Pennsylvania DOT, I-90


LOCATION: I-90 Test Site (Erie County Segment 280, Offset 0010-0265)


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 concrete pavements following injection of high-density polyurethane. Expansive, high-density, two-component, water-resistant 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-90 Test Site:

Pavement Cross-Section

  • 0.625″ Ultra-thin Friction Course – 13.0″ PCC
  • 4.0″ Open-Graded Subbase (OGS) – 6.0″ A-2 Subbase
  • Subgrade = Composition Unknown

Problems Cited by PennDOT

  • Poor joint load transfer
  • High incidence of water in base and subbase – Intermittent reflective cracking in friction course

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

URETEK USA stabilized 140 continuous feet of the eastbound (EB) travel lane for a segment of I-90 (identified by PennDOT) using the traditional URETEK Deep Injection (UDI) process. In addition, URETEK USA also stabilized 6 transverse joints within that 140’ test area using a specialized application of the UDI process known as Joint Vicinity Injection (JVI).

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