Use of Precast Slabs for Pavement Rehabilitation on I-66

About the report:

Highway agencies continuously strive to expedite pavement construction and repairs and to evaluate materials and methods to provide long-lasting pavements.  As part of this effort, agencies have used precast concrete slabs for more than 10 years with successive improvements in processes and systems.

The Virginia Department of Transportation recently used two precast systems along with conventional cast-in-place repairs on a section of jointed reinforced concrete pavement on I-66 near Washington, D.C.  One precast system, precast concrete pavement (PCP), used doweled joints.  The other precast system, prestressed precast concrete pavement (PPCP), used transversely prestressed slabs post-tensioned in the longitudinal direction.

Both precast systems are performing satisfactorily after 1.5 years of traffic, and the contractor was satisfied with the constructability.  In multiple locations, transverse expansion joints in PPCP were observed to be wider than the ½-in width specified; excessively wide joints often compromise joint sealant performance, and erosion from water flowing through such joints may result in eventual loss of support over time.  There were a few cracks in the PPCP section, originating mainly from grouting holes, cracks in the block-out patches, cracks and loss of epoxy at lifting hook holes, and corner breaks.  There were some mid-slab cracks in the PCP slabs immediately after opening to traffic, but they are still tight and stable after 1.5 years of traffic.

Even though the precast slabs initially cost more than the cast-in-place repairs to construct, the ability to construct the pavement within a short period of lane closure per day and the probability of improved quality control of plant-cast concrete warrant their use.  Since this was the first application in Virginia, certain issues occurred and most were overcome, such as matching of slabs and grout leakage.  The project was successfully completed and further implementation is recommended.

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