Evaluation of Composite Pavement Unbonded Overlays: Phases I and II
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Evaluation of Composite Pavement Unbonded Overlays: Phases I and II Department of Civil, Construction, and Environmental Engineering Sponsored by the Federal Highway Administration, U.S. Department of Transportation, Project DTFH6101X00042-CTRE Phases I and II, Project #2 and the Iowa Department of Transportation and the Iowa Highway Research Board, Construction Report Project HR-1093, TR-478 April 2003 DISCLAIMER The opinions, findings, and conclusions expressed in this publication are those of the authors and not necessarily those of the U.S. Department of Transportation, Federal Highway Administration, Iowa Department of Transportation, or Iowa Highway Research Board. The contents of this report reflect the views of the authors, who are responsible for the facts and the accuracy of the information presented herein. This document is disseminated under the sponsorship of the U.S. Department of Transportation, Federal Highway Administration, in the interest of information exchange. The U.S. government assumes no liability for the contents or use thereof. The sponsors do not endorse products or manufacturers. Trade and manufacturers names appear in this report only because they are considered essential to the objective of this document. The mission of the Center for Portland Cement Concrete Pavement Technology (PCC Center) is to advance the state of the art of portland cement concrete pavement technology. The center focuses on improving design, materials science, construction, and maintenance in order to produce a durable, cost-effective, sustainable pavement. Technical Report Documentation Page 1. Report No. 2. Government Accession No. 3. Recipient’s Catalog No. FHWA Project DRFH6101X00042- CTRE Phases I and II, Project #2 Iowa DOT Project HR-1093, TR-478 4. Title and Subtitle 5. Report Date Evaluation of Composite Pavement Unbonded Overlays: Phases I and II April 2003 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report No. J.K. Cable, M.L. Anthony, F.S. Fanous, and B.M. Phares CTRE Project 01-95 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) Center for Portland Cement Concrete Pavement Technology Iowa State University 11. Contract or Grant No. 2901 South Loop Drive, Suite 3100 Ames, IA 50011-8634 12. Sponsoring Organization Name and Address 13. Type of Report and Period Covered Federal Highway Administration Construction Report U.S. Department of Transportation 14. Sponsoring Agency Code Washington, DC 20590 Iowa Highway Research Board Iowa Department of Transportation 800 Lincoln Way Ames, IA 50011 15. Supplementary Notes 16. Abstract In recent years, thin whitetopping has evolved as a viable rehabilitation technique for deteriorated asphalt cement concrete (ACC) pavements. Numerous projects have been constructed and tested; these projects allow researchers to identify the important elements contributing to the projects’ successes. These elements include surface preparation, overlay thickness, synthetic fiber reinforcement usage, joint spacing, and joint sealing. Although the main factors affecting thin whitetopping performance have been identified by previous research, questions still existed as to the optimum design incorporating these variables. The objective of this research is to investigate the interaction between these variables over time. Laboratory testing and field-testing were planned in order to accomplish the research objective. Laboratory testing involved shear testing of the bond between the portland cement concrete (PCC) overlay and the ACC surface. Field-testing involved falling weight deflectometer deflection responses, measurement of joint faulting and joint opening, and visual distress surveys on the 9.6-mile project. The project was located on Iowa Highway 13 extending north from the city of Manchester, Iowa, to Iowa Highway 3 in Delaware County. Variables investigated included ACC surface preparation, PCC thickness, synthetic fiber reinforcement usage, and joint spacing. This report documents the planning, equipment selection, construction, field changes, and construction concerns of the project built in 2002. The data from this research could be combined with historical data to develop a design specification for the construction of thin, unbonded overlays. 17. Key Words 18. Distribution Statement portland cement concrete pavement overlays, maturity, temperature- No restrictions. monitoring systems 19. Security Classification 20. Security Classification 21. No. of Pages 22. Price (of this report) (of this page) Unclassified. Unclassified. 28 + appendixes NA EVALUATION OF COMPOSITE PAVEMENT UNBONDED OVERLAYS: PHASES I AND II FHWA Project DTFH6101X0042-CTRE Phases I and II, Project #2 Iowa DOT Project HR-1093, TR-478 CTRE Project 01-95 Principal Investigator J.K. Cable Associate Professor of Civil Engineering, Iowa State University Co-Principal Investigators F.S. Fanous Professor of Civil Engineering, Iowa State University B.M. Phares Manager, Bridge Engineering Center, Iowa State University Associate Director for Bridges and Structures, Center for Transportation Research and Education Research Assistant M.L. Anthony Authors J.K. Cable, M.L. Anthony, F.S. Fanous, and B.M. Phares Preparation of this report was financed in part through funds provided by the Iowa Department of Transportation through its research management agreement with the Center for Transportation Research and Education. Center for Portland Cement Concrete Pavement Technology Iowa State University 2901 South Loop Drive, Suite 3100 Ames, IA 50010-8634 Phone 515-294-8103; Fax 515-294-0467 www.ctre.iastate.edu/pcc/ Construction Report • April 2003 TABLE OF CONTENTS ACKNOWLEDGEMENTS........................................................................................................... ix INTRODUCTION ...........................................................................................................................1 Background................................................................................................................................1 Research Objectives...................................................................................................................1 REVIEW OF CONCRETE OVERLAY PROJECTS......................................................................2 Ultrathin Whitetopping Experiences..........................................................................................2 Unbonded Overlay Experience on County Roads .....................................................................3 TEST SITE DESCRIPTION............................................................................................................4 Soil Conditions...........................................................................................................................7 Design Traffic ............................................................................................................................8 EXPERIMENTAL DESIGN ...........................................................................................................9 CONSTRUCTION.........................................................................................................................14 Construction Concerns.............................................................................................................21 Field Changes...........................................................................................................................23 TEST FREQUENCY AND METHODS.......................................................................................25 Lab Shear Testing ....................................................................................................................25 Field Testing ............................................................................................................................26 Falling Weight Deflectometer Testing...............................................................................26 Joint Openings and Faulting Measurements......................................................................26 Visual Distress Surveys .....................................................................................................27 Weigh-in-Motion Device Measurements...........................................................................27 Cross Sectional Structural Analysis...................................................................................27 SUMMARY...................................................................................................................................28 REFERENCES ..............................................................................................................................28 APPENDIX A: MATURITY MEASUREMENT EQUIPMENT EVALUATION ................... A-1 APPENDIX B: FALLING WEIGHT DEFLECTOMETER DATA...........................................B-1 APPENDIX C: JOINT OPENING AND FAULTING DATA....................................................C-1 APPENDIX D: CROSS SECTIONAL STRUCTURAL ANALYSIS....................................... D-1 iii LIST OF FIGURES Figure 1. Project Location............................................................................................................... 5 Figure 2. Pavement Layers and the Dates of Construction............................................................. 6 Figure 3. Longitudinal Cracking and Current Condition of the Roadway ..................................... 6 Figure 4. Typical Cross Section for the