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Whitetopping: The Minnesota Experience

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A presentation given during the 39th Annual NCPA Concrete Paving Workshop. By Matt Zeller, P.E., Concrete Paving Association of Minnesota

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Whitetopping: The Minnesota Experience

  1. 1. Whitetopping: The Minnesota Experience Matthew (Matt) Zeller, PE Concrete Paving Association of MN Nebraska Concrete Paving Association 39th Annual Concrete Paving Workshop Tuesday January 16th, 2018 Cornhusker Marriott Hotel, Lincoln, NE
  2. 2. Concrete Overlays: The Minnesota Experience Nebraska Concrete Paving Association 31st Annual Concrete Paving Workshop Tuesday January 19th , 2010 Cornhusker Hotel, Lincoln, NE Matt Zeller, PE Concrete Paving Assoc. of MN
  3. 3. Concrete Overlays  Concrete over existing asphalt or concrete  Ultra-thin (less than 4”)  Thin (4” to 6”)  Conventional (greater than 6”)  Old Teminology  Unbonded Overlay (UBOL)  Whitetopping
  4. 4. Minnesota Market Year TOTAL CONCRETE PAVING - S.Y. Rolling 3 Year Average STATE AIRPORT COUNTY 2007 1,489,201 1,312,562 1,015,999 217,564 167,308 2008 1,597,218 1,275,176 980,122 129,748 309,898 2009 3,695,387 2,260,602 2,816,691 251,378 490,290 2010 3,055,392 2,782,666 2,137,367 68,775 782,697 2011 2,557,705 3,102,828 1,975,435 78,132 396,982 2012 3,170,562 2,927,886 2,241,083 58,721 729,953 2013 1,936,729 2,554,999 1,218,095 60,787 522,028 2014 3,602,432 2,903,241 2,863,843 8,038 586,750 2015 3,025,504 2,933,807 2,061,774 114,083 748,356 2016 2,084,330 2,763,911 1,181,931 91,590 702,394 2017(est.) 3,125,876 2,754,974 2,228,992 24,995 837,568
  5. 5. 2017 Overlay Breakdown Market SY Air 24,995 City 34,321 County 837,568 595,523 SY OL 595,523 Thin OL MnDOT 2,228,992 1,026,406 SY OL 680,000 Thin OL TOTAL: 3,125,876 52% overlays 41% Thin Overlays
  6. 6. 2016 Overlay Breakdown
  7. 7. County Market Trend
  8. 8. Price Estimating
  9. 9. Website Tools  www.concreteisbetter.com  Case Studies  Recent Abstracts  Sample Plans  Workshop Presentation
  10. 10. Recent Abstracts
  11. 11. Sample Plans
  12. 12. Overlays PCC vs ACC Concrete  Over concrete  Over asphalt  Short life  Long life Asphalt  Over concrete  Reflective cracks  Over asphalt  Reflective cracks  Short life (typical)  Long life ???
  13. 13. MnROAD MnROAD
  14. 14. MnROAD Phase II Mainline Details  Cell 5  Unbonded Overlay  300’ – 4”  300’ – 5”  1” asphalt bond breaker or fabric bond breaker  No steel  15’ joint spacing Unbonded PCC Overlay 105 205 305 405 5 5 5 5 1" PSAB 1" PSAB 1" PSAB 1" PSAB Oct 08 Oct 08 Oct 08 Oct 08 Current Current Current Current Clay LTine Clay LTine 7.1" cracked '93 PCC 3"cl4sp 27" Cl3sp Orig 20x14 20x13 HMA Should 1" dowel Clay LTine 5"4" 7.1" cracked '93 PCC 5" 7.1" '93 PCC 3"cl4sp 27" Cl3sp Orig 20x14 20x13 HMA Should 1" dowel 7.1" '93 PCC 3"cl4sp 27" Cl3sp Orig 20x14 20x13 HMA Should 1" dowel 4" 3"cl4sp 27" Cl3sp Orig 20x14 20x13 HMA Should 1" dowel Clay LTine
  15. 15. MnROAD 2017  Cell 5 (705 & 805)  Old cells 305 & 405 were in service for 9 years (9 million ESALs)  5” Unbonded Overlay  250’ – Fibers/Long joints  300’ – No Fibers/ Short Joints  Fabric Bond Breaker  Note cells 505 & 605 replaced Cells 105 & 205 (4” UBOL) in 2011
  16. 16. 3” FRC 6’x6’ panels, 6.5 lb/yd3 Propex fibers Fabric interlayer (standard/thin) Silty/Clay Thickened-edge PCC 5.5-7” design (1993) 5” Class 5 Sp (1993) Silty/Clay Cell 40: Faulted joints (undoweled), cracked panels, skewed joints Ultrathin Unbonded Concrete Overlay Cells 140 and 240 Constructed in 2013 over LVR Cell 40 Nonwoven geotextile fabric interlayer  Standard weight (Cell 240)  ½ of standard weight (Cell 140)
  17. 17. MnROAD Results
  18. 18. MN TH 65 Whitetopping
  19. 19. MN TH 59 4.5” Whitetopping
  20. 20. MN TH 59 4.5” Whitetopping
  21. 21. McLeod Co 3
  22. 22. Steele Co 45
  23. 23. Cottonwood Co 1
  24. 24. I-35 North of Twin Cities “6 x 6 x 6”
  25. 25. I-35 North of Twin Cities “6 x 6 x 6”
  26. 26. Anoka Co
  27. 27. Anoka Co
  28. 28. Anoka Co
  29. 29. Clay Co
  30. 30. Scott Co
  31. 31. Washington Co
  32. 32. Washington Co
  33. 33. Washington Co
  34. 34. Moorhead
  35. 35. Moorhead
  36. 36. Olmsted Co
  37. 37. Olmsted Co
  38. 38. Olmsted Co
  39. 39. Benefits of Concrete Overlays  Provides cost effective solutions - $ for $ the best long term rehabilitation option  Construct quick and conveniently  Typically, no need to remove existing pavement  Little pre-overlay repairs required in most cases  Uses standard concrete paving equipment  Accelerated practices can be used - can be opened in a day
  40. 40. Benefits of Concrete Overlays  Can be repaired easily  Durable - Olmsted Co 10 (1982 – 35 years old)  One major repair after 33 years  Looking for 20+ more years  Inherent sustainable properties  Cool  Long life  Improved mileage
  41. 41. Benefits of Concrete Overlays  Increased safety  Better skid resistance  No rutting or shoving  Improved visibility  Partial bond creates composite section adding to design life  Short panels reduce curling and warping stresses as well as minimizing expansion/contraction
  42. 42. P.S.  In one two minutes or less…
  43. 43. Fiber Reinforced Concrete
  44. 44. MnROAD – City Street Section
  45. 45. MnROAD – Early Opening
  46. 46. The Experiment • Paved Cells 524 to 124, so 124 was the youngest before loading • Cells 124 to 524 Longitudinal Test • Cell 124 – Torture test • Cell 224 – 5-3/4 hours old • Cell 324 – 8-1/3 hours old • Cell 424 – 10-1/2 hours old • Cell 524 – Control • Cell 624 Transverse Test
  47. 47. The Experiment – Longitudinal 124 224 324 424 524 3 hrs. 5-3/4 hrs. 8-1/3 hrs. 10-1/2 hrs. No Load Concrete Age: Burnham - NCC 2017
  48. 48. 3 hours
  49. 49. 2 hours
  50. 50. MnROAD – Early Opening
  51. 51. Thank You Questions?

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