Pennsylvania DOT, I-80


LOCATION: I-80 Test Site (Mercer County Segment 100, Offset 0450-0700)


SITUATION: Pursuant to meetings between URETEK USA and PennDOT, a cooperative pilot project was developed and executed in 2012. The purpose of the pilot project was to assess the improvement of transverse joint performance in composite pavements following injection of high-density polyurethane. Expansive, high-density, two-component, waterresistant polyurethane was injected into the foundation soils of the pavement system using the URETEK Deep Injection (UDI) process.


PennDOT provided URETEK USA the following information regarding the I-80 Test Site:


Pavement Cross-Section

  • 3.5” AC (constructed 1992-94)
  • 13.0” PCC (constructed early 1980’s)
  • 4.0” Open-Graded Subbase (OGS)
  • 8.0” A-2 Subbase
  • Subgrade = Mixed Materials (Exact Composition Unknown)

Problems Cited by PennDOT

  • Curling due to loss of fines at joints
  • Excess Water in Subgrade

Pre-injection Falling Weight Deflectometer (FWD) data (see the PennDOT-provided table)

URETEK USA executed a specialized application of the UDI process known as Joint Vicinity Injection (JVI) on successive transverse joints in an eastbound (EB) travel lane segment of I-80 identified by PennDOT.

PennDOT performed post-injection Falling Weight Deflectometer (FWD) testing and analysis to assess void reduction and improvement in load transfer efficiency (LTE). Post-injection testing occurred at least 24 hours after completion. Post-injection results are also presented in the PennDOT-provided table.


After injecting the test area using the URETEK Deep Injection (UDI) process, post-injection FWD testing and data analysis by PennDOT revealed:

  • Significant reduction in the size of voids in the vicinity of the joints
  • Dramatic improvement in the LTEs for the transverse joints