Product Being Replaced: Broken and damaged pavement concrete.
Products Applied: Phoscrete 601, Phoscrete 601-L, and Phoscrete 601-Q (product formulas selected based upon varying seasonal temperatures).
Method of Installation: Poured in place.
Equipment Used: Diamond concrete saws, jackhammers, electric drill motor with a paddle-type mixer, and standard concrete hand tools.
Scope of Work (Full Depth Repairs): Remove existing concrete to the sub-base and use Type II Portland Concrete for full slab replacements.
Scope of Work (Partial Depth Repairs): Remove raised pavement markers and other damaged concrete to depths from 2.5” to 3.5” using jackhammers and concrete saws. Clear the area of debris. Using a paddle mixer, mix Phoscrete dry-aggregate and pre-measured liquid activator in 5 gallon pails and pour in place. Because Phoscrete is self-consolidating, minimal finishing was required. After installation, diamond-ground repairs for rideability.
Over 10,000 partial depth repairs were performed on 50 linear miles (140 lane miles) on the Northbound and Southbound lanes of I-65, one of the largest partial depth projects ever.
Savings Using Phoscrete: Including the removal of 7,500 raised pavement markers, over 10,000 permanent repairs were completed over the course of seven months. On average, repairs were ready for heavy duty rubber tired traffic less than 50 minutes after placement.
Installation Date: June through mid-December 2009
Weather Conditions: High Temperature in June 2009: 96°F. Low Temperature in December 2009: 18°F. To counteract the harsh winter weather conditions in their North-Central Region, the Kentucky DOT uses a combination of Salt Brine, Rock Salt and Snow Plows on I-65 to maintain safe driving conditions on this heavily traveled roadway.
Follow Up: January 2010. Phoscrete repairs are performing exceptionally well under extreme traffic loads, freeze/thaw cycling and heavy concentrations of sodium chloride chemicals (in winter). Phoscrete bonds to the original concrete remain tight. Surfaces remain free from hairline shrinkage cracks.
Phoscrete Repair Inspections, I-65 Highway Renewal Project:
Periodic inspections are scheduled for the remainder of 2010.