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Tools for using precast concrete pavement (PCP) systems to reduce the duration of construction closures on critical roadways and to provide long-life performance.

Precast Concrete Pavement (R05)

Challenge

Roadway repair causes congestion and traffic delays for drivers. The duration and scheduling of work zones influences the exposure of both construction workers and travelers to traffic and related risk for accidents. A faster, safer, and longer-lasting method for replacing or rehabilitating roadway surfaces would reduce delays and ease congestion.

Solution

PCP systems are comprised of high-quality, prefabricated concrete panels that are formed offsite and installed during off-peak travel times. PCP is a versatile approach that can be used for repair and rehabilitation of roadways, toll plazas, intersections, bridge approach slabs, and tunnels, in addition to new roadway construction. Cast in plants under ideal conditions, precast panels are subjected to high quality control standards during the fabrication process, which results in a durable and ready-for-traffic road surface. The required smoothness typically is achieved by routine grinding of the panels soon after placement. Modular concrete panels that are installed onsite when the traffic volume is low reduce overall traffic congestion and provide a number of other advantages, such as safety of workers and highway users and avoidance of interrupted commerce.

The SHRP2 PCP solution offers a series of guidelines and model specifications to help agencies effectively select projects for PCP, and to design, fabricate, and install long-life jointed and prestressed PCP systems. Further, the report recognizes that the cost of PCP panels has dropped significantly in the past decade. Coupled with shorter construction-related closures and potential long-life performance, PCP offers transportation agencies significant short- and long-term advantages.

Benefits

The use of PCP can significantly reduce traffic impacts of roadway repair and reconstruction projects, particularly on heavily traveled routes. The technology is applicable to both small segments, enabling flexibility in construction phasing, as well as for use in corridor-wide pavement reconstruction. The R05 report will further the understanding of PCP for roadway repair and rehabilitation. Benefits include:

  • Shorter installation time
  • Reduced traffic impacts, and improved safety of workers and drivers
  • Pavement is ready for traffic upon installation—no curing time
  • Slabs are cast in plants under ideal conditions for optimum quality and durability
  • Installation can take place at night or under adverse weather conditions, extending the construction season
  • Longer-life performance than traditional cast-in-place (CIP) solutions

In the Field

State Project Description Activity Contact
California Using precast concrete pavement Research Mehdi Parvini (California DOT) mehdi.parvini@dot.ca.gov
Delaware Using precast concrete pavement Research Jim Pappas (Delaware DOT) james.pappas@state.de.us
Illinois Using precast concrete pavement Research Steven L. Gillen (Illinois Tollway) sgillen@getipass.com
Minnesota Using precast concrete pavement Research Tom Burnham (Minnesota DOT) tom.burnham@state.mn.us
Missouri Using precast concrete pavement Research John Donahue (Missouri DOT) john.donahue@modot.mo.gov
Hawaii Implementation Assistance Program - DOT: Project description coming soon. Lead Adopter Incentive Sam Tyson (FHWA) sam.tyson@dot.gov
Illinois Implementation Assistance Program - Illinois Tollway: Project description coming soon. Lead Adopter Incentive Sam Tyson (FHWA) sam.tyson@dot.gov
Texas Implementation Assistance Program - DOT: Project description coming soon. Lead Adopter Incentive Sam Tyson (FHWA) sam.tyson@dot.gov
Kansas Implementation Assistance Program - DOT: Project description coming soon. Lead Adopter Incentive Sam Tyson (FHWA) sam.tyson@dot.gov
Wisconsin Implementation Assistance Program - DOT: Project description coming soon. Lead Adopter Incentive Sam Tyson (FHWA) sam.tyson@dot.gov

Field activities also performed in Michigan, New Jersey, New York and Virginia during the research phase.

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