Case Study of Premature Failure of a Concrete Block Pavement System at a Shipping Container Logistics Site

Abstract

The trackway of a high-load gantry crane system at a shipping container logistics site in northern Israel underwent serious premature damages, which jeopardized the continued use of the system. The trackway pavement system was based on concrete paving blocks. Measurements made of the trackway surface profile and elevation profile on the surface of the uppermost granular bearing layer illustrated severe rutting and loss of paving block interlock. Considering surface and near-surface measurements, photographic and physical documentation of the materials used in the structural layering of the pavement system revealed three focal reasons for the development of damage to the trackway: improper designation of edge restraint, improper designation of bedding and joint filler sand, and excessive bedding sand thickness. The first two issues are design errors, and the third is a construction flaw. Actions taken to remedy the damages have been outlined and illustrated.