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Full-Depth Recycling Study STATE OF CALIFORNIA • DEPARTMENT OF TRANSPORTATION ADA Notice TECHNICAL REPORT DOCUMENTATION PAGE For individuals with sensory disabilities, this document is available in alternate TR0003 (REV 10/98) formats. For information call (916) 654-6410 or TDD (916) 654-3880 or write Records and Forms Management, 1120 N Street, MS-89, Sacramento, CA 95814. 1. REPORT NUMBER 2. GOVERNMENT ASSOCIATION NUMBER 3. RECIPIENT'S CATALOG NUMBER CA 17-2707 4. TITLE AND SUBTITLE 5. REPORT DATE Full-Depth Recycling Study: Test Track Construction and First-Level Analysis of Phase 1 and Phase 2 HVS Testing, Forensic Investigation, and Phase 1 Laboratory Testing 07/11/2016 6. PERFORMING ORGANIZATION CODE 7. AUTHOR(S) 8. PERFORMING ORGANIZATION REPORT NO. D. Jones, S. Louw, and R. Wu UCPRC-RR-2015-02 9. PERFORMING ORGANIZATION NAME AND ADDRESS 10. WORK UNIT NUMBER University of California Pavement Research Center Department of Civil and Environmental Engineering, UC Davis 1 Shields Avenue 11. CONTRACT OR GRANT NUMBER Davis, Ca 95616 65A0542 12. SPONSORING AGENCY AND ADDRESS 13. TYPE OF REPORT AND PERIOD COVERED California Department of Transportation Research Report Division of Research, Innovation, and System Information October 2014 - September 2017 P.O. Box 942873 14. SPONSORING AGENCY CODE Sacramento, CA 94273-0001 RPMD Task ID: 2707 15. SUPPLEMENTARY NOTES 16. ABSTRACT This First-level report describes the first two phases of a study comparing the performance of four different full-depth pavement reclamation strategies, namely pulverization with no stabilization (FDR-NS), stabilization with foamed asphalt and portland cement (FDR-FA), stabilization with portland cement only (FDR-PC), and stabilization with engineered asphalt emulsion (FDR-EE). A literature review, the test track layout and design, stabilization and asphalt concrete mix design, and test track construction are discussed, as well as the results of Heavy Vehicle Simulator (HVS) and preliminary laboratory testing, and a forensic investigation of the HVS test sections. Refer to Final Report for rest of Abstract. 17. KEY WORDS 18. DISTRIBUTION STATEMENT Full Depth Recycling, pulverization, foamed asphalt, asphalt emulsion, No restrictions. This document is available to the public through the portland cement, pavement National Technical Information Service, Springfield, VA 22161 19. SECURITY CLASSIFICATION (of this report) 20. NUMBER OF PAGES 21. COST OF REPORT CHARGED Unclassified 264 Reproduction of completed page authorized. DISCLAIMER STATEMENT This document is disseminated in the interest of information exchange. The contents of this report reflect the views of the authors who are responsible for the facts and accuracy of the data presented herein. The contents do not necessarily reflect the official views or policies of the State of California or the Federal Highway Administration. This publication does not constitute a standard, specification or regulation. This report does not constitute an endorsement by the Department of any product described herein. For individuals with sensory disabilities, this document is available in alternate formats. For information, call (916) 654-8899, TTY 711, or write to California Department of Transportation, Division of Research, Innovation and System Information, MS-83, P.O. Box 942873, Sacramento, CA 94273-0001. September 2015 Research Report: UCPRC-RR-2015-02 Full-Depth Recycling Study: Test Track Construction and First- Level Analysis of Phase 1 and Phase 2 HVS Testing, Forensic Investigation, and Phase 1 Laboratory Testing Authors: D. Jones, S. Louw, and R. Wu Partnered Pavement Research Center (PPRC) Contract Strategic Plan Element 4.59 (DRISI Task 2707): Guidelines for Full-Depth Reclamation of Pavements PREPARED FOR: PREPARED BY: California Department of Transportation University of California Division of Research, Innovation, and System Information Pavement Research Center Office of Materials and Infrastructure Roadway Research UC Davis, UC Berkeley DOCUMENT RETRIEVAL PAGE Research Report: UCPRC-RR-2015-02 Title: Full-Depth Recycling Study: Test Track Construction and First-Level Analysis of Phase 1 and Phase 2 HVS Testing, Forensic Investigation, and Phase 1 Laboratory Testing Authors: D. Jones, S. Louw, and R. Wu Caltrans Technical Lead: D. Maskey Prepared for: FHWA No.: Report Submitted: Final Publication Date Caltrans CA172707A 04/21/2016 07/11/2016 Strategic Plan Element No: DRISI Task No.: Status: Version No.: 4.59 2707 Final 1 Abstract: This first-level report describes the first two phases of a study comparing the performance of four different full-depth pavement reclamation strategies, namely pulverization with no stabilization (FDR-NS), stabilization with foamed asphalt and portland cement (FDR-FA), stabilization with portland cement only (FDR-PC), and stabilization with engineered asphalt emulsion (FDR-EE). A literature review, the test track layout and design, stabilization and asphalt concrete mix designs, and test track construction are discussed, as well as the results of Heavy Vehicle Simulator (HVS) and preliminary laboratory testing, and a forensic investigation of the HVS test sections. A number of problems were experienced during construction of the FDR-PC and FDR-EE lanes on the test track and consequently only the FDR-NS and FDR-FA lanes and one section of the FDR-PC lane (5 percent measured cement content) were considered satisfactorily uniform for the purposes of HVS testing. The FDR-FA and FDR-PC sections performed very well under both dry and wet conditions, with testing under dry conditions terminated long before the terminal rut of 0.5 in. (12.5 mm) or average crack density of 0.75 ft/ft2 (2.5 m/m2) were reached (cracks were observed on the wet tests only). The two FDR-NS sections tested performed acceptably, with a section with thicker asphalt surfacing (0.4 ft [120 mm]) outperforming a section with thinner asphalt surfacing (0.2 ft [60 mm]) under both dry and wet conditions, as expected. Terminal rut was reached on both sections. No cracks were observed during dry tests, but cracking was severe after completion of the wet tests. Observations during a forensic investigation confirmed the measurements taken during HVS testing. The performance advantages of full-depth reclamation strategies that either use foamed asphalt with cement or cement only over those with no stabilization are clearly evident from the results. Additional laboratory and field testing is in progress to collect sufficient data for the development of mechanistic- empirical design criteria (and revised gravel factors) for full-depth reclaimed pavements. However, there is sufficient evidence to show that pavements that are rehabilitated using full-depth reclamation strategies will satisfactorily withstand design traffic levels common in California. Rehabilitation using this approach offers additional advantages of speed of construction, minimal disruption to traffic, reuse of all materials, and does not require removal of material from the site. FDR with these stabilization approaches also effectively replaces extensively cracked existing asphalt layers, providing a new base and thus preventing the reflective cracking that is common in more traditional overlay projects. Future research should include life cycle cost analysis (LCCA) and environmental life cycle assessment (LCA) to compare FDR with overlay strategies for the range of pavement, climate and traffic conditions where the two strategies might be used. Future research on partial- and full-depth reclamation should be coordinated to facilitate consistent design and specification documentation, and to facilitate the preparation of a comprehensive guide covering all forms of pavement recycling. Keywords: Full-depth reclamation; full-depth recycling; FDR; foamed asphalt, foamed bitumen, portland cement Proposals for implementation: Full-depth reclamation should be considered as an alternative to mill and overlay rehabilitation strategies on severely cracked or rutted pavements. Related documents: UCPRC-GL-2008-01, UCPRC-RR-2008-07, UCPRC-RR-2014-03 Signatures: D. Jones J.T. Harvey D. Spinner J.T. Harvey D. Maskey T.J. Holland 1st Author Technical Review Editor Principal Caltrans Technical Caltrans Contract Investigator Lead Manager UCPRC-RR-2015-02 i DISCLAIMER STATEMENT This document is disseminated in the interest of information exchange. The contents of this report reflect the views of the authors who are responsible for the facts and accuracy of the data presented herein. The contents do not necessarily reflect the official views or policies of the State of California or the Federal Highway Administration. This publication does not constitute a standard, specification or regulation. This report does not constitute an endorsement by the Department of any product described herein. For individuals with sensory disabilities, this document is available in alternate formats. For information, call (916) 654-8899, TTY 711, or write to California Department of Transportation, Division of Research, Innovation and System Information, MS-83, P.O. Box 942873, Sacramento, CA 94273-0001. PROJECT OBJECTIVES The ultimate goal of the Caltrans/UCPRC pavement recycling initiative is the development of a comprehensive guideline document for the rehabilitation and Capital Maintenance (CAPM) design of pavements using full- and partial depth reclamation techniques. The objective of this part of the research is to develop a guideline document for pavement rehabilitation design using full-depth reclamation.
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