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PCC Pavement
Repair vs. Overlay vs. Reconstruction
Brandon Varilek, P.E., PMP
Outline
• Maintenance (Repair)
• Options
• Considerations
• Impacts
• Example Projects
• Cost
• 3R; Resurfacing, Restoration, Rehabilitation (Repair & Overlay)
• Options
• Considerations
• Impacts
• Example Projects
• Cost
• Reconstruction
• Options
• Considerations
• Impacts
• Example Projects
• Cost
Maintenance
• Options
• PCC Rpr, Joint Seal
• PCC Repair, Joint Seal, Concrete Sealer
• PCC Repair, Joint Seal, Diamond Grind
• Considerations
• Thickness Caution against grinding PCC <8”
• Age vs. Design Life DOT: 35 yr initial + 15 yr Overlay = 50 yrs
• Condition
• < 5% PCC Rpr
• Roughness - Faulting, construction, previous and future repairs
• Material Defects (ASR)
• Traffic
• Truck traffic Steady? Increasing?
• Detour Road Standard 47B w/1P cement – Durable, permanent repair
• Open Daily PR Concrete – Brittle, susceptible to ASR, 10 yr+ life
• Budget
• Impacts
• Minimal – No grade raise, no earthwork, no ROW, etc.
PCC Repair Costs: 8” x 24’ x 1mi
0
100
200
300
400
500
600
700
0 5 10 15 20 25 30
$/mix1000
% PCC Repaired
PCC Repair Costs
$500K ~ 1/2 Cost of Reconstruction
Reconstruction
*Data limited to 12 recent DOT projects
Assumes 8”x24’x1 mile PCC
Maintenance
• Options
• PCC Rpr, Joint Seal
• PCC Repair, Joint Seal, Concrete Sealer
• PCC Repair, Joint Seal, Diamond Grind
• Considerations
• Thickness Caution against grinding PCC <8”
• Age vs. Design Life DOT: 35 yr initial + 15 yr Overlay = 50 yrs
• Condition
• < 5% PCC Rpr
• Roughness - Faulting, construction, previous and future repairs
• Material Defects (ASR)
• Traffic
• Truck traffic Steady? Increasing?
• Detour Road Standard 47B w/1P cement – Durable, permanent repair
• Open Daily PR Concrete – Brittle, susceptible to ASR, 10 yr+ life
• Budget
• Impacts
• Minimal – No grade raise, no earthwork, no ROW, etc.
Alkali Silica Reaction
• Alkalis (cement) react with Silica (sand and gravel)
and Water to form an expansive gel that crack
concrete from within
• National problem resulting from multiple factors
• Higher alkali content in cement due to new environmental
regulations
• NDOT pavement
• Significant from ~ 1985 – 1995
• Partially/Fully Mitigated ~ 1995 – 2005
• Eliminated ~ 2005
Maintenance
• Options
• PCC Rpr, Joint Seal
• PCC Repair, Joint Seal, Concrete Sealer
• PCC Repair, Joint Seal, Diamond Grind
• Considerations
• Thickness Caution against grinding PCC <8”
• Age vs. Design Life DOT: 35 yr initial + 15 yr Overlay = 50 yrs
• Condition
• < 5% PCC Rpr
• Roughness - Faulting, construction, previous and future repairs
• Material Defects (ASR)
• Traffic
• Truck traffic Steady? Increasing?
• Detour Road Standard 47B w/1P cement – Durable, permanent repair
• Open Daily PR Concrete – Brittle, susceptible to ASR, 10 yr+ life
• Budget
• Impacts
• Minimal – No grade raise, no earthwork, no ROW, etc.
Maintenance Example
PCC Rpr, Diamond Grind, Jnt Seal, Concrete Sealer
• Hwy 2, Mason City SE
• 9” non-doweled PCC
• 24 yrs old
• 365 Trucks
• <0.5% repairs, $7K/mile
• 1.4 mm faulting
• Driving factor(s) for Rehab
• ASR Susceptible
• Roughness
Penetrating Concrete Sealers
• Clear, breathable, penetrating water repellent
• Purpose
• Seal PCC pavements in good condition but susceptible to ASR
• Materials
• 100% Silane – NDOT Approved Products List
Maintenance Example
Rpr, Grind, Jnt Seal
• Hwy 77, Ceresco South
• 10” non-doweled PCC
• 23 yrs old (2019)
• 950 Trucks
• 1% repairs, $24K/mile*
• 5.6 mm faulting
• 4-lane allows lane closures for 47B
• Driving factor(s) for Rehab
• Roughness
*Converted to 24’ Rdwy
Maintenance Cost
• Assume 8”x24’x1mile PCC
• PCC Rpr and Joint Seal
• ~2% PCC Rpr ~ 282 SY
• ~ $45K/mile Rpr + $47K/mile Seal = $92K/mile
• PCC Rpr, Joint Seal, Concrete Sealer
• ~2% PCC Rpr = 282 SY
• ~ $45K/mile Rpr + $47/mile Jnt. Seal + $25K/mile Concrete Sealer = $117/mile
• PCC Rpr, Joint Seal, Diamond Grind
• ~2% PCC Rpr = 282 SY
• ~ $45K/mile Rpr + $47K/mile Jnt. Seal + $87K/mile Grind = $179K/mile
3R
• Options
• PCC Rpr, HMA or PCC Overlay
• Considerations
• Thickness Added Structure
• Age vs. Design Life
• Condition
• 3 -20% PCC Rpr
• Roughness Corrected w/overlay
• Material Defects (ASR) HMA Overlay will seal
• Traffic
• Truck Traffic Steady? Increasing?
• Detour Road Less important for HMA- PR concrete adequate
Likely Needed for PCC
• Budget
• Impacts
• 3-4” Grade raise w/HMA, 5-6” w/PCC
• Significant shouldering, grading
• Reduced drainage capacity
• Potential ROW issues, sensitive areas; wetlands, historic properties, etc.
0
100
200
300
400
500
600
700
0 5 10 15 20 25 30
$/mix1000
% PCC Repaired
PCC Repair Costs
3R Example
PCC Rpr, 4” HMA Overlay
• Hwy 6 & 34, Culbertson - McCook
• 8” RCP
• 44-49 Yrs old (2012)
• 300 Trucks
• 5% Rprs, $92K/mile
• Driving factor for Rehab
• Roughness
• Spalled joints, 3mm faulting
• Grade raise acceptable
• (ROW, Sensitive Areas, etc.)
3R Example
PCC Rpr, PCC Overlay
• Hwy 30 Sutherland - Hershey
• 5”+ HMA/7”PCC
• 17 yr old HMA Surface
• 270 Trucks
• 1.3% Rprs, $40K/mile
• Driving factor for Rehab
• Old, oxidized surface
• Transverse, longitudinal cracks
• Rutting
• Detoured road for construction
3R Costs
• Assume 8”x24’x1mile PCC
• PCC Rpr, 4” HMA Overlay
• ~10% PCC Rpr ~ 1400 SY
• ~ $220K/mile Rpr + 268K/mile HMA Overlay= $488K/mile
• PCC Rpr, 5” PCC Overlay
• ~10% PCC Rpr = 1400 SY
• ~ $220K/mile Rpr + $397K/mile PCC Overlay= $617K/mile
Reconstruction
• Options
• New Doweled PCC, Foundation Course & Drains
• Considerations
• Age vs. Design Life
• Condition
• 15% + Rpr Often due to Alkali Silica Reaction
• Subgrade and/or moisture issues
• Traffic Handling
• Generally requires road closure & detours
• Budget
• Final Product
• PCC repair and overlay rarely approaches cost of N&R
• Vastly different end products
• Impacts
• Scope increase
• Urban – Water/Sewer work, ADA, ROW
• Rural – Wider pavement, surfaced shoulders, bridge work, culvert extensions, grading to correct geometrics, etc
0
100
200
300
400
500
600
700
0 5 10 15 20 25 30
$/mix1000
% PCC Repaired
PCC Repair Costs
Reconstruction Example
10” DCP, 4” FC, Prepared Subgrade
• Hwy 6 In Hastings
• 9” PCC
• 29 Yrs old
• 875 Trucks
• ?% Rprs
• Driving Factor for Reconstruction
• Severe ASR Deterioration
• ~3 mm faulting
Reconstruction Example
10” DCP on Stabilized Subgrade
• Hwy 50/Platteview Rd Intersection Impr.
• ?” PCC
• ? Yrs old
• Driving Factor for Reconstruction
• Intersection Improvement (Turn lane)
• Shattered slabs
• No solid pavement to tie Turn lane PCC to
Reconstruction Cont.
• Assume 8”x24’x1mile PCC
• 8” DCP on Prepared Subgrade
• ~ 14K SY ~ $988K/mile
• Pavement Only!
0
200
400
600
0 10 20 30
$/mix1000
% PCC Repaired
PCC Repair Costs
Summary
Repair vs. Overlay vs. Reconstruction
• Considerations
• Thickness
• Age
• Condition
• Traffic
• Budget
Reconstruction; 8” DCP on Prep ~ $990K/mi
3R Rpr (10%)/4” HMA Overlay ~ $490K/mi
Maintenance Rpr (2%)/Jnt Seal ~ $90K/mi

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PCC Pavement: Repair vs. Overlay vs. Reconstruction

  • 1. PCC Pavement Repair vs. Overlay vs. Reconstruction Brandon Varilek, P.E., PMP
  • 2. Outline • Maintenance (Repair) • Options • Considerations • Impacts • Example Projects • Cost • 3R; Resurfacing, Restoration, Rehabilitation (Repair & Overlay) • Options • Considerations • Impacts • Example Projects • Cost • Reconstruction • Options • Considerations • Impacts • Example Projects • Cost
  • 3. Maintenance • Options • PCC Rpr, Joint Seal • PCC Repair, Joint Seal, Concrete Sealer • PCC Repair, Joint Seal, Diamond Grind • Considerations • Thickness Caution against grinding PCC <8” • Age vs. Design Life DOT: 35 yr initial + 15 yr Overlay = 50 yrs • Condition • < 5% PCC Rpr • Roughness - Faulting, construction, previous and future repairs • Material Defects (ASR) • Traffic • Truck traffic Steady? Increasing? • Detour Road Standard 47B w/1P cement – Durable, permanent repair • Open Daily PR Concrete – Brittle, susceptible to ASR, 10 yr+ life • Budget • Impacts • Minimal – No grade raise, no earthwork, no ROW, etc.
  • 4. PCC Repair Costs: 8” x 24’ x 1mi 0 100 200 300 400 500 600 700 0 5 10 15 20 25 30 $/mix1000 % PCC Repaired PCC Repair Costs $500K ~ 1/2 Cost of Reconstruction Reconstruction *Data limited to 12 recent DOT projects Assumes 8”x24’x1 mile PCC
  • 5. Maintenance • Options • PCC Rpr, Joint Seal • PCC Repair, Joint Seal, Concrete Sealer • PCC Repair, Joint Seal, Diamond Grind • Considerations • Thickness Caution against grinding PCC <8” • Age vs. Design Life DOT: 35 yr initial + 15 yr Overlay = 50 yrs • Condition • < 5% PCC Rpr • Roughness - Faulting, construction, previous and future repairs • Material Defects (ASR) • Traffic • Truck traffic Steady? Increasing? • Detour Road Standard 47B w/1P cement – Durable, permanent repair • Open Daily PR Concrete – Brittle, susceptible to ASR, 10 yr+ life • Budget • Impacts • Minimal – No grade raise, no earthwork, no ROW, etc.
  • 6. Alkali Silica Reaction • Alkalis (cement) react with Silica (sand and gravel) and Water to form an expansive gel that crack concrete from within • National problem resulting from multiple factors • Higher alkali content in cement due to new environmental regulations • NDOT pavement • Significant from ~ 1985 – 1995 • Partially/Fully Mitigated ~ 1995 – 2005 • Eliminated ~ 2005
  • 7. Maintenance • Options • PCC Rpr, Joint Seal • PCC Repair, Joint Seal, Concrete Sealer • PCC Repair, Joint Seal, Diamond Grind • Considerations • Thickness Caution against grinding PCC <8” • Age vs. Design Life DOT: 35 yr initial + 15 yr Overlay = 50 yrs • Condition • < 5% PCC Rpr • Roughness - Faulting, construction, previous and future repairs • Material Defects (ASR) • Traffic • Truck traffic Steady? Increasing? • Detour Road Standard 47B w/1P cement – Durable, permanent repair • Open Daily PR Concrete – Brittle, susceptible to ASR, 10 yr+ life • Budget • Impacts • Minimal – No grade raise, no earthwork, no ROW, etc.
  • 8. Maintenance Example PCC Rpr, Diamond Grind, Jnt Seal, Concrete Sealer • Hwy 2, Mason City SE • 9” non-doweled PCC • 24 yrs old • 365 Trucks • <0.5% repairs, $7K/mile • 1.4 mm faulting • Driving factor(s) for Rehab • ASR Susceptible • Roughness
  • 9. Penetrating Concrete Sealers • Clear, breathable, penetrating water repellent • Purpose • Seal PCC pavements in good condition but susceptible to ASR • Materials • 100% Silane – NDOT Approved Products List
  • 10. Maintenance Example Rpr, Grind, Jnt Seal • Hwy 77, Ceresco South • 10” non-doweled PCC • 23 yrs old (2019) • 950 Trucks • 1% repairs, $24K/mile* • 5.6 mm faulting • 4-lane allows lane closures for 47B • Driving factor(s) for Rehab • Roughness *Converted to 24’ Rdwy
  • 11. Maintenance Cost • Assume 8”x24’x1mile PCC • PCC Rpr and Joint Seal • ~2% PCC Rpr ~ 282 SY • ~ $45K/mile Rpr + $47K/mile Seal = $92K/mile • PCC Rpr, Joint Seal, Concrete Sealer • ~2% PCC Rpr = 282 SY • ~ $45K/mile Rpr + $47/mile Jnt. Seal + $25K/mile Concrete Sealer = $117/mile • PCC Rpr, Joint Seal, Diamond Grind • ~2% PCC Rpr = 282 SY • ~ $45K/mile Rpr + $47K/mile Jnt. Seal + $87K/mile Grind = $179K/mile
  • 12. 3R • Options • PCC Rpr, HMA or PCC Overlay • Considerations • Thickness Added Structure • Age vs. Design Life • Condition • 3 -20% PCC Rpr • Roughness Corrected w/overlay • Material Defects (ASR) HMA Overlay will seal • Traffic • Truck Traffic Steady? Increasing? • Detour Road Less important for HMA- PR concrete adequate Likely Needed for PCC • Budget • Impacts • 3-4” Grade raise w/HMA, 5-6” w/PCC • Significant shouldering, grading • Reduced drainage capacity • Potential ROW issues, sensitive areas; wetlands, historic properties, etc. 0 100 200 300 400 500 600 700 0 5 10 15 20 25 30 $/mix1000 % PCC Repaired PCC Repair Costs
  • 13. 3R Example PCC Rpr, 4” HMA Overlay • Hwy 6 & 34, Culbertson - McCook • 8” RCP • 44-49 Yrs old (2012) • 300 Trucks • 5% Rprs, $92K/mile • Driving factor for Rehab • Roughness • Spalled joints, 3mm faulting • Grade raise acceptable • (ROW, Sensitive Areas, etc.)
  • 14. 3R Example PCC Rpr, PCC Overlay • Hwy 30 Sutherland - Hershey • 5”+ HMA/7”PCC • 17 yr old HMA Surface • 270 Trucks • 1.3% Rprs, $40K/mile • Driving factor for Rehab • Old, oxidized surface • Transverse, longitudinal cracks • Rutting • Detoured road for construction
  • 15. 3R Costs • Assume 8”x24’x1mile PCC • PCC Rpr, 4” HMA Overlay • ~10% PCC Rpr ~ 1400 SY • ~ $220K/mile Rpr + 268K/mile HMA Overlay= $488K/mile • PCC Rpr, 5” PCC Overlay • ~10% PCC Rpr = 1400 SY • ~ $220K/mile Rpr + $397K/mile PCC Overlay= $617K/mile
  • 16. Reconstruction • Options • New Doweled PCC, Foundation Course & Drains • Considerations • Age vs. Design Life • Condition • 15% + Rpr Often due to Alkali Silica Reaction • Subgrade and/or moisture issues • Traffic Handling • Generally requires road closure & detours • Budget • Final Product • PCC repair and overlay rarely approaches cost of N&R • Vastly different end products • Impacts • Scope increase • Urban – Water/Sewer work, ADA, ROW • Rural – Wider pavement, surfaced shoulders, bridge work, culvert extensions, grading to correct geometrics, etc 0 100 200 300 400 500 600 700 0 5 10 15 20 25 30 $/mix1000 % PCC Repaired PCC Repair Costs
  • 17. Reconstruction Example 10” DCP, 4” FC, Prepared Subgrade • Hwy 6 In Hastings • 9” PCC • 29 Yrs old • 875 Trucks • ?% Rprs • Driving Factor for Reconstruction • Severe ASR Deterioration • ~3 mm faulting
  • 18. Reconstruction Example 10” DCP on Stabilized Subgrade • Hwy 50/Platteview Rd Intersection Impr. • ?” PCC • ? Yrs old • Driving Factor for Reconstruction • Intersection Improvement (Turn lane) • Shattered slabs • No solid pavement to tie Turn lane PCC to
  • 19. Reconstruction Cont. • Assume 8”x24’x1mile PCC • 8” DCP on Prepared Subgrade • ~ 14K SY ~ $988K/mile • Pavement Only!
  • 20. 0 200 400 600 0 10 20 30 $/mix1000 % PCC Repaired PCC Repair Costs Summary Repair vs. Overlay vs. Reconstruction • Considerations • Thickness • Age • Condition • Traffic • Budget Reconstruction; 8” DCP on Prep ~ $990K/mi 3R Rpr (10%)/4” HMA Overlay ~ $490K/mi Maintenance Rpr (2%)/Jnt Seal ~ $90K/mi

Editor's Notes

  1. When do we do Maint, 3R, Reconstruction
  2. 61596, Mason City SE – Rpr/Silane Sealer – 0.3% - $7K/mile (Driven by ASR Susceptibility) 13329, Syracuse East – Rpr/Grind – 0.4% 13286, Ceresco South – Rpr/Grind – 0.9% 42510, Kearney to Minden – Rpr/Silane Sealer – 1.6% - $41K/mile (24’) (Driven by ASR Susceptibility) 42764, In St Paul & North – Rpr/Grind – 15% - $253K/mi (Grinding of some thin pavement not ideal)
  3. 61596, Mason City SE – Rpr/Silane Sealer – 0.3% - $7K/mile (Driven by ASR Susceptibility) 13329, Syracuse East – Rpr/Grind – 0.4% 13286, Ceresco South – Rpr/Grind – 0.9% 42510, Kearney to Minden – Rpr/Silane Sealer – 1.6% - $41K/mile (24’) (Driven by ASR Susceptibility) 42764, In St Paul & North – Rpr/Grind – 15% - $253K/mi (Grinding of some thin pavement not ideal)
  4. 61596, Mason City SE – Rpr/Silane Sealer – 0.3% - $7K/mile (Driven by ASR Susceptibility) 13329, Syracuse East – Rpr/Grind – 0.4% 13286, Ceresco South – Rpr/Grind – 0.9% 42510, Kearney to Minden – Rpr/Silane Sealer – 1.6% - $41K/mile (24’) (Driven by ASR Susceptibility) 42764, In St Paul & North – Rpr/Grind – 15% - $253K/mi (Grinding of some thin pavement not ideal)
  5. 2-3(122), Mason City SE, 61596, – Rpr/Silane Sealer – 0.3% - $7K/mile (Driven by ASR Susceptibility)
  6. 2-3(122), Mason City SE, 61596, – Rpr/Silane Sealer – 0.3% - $7K/mile (Driven by ASR Susceptibility)
  7. 77-2(164), Ceresco South, CN 13286
  8. 13341, Princeton South, 1.5” HMA (ASR), 1.6% - $34K/mile 32150, Hubbard SW – Overlay, 3.3% - $61K/mile 22455, In Snyder and East – Overlay, 3.4% - $73K/mile 13340, Pickrell South, 1.5” HMA (ASR) – 4.0% - $84K/mile 70881, Culbertson – McCook, 4” HMA, 4.7% Rpr 22690 Ramblewood – 156th – Overlay, 8.2%- $228K/mi 22689, 156th – 108th – Overlay, 12.4% - $333K
  9. 30-2(143), Sutherland – Hershey, CN 61568
  10. 6-4(129) US 6 & 34, Hastings, CN 42788, Build 2021
  11. 50-2(136), N50/Platteview Rd, CN 22726
  12. 61596, Mason City SE – Rpr/Silane Sealer – 0.3% - $7K/mile (Driven by ASR Susceptibility) 13329, Syracuse East – Rpr/Grind – 0.4% 13286, Ceresco South – Rpr/Grind – 0.9% 42510, Kearney to Minden – Rpr/Silane Sealer – 1.6% - $41K/mile (24’) (Driven by ASR Susceptibility) 42764, In St Paul & North – Rpr/Grind – 15% - $253K/mi (Grinding of some thin pavement not ideal)