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Application Report

KDOT Highway Partial Depth Road Repairs

 

Summary: In 2009, over 10,000 partial depth repairs were made on Kentucky highways in summer, fall, and winter as part of a highly successful highway renewal program using Phoscrete!  

Customer: Kentucky Department of Transportation  

Location: I-65 Northbound and Southbound Lanes, MP 127.560 to MP 101.112 

Problem: Exposed to heavy duty traffic and traffic loads for nearly 40 years (twice the designed service life), portions of the pavement on I-65 in Kentucky from Jefferson County to Hardin County were uneven. Corrective measures were needed to improve pavement safety and ride-ability. The option of total highway replacement was cost-prohibitive, being extremely expensive and labor intensive and requiring extended lane closures.   

Analysis: After extensive engineering studies and pavement testing, KDOT Highway Engineers determined that the service life of the highway could be extended by renewing the existing pavement; using a combination of replacing full depth slabs and making partial depth repairs on a where-needed basis.  A requirement for the partial depth repair material was an anticipated service life similar to that of new concrete.    

Solution: Install Phoscrete to create a fast-setting permanent bond to the existing concrete for long-lasting partial-depth repairs. 

 

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): Removed existing concrete to the sub-base and use Type II Portland Concrete for full slab replacements.  

Scope of Work (Partial Depth Repairs): Removed raised pavement markers and other damaged concrete to depths from 2.5” to 3.5” using jackhammers and concrete saws. Cleared the area of debris. Using a paddle mixer, mixed Phoscrete dry-aggregate and pre-measured liquid activator in 5 gallon pails and poured in place. Because Phoscrete is self-consolidating, minimal finishing was required.  After installation, diamond-ground repairs for ride-ability. 

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 done.

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 2011.

For additional information concerning this application report, please contact Dennis Buckshaw at dennis.buckshaw@phoscrete.com

Join The Phoscrete FIQS Program And
Fix Your Concrete Repair Problems
Once And For Good!

 

Stellar Materials is pleased to offer Qualified Partners the opportunity to participate in The Phoscrete FIQS (Fix-It Quick Stocking) Program

 

FIQS Program details:

 Phoscrete Installation Guide.

 

Qualified Partners must be:

• Responsible for Concrete Repair Projects with a government agency (Federal, State, County or Municipal).
• Authorized to buy concrete repair materials.
• Qualified by Stellar Materials to install Phoscrete through an informational presentation at your facility (or ours) that involves:
• Mixing and placing demonstration
• Technical presentation
• On-site repair of a damaged concrete structure (road, bridge, parking deck, etc.)

Click here for additional information concerning this program.

 

 

 

 

 

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