, evening or night when cooler
Increase dosage of air-entraining admixture
Keep subbase, forms, equipment cool and damp
Use temporary sunshades and/or windbreakers
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10/30/2014
Rained on Pavements
Irony: rainy cold front is conducive to concrete curing
If
rain occurs before final set, can leave imprints on

surface or wash away paste at surface
If
rain occurs after final set, can lead to rapid cooling
of the surface and differential stresses
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10/30/2014
Rained on Pavements
Mitigation:
For slipform operations,
advantageous to install

forms where severe
erosion of edges occurs
If it starts to rain during
placing, cover the fresh
concrete with plastic or
burlap as soon as the
surface sets, texture and
apply curing
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10/30/2014
Rained on Pavements
Protect surface with plastic sheeting if possible
Expect some marring of the surface from the sheet

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10/30/2014
Rained on Pavements
Finish
rain into the surface = higher w/cm at surface =
a non-durable layer = crazing, scaling, dusting

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10/30/2014
Rained on Pavements
Petrographicexamination is usually not
necessary but can be useful in determining the
extend of damage

Repair:
If surface is damaged or rain is finished into surface to
increase w/cm, recommended repair is diamond grinding
If pavement edges are compromised, make cut a
minimum of 2 ft (0.6 m) from pavement edge, remove,
and replace w/tiebars
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10/30/2014
Night Paving
Might consider to mitigate hot weather; minimize
traffic; maximize production rates; etc.

Observe precautions such as safety meetings; traffic
control; ample lighting; subscription to weather
service; maint. of haul roads during day; sawcut timing
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Troubleshooting

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10/30/2014
Questions?
Robert Rodden, P.E.
www.robertrodden.com
117

Roadway Paving Operations

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10/30/2014

Construction of Concrete Pavements

Available in ACPAs online bookstore:

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements

HAVE ENOUGH TRUCKS to deliver concrete to

Construction of Concrete Pavements

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements 10/30/2014

Construction of Concrete Pavements 10/30/2014