Concrete Pavement

Overlay Design
Jeffery Roesler, Ph.D., P.E.
Professor
Department of Civil & Env. Eng.
University of Illinois Urbana-Champaign

22 January 2015
ACPA Webinar
Webinar Design Overview
Overlay Design Objectives
Overlay Design Guides
Inputs & critical variables
Bonded Concrete Overlays
Concrete-Asphalt
Concrete-Concrete
Unbonded Concrete Overlays
Whitetopping & Composites
Reference O/L design review
Summary of Overlay Design
Concrete Overlay Design: Objectives
Achieve desired concrete pavement overlay
service life given:
Existing pavement condition
Expected traffic
Layer and material properties
Interface condition SCinitial
SCOverlay
Slab geometry
Climatic conditions SCfuture traffic
SCeffective

Load Applications
Guide on Existing Overlay Design Methods
Not a design procedure
Background on
recommended overlay
design methods
18 pages
Detailed design examples
35 pages
StreetPave12 released
after this guide
http://www.cptechcenter.org/technical-library/documents/Overlays_Design_Guide_508.pdf
How to start design of concrete O/L?
Roadway site evaluation
Existing pavement structure
New pavement performance objectives
Select candidate Overlay Options
Collect input data & choose design features
Support layers, Slab size, etc.
Use appropriate overlay design methods
Optimize design
Write construction specs to reflect design objectives
Concrete Overlays: General Types

Bonded Concrete to Concrete Unbonded Concrete w/ Separation Layer

Whitetopping (unbonded) Bonded Concrete Overlay Asphalt (BCOA)

Concrete Overlay Guide, Third Edition
Contents
Overview of Overlays
Overlay types and uses
Evaluations & Selections
Six Overlay Summaries
Design Section
Misc. Design Details
Overlay Materials Section
Work Zones under Traffic
Overlay Construction
Accelerated Construction
Specification
Considerations
Repairs of Overlays

http://www.cptechcenter.org/technical-library/documents/Overlays_3rd_edition.pdf
Concrete Overlays Categories

Thinner Concrete Overlays Thicker

Bonded Overlay Group Unbonded Overlay Group

Bonded Bonded Bonded Unbonded Unbonded Unbonded

Concrete Concrete Concrete Concrete Concrete Concrete
Resurfacing Resurfacing Resurfacing Resurfacing Resurfacing Resurfacing
of of of of Concrete of Asphalt of
Concrete Asphalt Composite Pavements Pavements Composite
Pavements Pavements Pavements Pavements

Bond is integral to design Old pavement is base layer

 Thinner Concrete Pavement Options
Bonded Overlay Systems Unbonded Systems

Thin Bonded Bonded Unbonded Unbonded Thinner

Concrete Concrete Concrete Concrete Concrete Concrete
Inlay - Resurfacing Resurfacing Resurfacing Resurfacing Pavement or
Preservation of of of Concrete of Asphalt Short Slabs
Asphalt Composite Pavements Pavements
Pavements Pavements

h=2 to 3.5 inch

L=4 to 6 ft
Emerging
Colorado Method Opti-Pave
ACPA BCOA or BCOA ME h=2.5 to 9 in.
6in. x 6ft x 6ft
h=3 to 6 in. L=4 to 9 ft
L=4 to 6 ft
Which Overlay Design Method(s)?
Concrete Overlay Type Design Methods
Unbonded on Asphalt, AASHTO ME, ACPA StreetPave 12,
Composite, or Concrete AASHTO 93, OptiPave 2.0
Bonded on Asphalt or ACPA BCOA, ACPA StreetPave 12,
Composite BCOA ME, CO 6x6x6
Bonded on Concrete AASHTO ME, ACPA StreetPave 12,
AASHTO 93
What are main Concrete Overlays Design Inputs?
Slab thickness
Concrete Strength, CTE, Modulus, fibers (?)
Concrete-Asphalt Interface
Support layers (surface, base/subbase, soil)
Joint Spacing
Edge Support
Load Transfer
Subgrade Support
Traffic
Climate
Other Important Considerations in
Overlay Design
Required Future Design Life of the Overlay
Traffic Loading (ESALs)
Pre-overlay Repair
Reflective Crack Control
Sub-drainage
Structural vs Functional Overlays
Recycling Existing Pavement (PCC & AC)
New concrete durabilityShoulders
Existing PCC Slab Durability
PCC Overlay Joints
PCC Overlay Reinforcement
PCC Overlays Bonding / Separation Layers
Overlay Design Reliability Level & Overall Standard
Deviation
P t Wid i
 BCOA vs. Whitetopping
Whitetopping (h > 6 in.)
More conventional slab sizes (6ft to 15ft)
30+ years experience
Ignores interface bond (unbonded)

Bonded Concrete Overlay Asphalt (h 6 in.)

20+ years experience (1991)
Smaller slab sizes ( 6ft)
Concrete/AC bond is essential
Ultra-Thin Whitetopping (UTW)
Composite Behavior Mechanics

Neutral Axis
PCC PCC

Bit. Bit.

Unbonded Bonded
Whitetopping Bonded Concrete Overlay Asphalt

Riley
Bonding Effects on Edge Stress
P = 9,000 lbs

Concrete NA Concrete
NA
= 793 psi Comp. = 398 psi Comp.

Asphalt
Asphalt
Tension Tension

Unbonded Bonded
Whitetopping Bonded Concrete Overlay Asphalt
Concrete Overlay Solutions:
Rehabilitation and Maintenance
Site Visit: Existing Pavement Condition
 Why use smaller slab sizes?
Interface bond assumption (BCOA)
-Reduce de-bonding of concrete and asphalt at early ages
Short slab sizes reduce bending and curling stresses

>2m
1.2m 1.2m 1.2m
Thickness Design for Concrete Overlays
Highways/Roads
AASHTO Pavement ME (2011) or MEPDG
StreetPave 12 (ACPA)
ACPA (Whitetopping/UTW) 1998
Illinois DOT (2009) new fatigue eqn. & fibers
BCOA Calculator (2012) add climate database
BCOA ME (2012) Univ. of Pittsburg
AASHTO (1993)
Airports:
Federal Aviation Administration (FAARFIELD)
AASHTO Pavement ME
or formerly known as MEPDG
AASHTO Pavement ME - INPUTS!
INPUTS, cont
Many OUTPUTS to Synthesize
 Bonded Concrete Overlay Options

Thinner overlays (3 to 6 in)

Constructed over concrete, Bonded Overlay Options

asphalt, and composite

sections. Bonded Bonded Bonded
Concrete Concrete Concrete
Existing pavement condition Resurfacing
of
Resurfacing
of
Resurfacing
of

fair to good Concrete

Pavements
Asphalt
Pavements
Composite
Pavements

Interface Bond is Critical!

Bonded Concrete Overlay Software Programs

Recommended Design Procedures (see previous page for links)

1. Bonded Concrete Overlay on Asphalt (BCOA) Thickness Designer (ACPA 2012)
2. BCOA ME (Vandenbossche 2013) Concrete Overlay Guide
3. Guide for Design of Pavement Structures. 4th ed. (AASHTO 1993)
4. Mechanistic-Empirical Design GuideA Manual of Practice (AASHTO 2008)
(Harrington et al. 2014)
5. StreetPave (ACPA 2012)
7. Flowable Fibrous Concrete for Thin Pavement Inlays (Bordelon and Roesler 2011) (see Appendix C)
8. Illiniois DOTs spreadsheet for bonded concrete inlay/overlay of asphalt design (Roesler et al. 2008) 5-25
Design Methods for Concrete Overlay
Mechanistic-Empirical Procedures
AASHTO Pavement ME (2011)
IDOT (2009) / Pitt BCOA ME (2013)
ACPA StreetPave 12 (2014)
Federal Aviation Administration -Airfield
Empirical Method
Effective thickness approach (AASHTO 1993)
Dn0L = Dnf - (Deff)n
Df = new concrete thickness
Deff = effective thickness
n = 1 for bonded; n = 2 for unbonded
Bonded Concrete Overlay of Asphalt
AASHTO 1993
Not applicable

AASHTO Pavement ME (2011)

Thickness 6 in.
Unbonded Concrete
Overlay of HMA
Slab length 10ft

ACPA (2012);IDOT (2009);Pitt BCOA ME (2013)

Ultra-Thin Whitetopping
Thickness 6 in. http://apps.acpa.org/apps/bcoa.aspx

Slab length 6ft

Thin Bonded Concrete Overlays of Asphalt
Pavements (UTW) Relatively Thin Slabs
(3 to 6 in)
Square Slabs
(4ft by 4ft to 6ft by 6ft)

Milled
Surface
preferred
BCOA Critical Locations (Concrete and AC Layers)

40kN 40kN

PCC
t EPCC
t hPCC

HMA EAC, AC AC hAC

Bonded
Base

Subgrade k-value
Fibers
Structural vs. non-structural (plastic shrinkage)

5
4

Load (kN)
3
2
1
Structural 0
Macro-Fibers 0 10 20 30 40
CMOD (mm)

Micro-Fibers
(non-structural)
 Concrete Thickness Calculation
PCC Inlay / Overlay Design Sheet, Required Thickness of PCC Default Inputs
Help Variable Default Value
Design Traffic Factor (BDE Manual, Figure 54-4C) TF 2.50
Modulus of Rupture (3-point bending, 14-day average) MOR 750 psi MOR 750 psi (Note 1)
150
FRC Residual Strength Ratio R150 20% 0% (w/o fiber reinforcement)
150
R150
Remaining Thickness of Asphalt h ac 3.0 in. 20% (w/ fiber reinforcement)
Joint Spacing L 72 in. L 48 in. or 72 in.

Elastic Modulus of Concrete Ec 3,600,000 psi Ec 3,600,000 psi

-6
Coefficient of Thermal Expansion CTE 5.50E-06 in./in./F CTE 5.50 x 10 in./in./F
Elastic Modulus of Asphalt E AC 350,000 psi 100,000 psi (poor)
Modulus of Subgrade Reaction k 100 pci E AC 350,000 psi (moderate)
600,000 psi (good)
k 100 pci
Compute Concrete
Thickness of Concrete hc 5.48
in. Thickness
Solved

Note 1: The design MOR is the mean design strength, not the minimum 550 psi flexural strength (center-point loading)
specified for opening to traffic. Also note that as MOR increases the risk of debonding increases and the effectiveness of
synthetic fibers decreases.

http://www.dot.state.il.us/desenv/pdp.html
 Asphalt Modulus (Eac)
6

5 k = 100 pci
Concrete Thickness hc (in)

MOR = 650 psi

4
R150 = 0%
Eac = 100,000psi
3 Eac = 350,000psi hac = 3 in
Eac = 600,000psi
L = 4 ft
2
T/h = -0.65 F/in
1
35 % time

0
1E+04 1E+05 1E+06 1E+07
ESALs
 Effect of Asphalt thickness
6

5
k = 100 pci
Concrete Thickness hc (in)

4 MOR = 650 psi

hac = 3 in
hac = 4 in R150 = 0%
3
hac = 5 in Eac = 350,000 psi
hac = 6in
2 L = 4 ft
T/h = -0.65 F/in
1
35 % time

0
1E+04 1E+05 1E+06 1E+07
ESALs
R150= Residual Strength Ratio Concept
6

5
k = 100 pci
MOR = 650 psi
Concrete Thickness hc (in)

4
R150,3 = 0%
Eac = 350,000 psi

3
R150,3 = 15% hac = 3 in
R150,3 = 20%
R150,3 = 25% L = 4 ft
2
T/h = -0.65 F/in
1 35 % time

0
1E+04 1E+05 1E+06 1E+07
ESALs
 Effect of Slab Size (L)
8

7 k = 100 pci
MOR = 650 psi
Concrete Thickness hc (in)

5 R150 = 0%
L = 12 ft
Eac = 350,000 psi
4 L = 6 ft
L = 4 ft hac = 3 in
3
T/h = -0.65 F/in
2
35 % time
1

0
1E+04 1E+05 1E+06 1E+07
ESALs
ACPA Bonded O/L of Asphalt

http://apps.acpa.org/applibrary/BCOA/ (2012)
Hamilton County, IL (Sept. 16, 2014)
FRC UTW (4 in.)
Existing Asphalt Concrete (3 in.)
Cement Treated Soil (8 in)
Natural Soil
Built in 9/2014

Built in 9/2014

Built in 2013
 BCOA ME failure modes 10 x 12 ft
5 to 7 ft 12 x 12 ft
< 4.5 ft Long. & Diag 12 x 15 ft
Corner Break Crack Trans. Crack

Positive T
Negative T Positive T

Vandenbossche (2013)
Pitt BCOA-ME
PCA Model
Stress for corner
Jt. Spacing cracks
< 4.5 ft
ACPA Model
Jt. Spacings
5 to 6 ft Stress for long. & Fatigue
Inputs hpcc
diag. cracks model
Pitt Model
Jt. Spacings
10 x 12 ft Stress for trans.
12 x 12 ft cracks
15 x 12 ft
CDOT Model

Vandenbossche (2013)
 Joint spacing Vandenbossche (2013)

7 ACPA- 4 ft x 4 ft
BCOA-ME- 4 ft x 4 ft
6 BCOA-ME- 6 ft x 6 ft
PCC thickness, in

BCOA-ME- 12 ft x 12 ft
5

1
HMA = 6 in

0
1,000 10,000 100,000 1,000,000 10,000,000
ESALs
University of Pittsburgh Department of Civil & Environmental Engineering
Guide to Concrete
Overlays of Asphalt
Parking Lots (2012)
Contents:
Parking Lot Features

Existing Pavement
Condition
Concrete Overlay
Design
Jointing

Parking lot details

Materials

Construction

Fibers

www.rmc-foundation.org/images/Concrete_Overlay_Guide_11-14-12.pdf
Surface Preparation
Milling AC surface.
Remove rutting
Restore profile
Enhance bond
Minimum AC thickness
remaining after milling:
6.5 cm
Surface cleaning
Waterblast - preferred
Sweeping
 Bonded Concrete Overlay

Excellent
Interface
Bond
Concrete Overlay hol

Existing Concrete he
Pavement
Bonded Concrete O/L Design Methods
AASHTO Pavement ME (2011)
Slab thickness based on following:
Slab geometry, climate, structure, concrete
material and layer properties
Complete interface bond
hol = hf - heff

AASHTO 1993
Dol = Df - Deff
AASHTO Pavement ME: Bonded Concrete
O/L Design
JPCP or CRCP type
Full interface bond
Traffic load spectra
Climate - local
Structure - layers
% Cracked slabs
Materials
Existing concrete layer stiffness
AASHTO 1993: Bonded Concrete O/L Design
Dol
Dol = Df Deff Deff
Df

Base

Subgrade

Deff = Fjc*Fdur*Ffat*D
Df = new slab thickness
D = existing slab thickness
Fjc = Joint and cracks adjustment factor
Fdur = Durability adjustment factor:
Ffat = Fatigue damage adjustment factor
Surface Preparation
Bond is Critical
Curing Management
Waterblasting

Milling

Shotblasting
Unbonded Concrete Overlay Options
Thicker concrete overlays
Unbonded Overlay Option
than bonded.

Constructed on existing Unbonded Unbonded Unbonded

concrete, asphalt, or Concrete Concrete Concrete
Resurfacing Resurfacing Resurfacing
composite pavements. of Concrete of Asphalt of Composite
Pavements Pavements Pavements

Bond is NOT considered

in the design.

Slab sizes vary depending

Whitetopping
on type of design
Unbonded Concrete Overlays of
Existing Concrete Pavements

Pavement evaluation establishes whether existing concrete and subbase can provide uniform
support and, if not, what actions are necessary to obtain that uniformity.
Look for movement in the slab. Profile is a good check.
Unbonded Concrete Overlay Software Programs

Recommended Design Procedures (see previous page for links)

3. Guide for Design of Pavement Structures. 4th ed. (AASHTO 1993)
4. Mechanistic-Empirical Design GuideA Manual of Practice (AASHTO 2008)
5. StreetPave (ACPA 2012) 5-53
6. Optipave V2.0. (TCPavements 2010) Concrete Overlay Guide (Harrington et al. 2014)
Unbonded Concrete Overlay of PCC

Concrete Overlay hol

Existing Concrete he
Pavement Separator
layer

- Asphalt Concrete Interlayer 5cm

Unbonded Concrete O/L Design Methods
AASHTO Pavement ME (2011) or MEPDG
Slab geometry, climatic factors, concrete
material and layer
Assumes unbonded interface without friction

AASHTO (1993)
D20L = D2f - (Deff)2

StreetPave 12
Separation Layer
Good Performance.
Isolate overlay from existing
pavement:
Prevent reflection cracking.
Prevent bonding/mechanical
interlocking.
Provide level surface for overlay
construction.
Interlayer material:
2.5 to 5cm dense-graded HMA.
GEOTEXTILE (Missouri 2008)
AASHTO 1993: Unbonded Concrete O/L
D2ol = D2f D2eff
Dol
Separator Layer
Deff
Base
Subgrade

Deff = Fjcu*D
D = existing slab thickness

Fjcu = Joint and cracks adjustment factor

I-57/I-64 Alternatives (2010-2013)
HMA overlay of existing CRCP
Rubblization with HMA
JPCP and CRCP options
MEPDG & IDOT designs
Milling options vs. rubblization
Interlayer type
Thickness options
Poor Section I-57/I-64 NB
MEPDG CRCP Overlay: Inputs
20-year design life
Mattoon-Charleston, IL Climate
ESALs
80x106
A-7-6 soil type
k=200 psi/in
Tied concrete shoulder
40 to 80% LTE
CRCP Steel properties
3.5 inch depth; #6 bar; 0.7% steel content
MEPDG CRCP Design: Results
New CRCP = 11 inches
HMA base unbonded = 4inches

Unbonded CRCP = 9 inches

AC base interlayer = 2 inches
CRCP (existing) = 8 inches

Unbonded CRCP = 10.5 inches

HMA interlayer = 1 to 2 inches
CRCP (rubblized) = 8 inches
I-57 / I-64 Mt. Vernon (2011-2013)
Mill existing HMA overlay
Rubblize existing 8-inch CRCP
Place 3-inch HMA interlayer
10.5-in. CRCP overlay w/ 0.7% steel
2012 Unbonded CRCP Overlay (I-57)
Unbonded Concrete O/L of Asphalt Concrete

Dol = Df

Dol = Df
Existing Asphalt
Base
Subgrade

Df = new concrete slab thickness

Unbonded Bonded Concrete O/L of Asphalt

AASHTO Pavement ME (2011)-whitetopping

Thickness > 6 inches

Slab length > 10ft

OptiPave 2.0 (2012) - TCPavements

Short jointed slab systems

Slab sizes < 10ft & thickness 2 in.

AASHTO 1993
Existing asphalt treated as base layer
(Thin) Unbonded Concrete O/L
Interlayer or thicker slab required relative to
BCOA
Empirical designs to date in U.S.

TCPavements, Inc. (2007) Chile, S.A.

OptiPave 2.0 (2012)
Only current design method for short jointed
unbonded concrete overlay
Final Day Paving
Oak Park, July 2001

10 cm Fast-Track Unbonded, Steel-Fiber

Reinforced Concrete Inlay
Mirafi 500N Woven Geotextile
Pavement Depth
Oak Park, IL: Marion Street (2001)
10 cm concrete over original concrete layer
UNBONDED- woven geotextile placed between the layers at the time
of casting
2.0m x 1.5m panels
24 kg/m3 crimped steel fibers

2012
What is Flowable Fibrous Concrete (FFC)?
Ultra-Thin
Whitetopping
Flowable Fibrous
Concrete Cost-Effective
Thin Pavement

Conventional
Paving Mixture

HPFRSCC
Self- (ECC)
Consolidated
Ease of
Concrete
Placement
Fiber-
Reinforced
High Toughness/
Concrete
Reduced Cracking 71
Flowable Fibrous Concrete (FFC) for Thin
Pavement Preservation Inlays
Lower speed applications
Slab thickness < 8 cm
10-year service life
Concrete wearing surface (Preservation)
Asphalt-concrete bond essential
Loads transmitted to substrate layers
Other sustainability enhancements:
Reflectivity, skid, air pollutant reducer
Bordelon & Roesler (2010)
 FFC Field Project (ATREL)
Ensure Good Bond with Underlying HMA
Milled and cleaned surface
Measured the FFC inlay bond with 10 cm diameter core, sheared off at greater
than 500 Nm torque (HMA overlays typically ~400 Nm)

Check Workability & Constructability of FFC

Placed 5 cm thick inlay directly from truck
Vibrated with screed and bull float finish

Joint Cracking Monitored

Slabs sawcut at spacing 1.1 to 3.4 m (4 to 11 ft)
Crack widths average from 0.4 to 1 mm wide after 20 days
Field Demonstration 2in (5 cm)
 Fiber Alignment Sthli et al., Mat&Sci 2008

Due to boundary surface

Fiber packing along wall
Due to flow direction
Fibers oriented parallel with flow direction (Torrijos et al. 2009; Zerbino et
al. 2011)
FFC placed randomly or with directional flow into thin plate
Bordelon (2011)
Polar Angle (degrees from vertical)
overall = 80 0 15 30 45 60 75 90
0
Diatance from cast surface

12
Directional Flow
24
(mm)

overall = 76
36
90 Polar Angle =
48 Fibers aligned fibers in 2D plane
Random Placement
Concrete Overlay: Summary
Existing pavement condition assessment
Select new concrete pavement type
Define interface assumption
Available structural design methods
AASHTO Pavement ME (2011)
ACPA (BCOA Calculator & StreetPave12)
Pitt BCOA ME
FAARFIELD- airfield
Construction details essential!!
Questions?

141 fibers 131 fibers

Bordelon (2011)
Acknowledgements
Illinois Department of Transportation
Illinois Center for Transportation
www.ict.illinois.edu
Randell Riley
IL-ACPA
Amanda Bordelon
Asst. Prof. @ University of Utah
National Concrete Pavement Technology Center
Dale Harrington
American Concrete Pavement Association (ACPA)
Rob Rodden
Daniel King (2012-2015)
Research Assistant, UIUC
Dr. Julie Vandenbossche
University of Pittsburg
 Annotated Bibliography
Harrington, D. et al. (2012), Guidance for the Design of Concrete Overlays
Using Existing Methodologies, National Concrete Pavement Technology Center,
Iowa State University, Ames, IA.
Roesler, J. R., Bordelon, A., Ioannides, A. M., Beyer, M., and Wang, D. (2008),
Design and Concrete Material Requirements for Ultra-Thin Whitetopping, Final
Report, Illinois Center for Transportation Series No. 08-016, University of
Illinois, Urbana, IL, 181 pp.
Rasmussen, R., Rogers, R., Ferragut, T. (2009), Continuously Reinforced
Concrete Pavements Design and Construction Guidelines, FHWA-CRSI.
Harrington, D. et al. (2014), Guide to Concrete Overlays Sustainable Solutions
for Resurfacing and Rehabilitating Existing Pavements, National Concrete
Pavement Technology Center, Iowa State University, Ames, IA.
Smith, K.D., H. Yu, D. Peshkin, (2002), Portland Cement Concrete Overlays:
State of the Technology Synthesis, Federal Highway Administration,
Washington, DC.
Vandenbossche (2011) Development of a Design Guide for Thin and Ultrathin
Concrete Overlays of Existing Asphalt Pavements, TPF-5(165)