Whats Trending in Concrete Pavements Greg Dean Executive

What’s Trending in Concrete Pavements? Greg Dean Executive Director CLT UNC-C Airport Engineering Seminar

Carolinas Concrete Paving Association Local Voice of the Concrete Pavement Industry Who are we? • Member-Driven Organization ▫ Contractors Highway, Airports, S&LR, Preservation, RCC Some specialize only in airports (FAA P-501) ▫ Material Suppliers (i. e. Cement, Admixtures, etc. ) • Agency Responsive

Resources – Regional and National Years of airfield pavement experience Familiarity with 150/5320 -6 F & 150/5370 -10 H ACPA-SE Chapter Gerald Jasper, P. E. ACPA National Gary Mitchell, P. E.

ACPA Resources - Publications

Open Houses Opportunities to see up close Lancaster County Airport Concrete Overlay of Asphalt Charleston Exec Airport Concrete Overlay of Concrete

What Trending? Airfield Applications • CONCRETE…three R’s ▫ Restoration, Rehabilitation, and Reconstruction • Today, it’s all about… ▫ Resurfacing (overlays), Recycling, and Resiliency

Timing is Important… Restoration Resurfacing Reconstruction

Definition: Concrete Overlays are part of the resurfacing family and are defined as a new or fresh surface on a existing pavement.

Concrete Overlays Local Streets & Highway Applications

Concrete Overlays!

TYPES OF CONCRETE OVERLAYS Bonded Landside Potential Unbonded Airside Potential

Denver (DIA) Use of 5 -Inch Overlay Landside Park & Ride Lot (64 -Acre)

Unbonded Over Asphalt or Composite Keys to Success • Milling to eliminate surface distortions of 2 in. or more • Complete repairs at isolated spots where structural integrity needs restoring • Concrete patches in the existing pavement should be separated from the overlay Composite • Surface temperature of existing asphalt pavement should be maintained below 120ºF (48. 9ºC) when placing overlay • Partial bonding between the overlay and the existing asphalt pavement is acceptable and may even improve load -carrying capacity

Lancaster County (SC) Airport TEN Contractors • 2 PCCP & Asph • 2 Asph only • 6 PCCP only April 2009 Bid Contractor Alternative Bid Amount ($) Asphalt / FDR Concrete A $2, 326, 545 - B $2, 453, 970 - C - $2, 377, 577 D - $2, 497, 931

Lancaster County Completed – 7. 5” WT

Laurens County (SC) Airport ½ Width Paving – 37. 5’ 5 -Inch, SCDOT 501 Spec (substituted for P-501), Min of 4400 psi

Grand Strand Airport (CRE) May 2018 Bid Contractor 4 Contractors • 2 Base Bid (PCCP) • Connectors • 2 Additive Bids • Parallel TW 7. 5 -inch Concrete Overlay (66, 640 SY) Project Bids Concrete A $6, 859, 463 $46. 50/SY B $7, 001, 427 $40. 40/SY C $7, 261, 864 $47. 71/SY D $8, 174, 051 $47. 29/SY

Grand Strand (SC) Airport 7. 5 -inch Runway Overlay

Grand Strand (SC) Airport 7. 5 -inch Runway Overlay

NC/SC/GA Airports – Concrete Overlays AIRPORT (Alphabetical Order) Engineering Consultant PCCP Contractor Augusta Regional RW (14”) Campbell & Paris Ballenger Paving (Mc. I) Berkeley Co RW WK Dickson Inc Ballenger Paving (Mc. I) Charleston Exec (UBO) ADC Engineers Ballenger Paving (Mc. I) Cobb Co RW Michael Baker Inc (LPA) Six-S Inc Darlington Co RW Michael Baker Inc Hi-Way Paving Grand Strand RW Holt Inc HI-Way Paving Greenwood Co RW Michael Baker Inc Mc. Carthy Improvement Lancaster Co RW Michael Baker Inc (LPA) Hinkle Contracting Laurens Co RW & TW Michael Baker Inc (LPA) Ballenger Paving (Mc. I) Williamsburg Co Ramp Wilbur Smith Assoc ? Wilmington FBO Ramp Talbert & Bright Inc Trader Construction BLUE = Commercial Service Airport, RED = Unbonded of Concrete

JFK International Airport Port Authority of NY / NJ RUNWAY 13 L-31 R RUNWAY 13 R-31 L

Runway Cross Section C L Runway 80 Feet ASPHALT Grass Safety Area ASPHALT 200 -ft Concrete SHOULDERS/ EROSION CL Light Pavement SHOULDERS/ Grass EROSION Safety Area Pavement Existing Runway Concrete Runway Typical Section • • • 22 Over 200, 000 Cubic yards of concrete 240, 000 Dowels 55 miles of joint seals 325, 000 tons of asphalt base and HMA 12 miles of drainage pipe 1500 in-pavement lights Edge Light Typical

RW 13 R-31 L Final Project Design

Resiliency of Concrete Recognized Port Authority of NY & NJ Press Release (4 -3 -2019) Reconstruction of Runway 13 L-31 R at JFK The rehabilitation will provide aircraft a solid concrete runway that is more RESILIENT than asphalt and will increase the useful life of runway by four times Use of Concrete will extend runway’s useful life to 40 years, rather than 8 -12 years with asphalt.

Unbonded Overlay of Concrete Pavements: Keys to Success • Full-depth repairs -only where structural integrity is lost at isolated spots. • Separator layer (normally 1” asphalt or non-woven geotextile fabric) • Use to restore structural capacity of the existing pavement and increase pavement life equivalent to full-depth pavement. • Faulting of 3/8 in. or less in the existing concrete pavement • Shorter joint spacing helps minimize curling and warping stresses. • Best not to match joints with those of the underlying concrete pavement.

Unbonded Concrete Overlay ILM – North General Aviation Ramp

350’ Extension Batch Plant On-Site Crushing Operation – Base Material RW Width reduced to 100’ WW II Era PCCP Asphalt Sep Layer

CONCRETE OVERLAY COMPLETED 59, 700 SY of 11 -inch P-501

Quotes from (JZI) Open House • A Concrete Overlay kept us “out of the subgrade” vs. reconstruction option. • A Concrete Overlay raised our pavement elevation out of the high water table • Inch per Inch concrete was less expensive than the asphalt leveling (sep) layer • Our original PCCP surface lasted 60+ years, no reason why this surface cannot last another 60 years!

End Uses for Recycled Concrete Source: Recycling Concrete Pavement Materials: A Practitioner’s Ref Guide

Wilmington (ILM) GA Ramp

Projects using Recycled Concrete Agg AIRPORT Used for PCCP Contractor (Alphabetical Order) Atlanta Hartsfield (ATL) P-304 (CTB) Various CAFB & North Field Aux (NAF) Unbound base Summers Concrete Charleston Exec (JZI) P-209 Ballenger Paving Charlotte International (CLT) P-209, P-304 (CTB) Hi-Way Paving Florence Regional Airport P-209 Summers Concrete Myrtle Beach Int’l P-209, P-304 Summers Concrete Nashville International (BNA) P-209, P-306 Harper Company Pittsburgh International (PIT) P-209, P-304 Hi-Way Paving Seymore Johnson AFB Unbound base Summers Concrete Shaw AFB Unbound base Summers Concrete Wilmington (ILM) FBO Ramp P-209 RC Construction Sources: Recycling Concrete Pavement Materials: A Practitioner’s Ref Guide and Report IPRF-01 -G-002 -03 -5

Elizabeth City (NC) Regional Ramp FULL-DEPTH RECLAMATION

Pavement Alternatives Analysis Parrish & Partners Of NC, PLLC Criteria – Scoring Scale 1 to 5 (Highest Score Wins) Alternative D (8” FDR & 9” P-501) Provided Greatest Flexibility Reduced Need for New Aggregates (Very High local Cost) Alt A = 5” Asphalt Overlay, Alt B = 9. 5” concrete overlay, Alt C = PCCP Full-Depth with CTB

Full-Depth Reclamation (FDR) Sampling of projects AIRPORT (Alphabetical Order) Engineering Consultant FDR / PCCP Contractor Anderson Co TW Michael Baker Inc ? / Ballenger Paving Elizabeth City Regional Parrish & Partners Slurry Pavers / Mc. I Harnett Co Regional Talbert & Bright Site Prep Montgomery County Talbert & Bright Site Prep Mt. Airy Airport Parrish & Partners Slurry Pavers Raleigh Exec Jetport Michael Baker Slurry Pavers Rocky Mount-Wilson WK Dickson Mt Carmel Stabilization Siler City Municipal WK Dickson ? Etc. (lots more across SE) AC 15/5370 -10 H contains new specification P-207 Full-Depth Reclamation

All Kinds of Transportation Infrastructure Impacted Hurricanes Matthew (2016), Florence (2018) & Dorian (2019) As Hurricane Florence departs… I-95 Lumberton, NC (2018) I-40 Pender County 4 -Days post hurricane (2018) NC Gov, Roy Cooper proposes recovery package that he says will ensure stronger and smarter infrastructure. His plan is intended to make infrastructure more RESILIENT.

IN A FLOOD SITUATION THE SUBGRADE BECOMES SUPERSATURATED Moisture infiltrates base, pushes the subgrade particles apart and weakens the system Concrete Pavements are Rigid Asphalt Pavements are Flexible • • • Lower subgrade strength, and reduced modulus means the pavement can not support the loads • Research shows it takes ~1 year to regain strength Loading during this times increases road damages and accelerate pavement deterioration Greatly reduces pavement’s intended design life that is often not recognized 7000 lbs load. • • Concrete pavement maintains high level of strength and stiffness, even when saturated Spreads the load over a large area. The subgrade is weak, but still provides uniform support The spreading of the load means subgrade is not overstressed Has little impact on the pavement serviceability 7000 lbs load. pressure ~3 - 7 psi pressure ~ 15 - 20 psi The flooded support does not impact the concrete’s load carrying capacity to the same degree as asphalt’s

CONCRETE PAVEMENT’S STIFFNESS MEANS IT IS MORE RESILIENT TO INUNDATION FLOODING Performance 1) Greater Redundancies (less dependence on subgrade / base strength Concrete Asphalt 2) Lower drop in performance (Higher Robustness) Concrete is less impacted by subgrade strength loss and recovers faster 3) Shorter Recovery time Time Pavement Resilience with respect to an event (e. g. Flooding) is characterized by two parameters: 1. Drop in performance, induced by a the event (e. g. reduced ability to carry load). 2. Recovery time to reinstate or improve performance.

The Opportunities… Where is the Best Place to start? Airside & Landside Applications • Look for Concrete Overlay opportunities ▫ Existing Asphalt (or Concrete) with low, below 70 PCI’s ▫ Large Cracks in the pavement are the normal – it can be addressed ▫ Rural Areas where competition has been lacking, high Asphalt prices • ACPA Explorer Database ▫ Where have concrete overlays on airports been completed? ▫ http: //overlays. acpa. org

THANK YOU Questions? GDean@pavementse. com