Download - COMPOSITE PAVEMENT OVERLAY
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COMPOSITE PAVEMENT OVERLAYPROJECT: US 130 MAIN STREET TO US ROUTE 1
NUSRAT S MORSHED, P.E. PAVEMENT DESIGN
2018 NJ Asphalt Paving Conference
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Acknowledgement◦ Robert Blight
Supervising Engineer, Pavement Design Unit, NJDOT◦ Narinder S Kohli, P.E.
Project Engineer, Pavement Design Unit, NJDOT◦ Vasudevan Ganarajan
Senior Engineer, Pavement Design Unit, NJDOT◦ Thomas Bennert, Ph.D.
Associate Professor, Rutgers University
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Outline
◦Basic Information of Composite Pavement◦Challenges of Composite Pavement◦Composite Pavement Rehabilitation Strategies ◦Case Study-Route 130
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Basic Information of Composite Pavement
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COMPOSITE PAVEMENT
CONCRETEHMA/ASPHALT
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Improve Pavement Condition
Improve Ride Quality
Improve Safety
Extend Life
Typically Functional Overlay – Minor Rehab
Sometimes A Structural Overlay – Major Rehab
Reduce Life Cycle Costs
Increase Customer Satisfaction◦ Noise Reducing Surface(s)
Composite Pavement Rehabilitation Goals
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Challenges of Composite Pavement
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Risk of Removing HMA Overlay
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Challenges of Removing HMA Overlay:
Pavement Recommendation:
Mill 3” and Pave with 3” SMA 12.5 MM Surface Course
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Challenges of Removing HMA Overlay:
Core Information:
Lane 1 Core information was 5.25” to 7.75” HMA over PCC.
Lane 2 Core information was not available during design.
Lane 3 Core information was 3.5” to 19.5” HMA over PCC.
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Challenges: Pavement ME Analysis for Composite Pavement
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Challenges: Pavement ME Analysis for Composite Pavement
3” AC Over JPCP 8” AC Over JPCP
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Challenges: Composite Pavement
NJDOT’s concrete/composite pavement infrastructure continuing to ageand deteriorate
PCC reconstruction costly
Rubblization is option, but require minimum of 6 inches Overlay
PCC rehabilitation generally not successful
Most simple rehabilitation technique – Hot Mix Asphalt (HMA)Overlay Unfortunately, high deflections at PCC joints/cracks creates excessive
straining in HMA overlay
Most cases, cracking initiated in HMA above crack/joint in PCC (called Reflective Cracking)
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When reflective crack reaches pavement surface Affects overall integrity of pavement▪ Smoothness – intermittent cracking also
affects safety▪ Pathway for water intrusion▪ Area for immediate raveling
Little guidance on how to design HMA overlays for PCC pavements HMA material/mixture selection
Challenges: Composite Pavement
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Mode 1 – Poor Load Transfer at joint/crack results in independent movement of PCC slabs
Mode 2 – Excessive VerticalBending at PCC joint/crack(Pure Tensile Straining)
Mode 3 – HorizontalDeflections (PCC slab expansion and contraction) due to environmental cycling
Modes of Reflective Cracking
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Mode 1 – Poor Load Transfer atjoint/crack results in independentmovement of PCC slabs
Reflective Cracking: Mode 1
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“Poor load transfer…”
Mode 1: Vertical Shear Stress
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“Poor load transfer…”
Mode 1: Vertical Shear Stress
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“causes shear stresses in the overlay.”
Mode 1: Vertical Shear Stress
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“causes shear stresses in the overlay.”
Mode 1: Vertical Shear Stress
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“causes shear stresses in the overlay.”
Mode 1: Vertical Shear Stress
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“causes shear stresses in the overlay.”
Mode 1: Vertical Shear Stress
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Mode 1: Vertical Shear Stress
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Mode 1: Vertical Shear Stress
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“Over many repeated loads…”
Mode 1: Vertical Shear Stress
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Mode 1: Vertical Shear Stress
“Over many repeated loads…”
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“reflection cracks develop.”
Mode 1: Vertical Shear Stress
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Mode 1: Vertical Shear Stress
“reflection cracks develop.”
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Mode 1: Vertical Shear Stress
“reflection cracks develop.”
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Mode 1: Vertical Shear Stress
“reflection cracks develop.”
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Mode 1: Vertical Shear Stress
“reflection cracks develop.”
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Reflective Cracking: Mode 2
Mode 2 -Tensile stress at bottomof AC layer Poor supportWeak base Load Associated Problem
(Traffic Loading)
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“Traffic loads at the joint…”
Mode 2: Horizontal Tensile Stress due to load
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“Traffic loads at the joint…”
Mode 2: Horizontal Tensile Stress due to load
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“cause tensile stresses at the bottom of the overlay.”
Mode 2: Horizontal Tensile Stress due to load
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“cause tensile stresses at the bottom of the overlay.”
Mode 2: Horizontal Tensile Stress due to load
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Mode 2: Horizontal Tensile Stress due to load
“cause tensile stresses at the bottom of the overlay.”
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“Over many repeated loads…”
Mode 2: Horizontal Tensile Stress due to load
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Mode 2: Horizontal Tensile Stress due to load
“Over many repeated loads…”
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Mode 2: Horizontal Tensile Stress due to load
“Over many repeated loads…”
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Mode 2: Horizontal Tensile Stress due to load
“reflection cracks develop.”
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Mode 2: Horizontal Tensile Stress due to load
“reflection cracks develop.”
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Mode 2: Horizontal Tensile Stress due to load
“reflection cracks develop.”
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Mode 3 – Horizontal Tensile Stress Thermally Induced stresses Magnitude depends on Slab length (or
Crack spacing), 24 hour temperaturechange, and coefficient of thermalexpansion of PCC
Reflective Cracking: Mode 3
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“Slab shrinkage under cooling temperature…”
Mode 3: Horizontal Tensile Stress due to climate
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Mode 3: Horizontal Tensile Stress due to climate
“Slab shrinkage under cooling temperature…”
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Mode 3: Horizontal Tensile Stress due to climate
“Slab shrinkage under cooling temperature…”
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Mode 3: Horizontal Tensile Stress due to climate
“causes tensile stresses in the overlay.”
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Mode 3: Horizontal Tensile Stress due to climate
“causes tensile stresses in the overlay.”
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Mode 3: Horizontal Tensile Stress due to climate
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Mode 3: Horizontal Tensile Stress due to climate
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Mode 3: Horizontal Tensile Stress due to climate
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“Over many cycles…”
Mode 3: Horizontal Tensile Stress due to climate
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Mode 3: Horizontal Tensile Stress due to climate
“Over many cycles…”
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“reflection cracks develop.”
Mode 3: Horizontal Tensile Stress due to climate
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Mode 3: Horizontal Tensile Stress due to climate
“reflection cracks develop.”
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Composite Pavement Rehabilitation Strategies
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Full Depth Repairs before Milling◦ Full Depth Concrete Pavement Repair, HMA (453006)◦ Hot Mix Asphalt Pavement Repair (401021)
Mill and Overlay with Better Mixes◦ AROGFC◦ Polymer modified HMA◦ HPTO◦ SMA◦ Reflective Crack Relief Interlayer (RCRI) or Strata◦ Binder Rich Intermediate Course, 4.75 MM
Composite Pavement Rehabilitation Strategies
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Full Depth Repair with HMA (typically before milling)
Proposed HMA Surface Course
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Mill & Overlay with HMA
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Why premium mixes?
Better fatigue life
Better durability
Increased skid/safetyReduced noise
Increased customer satisfaction
Better reflective crack resistance 12.5ME
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Asphalt Rubber Open Graded Friction Course
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High Performance Thin Overlay
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SMA 12.5mm Surface Course
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Rt.202 SB (MP 13.4-17.03) –Maintenance Resurfacing Contract No. 268 (2007)
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Visual Survey of JRC Pavement
Rehab. Design of Asphalt Outside Shoulder◦ Roadway Excavation◦ Pave with 3” min. & var. HMA 25M64 Base Course◦ Pave with 4” (2 lifts) of high quality HMA
Full Depth Concrete Repairs with Very Early Strength Concrete
Overlay Design with 4” (2 lifts) of high quality HMA
3 test sections and 1 control section
Rt.202 SB – Maintenance Resurfacing Contract No. 268 (2007)
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Rt.202 SB – Maintenance Resurfacing Contract No. 268 (2007)
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BEFORE REHAB
SDI = 5.0
Ride Quality◦ MP 13.4-14.75, IRI=88.3◦ MP 14.75-15.25, IRI=78.0◦ MP 15.25-15.75, IRI=77.7◦ MP 15.75-17.03, IRI=75.0
Ride Quality for the project, IRI=80.4
Rt.202 SB – Maintenance Resurfacing Contract No. 268 (2007)
AFTER REHAB
SDI = 2.07
Ride Quality◦ MP 13.4-14.75, IRI=197.2◦ MP 14.75-15.25, IRI=154.7◦ MP 15.25-15.75, IRI=143.8◦ MP 15.75-17.03, IRI=151.5◦ Ride Quality for the project,
IRI=168.6
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BEFORE REHAB
Rt.202 SB – Maintenance Resurfacing Contract No. 268 (2007)
AFTER REHAB
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Rt.202 SB – Maintenance Resurfacing Contract No. 268 (2007)
0
50
100
150
200
250
2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
IRI Versus Year
13.4 to 14.7 14.7 to 15.7 15.7 to 17
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Rt.70 (MP8.61-12.06)- Maintenance Roadway Repair Contract No. 327 (2007)
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Located high deflection joints (> 15 mils deflection) with FWD during construction
Failed joints were successfully (reduced deflection < 10 mils) grouted with HDP by Uretek
Full Depth Repairs with HMA were performed on high severity joints/areas
Rt.70 (MP8.61-12.06)- Maintenance Roadway Repair Contract No. 327 (2007)
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BEFORE REHAB
SDI = 4.9
Ride Quality IRI = 94
Rt.70 (MP8.61-12.06)-Maintenance Roadway Repair Contract No. 327 (2007)
AFTER REHAB
SDI = 1.56
Ride Quality IRI = 157
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BEFORE REHAB
Rt.70 (MP8.61-12.06)-Maintenance Roadway Repair Contract No. 327 (2007)
AFTER REHAB
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Rt.70 (MP8.61-12.06)-Maintenance Roadway Repair Contract No. 327 (2007)
0
20
40
60
80
100
120
140
160
180
2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
IRI Versus Year
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Case Study-Route 130
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Limit of the project:MP 72.68 to MP 74.12MP 76.03 to MP 80.97MP 81.59 to MP 83.58
Total Lane Miles of the project: 33.56
Prime Contractor: Trap Rock Industries, LLC
Letting Date: June 23, 2015
Project Completed: June 17, 2016
Route 130 Main St to Rt 1 Resurfacing -2016
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Visual Survey of Composite Pavement
Cores performed to establish proper milling depth
Full Depth Repair areas identified by visual survey during final design
Calculated approximately 20 million ESAL’s
Overlay Design consisted of milling 3” depth and resurfacing with:◦ 2” Stone Matrix Asphalt 12.5 MM Surface Course◦ 1” Binder Rich Intermediate Course, 4.75 MM
Route 130 Main St to Rt 1 Resurfacing -2016
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BRIC - SPECIFICATION
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BRIC - SPECIFICATION
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BRIC - SPECIFICATION
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BRIC – Performance Analysis Evaluated changes in SDI to evaluate performance of
BRIC on New Jersey pavement sections BRIC analysis difficult as always overlaid with a
surface course Analysis looked at performance with and without
BRIC Analysis looked at different surface courses
Compared performance life for different scenarios All data averaged for same “system” compared An SDI value of 2.4 is a trigger for rehabilitation
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0
0.5
0 4 5 6Time After Construction (Years)
7 8 9 10
SDI
9.5mm SMA with BRIC12.5mm SMA with BRIC
9.5mm SMA with 12.5M64
12.5mm SMA with 12.5M64
12.5mm Surface with BRIC
9.5 or 12.5 Surface - No BRIC
1 2 3
1
1.5
5
4.5
4
3.5
3
2.5
2
BRIC – Performance Analysis
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Performance of BRIC material highly dependent on the surface course overlaying the BRIC SMA overlays performed best▪ Still “flexible” enough to withstand residual vertical straining
Dense graded overlays performed the worst▪ Too “stiff” – can not withstand residual flexing
SMA alone provides a good alternative Not as good performance but could be beneficial for
areas of “good” concrete conditions
BRIC – In- Service Life Evaluation
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BEFORE REHABSDI = 5Ride Quality IRI = 65
Route 130 Main St to Rt 1 Resurfacing -2016
AFTER REHABSDI = 2.4Ride Quality IRI = 178
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Route 130 Main St to Rt 1 Resurfacing -2016
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Application of New Technique: ◦Thermal Profile System (Item# 401019P)◦ Intelligent Compaction (Item# 401023P)
Special Mix for Skid Resistance: ◦High Friction Surface Treatment (Item# 423003M)
Route 130 Main St to Rt 1 Resurfacing (MP72.68-83.58)-2016
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Paver Mounted Thermal Profile (PMTP) Method:A system that continually monitors the surface temperature readings of the mat immediately behind the paver screed during placement operations.
Thermal Profile System
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IC rollers are vibratory rollers equipped with instrumentation fed to a documentation and feedback control system that processes compaction data in real time for the roller operator.
Intelligent Compaction
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Intelligent Compaction
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High friction surface treatments (HFST) are pavement treatments that dramatically and immediately reduce crashes, injuries, and fatalities associated with friction demand issues, such as:◦A reduction in pavement friction during wet
conditions, and/or◦A high friction demand due to vehicle speed
and/or roadway geometrics.
HFST
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HFST
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HFST
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HFST
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HFST
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