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Use of Polyurethane Grout for Concrete Pavement Slab Stabilization

Lessons Learned. Indiana County. Use of Polyurethane Grout for Concrete Pavement Slab Stabilization. District 10-0. SR 422 Sec. 6 Indiana By Pass Slab Stabilization Project. Existing Pavement Conditions. Original construction 1995 4 lane Limited Access Highway

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Use of Polyurethane Grout for Concrete Pavement Slab Stabilization

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  1. Lessons Learned Indiana County Use of Polyurethane Grout for Concrete Pavement Slab Stabilization District 10-0

  2. SR 422 Sec. 6 Indiana By Pass Slab Stabilization Project

  3. Existing Pavement Conditions • Original construction 1995 • 4 lane Limited Access Highway • Two 12 ft lanes each direction • Project length ~3miles • 12 lane miles treated • Shoulders 4 ft left, 10 ft right • 20 ft joint spacing

  4. Existing Pavement Conditions cont. • Pavement section • 10 inch unreinforced PCCP • Subbase • 4 inch OGS • 4 inch 2A • Joints are in good condition • Main Problems – • Mid Bay Slab Cracks • Slab settlement • Rocking • Some pavement distress

  5. SR 422 Sec. 6 Mid-bay Crack Project • Project traffic and Length 7% Trucks Total 12 lane miles

  6. Slab Stabilization Scope of Work • Slab Stabilization using Polyurethane Grout • Slab Stabilization using Cement Grout(Comparison Section) • Concrete Pavement Patching full depth • Dowel Bar Retro Fit Repairs • Crack Cleaning and Sealing • Joint Cleaning and Sealing

  7. Project Overview

  8. The existing joints are in Good Condition

  9. Some Joint Distress but not extensive

  10. Mid-Bay Cracks

  11. Mid-Bay Cracks

  12. Mid-bay slab cracking 20 ft Joint Spacing Mid-bay Crack 10 in PCCP 4” OGS 4” 2A Subgrade (Stiff to Hard Gravelly Silty Clay)

  13. Slab Curling 20 ft Joint Spacing Mid-bay Crack 10 in PCCP 4” OGS 4” 2A Subgrade (Stiff to Hard Gravelly Silty Clay)

  14. OGS Degradation 20 ft Joint Spacing Mid-bay Crack 10 in PCCP 4” OGS 4” 2A Subgrade (Stiff to Hard Gravelly Silty Clay)

  15. Dowel Bar Retrofit - Grout Stabilization 20 ft Joint Spacing Mid-bay Crack 10 in PCCP 4” OGS 4” 2A Subgrade (Stiff to Hard Gravelly Silty Clay)

  16. Comparison of distress between Travel Lanes and Passing Lanes Quantities as originally designed *DBR Dowel Bar Retrofits

  17. Grout Hole Spacing Traffic 6ft 6ft 3ft 12 ft 12 ft 20 ft 20 ft

  18. Drilling Grout Holes

  19. Mix Ratio Mix Ratio 50/50 by volume B/A=8.95/10.16 = 0.88 by density

  20. Grout Application Rate Per Lineal Foot Of 12ft wide Pavement Slab *Highest application rate occurred in areas where slab was raised ½ to 1 inch. Unit Bid Price of Material is $4.30/pound

  21. Grout Application Rate Per Hole Unit Bid Price of Material is $4.30/pound

  22. Application Rate Per Day With 4 Trucks * Equipment break down and or low air temperatures

  23. Total Polyurethane Grout Cost • Original Estimated Quantity 380,000 pounds $1.63M • Actual Quantity 627,700 pounds $2.67M

  24. Iowa State Mobile Lab

  25. Iowa State Mobile Lab

  26. Iowa State University- an overview of testing and some very preliminary results Tests were done before and after injection at both pavement joints and at mid bay cracks Falling Weight Deflectometer (FWD) testing measured both modulus and deflection giving joint efficiency Various subgrade density and modulus testing devices were used Load transfer efficiency Pavement Elevation profile Insitu densities Subbase gradation Subgrade Temperature probe

  27. Example of Data presentation

  28. Some key findings are as follows: • Load transfer efficiency for the joints is about 79% before and after stabilization • Load transfer efficiency for the mid-panel cracks is about 43% before stabilization and 88% after stabilization • Corner slab deflections post-stabilization are less than 0.5 mm

  29. Slab elevation changes • There was an elevation change of about 0.25in. on average in test section 6 • There was an elevation change of about 0.8in on average in test section 7. This section also took twice as much material

  30. Comparison with Portland Cement Grout • The polyurethane performance will be compared to a 1,300 foot (~67 slabs) test section which will be grouted using portland cement grout during the construction season of 2010.

  31. Summary and observations • The OGS showed signs of particle degradation allowing for some slab rocking • The 2A appeared to be stable • The subgrade was stiff to hard • The mid-bay cracks appear to be due to slab curling. • The polyurethane grout is effective in stabilizing slab movements

  32. Summary and Observations Cont. • The Grout was effective at penetrating the clean OGS layer but it did not penetrate the 2A layer • The grout is effective at lifting the slabs but it appeared difficult to accurately control the movement • The grout coated the bottom of the slab with ¼ to 1 inch thick layer • The grout did not block the drainage system

  33. Based on the observations and information collected the following contract changes have been made • We increased the polyurethane quantity to include total grouting of the passing lane • We reduced the quantity of full depth patches and increased the quantity of DBRs. • The DBRs cost about ½ the amount of a patch and reduces the number of pavement joints. • We are considering the elimination of the diamond grinding

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