Overnight Concrete Pavement Replacement Using a Precast Panel and Expanding Polymer Positioning Technique—Washington Dulles International Airport Case Study

In June 2001, the rapid replacement of three rigid airfield pavement panels was conducted at Washington Dulles International Airport, Washington, DC (IAD). The project involved the demonstration of a new technique for full-depth, overnight concrete panel replacement on an active taxilane and an active taxiway that allows for full reopening of the pavement to normal traffic each morning. The technique consists of excavation and removal of damaged panels and their replacement with precast concrete panels. This is followed by the controlled injection of an expanding high density polyurethane (HDP) polymer mixture under the panels which underseals and accurately lifts the panel to the required elevation. The rigid high density polyurethane forms a stable bearing surface for the precast replacement panels. The pavement may be open to traffic at this point, non-corroding composite inserts are subsequently installed to tie the panels together and establish load transfer capability at the newly formed joints. This same technology has been applied successfully during the past three years for the Colorado DOT, CalTrans (California Department of Transportation) and the Transit Authority in Seattle, Washington for the overnight replacement of highway pavement and pavement in large municipal parking areas. Washington Dulles International Airport was the first airport to use this technique and evaluate precast panel repair. Based on this and the experience gained in this demonstration, it may be concluded that this technique is viable for the rapid rigid pavement replacement under circumstances where an airport cannot tolerate traffic disruption during its normal operating schedule.