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Design & Construction of Heavy-Duty Pavements, Second Edition (QIP-123)

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Design & Construction of Heavy-Duty Pavements, Second Edition (QIP-123) Quality Improvement Series 123 Design & Construction of Heavy-Duty Pavements Second Edition This publication is provided by the Members of the National Asphalt Pavement Association (NAPA), who are the nation’s leading asphalt producer/contractor firms and those furnishing equipment and services for the construction of quality asphalt pavements. NAPA Members are dedicated to providing the highest quality asphalt paving materials and pavements, and to increasing the knowledge of quality asphalt pavement design, construction, maintenance and rehabilitation. NAPA also strongly supports the development and dissemination of research, engineering and educational information that meets America’s needs in transportation, recreational, and environ- mental pavements. NAPA Building 5100 Forbes Blvd. Lanham, MD 20706-4407 Tel: 301-731-4748 Fax: 301-731-4621 Toll free 1-888-468-6499 www.AsphaltPavement.org [email protected] Audrey Copeland, Ph.D., P.E. President & CEO J. Richard Willis, Ph.D. Vice President for Engineering, Research, & Technology This publication is designed to provide information of interest to NAPA Members and is not to be considered a publication of standards or regulations. The views of the authors expressed herein do not necessarily reflect the decision making process of NAPA with regard to advice or opinions on the merits of certain processes, procedures, or equipment. COPYRIGHT NOTICE Publications produced and published by the National Asphalt Pavement Association (NAPA) are copyrighted by the Association and may not be republished or copied (including mechanical reproductions) without written consent. To obtain this consent contact the Association at the address given above. Cover photo: APM Terminals Elizabeth Yard container facility at Port Elizabeth, New Jersey pb 2010 by Capt. Albert E. Theberge, NOAA Corps, Ret. Inset: A Southwest Boeing 737 takes off from San Diego International Airport cbd 2016 by Paul Sullivan. © 2019 National Asphalt Pavement Association Quality Improvement Series 123 — Second Edition Printed 08/19 Quality Improvement Series 123 Design & Construction of Heavy-Duty Pavements Second Edition By Harold L. Von Quintus, P.E. Applied Research Associates Inc. Charles S. Hughes, P.E. NATIONAL ASPHALT PAVEMENT ASSOCIATION NAPA Building 5100 Forbes Blvd. Lanham, MD 20706-4407 Tel: 301-731-4748 Fax: 301-731-4621 Toll free 1-888-468-6499 www.AsphaltPavement.org [email protected] NATIONAL ASPHALT PAVEMENT ASSOCIATION • QIP 123 Design & Construction of Heavy-Duty Pavements 1 Technical Report Documentation Page 1. Report No. 2. Report Date Quality Improvement Series QIP-123 August 2019 3. Title and Subtitle Design & Construction of Heavy-Duty Pavements, 2nd Edition 4. Author(s) Harold L. Von Quintus, P.E., & Charles S. Hughes, P.E. 5. Performing Organization Name and Address 6. Type of Report and Period Covered National Asphalt Pavement Association Final 5100 Forbes Blvd. 7. Contract or Grant No. Lanham, MD 20706-4407 8. Supplementary Notes This project was funded under FHWA Cooperative Agreement DTFH61-13-H-00027 “Deployment of Innovative Asphalt Technologies.” 9. Abstract A revised and updated version of Design, Construction, and Performance of Heavy-Duty Mixes (QIP-123), originally published by the National Asphalt Pavement Association in 2002. Heavy duty mixes are needed in any pavement structure subjected to severe loading conditions as evidenced by the number and weight of heavy loads, heavy static loads, and/or high tire pressures. As pavements meeting these conditions increase, heavy-duty mixes designed to withstand these loads are being used more frequently. Integrating the pavement structural and mixture designs is essential to provide a long- lasting, durable pavement under severe traffic conditions. This publication provides a state-of-the-practice of the material selection, mixture design, structural design, and construction of asphalt mixtures and pavements used under heavy truck traffic or specialized loading conditions, including discussing the use of large-stone mixtures, polymers, and other additives commonly used to provide higher strengths for heavy-duty asphalt mixtures. Because the aggregate skeleton must carry much of the load, it is important that a good quality crushed aggregate is used and that the gradation meets the appropriate requirements. The gradation requirements typically require large nominal maximum size aggregate. Although segregation of the large stone can be a problem, using good production and construction practices can minimize this. Three principal problems that may arise when using large maximum size aggregate are segregation, aggre- gate fracture, and a slight increase in equipment wear. These problem areas are discussed with an emphasis on the causes of, and steps that can be taken to overcome, segregation. 10. Key Words 11. Distribution Statement heavy-duty mix, asphalt pavement, Superpave, pavement design, mix design, stone- No restrictions. on-stone contact, plant production, construction practices, segregation, large-stone mix 12. Suggested Citation 13. Price Von Quintus, H.L., & C.S. Hughes (2019). Design & Construction of Heavy-Duty Pavements, 2nd Edition (Quality N/A Improvement Series QIP-123). National Asphalt Pavement Association, Lanham, Maryland. 14. No. of Pages 74 2 Design & Construction of Heavy-Duty Pavements NATIONAL ASPHALT PAVEMENT ASSOCIATION • QIP 123 CONTENTS 1 Introduction ....................................................................................................................................5 Definition of Heavy-Duty Mixes ................................................................................................ 5 Need for Heavy-Duty Mixes ..................................................................................................... 6 2 A Brief History of Heavy-Duty Mixtures ....................................................................................9 3 Structural Design Considerations ............................................................................................11 Layer Thickness Design Procedures ...................................................................................... 11 Empirical-Based Design (1993 AASHTO) ....................................................................... 11 ME-Based Thickness Design.......................................................................................... 12 Perpetual Pavement Thickness Design .......................................................................... 14 Critical Pavement Responses for Design ....................................................................... 16 Integration of Structural & Mixture Design ............................................................................. 17 4 Layer Stiffness Properties & Factors for High-Stress Loading ..........................................19 Subsurface Layers — Aggregate Base & Subgrade .............................................................. 20 Types of Asphalt Mixtures/Layers .......................................................................................... 22 Modified Binders/Mixtures ............................................................................................. 22 Recycled/Reclaimed Asphalt Materials .......................................................................... 23 Warm-Mix Asphalt .......................................................................................................... 25 NMAS & Minimum Asphalt Layer/Lift Thickness ................................................................... 25 5 Material Selection & Requirements .........................................................................................27 Aggregate Properties ............................................................................................................. 27 Coarse Aggregate Properties ......................................................................................... 28 Fine Aggregate Properties .............................................................................................. 29 Asphalt Binder Selection ........................................................................................................ 30 6 Mixture Design for Heavy-Duty Pavements............................................................................35 Asphalt Mixture Design Methods & Specifications ................................................................ 35 Modified Marshall Mixture Design Method for Heavy-Duty Large-Stone Mixes ............ 35 Superpave Mixture Design Method ................................................................................ 36 FAA Mix Design Specifications ....................................................................................... 38 Mixture Design Steps ............................................................................................................. 39 Performance Testing to Confirm Mixture Design ................................................................... 46 7 Production & Placement of Heavy-Duty Mixtures .................................................................49 Challenges & Considerations in Constructing Heavy-Duty Mixes ......................................... 49 Segregation ............................................................................................................................ 50 Building Aggregate Stockpiles ..............................................................................................
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