Evaluation of Bonded Concrete Overlays on Asphalt Pavements (2022)

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2022 N A T I O N A L C O O P E R A T I V E H I G H W A Y R E S E A R C H P R O G R A M NCHRP RESEARCH REPORT 1007 Evaluation of Bonded Concrete Overlays on Asphalt Pavements Linda M. Pierce Sarah E. Stolte Nick Weitzel Jose Medina Tom Van Dam Kevin Senn Nichols Consulting Engineers, CHTD Reno, NV Je Roesler Gail M. Scott Sushobhan Sen Omar A. Jadallah University of Illinois Urbana-Champaign, IL Urbana, IL Ken Maser Adam Carmichael Infrasense Woburn, MA Kelly Smith Kurt Smith Applied Pavement Technology, Inc. Urbana, IL Subscriber Categories Design • Materials • Pavements Research sponsored by the American Association of State Highway and Transportation Ofcials in cooperation with the Federal Highway Administration

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C O O P E R A T I V E R E S E A R C H P R O G R A M S AUTHOR ACKNOWLEDGMENTS The research reported herein was performed under NCHRP Project 01-61 by Nichols Consulting Engineers, CHTD, with assistance from Applied Pavement Technology, Inc., Infrasense, and the Uni- versity of Illinois Urbana-Champaign. Field evaluation of in-service bonded concrete overlays on asphalt pavement could not have been com- pleted without the assistance of participating state highway agency personnel from Colorado, Illinois, Iowa, Kansas, Louisiana, Minnesota, Missouri, Montana, and Pennsylvania. The tomograph testing device was provided to the research team by the Federal Highway Administration. CRP STAFF FOR NCHRP RESEARCH REPORT 1007 Christopher J. Hedges, Director, Cooperative Research Programs Waseem Dekelbab, Deputy Director, Cooperative Research Programs, and Manager, National Cooperative Highway Research Program Sid Mohan, Associate Program Manager, Implementation and Technology Transfer, National Cooperative Highway Research Program Christopher T. McKenney, Senior Program Officer Robert Turner II, Senior Program Assistant Natalie Barnes, Director of Publications Heather DiAngelis, Associate Director of Publications NCHRP PROJECT 01-61 PANEL Field of Design—Area of Pavements Thomas R. Burnham, Minnesota Department of Transportation, Maplewood, MN (Chair) Bismark Agbelie, Catholic University of America, Washington, DC Alexander K. Appea, Virginia Department of Transportation, Fredericksburg, VA Peter C. Capon, Rieth-Riley Construction Company, Inc., Bristol, IN Dar Hao Chen, Texas A&M University, Austin, TX Mohamed Mahgoub, New Jersey Institute of Technology, Newark, NJ Larry A. Scofield, American Concrete Pavement Association (ACPA), Mesa, AZ Jerzy Z. Zemajtis, American Concrete Institute, Farmington Hills, MI Nadarajah Sivaneswaran, FHWA Liaison

NCHRP Research Report 1007 presents representative performance prediction curves for bonded concrete overlays on asphalt (BCOAs). The representative performance prediction curves are based on comprehensive laboratory and field investigations for determining best practices for scoping, design, material selection, construction, maintenance, repair, and rehabilitation of BCOA pavements. This report will be of immediate interest to construction and maintenance engineers. BCOA pavements are a fast-growing pavement preservation and rehabilitation treatment in the United States. They have demonstrated their effectiveness in correcting areas with excessive rutting and shoving caused by slow, heavy loads, such as at intersections, as well as for a longer term overlay option on regular mainline pavements. Most BCOA projects consist of a 3- to 7-in. thick concrete overlay, with or without fibers, with panel sizes ranging from 4 to 12 ft. Major advancements have been made recently in design methods for BCOAs. However, there was a need for information on key topics such as optimal BCOA mix design propor- tioning, construction practices, maintenance, repair, and rehabilitation, as well as a com- prehensive review of overall performance. Current assumptions about anticipated design lives of BCOAs are derived from localized studies. Variables impacting design life include the previous condition of the existing pavement structure, the time-dependent degree of bond between layers, overlay thickness, panel size, construction practices, environment, and traffic. Typical BCOA design lives are uncertain, and the timing and types of mainte- nance and repair activities need further study and definition. Some highway agencies are reluctant to use BCOAs because of a lack of experience and information. Thus, research was needed to determine expected BCOA performance. Other aspects of BCOAs such as construction practices (“do’s and don’ts”) and maintenance, repair, and rehabilitation requirements and procedures also need attention. Under NCHRP Project 01-61, “Evaluation of Bonded Concrete Overlays on Asphalt Pavements,” Nichols Consulting Engineers was asked to (1) investigate factors that may impact BCOA performance including design procedures, specifications, mix design pro- portioning, construction practices, and maintenance and repair techniques; (2) document in-service BCOA performance through a literature review and survey; (3) conduct field surveys of selected BCOA projects; (4) develop representative performance prediction curves suitable for use in BCOA design selection based on the documented performance of a range of BCOA projects; and (5) compare actual versus predicted BCOA performance using current design procedures. F O R E W O R D By Christopher T. McKenney Staff Officer Transportation Research Board

In addition to NCHRP Research Report 1007, which documents the entire research effort, a number of deliverables, provided as Appendices A through G, are available on the National Academies Press website (www.nap.edu) as NCHRP Web-Only Document 329: Bonded Concrete Overlays on Asphalt Pavements: Resources for Evaluation.

1 Summary 3 Chapter 1 Background 5 Chapter 2 Literature Review 5 Past Performance Studies 10 Significant Findings from Past Pavement Studies 16 Concrete Materials 18 Construction Practices 19 Maintenance Practices 19 Summary 22 Chapter 3 State of the Practice 22 Experience and Use 22 Project Selection and Evaluation 25 Design 26 Materials 26 Construction 27 Maintenance and Repair Techniques 27 Availability of Performance Data 28 Willingness to Participate in Phase II 28 Site Selection for Phase II 30 Summary 33 Chapter 4 Field Performance of Selected Projects 33 Automated Distress Surveys 44 Ground-Penetrating Radar Surveys 50 Detailed On-Site Evaluations 62 Ultrasonic Tomography 64 Falling Weight Deflectometer Testing 68 Coring, Dynamic Cone Penetrometer Testing, and Unbound Material Sampling 73 Laboratory Testing 84 Summary 89 Chapter 5 Performance Prediction 89 Structural Design Methods 94 Sensitivity Analysis 106 Design Results 128 Summary C O N T E N T S

129 Chapter 6 Conclusions and Further Research 129 Conclusions 133 Further Research 134 References 137 Appendices A Through G Note: Photographs, figures, and tables in this report may have been converted from color to grayscale for printing. The electronic version of the report (posted on the web at www.nap.edu) retains the color versions.