Detailed Forensic Investigation and Rehabilitation Recommendation on Interstate Highway-30

The main objective of this study is to identify the cause of the punchouts observed on Interstate Highway 30 (IH-30), and to identify possible rehabilitation alternatives. Several nondestructive tests, as well as coring and trenching, were conducted in both distressed and nondistressed areas. Middepth horizontal cracks were found during routine repair and by the trenching performed in this study. It is believed that due to temperature variation at an early stage, horizontal cracks developed at the middepth interface between the steel and concrete. The truck traffic caused the horizontal cracks to deteriorate further. Repetitive truck traffic and thermal loading forced the concrete to crack vertically from the middepth where there were horizontal cracks. The closely spaced transverse and longitudinal cracks, along with the delamination, caused punchouts. Although the problem is not imminent, an immediate seal plus a 75 mm heavy-duty stone matrix asphalt (SMA) overlay will probably provide the most cost-effective remedy for this section of IH-30. Existing distressed areas should be repaired before the rehabilitation. To slow the deterioration, the district should use a latex modified chip seal or asphalt rubber seal (AC15-5TR) followed by a 75 mm heavy duty SMA. This is to provide bonding between the concrete and SMA overlay. If the district chooses to do nothing at this time, it will become costly in 2–3 years if current environmental and traffic conditions hold. The cost to repair a severely deteriorated continuously reinforced concrete pavement (CRCP) would be several times more than the 75 mm heavy duty SMA overlay.