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Nevada’s I-80 Receives Fast-Track Repair

State’s first use of rapid-setting cement for full-depth panel proves successful

Near Lockwood, Nev., a critical section of I-80 experienced a unique repair situation, not from typical interstate wear and tear. Instead, the damage occurred at the hands of Mother Nature when boulders rolled down a hillside onto the interstate. Affecting the westbound number two lane, the damaged pavement created a significant disruption. Nevada Department of Transportation (NDOT) needed a permanent, high-performance repair that would cause minimal disturbance to the public.

For the repair, NDOT desired a rapid-setting, rapid-strength cement with long-lasting performance. NDOT had previous experience with rapid-setting cement from CTS Cement Manufacturing Corporation on dowel bar retrofit projects and specified Rapid Set® Cement for the first time for this type of full-depth panel replacement. Until all aspects of the permanent repair could be coordinated, NDOT performed a temporary asphalt patch.

Following California specifications, NDOT and concrete producer Anozira Inc. of Concord, Calif., found guidance through representatives at CTS. California’s long history of panel replacements with Rapid Set Cement provided a model for this type of repair in Nevada, and NDOT followed California specifications.

Granite Construction Inc. of Watsonville, Calif., was contracted for the repair. Work began the first weekend in May of 2013 under clear skies with an ambient temperature of 67 degrees Fahrenheit. NDOT wanted Granite Construction to complete the repair within one weekend. CTS helped crews meet the tight timeframe required for the job.

The repair encompassed four panels, each measuring 12 feet wide by 15 feet long. First, Granite’s crews removed the existing panels with a mini excavator.

“The concrete was mixed with a volumetric mixer, minimizing over-production and allowing fresh concrete on the jobsite as needed,” said Art Bigelow, Field Technician, Engineering Sales for CTS.

What’s more, the volumetric mixer permitted crews to start and stop when required. Producing the concrete on the jobsite saved time and minimized waste. When some of the base material came out as the original panels were removed, the volumetric mixer allowed the team to change the mix design on site in order to fill the base, let it harden and then place the panels.

“Crews poured in the base and waited approximately 10 minutes,” said Bigelow. “The consecutive pours for the panels only took about 20 minutes.”

Panels were then finished with a Bunyan screed and a curing compound was applied. The specifications called for 3,000 psi compressive at four hours, and the concrete achieved 3,460 psi at one hour and 5,260 psi at 10 days.

The panel placement was completed faster than expected, and I-80 opened a day and a half early. The panels have performed well with no issues or cracking. The time savings with rapid-setting cement proved essential for the project. The I-80 repair near Lockwood demonstrates rapid-setting concrete’s effectiveness for rehabilitating and repairing concrete, while minimizing inconvenience to the public.



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