Precast Concrete Pavement Technology Resources

This report from the second Strategic Highway Research Program (SHRP 2), which is administered by the Transportation Research Board of the National Academies, provides guidance on the design, fabrication, construction, and maintenance of precast concrete pavement (PCP) systems. It includes an assessment of the state of the practice for PCP technology as well as guidelines for pavement selection, the decision-making process, and model specifications for PCP systems.

"TRB's second Strategic Highway Research Program (SHRP 2) Report S2-R05-RR-1: Precast Concrete Pavement Technology reviews the available precast concrete pavement (PCP) systems; summarizes PCP applications; and offers suggested guidelines for the design, fabrication, installation, and selection of PCP systems. " -- Publisher's description.

This TechBrief provides a summary of the technical resources available to engineers and planners seeking an understanding of PCP technology. Weblinks are provided for access to recent documents covering a range of PCP topics.

This project is a national effort to support the implementation of products developed under the recently completed Strategic Highway Research Program 2 (SHRP2) Project R05 on Precast Concrete Pavement Technology. Managed by the Federal Highway Administration (FHWA) through partnership with the American Association of Highway and Transportation Officials (AASHTO), the goals of this project are to accelerate the implementation of PCP technology for rapid repair and rehabilitation of the nation's highway system, thereby reducing construction related congestion, improve safety, lower life cycle costs, improve performance of repair and rehabilitation treatments, and foster innovation.

This TechBrief describes the application of precast prestressed concrete pavement for new construction and for rehabilitation of existing asphalt and concrete pavements. The background of the development of precast prestressed pavement technology is briefly summarized. The details of several field trials of this innovative technology are presented, and recommendations for ensuring successful precast prestressed concrete pavement installation are provided.

The general objectives of this research are to (1) investigate and analyze the current state- of-the-art, (2) examine and possibly improve the current design features, (3) perform structural analysis to evaluate pavement performance and limitations, (4) conduct laboratory tests to examine and verify proposed improvements and analysis results, (5) investigate means to make precast pavement more durable and economical.

Precast concrete pavement (PCP) technology is gaining wider acceptance in the U.S. for rapid repair and rehabilitation of concrete pavements, as well as for reconstruction of heavily trafficked asphalt concrete intersections. Widespread use in the U.S. is fairly recent, with most projects in service less than about 14 years. Nonetheless, dozens of projects have been constructed, and advances continue to be made in all aspects of the technology, including panel design, fabrication, and installation. PCP technology is being used for intermittent repairs (both full-depth repairs and full panel replacement) and for continuous applications (longer-length/wider-area rehabilitation) with service life expectations of at least 20 years for repairs and at least 40 years for continuous applications, without significant future corrective treatment.

The production use of precast concrete pavement (PCP) has come a long way over the last 15 years. The technology is gaining wider acceptance in the U.S. for rapid repair and rehabilitation of concrete pavements as well as for heavily trafficked asphalt concrete pavements and intersections. Several U.S. highway agencies, including Caltrans, Illinois Tollway, and the New Jersey, New York, and Utah State Departments of Transportation, have implemented the PCP technology, and other agencies have constructed demonstration projects. In the U.S., the PCP technology is being used on concrete pavements for intermittent repairs (full-depth joint repairs or full panel replacement) and for continuous applications (longer length/wider area rehabilitation) with service life expectations of at least 20 years for intermittent repairs and at least 40 years for continuous applications, without significant future corrective treatment. The use of PCP on asphalt pavements includes the replacement of ramps, intersections and bus pads. The Strategic Highway Research Program 2 (SHRP2) Project R05 was conducted from 2008 to 2012 to develop technical information and guidelines that would encourage the rapid and successful adoption of PCP technology. In 2013, the SHRP2 Implementation Assistance Program (IAP) was created to help State DOTs, metropolitan planning organizations, and other interested organizations deploy SHRP2-developed products to deliver more efficient, costeffective solutions to meet the complex challenges facing transportation agencies. On March 28, 2014, the Federal Highway Administration—in partnership with the American Association of State Highway and Transportation Officials—announced the selection of several transportation agencies receiving implementation and technical assistance awards as part of round 3 of the SHRP2 IAP. The Texas Department of Transportation, one of the agencies selected as a lead adopter of Project R05 technology, received an award of 300,000 [dollars] to help offset the cost of constructing a PCP project. This case study report provides details of the 2016 PCP use for rehabilitation of a distressed asphalt concrete pavement at the intersection of Route 97 and Route 72 in McMullen/LaSalle County, Texas.

This evaluation assesses the outcomes of the Federal Highway Administration’s (FHWA’s) investment in precast concrete pavement (PCP). The evaluation team determined the benefits and costs of individual PCP projects and, where possible, extrapolated findings from the data based on overall themes. Additionally, the evaluation team determined the outcomes and impacts of FHWA research, demonstrations, workshops, and related activities and developed recommendations to facilitate the continued adoption of the technology. FHWA’s efforts were found to be largely successful and contributory to the development and adoption of PCP. FHWA has overseen initial research and prototypes and has helped the use of PCP technology become routine in some States. PCP is an effective and efficient way to conduct roadway maintenance, repairs, and reconstruction. Benefits significantly exceed costs in high-volume areas or unique roadway sections that would lead to significant detours if closed for long periods of time. PCP also allows for innovative maintenance practices and cost savings, such as the reuse of concrete panels for temporary repairs.

Many countries are exploring the use of concrete to improve the reliability of their road networks. However, many developers, agencies, and companies in the construction industry do not yet have sufficient experience in the use of concrete pavement. This can lead to poorly planned, supervised, or executed infrastructure that requires premature and costly repairs or maintenance. This guide explains the factors to investigate and considerations to evaluate as well as the potential risks and mistakes to avoid when planning and constructing concrete pavement. It is a comprehensive resource that will be especially useful for stakeholders in developing countries.