Field Investigations of Cracking on Concrete Pavements

This paper presents the results of several investigations to identify the underlying causes of longitudinal cracking problems in Portland cement concrete (PCC) pavement. Longitudinal cracking is not intended and detrimental to the long-term performance of PCC pavement. Longitudinal cracking problems in five projects were thoroughly investigated and the findings indicate that longitudinal cracking was caused by: (1) late or shallow saw cutting of longitudinal joints; (2) inadequate base support under the concrete slab; and (3) the use of high coefficient of thermal expansion (CTE) aggregates. When the longitudinal cracks were caused by late or shallow saw cutting of longitudinal joints, cracks developed at a very early stage. However, when there was adequate base support, the longitudinal cracks remained relatively tight even after decades of truck trafficking. Another cause of longitudinal cracking was inadequate base support, and cracking due to this mechanism normally progressed to rather wide cracks. Some cracks were as wide as 57?mm. Evaluations of base support by dynamic cone penetrometer in areas where longitudinal cracks were observed indicate quite weak subbase in both full-depth repaired areas and surrounding areas. This implies that the current requirements for the subbase preparation for the full-depth repair are not adequate. Another cause of longitudinal cracking was due to the use of high CTE aggregate in concrete. Large volume changes in concrete when coarse aggregate with high CTE is used could cause excessive stresses in concrete and result in longitudinal cracking. To prevent longitudinal cracking, attention should be exercised to the selection of concrete materials (concrete with low CTE) and the quality of the construction (timely and sufficient saw cutting and proper selection and compaction of subbase material).     

Performance of Dowel Bar Retrofit Projects in Texas

In Texas, many miles of plain jointed concrete pavement (JCP) were constructed without proper load transfer devices such as dowels. After a number of years of service, some JCP sections without dowels showed distresses in the form of faulting at transverse joints. Some of the sections were designed in accordance with the AASHTO 1986 Guide, which required 50–75?mm thicker slabs in exchange for not using dowels. This pavement design did not work, with faulting at transverse joints that cause poor ride. Dowel bar retrofit (DBR) was performed on four projects to restore the pavement condition. Overall, DBR restored load transfer efficiency and resulted in improvement of ride quality. Even where the subbase stiffness is 5–10 times less than the minimum value required for proper performance of JCPs, properly installed DBR effectively restored pavement condition with minimum faulting after decades of service. Therefore, it indicated that DBR is able to minimize the faulting even where there is poor base/subgrade support. This is significant in that there are no effective and practical methods to improve subbase conditions in existing concrete pavement, whereas DBR can restore pavement conditions at a reasonable cost. However, not all DBR projects were successful. In one DBR project, faulting in the range of 6.4–9.5?mm occurred after less than 2 years of treatment. Forensic investigation revealed voids under the dowel bars, which indicates poor consolidation of the grout material. Efforts are currently underway in TxDOT to improve specifications for grout materials and DBR construction.     

Investigation of a Pavement Premature Failure on a Weak and Moisture Susceptible Base

An investigation was conducted to determine the root cause of the premature pavement failure. The premature pavement failure occurred in the form of rutting and alligator cracking. Although the affected portion was repaired by removing and replacing the top 75-mm asphalt concrete (AC), the repaired AC experienced recurring rutting and alligator cracking in a few weeks. Through extensive field and lab testing, it was found that the weak base is the root cause of the premature failure and the brittleness of the AC is secondary. However, both the base and AC were built according to plan and met the current material and field density requirements. It was concluded that density alone for construction quality control is not sufficient, as it was not able to protect against premature failures from occurring. Although there are many different ways to minimize premature failures, an immediate action is to include proof rolling in construction quality control. Proof rolling has been used with success to ensure proper compaction and to locate unstable areas, as the stability is greatly influenced by the degree of densification achieved during compaction.     

Shanghai’s Experience on Utilizing the Rubblization for Jointed Concrete Pavement Rehabilitation

As agencies continue looking for cost-effective methods to rehabilitate deteriorated jointed concrete pavement (JCP), rubblization using a resonant breaker has been experimented by the Shanghai Municipal Roadway Authority (SMRA). It was demonstrated that rubblization using a resonant breaker offers a viable option for the SMRA because the rubblized pavement sections have been performing very well with no visible distress. Based on field observation for a typical hot mix asphalt concrete (HMAC) overlay on a nonrubblized JCP, it was found the treatment normally would have reflective cracking for the same overlay thickness in the first three years. Besides the cost advantage over the reconstruction, a resonant breaker also had yielded the minimum disturbance during the rubblization. It was observed that it was very effective to use water during compaction on a rubblized JCP surface to improve compaction efficiency and to control dust. Furthermore, there is no need to apply a prime coat before the HMAC overlay, as there was no detrimental effect that could be identified. The average rubblized JCP moduli were found to be 1,323?to?1,375?MPa, which are within the range reported in the literature. It was believed that there were high possibilities to increase rubblized JCP moduli without sacrificing the performance by increasing the particle size, because a reduction of 200?mm of HMAC was observed when rubblized JCP increased from 345?to?3,445?MPa at a subgrade modulus of 138?MPa and traffic of 30 million ESAL. However, further research is needed to optimize the rubblized JCP moduli in an attempt to reduce overlay thickness without creating reflective cracking.     

Case Study of Urban Concrete Pavement Reconstruction on Interstate 10

Many urban concrete pavements in California need to be reconstructed, as they have exceeded their design lives and require frequent maintenance and repair. Information is needed to determine which methodologies for pavement design, materials selection, traffic management, and reconstruction strategies are most suitable to achieve the objectives of California Department of Transportation’s (Caltrans) long-life pavement rehabilitation strategies (LLPRS) program. To develop construction productivity information for several construction windows, a case study was performed on a Caltrans concrete rehabilitation demonstration project near Los Angeles on Interstate-10, where 20 lane-km was successfully rebuilt using fast setting hydraulic cement concrete (FSHCC) with one weekend closure for 2.8 lane-km and repeated 7- and 10-h nighttime closures for the remaining distance. The concrete delivery and discharge controlled the overall progress. In terms of the number of slabs replaced per hour, the 55-h weekend closure was 54% faster than the average nighttime closure. An excellent traffic management strategy helped to reduce the volume of traffic during the weekend closure and minimize the traffic delay through the construction zone.     

Sudden Failure of a Heavily Loaded Container Pavement

The case history of a sudden and unexpected failure in a pavement designed for 82?Mg axle loads at Port Botany in Sydney, Australia has been prepared using data derived from investigation of the failure. Failure of the pavement, comprised of an asphaltic concrete surface, unbound granular fine crushed rock base, crushed sandstone subbase, and sandy subgrade, and designed using the rational method—CIRCLY, occurred within days of being put into service. The failure resulted from a 20–30% increase in base course saturation levels following compaction that led to partial liquefaction under repeated heavy loading. There was a general failure throughout the storage area where trafficking was most intense and the pavement remained intact in lightly trafficked areas. The intact areas recovered over time without intervention through a moisture equilibration process as evidenced by an increase in measured pavement stiffness and loss of moisture within the pavement profile.     

Slippage Failure of a New Hot-Mix Asphalt Overlay

A premature pavement overlay failure had occurred only 1 day after it was opened to traffic. Crescent-shaped cracks were intermittently spread over a section about 3 mi in length. Dynamic cone penetrometer results demonstrated that the slippage cracks were not linked to weak base or subgrade. Loss of overlays on structurally sound pavements due to poor bonding is an expensive error. A tack coat is considered a simple, relatively inexpensive, yet essential step in the pavement construction process. It is theorized that the ineffective bonding due to poor quality tack coat and/or inappropriate application rate is the primary factor that led to the slippage cracks. Other contributing factors include low asphalt content and high aging ratio that reduced the effectiveness of the bond. The aging ratios exceed the maximum allowable 3.5 specified. Based the investigation results, the contractor did remove and replace the top 50 mm hot-mix asphalt (HMA) overlay at his own expense. Although selection of proper tack coat materials and quantities is essential, there is a lack of proper construction quality control and quality assurance procedure to ensure appropriate surface preparation prior to application of a HMA overlay.     

Evaluation of Full-Depth Asphalt Pavement Construction Using X-Ray Computed Tomography and Ground Penetrating Radar

In the past few years, a number of full-depth or perpetual pavements have been designed and constructed in the State of Texas. A study was conducted to examine the quality of the compaction of the thick asphalt layers within these pavements using advanced forensic tools such as X-ray computed tomography (X-ray CT) and ground penetrating radar (GPR). The GPR is a nondestructive tool for evaluating the uniformity of density in pavements at highway speed. X-ray CT is a laboratory tool that is used to conduct detailed analysis of air void distribution and uniformity in asphalt pavement cores. This paper presents the results of analyzing one of the perpetual pavements constructed in State Highway 114 (SH-114). In this project, two different structural asphalt pavement sections were placed, one included a 1?in. (25.4 mm) stone filled (SF) Superpave mix and the other included a traditional dense graded Type B material. The dense graded Type B material was found to be uniformly compacted. However, major compaction problems were identified with the coarse SF Superpave mix. The poor compaction and associated high percent air vsoids were found to permit moisture infiltration, which could potentially lead to rapid pavement deterioration. The analysis showed very good agreement between the GPR and X-ray CT results and demonstrated the efficiency of using GPR and X-ray CT in the evaluation of asphalt pavement compaction.     

Premature Cracking from Cement-Treated Base and Treatment to Mitigate Its Effect

A forensic study was conducted to investigate the premature cracking distress on an ongoing construction project on State Highway (SH) 24. Transverse cracks occurred at approximately every 9–15?m (30–50?ft) along the 9.6?km (5.9?mi) project. The field tests involved both destructive tests, including trenching and coring, and nondestructive tests, including falling weight deflectometer (FWD) and ground-penetrating radar (GPR) tests. The laboratory tests mainly included cement-treated base material and asphalt mixture material series tests. By integrating all the test results, it was concluded that the premature cracking was originating from the cement-treated base (CTB). Although CTB is not a new concept in pavement construction, stabilization of base materials is a complex process, which, if not handled properly, may lead to premature failures. The two primary factors that contributed to the premature failure are (1)?an excessive amount of cement in the CTB, and (2)?a high moisture content when the CTB was compacted (almost 2% above optimum moisture). It was believed the possibility of premature failure could be reduced significantly, if the lab verification tests were conducted on the CTB before construction started. Pavement life analysis was conducted to evaluate the current structure adequacy to sustain future traffic. In addition, extensive material design was conducted for the final wearing course asphalt mixture, which was intended to mitigate the effect of existing cracks by resisting crack propagation from the underlying structure.     

Case Study of a Full-Scale Evapotranspiration Cover

The design, construction, and performance analyses of a 6.1?ha evapotranspiration (ET) landfill cover at the semiarid U.S. Army Fort Carson site, near Colorado Springs, Colo. are presented. Initial water-balance model simulations, using literature reported soil hydraulic data, aided selection of borrow-source soil type(s) that resulted in predictions of negligible annual drainage ( ? 1?mm/year). Final construction design was based on refined water-balance simulations using laboratory determined soil hydraulic values from borrow area natural soil horizons that were described with USDA soil classification methods. Cover design components included a 122?cm thick clay loam (USDA), compaction ? 80% of the standard Proctor maximum dry density (dry bulk density ～ 1.3?Mg/m3), erosion control measures, top soil amended with biosolids, and seeding with native grasses. Favorable hydrologic performance for a 5?year period was documented by lysimeter-measured and Richards’-based calculations of annual drainage that were all <0.4?mm/year. Water potential data suggest that ET removed water that infiltrated the cover and contributed to a persistent driving force for upward flow and removal of water from below the base of the cover.     

Evaluation of Four Permeable Pavement Sites in Eastern North Carolina for Runoff Reduction and Water Quality Impacts

Four permeable pavement applications in North Carolina’s Coastal Plain were constructed and monitored to determine their effectiveness of reducing runoff quantity and improving water quality. Sites were either constructed of permeable interlocking concrete pavers (2), porous concrete (1), or concrete grid pavers (1). One site of each pavement type was monitored for runoff reduction for periods ranging from 10 to 26 months. Measured runoff depths from rainfall events over 50?mm were used to determine permeable pavement equivalent curve numbers for the sites, which ranged from 45 to 85. Only the two permeable interlocking concrete pavement (PICP) sites were monitored for water quality. Runoff and exfiltrate samples were intended to be collected, in addition to runoff monitoring, from the Swansboro PICP site. However, no runoff was produced during this study from the Swansboro PICP site for rainfall events up to 88?mm. From exfiltrate concentrations, nutrient retention was estimated to be 3.4 and 0.4?kg/ha/year for total nitrogen and total phosphorus, respectively. For the Goldsboro PICP site, water quality of asphalt runoff and PICP exfiltrate were compared. Analysis of water quality samples from the second site determined that concentrations of total Kjeldahl nitrogen, ammonia, total phosphorus, and zinc were significantly (p ? 0.05) lower in permeable pavement exfiltrate than asphalt runoff.     

DCP Criteria for Performance Evaluation of Pavement Layers

The potential use of the dynamic cone penetrometer (DCP) for evaluation of the pavement distress state is investigated. A model to predict the distress level of pavement layers using penetration rate (PR) values of the subgrade and aggregate base course (ABC) layers is proposed based on the coupled contribution of the subgrade and the ABC materials. The developed distress model is validated using field data from four test sites. The two sites with good condition rating values (equal to 4 and 3) are found to have an unconfined PR-ABC value <4 mm∕blow, a PR-subgrade value <25 mm∕blow, and an ABC layer thickness that exceeds 152 mm (6 in.). A discrepancy that seems to appear in the field data (a high field California bearing ratio value corresponding to a PR-ABC value >4 mm∕blow) is explained by the fact that field-measured California bearing ratio values for the ABC layer are affected by the strength of the underlying subgrade soils. This is especially observed in cases where the thickness of the ABC layer is <102 mm (4 in.). The framework of the established procedure can generally be used at other sites, properly taking into account differences in material properties.     

Factors Affecting Initial Roughness of Concrete Pavement

Past studies have shown that initial pavement roughness greatly affects future pavement roughness and roughness progression rate. Initial pavement roughness is also an important input to the roughness prediction model in mechanistic-empirical design guide. This study analyzed the design and construction factors affecting initial pavement roughness. Initial international roughness index of 90 concrete pavements constructed in Wisconsin from 2000 to 2004 were analyzed using multiple regression method. The factors considered in this study included concrete pavement slab thickness, project location, dowel bar placement, joint spacing, base type, and pavement length. The factors affecting initial pavement roughness were identified.     

Utilizing Advanced Characterization Tools to Prevent Reflective Cracking

To prevent premature failures of rehabilitated concrete pavements, transportation authorities need tools to characterize the prerehab pavement condition of its load carrying capacity, and to determine the resistance of the overlay material to underlying crack/joint movements. Two quantitative methods, the rolling dynamic deflectometer (RDD) and overlay tester (OT), along with field performance data were employed in rehabilitation studies involving reflective cracks. The RDD is able to continuously assess vertical differential movements at joints/cracks that represent the potential for reflective cracks on existing pavements. The OT has the ability to determine the resistance of the overlay material to underlying crack/joint movements. The RDD W1?W3 deflections were used to determine areas that have a high potential for reflective cracking due to poor load transfer across joints and cracks. This paper documents results from the RDD and OT on the following five rehabilitation projects: (1) SH225; (2) US96; (3) SH12; (4) SH342; and (5) IH35W. Based on the available test results from these five projects, it was observed that the W1?W3 threshold values of 5.5 mils (0.140 mm) for exposed concrete pavement and 6.5 mils (0.165 mm) for composite pavement with existing hot mix asphalt overlay and an OT threshold value of 700 cycles correlated well with the field performance. Ignoring either of these critical factors may lead to premature reflective cracking.     

Investigation of Heaving at Holloman Air Force Base, New Mexico

Heaving of pavements and a building foundation became progressively worse on a project at Holloman Air Force Base (AFB), N.M. The cause of the heaving was identified as sulfate attack on recycled concrete used as fill and base course below the buildings and pavements. This recycled concrete came from sulfate-resistant airfield Portland concrete pavement that had existed for decades at Holloman AFB without distress. However, severe sulfate exposure conditions, ready availability of water, the more permeable nature of the crushed recycled concrete, less common thaumasite attack, possible soil contamination as a secondary source of alumina, or some combination of these factors allowed sulfate attack to develop in the recycled material even though it had not in the original concrete pavement.     

Noise Evaluation for Pavement Maintenance in Metropolitan Highway Bridges

Dynamic response of a bridge under traffic load induces acoustic energy at the bridge surface. The acoustic energy change generates an additional coupled noise component caused by vibration of a bridge deck associated with the pavement conditions and moving velocity of the vehicle. This paper presents a three-dimensional finite-element method developed for the dynamic response and noise propagation model, and analyzes the coupled effect induced by traffic loading based on different pavement conditions. Even though vibration-induced noise at the bridge is below the audible frequency range of 20–20,000?Hz, it amplifies the traffic noise source to the highly annoyed level of noise in the metropolitan area. Among several factors that contribute to the traffic noise, interaction between pavement and vehicle is considered according to the different surface roughness and vehicle velocity. The result shows that poor pavement condition contributes to the increase of traffic noise at a high traveling speed of the vehicle. In the pavement maintenance stage, the coupled effect as an additional noise source should be considered to mitigate the traffic noise for its added value in conjunction with regulation of engine emission noise and construction of a noise barrier.     

Use of an Infrared Joint Heater to Improve Longitudinal Joint Performance in Hot Mix Asphalt Pavements

Longitudinal joint cracking is one of the most prevalent forms of distress in asphalt concrete pavements. The joint area does not achieve the same density as the mat due to an unconfined edge on the initial pass and a cold joint during the second pass. The lower density allows water to penetrate and the material cracks, usually within one?year of construction. There are many techniques for constructing longitudinal joints, one being to preheat the joint prior to paving the second lane. This paper describes a field study conducted in New Hampshire using an infrared joint heater. Thermocouples were embedded in the pavement to determine the extent of heat penetration from the infrared heaters. Cores were taken along the joint and in the travel lanes for both the control and test sections. Density and strength measurements were taken on the cores. Permeability measurements along the control and test joints were performed. A cracking survey performed one?year after construction showed that the section of pavement where the infrared heater was used had significantly less cracking than the control section.     

Effects of Induced Vibrations on Early Age Concrete

The purpose of this investigation was to conduct a laboratory test program on how much induced vibrations on concrete during the period between initial set and final set affect the attainable strength of concrete. To achieve this purpose, a laboratory test program was conducted. The laboratory program consisted of casting 144 76?mm by 152?mm (3×6?in.) concrete cylinders and subjecting them to one of two levels of vibration for either 1 or 2?min at five different ages ranging in time from before, during, and after the setting period for the concrete. The levels of vibration correspond to typical frequencies of vibratory soil compactors and the peak particle velocity produced by the compactors. Both compression and splitting tensile tests were performed. The results of the laboratory study indicate that vibratory soil compaction should not be considered a significant hazard to foundation strength as long as the vibrations are within the limits in this study.     

Investigation of Permeability on Indiana SR-38

In 1999, a 9.5 mm nominal maximum size hot-mix asphalt mixture, designed according to the Superpave mixture design method, was placed as an overlay on Indiana State Road 38. Within one year of construction, the pavement showed signs of significant distress, including aggregate pop-outs and degradation, the presence of free water (weeping) on the driving surface, and longitudinal and fatigue cracking. At the request of the District, an investigation was undertaken to determine the cause of the pavement distress. As part of the investigation, core samples were taken from the roadway surface and tested for compliance with material properties and volumetrics, and to determine the mixture permeability. The mixture met all applicable materials and volumetric specifications, but had a low in-place density and was permeable. The results indicate that the mixture was too coarsely graded to achieve compaction in the relatively thin lift specified by the Department of Transportation. The resulting recommendations were that the mixture be removed and replaced, and that the mixture specifications be revised to more closely control gradation and increase mixture lift thickness.     

Detailed Forensic Investigation and Rehabilitation Recommendation on Interstate Highway-30

The main objective of this study is to identify the cause of the punchouts observed on Interstate Highway 30 (IH-30), and to identify possible rehabilitation alternatives. Several nondestructive tests, as well as coring and trenching, were conducted in both distressed and nondistressed areas. Middepth horizontal cracks were found during routine repair and by the trenching performed in this study. It is believed that due to temperature variation at an early stage, horizontal cracks developed at the middepth interface between the steel and concrete. The truck traffic caused the horizontal cracks to deteriorate further. Repetitive truck traffic and thermal loading forced the concrete to crack vertically from the middepth where there were horizontal cracks. The closely spaced transverse and longitudinal cracks, along with the delamination, caused punchouts. Although the problem is not imminent, an immediate seal plus a 75 mm heavy-duty stone matrix asphalt (SMA) overlay will probably provide the most cost-effective remedy for this section of IH-30. Existing distressed areas should be repaired before the rehabilitation. To slow the deterioration, the district should use a latex modified chip seal or asphalt rubber seal (AC15-5TR) followed by a 75 mm heavy duty SMA. This is to provide bonding between the concrete and SMA overlay. If the district chooses to do nothing at this time, it will become costly in 2–3 years if current environmental and traffic conditions hold. The cost to repair a severely deteriorated continuously reinforced concrete pavement (CRCP) would be several times more than the 75 mm heavy duty SMA overlay.