Case Study
| Title: | Mainline Full Depth Armor Joint Replacement I-35 at Binz Engleman exit |
| Purpose: | To demonstrate the use of Mainline material for full depth armor joint replacements. |
| Location: | I-35 South at Binz Engleman in San Antonio, Texas. Western most travel lane, northern joint-grade beam cap. |
| Date: | May 20th, 2007 |
Procedure & Observations:
CERATECH personnel were onsite on I-35 Northbound at Binz Engleman on a bridge deck approach requiring a full depth armor joint replacement. Upon arrival I was shown the repair location and watched the bridge maintenance crew prepare the repair site. The site was the inside lane of I-35 North at Binz Engleman. The repair required the removal of the asphalt wearing surface and the full depth removal of the concrete and the existing failed armor joint. The repair was approximately 14’ long by 12” wide and 8” – 10” deep. Once all of the asphalt and concrete were removed the new armor joint was fabricated and installed.
The preparation of the deck was well done by the TX DOT Specialty Bridge crew and provided a strong, stable concrete surface. The Mainline material was mixed in a standard 6 cubic foot concrete mixer and transported to the repair site via wheel barrow. The material was poured into place and consolidated via a pencil vibrator and various concrete finishing tools. The preparation and replacement of the existing armor joint required approximately 4 hrs to complete the material mixing and placement was completed in approximately 45 minutes and then left to cure prior to applying the asphalt wearing surface and opening to traffic.
Product Placement:
The ambient temperatures were approximately 80 degrees Fahrenheit with rain in the forecast. The water and material temperatures were approximately 73 degrees Fahrenheit. Equilibrium was 74.5 degrees Fahrenheit @ 2mins and the surface temperature was 78 degrees Fahrenheit. Mix times averaged around 7 minutes with a total of 32 units of Mainline being mixed and placed. The area was kept closed for approximately 2.5 hrs and then the asphalt wearing surface was applied and compacted. Total curing time for the material prior to being opened to traffic was 3.5-4 hrs.
Conclusion:
This application has been monitored by TX DOT and they have been quite happy with the results. They have contacted CERATECH and are preparing a bid to order approximately 25 pallets of Mainline and DOTLine materials. We have been advised that this will be a regular order every 4-6 weeks once we get things rolling.
