Field Application of Modular Pavement Blocks for Port Infrastructure

This study aims to develop and field-verify an eco-friendly modular precast concrete pavement (PCP) system applicable to heavy-duty port facilities. Conventional cast-in-place pavements often suffer from long construction times and low maintainability under repetitive heavy loads from container handling equipment. To address these limitations, a modular PCP system was designed based on the Westergaard-Bradbury theoretical model, considering both vehicle and temperature loads. The optimal slab thickness was determined to be approximately 325 mm, with a minimum reinforcement ratio of 0.6% to control cracking under cyclic loading. In addition, a low-shrinkage, high-strength concrete incorporating blast furnace slag (40-60% replacement) was developed to enhance durability and reduce CO₂ emissions. Among all mixes, the BS50 mix achieved a 28-day compressive strength of 65 MPa while reducing cement content by 50%. A two-day pilot construction was carried out in an actual port yard to evaluate constructability and field performance. The modular pavement system demonstrated rapid installation (within 12 hours), surface evenness within ±5 mm, and excellent joint quality using polyurethane-based fillers. Under operational vehicle loading tests, no cracks or differential settlement were observed, confirming the system’s structural stability and load transfer efficiency. The results indicate that the proposed modular PCP system can significantly improve construction efficiency, quality consistency, and environmental performance in port infrastructure. This technology is expected to serve as a standard solution for rapid maintenance and rehabilitation of heavy-duty pavements in ports, airports, and logistics facilities.