Recent Advances In Jointed Precast Concrete Paving: Hawai’i H-1 Reconstruction

Abstract

Jointed precast concrete pavement was recently used to reconstruct large multi-lane areas of one of the busiest areas of Interstate H-1 near Honolulu, Hawai'i, USA. The design-build project was awarded in early January 2018 and more that 1200 precast panels were designed, fabricated and installed less than 7 months later using mostly 8-hour overnight work windows. There were several unusual and innovative aspects to this project, including: (1) variation in the type and layout of joints when replacing travel lanes with rectangular precast panels adjacent to existing skewed, random-length cast-in-place panels; (2) the use of ground-penetrating radar to map original pavement structures that varied greatly along the project length and between lanes; (3) the development of ``3-D'' design models for the new surface to improve ride quality and cross-slope; (4) the use of ``3-D'' panel fabrication techniques; (5) the use of laser-controlled construction equipment to construct contoured foundation surfaces that fully support the non-planar precast panels and allow immediate temporary use without grout, thereby extending productivity in short overnight work windows; (6) the use of optimized dowel placement (below mid-depth) and headed ``dowel-in'' tie assemblies to reduce slot sizes, improve panel integrity, and reduce panel grout requirements; (7) the placement of temporary asphalt layers to eliminate major drop-offs between lanes during construction; and (8) the development of specially shaped transition panels and bridge approach panels. This paper describes the unique aspects of precast pavement design and construction for this project and presents ``lessons learned'' and recommendations developed from the project.