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Advanced Concrete Pavement Technology (ACPT) Program-A Status Report on Available Products

Chapter 3: ACPT Product Availability

Introduction

To provide an understandable framework for ACPT products, the promising products are categorized by focus areas. The focus areas allow for a rational categorization of the many diverse ACPT products that show promise for deployment. A list of the most promising ACPT products already developed or to be developed within the next 3 to 5 years is provided next. The list is categorized in accordance with the following ACPT focus areas:

  • Focus Area 1: Advanced Designs-ACPT projects in this area are investigating ways to improve or advance pavement structural designs and optimizing use of cost-effective design features.
  • Focus Area 2: Improved Construction Materials-ACPT projects in this area are investigating ways to improve or advance concrete material selection processes and concrete mix design procedures to result in durable concrete paving mixes that can be placed and finished effectively for slipform operations.
  • Focus Area 3: Improved Construction Processes-In this focus area, ACPT projects are investigating the use of new or innovative equipment and technologies for improving all aspects of concrete pavement construction.
  • Focus Area 4: Rapid Repair and Rehabilitation-ACPT projects in this area are investigating ways to improve or advance concrete pavement rehabilitation technologies that will allow for faster and more durable repair and rehabilitation/reconstruction of concrete pavements.
  • Focus Area 5: Sustainable Concrete Pavements-Sustainability is a term used to describe the broad notion that we, as a society, should be able to meet our present-day needs without compromising the ability of future generations to meet their needs. In pavement engineering, the goal is to make pavement systems, materials, products, and processes more sustainable. ACPT projects in this area are exploring ways to extend the service life of existing concrete pavements, extend the service life of new concrete pavements, reuse and recycle construction materials, and adopt processes that reduce the carbon footprint.
  • Focus Area 6: Enhanced User Satisfaction-In this focus area, ACPT projects are aimed at increasing user satisfaction, which includes reducing congestion and improving functional performance (ride, safety, noise).

List of Recommended ACPT Products for Deployment

The following is a summary of the ACPT products identified for possible deployment over the next 5 years. The information is based on information on advanced concrete pavement technology activities presented in Chapter 2. The selection of these promising products was based on the following factors:

  1. Need for improved technology and identification of critical gaps.
  2. Potential cost savings-new construction and rehabilitation.
  3. Potential construction time savings.
  4. Potential resource conservation.
  5. New innovation or concept.
  6. Impact on user ride and safety.
  7. Environmental benefits.
  8. Sustainability benefits.
  9. Workforce training benefits.

ACPT Program Focus Area 1: Advanced Designs

  1. Mechanistic-Empirical Concrete Pavement Design
    1. NCHRP-developed and AASHTO-approved MEPDG (AASHTO 2008)
  2. Concrete Overlays Design
    1. NCPTC-funded project
    2. Pooled-fund project
  3. Concrete Pavement Design Catalogs
    1. Based on the European approach, using the MEPDG
    2. State DOT approaches
  4. Advanced Concepts for Joint Design
    1. Industry initiatives/DOT best practices-Optimizing round dowel bar design (diameter, length, spacing)
    2. Industry products-Corrosion-protection for load-transfer devices (clad dowels)
    3. ACPA study/European guidelines-Optimized tie-bar design
  5. Optimizing Design Features and Life Cycle Costs
    1. CPTP findings-Best practices for joint sawing and sealing
    2. NCHRP findings and FHWA guidelines-Best practices for pavement drainage
    3. Edge strengthening-Widened lane and tied concrete shoulder
    4. European approach-Improved foundation versus slab thickness
    5. European approach-High-strength concrete versus slab thickness
    6. European approach-Concrete slab/stabilized base interface-asphalt concrete interlayer and thick geotextile
    7. Best practices catalog of design sections
  6. Innovative Design Procedures for Concrete Pavements (CRCP, Prestressed, Precast, roller-compacted concrete pavement [RCCP])
    1. FHWA/Concrete Reinforcing Steel Institute cooperative agreement project-Improved CRCP design guidelines
    2. FHWA/Precast-Prestressed Concrete Institute cooperative agreement project-Improved precast concrete pavement guidelines
    3. Portland Cement Association-Best practices for RCC shoulder
    4. Texas DOT-Cast-in-place prestressed concrete pavement design

ACPT Program Focus Area 2: Improved Construction Materials

  1. Optimizing Use of Recycled Materials
  2. Advanced High-Performance Materials
    1. Lower cost materials
    2. Longer lasting materials (greater durability)
    3. Replacement materials
    4. Additive materials that extend or improve performance of conventional materials
    5. New/innovative materials
  3. Concrete Mixture Optimization
    1. Optimizing workability, strength, and durability using the FHWA COMPASS software and other industry-developed procedures
  4. Concrete Durability
    1. ASR test protocols
    2. ASR prevention guidelines
    3. ASR mitigation guidelines
  5. Concrete Testing
    1. Improved air void analyzer
    2. Improved impact-echo testing
    3. Improved permeability testing
    4. Remaining service life assessment
    5. Workability testing
    6. Improved coefficient of thermal expansion testing
    7. Testing for concrete material compatibility
    8. Accelerated strength testing

ACPT Program Focus Area 3: Improved Construction Processes

  1. Improved Processes for Construction Process Control and Acceptance Testing
    1. Dowel alignment testing
    2. In-situ concrete density testing
    3. Surface texture testing
    4. Concrete slab thickness testing
    5. Smoothness testing
  2. Performance-Related and End-Product Specifications
    1. PRS
  3. Improving Concrete Pavement Performance and Sustainability Through Two-Lift Construction

ACPT Program Focus Area 4: Rapid Repair and Rehabilitation

  1. Rapid Pavement Condition Evaluation
    1. Improved guidelines for falling-weight deflectometer load-transfer efficiency testing
    2. Remaining service life assessment
  2. Rapid Rehabilitation and Reconstruction of High-Volume Facilities
    1. Nighttime construction
    2. Weekend construction
    3. Full-closure construction
  3. Precast Panels for Repair (Tayabji et al. 2009)
    1. FHWA/generic systems
    2. U.S. proprietary systems
  4. Precast Panels for Reconstruction and Rehabilitation (Merritt and Tayabji 2009)
    1. FHWA PPCP system
    2. U.S. proprietary system
    3. Non-U.S. systems
  5. Innovative Repair and Rehabilitation Processes
    1. Industry-developed repair materials
  6. Construction Traffic Management
    1. Software-Minimize lane closures (FHWA 2009c)

ACPT Program Focus Area 5: Sustainable Concrete Pavements

  1. Sustainable Pavement Designs
    1. Two-lift concrete slabs
  2. Sustainable Use of Construction Materials
    1. Recycled concrete aggregate use
  3. Sustainable Construction Practices
    1. Improved construction traffic management
  4. Sustainable Repair and Rehabilitation Processes
  5. Catalog of Sustainable Concrete Pavement Practices
  6. Environmental Life Cycle Analysis Tools

ACPT Program Focus Area 6: Enhanced User Satisfaction

  1. Innovative Pavement Surface Texturing for Safety and Noise Reduction
  2. Techniques to Improve Pavement Ride

ACPT Product Matrix

The ACPT product matrix is summarized in Table 2.

Table 2. The Advanced Concrete Pavement Technology Program Product Matrix
No. ACPT Product FA 1
Design
FA 2
Concrete
FA 3
Construction
FA 4 Rapid Repair /Rehab FA 5
Sustainability
FA 6
User
Satisfaction
FOCUS AREA 1-ADVANCED DESIGNS
FA1-1 Mechanistic-Empirical Concrete Pavement Design P       S  
FA1-2 Concrete Overlays Design P       S  
FA1-3 Concrete Pavement Design Catalogs P       S  
FA1-4 Advanced Concepts for Joint Design P       S  
FA1-5 Optimizing Design Features and Life Cycle Costs P       S  
FA1-6 Innovative Design Procedures for Concrete Pavements P       S  
FOCUS AREA 2-IMPROVED CONSTRUCTION MATERIALS
FA2-1 Optimizing Use of Recycled
Materials
  P     S  
FA2-2 Advanced High-Performance
Materials
  P     S  
FA2-3 Concrete Mixture Optimization   P     S  
FA2-4 Concrete Durability   P     S  
FA2-5 Concrete Testing   P S      
FOCUS AREA 3-IMPROVED CONSTRUCTION PROCESSES
FA3-1 Improved Processes for
Construction Process Control and Acceptance Testing
    P      
FA3-2 Performance-Related and End-Product Specifications     P      
FA3-3 Improving Concrete Pavement Performance and Sustainability Through Two-Lift Construction     P      
FOCUS AREA 4-RAPID REPAIR AND REHABILITATION
FA4-1 Rapid Pavement Condition
Evaluation
      P    
FA4-2 Rapid Rehabilitation and Reconstruction of High-Volume Facilities       P    
FA4-3 Precast Panels for Repair       P    
FA4-4 Precast Panels for Reconstruction and Rehabilitation       P    
FA4-5 Innovative Repair and Rehabilitation Processes       P    
FA4-6 Construction Traffic Management     S P   S
FOCUS AREA 5-SUSTAINABLE CONCRETE PAVEMENTS
FA5-1 Sustainable Pavement Designs S       P  
FA5-2 Sustainable Use of Construction Materials   S     P  
FA5-3 Sustainable Construction Practices     S   P  
FA5-4 Sustainable Repair and
Rehabilitation Processes
      S P  
FA5-5 Catalog of Sustainable Concrete Pavement Practices         P  
FA5-6 Environmental Life Cycle Analysis Tools         P S
FOCUS AREA 6-ENHANCED USER SATISFACTION
FA6-1 Innovative Pavement Surface
Texturing for Safety and Noise Reduction
          P
FA6-2 Techniques to Improve Pavement Ride           P
P = Primary; S = Secondary

Deployment Timeline for ACPT Products

The timeline for delivery of the above promising ACPT products can be categorized as follows:

  1. Immediate availability for delivery.
  2. Within 24 months-ACPT product available, but requires further refinement or better packaging for delivery.
  3. Under development-product available within 24 months.
    1. Product ready for delivery.
    2. Product may require further refinement or better packaging for delivery.
  4. Under development-product available after 24 months.
    1. Product ready for delivery.
    2. Products may require further refinement or better packaging for delivery.

The specific timelines for the identified promising products will be included in the marketing plan to be developed under Task C of this contract.

Summary

A broad range of products are available or will soon be available to further advance concrete pavement technologies. These products have been categorized under six focus areas. Additional details on each product are provided in the next section.

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Updated: 04/07/2011

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United States Department of Transportation - Federal Highway Administration