Improvements of Full-Depth Repair Practices for Distresses in Continuously Reinforced Concrete Pavement

The Texas Department of Transportation has by far the most continuously reinforced concrete pavement (CRCP) lane miles in the nation, and sections as old as 50 years are still in service. Having served much longer than intended, some sections are showing distress. Full-depth repair (FDR) is one of the methods used to repair CRCP distresses in Texas. Over the years, various FDR methods have been used, and the effectiveness of each method has varied. In the most widely used FDR method, a full-depth cut is made at a minimum of 1.5 ft (0.46 m) inside the transverse repair boundaries, a partial-depth cut is made at repair boundaries, and the concrete between the cuts is removed to expose longitudinal steel. The method has inherent disadvantages, the longer repair time being the primary one. The full-depth cut FDR method, in which a full-depth cut is made at the repair boundaries and longitudinal tie bars are epoxy grouted into the existing concrete, has advantages over other methods, including a faster operation that minimizes roadway closure time. Because CRCP is normally used in areas with high traffic volume, the maximum time the Texas Department of Transportation allows for the FDR operation is usually 9 h, which makes the full-depth cut method the only acceptable repair method. Factors affecting the effectiveness of the full-depth cut method were investigated with laboratory testing and field evaluations. The method of epoxy injection, keeping the epoxy in the holes after insertion of the tie bars, restoring base support, and the length of the embedded tie bar were the most important variables affecting the performance of FDR. Recommendations were made to revise specifications for FDR and epoxy materials on the basis of these research findings. Implementation of the recommendations should result in improved FDR performance of CRCP.