50 Year Roads: Don't Accept Anything Less
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1 50 Year Roads: Don't Accept Anything Less Prepared By Thomas O. Malerk Director of Transportation Engineering Florida Concrete & Products Association NACE Annual Meeting April 22, 2015
2 Presented by Roger C. Schmitt, P.E. Director of District and Local Road Transportation Engineering Florida Concrete and Products Association
3 FACERS Fall Meeting 2016 The Old Way 1930 s Very Few Joints A Newer Way: Lots of Joints Roller Compacted Concrete
4 Thanks to: Jim Armaghani; Manny Uwaibi; Roger Schmitt; Jim Mack: Mike Dowell
5 Outline how to achieve a 50 year concrete roadway what are the cost and sustainability factors how a long life concrete pavement benefits people and business by eliminating frequent repair and replacement work a Florida example: a brief history of the upgrade of about 2 miles of asphalt roadway to concrete pavement in 1988 and how things are working out
6 It All Started Long, Long Ago
7
8 How Tom Got Interested
9 1961; 1978; 1984; 1997; 2002; 2015 Disney World
10 Some Concrete History
11 General Purpose of the State Road Department Supply hard-surfaced rural roads to join cities, counties, towns and villages
12 How Much Rigid Pavement is there in Florida?
13 State Highway System 42,829 lane miles of roadway 10% of the state roadway network; Carries 54% of all traffic in state 41,787 lane miles HMA (97.6%) US average: 94% Life Cycle: Avg=16yr (OGFC=12yr, DGFC=17yr) 1,042 lane miles PCC (2.4%) US average: 6% Life Cycle: set by FDOT Pavement Type Selection Manual at 23 years
14 2500 HISTORY OF FDOT RIGID PAVEMENT LANE MILES 1000 ADDED RIGID LANE MILES YEAR
15 The Dawn of Concrete Pavement Portland Cement patented: st use as concrete pavement: UK 1 st US concrete pavement: 1891 Widespread use post st Florida concrete pavement: st Florida State Road with concrete pavement: SR 1 Jacksonville to Lake City 1928
16 Oldest Concrete Pavement: 125 yrs. Court Avenue, Bellefontain, Ohio Built in layer 5,000 to 8,000 psi 1 ½ and ½ agg and 8% air Why use 2 layers of concrete?
17 US 41 Two Lift Concrete Pavement Placed in 1977
18 My wife Alida and I in 1977
19 Oldest Concrete Pavement Location in Florida
20 FDOT s Oldest Concrete Pavement US 17/92 in DeLand built 1939 (77 years) 2 C/L miles, 3-lanes slab thickness 7 (Reinforced) US 17/92 in Winter Park Built 1936 (80 years) 3.6 C/L miles, 5-lanes slab thickness 7 (Reinforced)
21 How to Make a Pavement Last for at Least 50 Years With Zero or Very Little Maintenance
22 How Thick? - The Idea Decide how long you want the pavement to last, then figure out the thickness considering the concrete properties, traffic, soils and climate. Longer Life = higher upfront, lower life time costs Shorter Life = lower upfront, higher life time costs 20 years is typical for design life calculations For concrete pavement use nothing less than a 50 year design life You decide when enough is enough!
23 Fit the Road to the User Vs
24 Concrete Pavement Types Jointed Plain ($ - 50 years) Continuously Reinforced ($$ - 75 years) Precast, Prestressed, Post Tensioned ($$$ yr)
25 THICKNESS DESIGN METHODS Empirical Design Based on observed performance for the AASHTO Road Test (WinPas) Mechanistic Design Based on calculated pavement response ACPA Design (StreetPave) Mechanical-Empirical (MEPDG) Based on combining calculated pavement responses with observed performance MEPDG to DARWin ME to AASHTO Pavement ME
26 Why did US do the road test in the 50s? The AASHO Road Test was a series of experiments carried out by the American Association of State Highway and Transportation Officials to determine how traffic contributed to the deterioration of highway pavements. Officially, the Road Test was "...to study the performance of pavement structures of known thickness under moving loads of known magnitude and frequency." This study, carried out in the late 1950s in Ottawa, Illinois, is frequently quoted as a primary source of experimental data when vehicle wear to highways is considered, for the purposes of road design, vehicle taxation and costing. The road test consisted of six two-lane loops along the future alignment of Interstate 80.
27 AASHTO Road Test 2016
28 A Real Active Example Here In Florida
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33 Pavement Sections Experimental Features
34
35 US 1 Concrete Pavement State Road #: SR 5 (US 1) Begin MP: End MP: Length: Direction: Southbound Only Total Lanes: 2 Opened to Traffic September, 1988 Current Age: 28 years Traffic 1988: 11,940 AADT; T= 7% Traffic 2014: 11,053 AADT; T= 4%
36 Concrete Pavement Construction Subbase/Base: Retain Limerock Base: 8.5 in Mill 4 in of average 5 in asphalt Place Type III Leveling: 1 in* Place Type S Asphalt: 1 in Place Slab Thickness: 6, 7, 8 Transverse Joint Spacing: Varies 12, 14, 16, 18 & 20 Longitudinal Joint Spacing: 12 Lanes Joints: Rectangular not skewed Dowel Diameter: ¾ to 1 Dowel Spacing: Variable; 3 dowels in each wheel path; no dowels in last 5 slabs of each test section Shoulder Design: Originally shoulders were natural soil but asphalt shoulders added later
37 1988 Cost Sheet
38 Concrete Pavement Prices 2016: FDOT 5 inch Concrete Pavement: $28.57 per syd* 6 inch Concrete Pavement: $34.29 per syd* 7 inch Concrete Pavement: $40.00 per syd* 8 inch Concrete Pavement: $55.00 per syd* Concrete 7 to 9 : $40 to $55 syd Concrete 9 to 11 : $45 to $60 syd Concrete 11 to 12.5 : $50 to $68 syd Concrete 12.5 to 14 : $52 to $70 syd
39 Performance September 1988 to March 2014
40 Asphalt Pavement
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44 Concrete Pavement
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47 10 PCS US 1 Concrete Pavement PCS Rating Cracking Ride Year
48
49
50 Performance 6 Concrete Thickness 35 years
51 Performance 8 Concrete Thickness > 50 Years
52 Life Cycle Cost Summary
53 Comparison on 50-year Life Cycle Costs $3.50 $3.00 Flex Life Cycle Cost $2.50 $2.00 6" 8" $1.50 $1.00 $0.50 $ % 1.40% None Discount Rate
54 cause Tom says so
55 5 X low upfront vs 1 X high upfront Even for a low traffic pavement concrete gives a much longer life span Under low traffic the primary effect on asphalt is cracking due to aging In a 50 year life assessment: 1 6 concrete rehabilitation vs 5 asphalt rehabilitations and no rehabs for 8 vs 5 asphalt rehabilitations It takes five years to program a pavement rehabilitation from the time the pavement reaches the terminal ride so, 25 of the 50 year life cycle is on defective pavement
56 For > 30 million ESAL - FDOT Design
57 Most Appropriate Areas for Concrete Pavement for State and Local Roads Intersections/Local Roads/Town Centers Deceleration and Acceleration Lanes at Intersections with Heavy Truck Traffic Roundabouts vs Four Way Stops Commuter Rail/Bus Stops and Parking Lots Sidewalks, Multi-Use Trails and Bike Paths Pervious and Colored Concrete
58 Successful Asphalt to Concrete Intersection Conversion and Retro-Fit Sample Road and Power Line Road Fort Lauderdale, Florida 22 nd Street Tampa, Florida
59 US 27 Broward County
60 Florida: Polk County Concrete Pavement Roundabout 2016
61 Polk County Roundabout
62 SunRail Station Debary: Concrete Pavement for Buses
63 Stadium Bike Trail: Tallahassee
64 Publix Store Zephyrhills, Florida Pervious Concrete Parking Lot
65 Colored and Stamped Concrete Cul-de-sac Frenchman s Creek Club House
66 Open forum.questions!
67 It s Time!
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