Two-Lift Concrete Paving:

Construction Overview

ACI Spring 2016 Convention

Milwaukee, Wisconsin
April 18, 2016
Kurt Smith
Applied Pavement Technology, Inc.
 Presentation Outline
Introduction/
Background
Modern Two-Lift
Paving
Construction
Overview
Summary
Introduction/Background
 What Is Two-Lift Concrete
Paving?
Placement of two distinct concrete paving
layers to form a monolithic pavement
structure
Placement of
Top Lift
Durable Aggregate, 2 3 in Wet-on-
Effective Surface Texture (typ) Wet
Monolithic Pavement
Recycled or Marginal 6 9 in Structure
Quality Aggregate (typ)

Placement of
Bottom Lift
 Two-Lift Paving

Bottom Lift Top Lift

 Two-Lift Paving:
New and Innovative?
Nomost early concrete
pavements (1900-1920) built
using two-lift paving practices
Technique used in 1940s-
1970s (steel placement for
JRCP designs)
1906 concrete
Process re-emerged again in pavement,
Calumet, MI
early 1990s (courtesy
Tom Van Dam)
Modern Two-Lift Paving
 Modern Two-Lift Paving
Use recycled (RCA,
RAP) or marginal/less
durable local materials in
lower lift
Use high-quality (less
available) materials in
top lift for durable,
polish-resistance surface
Engineered mix designs
for both lifts
 Why The Re-Emergence?
European Experience
(FHWA Scan Tours)
Diminishing sources of
high quality aggregate
Availability of marginal/ (courtesy Shiraz Tayabji)
recycled materials
Growing interest in being sustainable
SHRP2 Project R21 design and
construction guidelines
FHWA implementation efforts
Some Notable/Recent U.S. Two-
Lift Concrete Paving Projects
Mn/Road
Albertville, MN
(2010) I-75, Detroit
(1993)
I-70,
Abilene, KS
(2008) IL Tollway
(2013-2015)
K-96,
Haven, KS
(1997) US 41, Ft.
Myers, FL
Rt 141, I-65, (1978)
Chesterfield, MO Nashville
(2010) (2014)
Construction Overview
 Two-Lift Pavement
Construction
Generally conventional
construction practices
Special considerations in:
Batching/transport
Placement/paving
Dowel bars
Joint sawing
 Batching
Keys are
Preparing consistent materials
Preparing proper
quantities
 Transport
Delivery:
Keeping track of mixes/trucks
Maintaining appropriate delivery ratio
Timing and sequencing of operations:
Constant delivery of material
Approximately 100 ft between pavers
Limit of 45-90 minutes between lifts
 Operation Overview

Second
Paver
Ready-
First Paver Mix Truck

End Dump Belt Placer

 Placement: Bottom Lift
Spreaders or pavers
End load or belt placer
Placed narrower than final
paving width
Bottom Lift
Bottom Lift
Bottom Lift
 Placement: Top Lift
Placed using belt placer or with ready mix
trucks
Vibrators raised above lower layer to
prevent co-mingling of two lifts
Top lift paved slightly
wider than bottom lift
Top Lift
Top Lift
Top Lift
 Dowels Bars
Dowels placed at
mid-depth of total
concrete slab
thickness
Conventional bars/
sizes
 Joint Sawing
Conventional sawcut timing
Sawcut depth greater of:
1/3 of total concrete
thickness, or
Thickness of top lift
+ inch
Summary
 Summary
Two-lift concrete paving not a new
innovation
Several recent U.S. projects
More widespread future use anticipated
FHWA promoting technology through a
number of implementation activities
Thank
You!