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DESIGN MANUAL FOR ROADS AND BRIDGES

Your attention is drawn to Interim Advice Note 29, VOLUME 7 PAVEMENT DESIGN AND
which has been issued by the Highways Agency for MAINTENANCE
use on trunk roads and motorways in England. SECTION 2 PAVEMENT DESIGN AND
Click here to view this Interim Advice Note. CONSTRUCTION

PART 3

HD 26/94 AMENDMENT NO 3

DESIGN CRITERIA

SUMMARY
This amendment consists of a revised Chapter 5 to
HD 26/94. The changes reflect the latest understanding
about how flexible pavements deteriorate and gives
advice on terminology.

INSTRUCTIONS FOR USE


1. Remove existing Chapter 5 from Volume 7,
Section 2, Part 3 and archive as appropriate.

2. Insert revised Chapter 5 into Volume 7, Section 2,


Part 3.

3. Archive this sheet as appropriate.

Note: A quarterly index with a full set of Volume


Contents Pages is available separately from The
Stationery Office Ltd.

February 1998
Volume 7 home page
DESIGN MANUAL FOR ROADS AND BRIDGES HD 26/94
incorporating Amendment
No. 3 February 1998

THE HIGHWAYS AGENCY

THE SCOTTISH OFFICE DEVELOPMENT


DEPARTMENT

THE WELSH OFFICE


Y SWYDDFA GYMREIG

THE DEPARTMENT OF THE ENVIRONMENT FOR


NORTHERN IRELAND

Design Criteria

Summary: This amendment consists of a revised Chapter 5 to HD 26/94. The changes


reflect the latest understanding about how flexible pavements deteriorate
and gives advice on terminology.

Volume 7 home page


Volume 7 Section 2
Part 3 HD 26/94 Amendments

AMENDMENT NO. 3 (FEBRUARY 1998)


Replacement Pages

Page number Date

Chapter 5 - Pages 5/1 - 5/4 February 1998

The replacement front sheet supersedes that dated March 1995. The superseded pages should be archived as
appropriate.

Implementation

The replacement pages should be used forthwith on all schemes for the construction, improvement and maintenance
of trunk roads, including motorways.

February 1998
Volume 7 home page
DESIGN MANUAL FOR ROADS AND BRIDGES

VOLUME 7 PAVEMENT DESIGN


AND MAINTENANCE
SECTION 2 PAVEMENT DESIGN
AND CONSTRUCTION

PART 3

PAVEMENT DESIGN

Contents

Chapter

1. Introduction

2. Design Implementation

3. Roadbase Materials

4. Surfacing Materials

5. Design Criteria

6. The Analytical Approach

7. References and Bibliography

8. Enquiries

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I
Volume 7 Section 2 Chapter 1
Part3 HD 26194 Introduction

1. INTRODUCTION
General
1.1 This part details the materials and
thicknesses to be used for new pavement
construction, covering all standard pavement types.
It reviews the principles of design which have been
used, as well as mentioning the cost implications
and those environmental considerations which most
closely affect pavement design. It does not include
the estimation of design traffic [HD 24 (DMRB
7.2.1)], nor does it cover the design of pavement
foundations [HD 25 @MRB7.2.2)].

Implementation

1.2 This Part shall be used forthwith on all


schemes for the construction, improvement and
maintenance of trunk roads including motorways,
currently being prepared provided that, in the
opinion of the Overseeing Department this would
not result in significant additional expense or delay.
Design organisations should confirm its application
to particular to particular schemes with the
Overseeing Department.

Mutual Recognition

1.3 The construction and maintenance of


highway pavements will normally be carried out
under contracts incorporating the Overseeing
Department’s Specification for Highway Works
(MCHWI). In such casesproducts conforming to
equivalent standards and specifications of other
member states will be acceptable in accordance with
the terms of the 104 and 105 Series of Clauses of
that Specification. Any contract not containing
these Clauses must contain suitable clauses of
mutual recognition having the same effect regarding
which advice should be sought.

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ChaptPr 1 Volume 7 Section 2
Introduction Part 3 HD26/94

AIL ANALYTICAL
DESIGN

l/2 January 1994

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Volume 7 Section 2 Chapter 2
Part 3 HD26/94 Desien lmolementation

. 2. DESIGN IMPLEMENTATION
PAVEMENTTYPES

2.1 Four types of pavement are Thicknesses depend on the design traMc see
speclt%d by the Department, as follows:- HD 24 (DMRR 7.2.1). The thickness shall be
rounded up to the nearest Smm in each case.
Flexible; the surfacing and roadbase The thicknesses and permitted materials for
materials are bound with bituminous wearing course and basecourse are also given
binder. Permitted roadbase materials are in the notes to Figures 2.1 - 2.4.
as follows:-
Dense Bitumen Macadam (DBM)
Hot Rolled Asphalt (HRA)
Dense Tar Macadam @TM) Other Details
DBM + 50 penetration bitumen (DBMSO)
Heavy Duty Macadam (DDM) 2.4 For light and medium traffic levels, DBM,
HRA and DTM roadbase are considered to be of
a Phxible Comuosite; the surfacing and
upper roadbase materials are bound with
similar quality, their differing strengths and weaknesses
cancelling out. For this reason, a single design line is
bituminous binder on a lower roadbase of used for all three materials. However, for the heaviest
cement bound material (CBM). traffic loading categories (> 80 msa), the designs in
Figure 2.1 incorporate a l25mm lower roadbase layer
R&& concrete surface slabs in the of HRA, since it is easier to lay and compact than
following categories:- either DBM or DTM above an unbound granular
sub-base material, and is also better suited to sustain
Unreinforced Concrete (URC) the horizontal tensile strains present at this level.
Jointed Reinforced Concrete (JRC) DBM or DTM roadbase, both of which have slightly
Continuously Reinforced Concrete better deformation characteristics than HRA, is retained
(CRW for the upper roadbase to give the best resistance to
deformation in the zone which experiences higher
d Comuositg; continuously reinforced temperatures and shear stresses. Where DBM50 or
concrete roadbase (CRCR) with HDM roadbase is used, studies have shown the
bituminous surfacing. inclusion of an HRA lower roadbase to give no benefit.

a 2.5 Individual construction widths of


CBM roadbase shall not exceed 4.75m. This
2.2 For the design of a particular minimises the risk of longitudinal cracking
project there may be technical reasons induced by combined stresses in a flexible
why one or more of these pavement types composite pavement designed with
is preferred. However, in most cases, indeterminate life, (i.e. 200 mm of
designs shall be carried out for all bituminous material over 250 mm of CBM3
permitted options. or 230 mm of CBM4 - see Chapter 5).
Highway Construction Details (TWHW3) give
example joint layouts. Flexible composite
roads with determinate life (Le. thinner
lICKNESS construction) are more likely to deteriorate
by general cracking; consequently restricting
2.3 Flgurea 2.1- 2.4 give the the individual laid width will not necessarily
pavement material thickmuses appropriate lead to improved performance.
to each roadbase type.

a
InnWY 1994 2/l

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chapter 2 Volume 7 Section 2
Design Implementation Part 3 I-ID 26194
Volume 7 home page
FIGURE 2.1 Design Thicknesses for Flexible Pavements
2l2 January 1994
Volume 7 Section 2 chapter 2
Part 3 HD 26/94 Design Implementation

Notes on figure 2.1:- 9. Bituminous basecourse materials, and


roadbase materials where traffk
1. Bituminous surfacing shall consist exceds 8Omsa, shall wntain crushed
of either 45mm or SOmm of HRA rock, or slag coarse aggregate, unless
wearing course or 50mm of PA local experience exists of the
wearing wurse. For HRA successful use of gravel. For DTM
wearing wurse refer to Clause 911 basecourse the fine aggregate shall
of the Specification (MCHWl), to also be crushed rock or slag.
BSS94 Part 1: 1992: Annex B:
Table Bl - for references to 10. A DBM/HRAiDTM design for traffk
stability and flow values related to over 8Omsa shall include a 125mm
traflic loading. Design values for lower roadbase lnycr of HRA with
Scotland are given in the DBM/DTM as the remainder of the
Overseeing Department’s special roadbase material.
requirements in Clause
NG911S.SO (TWXW2).

2. IfPAistobeused,its
contribution to the bituminous
material design thickness is 20mm.
For PA refer to HD 27 (DMRB :sign Traffic 65 msa
7.2.4). dIa b
:sign Thickness 32omm
3. A 6Omm dense basewurse is
required beneath PA wearing Itions:-
wurse. 45mm HRA w/c*
55mm HDM or DBMS0 b/c
4. A basecourse is optional beneath 220mm HDM r/b
an HRA wearing course. If used
it shall be SOmm or 55mm thick, 45mm HRA w/c*
of any permitted material, except 275mm HDM r/b
see note 5.
50mm Porous Asphalt w/c
5. Either HDM or DBMS0 6Omm HDM or DBMS0 b/c
basecourse shall he used over 240mm HDM r/b
HDM or DBM50 roadbase.
The contractor may choose to lay 50mm HRA
6. HRA roadbase and basecourse wearing course (see Paragraph 2.6).
shall wntuin 50 penetration grade
hinder.

7. DBM roadbase and basecourse


shall wntain 100 penetration
grade binder.

8. DTM roadbase and basecourse


shall wntain CSO or C54 grade
Tar.

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chapter 2 Volume 7 Section 2
Design Implementation Part 3 HD 26/94
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FIGURE 2.2 Design Thicknesses for Flexible Composite Pavements
214 January 199;1
volu”le 7 section 2 Chapter 2
Part 3 HD 26/94 Design Implementation

Notes on Figure 2.2:- permitted as an alternative. In


Scotland the minimum thiclmess of
1. Bituminous surfacing shall consist CBM3 or 4 shall be 175mm.
of either 4Smm or 50mm of HRA I
wearing course. For HRA
wearing course refer to Clause 911
of the Specification (MCHWl), to
Bs594 Part 1: 1992: Annex B: Examnle
Table Bl for references to stability
and flow values related to traffic Design Traffic I3 msa
loading. Design values for Design Thicknesses 14Omm bituminous
Scotland are given in the 220mm CBM3
Overseeing Department’s special
requirements in Clause Options:-
NG91lS.SG (T+KDWZ). a) 45mm HRA w/c*
55mm DBM, DTM or HRA b/c
2. A basecourse is optional beneath 40mm DBM, DTM or HRA rib
an HRA wearing course. If it is 220mm CBM3
used it shall be at least 50mm
thlclt, of any permitted material. b) 45mm HRA w/c*
95mm DBM, DTM or HRA r/b
3. Where a bituminous roadbase is 220mm CBM3
required, it may be of any * The contractor may choose to lay 50mm HRA
permitted material.
wearing course (see paragraph 2.6).
4. HRA roadbase and basecourse
shall contain 50 penetration grade
binder.

5. DBM roadbase and basecourse


shall contain 100 penetration
grade binder.

6. DTM roadbase and basccourse


shall contain C50 or C54 grade
Tar.

7. Bituminous basecourse materials


shall contain crushed rock, or slag
coarse aggregate, unless local
experience exists of the successful
use of gravel. For DTM
basecourse the line aggregate shall
also be crushed roch or slag.

a. Cement Bound Material from


Figure 2.2 shall be CBM3 except
that, where the design tbiclcness is
greaterthan23Omm,thena
23Omm layer of CBM4 shall be

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chapter 2 Volume 7 Section 2
De@ Implementation Part 3 HD26/!M
I.

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I I I I I I I III n
FIGURE 2.3 Design Thicknesses for Rigid Pavements
216 January 1994
ExamDIe
Notes on Flpre 2.3~
Design Traffic I40 msa
1. Maximum transverse joint Pavement Type JRC
spacings - URC pavements:- Reinforcement 5OOmm*/m
Design Thickness 260mm
For slab thickness up to Transverse Joint Spacing 27m
(a)
230mm

- 4m for contraction joints


- 40m for expansion joints

(b) For slab thickness 230mm


and over

- 5m for contraction joints


- 60m for expansion joints

2. The maximum transverse joint


spacings for JRC pavements shall
be 25m except for slabs having
6OOmm* reinforcement or less,
where the maximum joint spacing
shall be read from the insert to
this figure. Every third joint shall
be an expansion joint, the
remainder being contraction
joints.

3. Intermediate values of slab


thichness, longitudinal
reinforcement area, and maximum
transverse joint spacing, for JRC
pavements, may be interpolated.

4. All transverse joint spacings, for


both URC and JRC pavements,
may be increased by 20% if
limestone coarse aggregate is used
throughout the depth of the slab.

5. Refer to the Specillcation (Series


1000) for periods when contraction
joints may be substituted for
expansion joints.

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chapter 2 Volume 7 Section 2
Design Implenwntation Part 3 I-ID 26/94
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FIGURE 2.4 Design Thicknesses for Continuous Rigid and Rigid Composite Pavements
2/g January 1994
Volume 7 Section 2 Chapter 2
Part 3 HD26/94 De&n Implementation

Notes on Figure 2.4:- area, comprising 16mm diameter


deformed steel bars. If required,
1. Bituminous surfaclng to CRCR transverse reinforcement shall be
pavements shall be either 45mm or 12mm diameter bars at 600mm
50mm of HRA wearing course spacings, for both CRCP and CRCR.
over 55mm or 50mm of DBM,
DTM or HRA basecourse, or 9. Longitudinal reinforcement in CRCR
5Omm of porous asphalt over pavements shall be 0.4% of the
either 60mm or !Mtmm of HRA concrete slab cross-sectional area,
basecourse (see note 2). For I-IRA comprising 12mm diameter bars.
wearing course refer to Clause 911
of the Specltication (MCHWI) to 10. Anchorages shall be provided in
BS594 Part 1: 1992: Annex B: CRCP pavements at ends and any
Table Bl for reference to stability discontinuities in the pavement
and flow values related to traffic (ground beam or steel beam).
loading. Design values for
Scotland are given in the 11. No anchorages are required in CRCR
Overseeing Department’s special pavements.
requirements in Clause
NG9llS.SO (MCHW2).

2. If PA wearing course is used,


either the basecourse shall be Examole
thickened to 90mm QI the CRCR
shall be increased by 10mm. Design Traffic 170 msa
Pavement Tvne CRCP
3. HRA basecourse shall contain 50 Desigc Thickness 230mm
penetration grade binder.
Optionx-
4. DBM basecourse shall contain 100
penetration grade binder. a) 45mm HRA w/c*
55mm DBM, DTM or HRA b/c
5. PA wearing course shall contain 230mm CRCR
modified binder.
b) 50mm Porous Asphalt w/c
6. DTM roadbase and basecourse 90mm HRA b/c
shall contain C50 or C54 grade 230mm CRCR
Tar.
d 50mm Porous Asphalt w/c
7. All bituminous basecourse 60mm HRA b/c
materials shall contain crushed 240mm CRCR
rock, or slag coarse aggregate, * The contractor may choose to lay 50mm HRA
unless local experience exists of the
successful use of gravel. For DTM wearing course (see Paragraph 2.6).
basecourse the ftne aggregate shall
also be crushed rock or slag.

8. Longitudinal reinforcement in
CRCP pavements shall be 0.6% of
the concrete slab cross+eetional

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chapter 2 Volume 7 Section 2


Design Implementation Part 3 HD 26194

2.6 If HRA wearing course is specified 2.11 Roth CRCP and CRCR shall he
then the contractor shall be offered the included as alternative pavement
option of either 45mm or SOmm eonstrudions where the design traffk loading
tbiclmessm wRb no overall reduction in exceeds 30 msa. Roth may be included in
the bituminous bound layers. Also SW Contracts with design trafilc loadings lower
HD27 (DMRR 7.2.4.4). than this figure where their advantages are
considered worthwhile. One of the
advantages is the elimination of transverse
joints with their continuing maintenance
liability.
2.7 In the case of JRC pavements, 4 I
design alternatives shall be given
corresponding to the 4 design curves
shown on Figure 2.3 for different
quantities of longitudinal reinforcement. 2.12 CRCP pavements develop a fine transverse
crack pattern soon after the concrete is laid. Initially
the crack spacing is about 3 or 4m. Further cracking is
usual after the road has been in service for a time.
The continuous longitudinal reinforcement holds the
2.8 Pigures 2.3 and 2.4 assume the cracks tightly closed, ensuring load transfer by
presence of a lm hardstrip or aggregate interlock and minimising corrosion of the
bardshoulder adjacent to the most heavily reinforcement. The crack propagation in CRCP
trafficked lane. Urban roads, and any pavements is closely related to the proportion of steel
other roads that do not have a lm and the strength of the concrete.
hardstrip or a hardshoulder adjacent to
the left hand lane will require thicker
slabs. The additional required thichness Additional Slab
is given in Figure 2.5. TrafRching of Tbicknws (mm)
right hand lanes and hardshoulders
dting future maintenance will be of
relatively short duration and need not be 4o1 I
considered in design.
35 4
30
2.9 Edge treatments and other construction
drawings are given in the Highway Construction 25
Details (MCHW3).
i..;:r;

!I
20 ’ I I I I
2.10 A separation membrane is 150 200 250 300 350
required between slPb and sub-base for Slab Design Tbickneaa (mm)
both URC and JRC pavements, mainly in
order to reduce loss of water from the
fresh concrete. It also helps to reduce the PIGURE 2.5 Additional Concrete Slab Thickness for
friction between the slab and the sub-base Pavements without lm Hardstrip
and thus inhibit the formation of mid bay
cracks.

I 2/10
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January 199d
Volume 7 ktlon 2 Chapter 2
Part 3 lID2q4 Design Implementation

2.13 The depth of reinforcement in the slab has


been chosen to reduce the risk of corrosion caused 2.16 The ends of CRCP shall either be
by salts penetrating the cracks. Transverse restrained by ground beam anchorages, or
reinforcement is only required for ease of movement is accommodated within wide
construction and may be omitted, except where flange steel beam expansion joints, to
there is a risk of differential settlement and where h ensure that forces are not transmitted to
is required to act as tie bars at joints in JRC structures and adjacent forms of
pavements The effect of the orientation of pavement construction by the expansion
transverse reinforcement is currently the subject of of the slab. Roth types are used in
research. There may be advantages in placing it at conjunction with transition slabs, as
an angle of less than 90” to the longitudinal shown in Highway Construction Details
reinforcement. The Overseeing Department should (MCHW3).
be consulted regarding the latest position.

2.14 Longitudinal steel may be welded or spliced


on site and positioned so that front loading of
concrete to a slip form paver is possible, provided 2.17 Ground beam anchorages shall not be
the bars are guided into the correct position in the used where the subgrade strength is poor,
slab through gates in the paver. If transverse especially on high embankments where
reinforcement is omitted from CRCP or CRCR, the consolidation may be insuffkient to restrain
interval between longitudinal joints should be movement of the beam downstands.
restricted to 4.2m (or Sm where limestone
aggregate us used).

2.15 The separation membrane is omitted from 2.18 A CRCP pavement can be considered as part of
CRCP construction to give a higher level of friction a staged construction, because it can be strengthened
between the concrete slab and the sub-base than for with a bituminous surfacing or a concrete overlay at a
jointed slabs. The restraint provided by the sub- later date. The implications for additional loading on
base reduces the amount of movement at the ends underbridges, clearance at overbridges, and problems
of the pavement and encourages the desired crack at wide-flange beam expansion joints should be
pattern. Discontinuities in the slab should be considered.
avoided wherever possible as they encourage the
formation of closely spaced cracks, with increased 2. I9 In rigid composite pavements, the bituminous
risk of spalling. Gullies and manholes should be surfacing helps to reduce water penetration into the
located outside the main CRCP slab for this reason. concrete slab and the potential for corrosion of the
If this is not possible, the slab around the gullies reinforcement. It also provides thermal protection
and manholes should be heavily reinforced as from rapid temperature changes for the concrete
shown in Highway Construction Details roadbase. A fully flexible transition zone is employed
(MCHW3). as shown in Highway Construction Details (MCHW3),
to minimise forces on structures.

2.20 In Figure 2.4, permitted rigid composite


pavements consist of continuously reinforced concrete
roadbase (CRCR) overlaid with at least 100 mm of
bituminous material. The use of only a wearing course
as bituminous surfacing material is not permitted as
experience suggests that the durability of a wearing
course laid directly on concrete would be insufficient to
achieve a maintenance free life of more than a few
years. In addition, anchorages would be required for
CRCR with just a wearing course surfacing, whereas
with I00 mm surfacing no anchorages are necessary,
because the slab is protectcal from large thermal
stresses.

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chapter 2 Volume 7 Section 2
Design Implementation Part 3 HD 26/P4

Ground Subject to Movement

2.21 Flexible composite and URC construction


are suitable in normal applications except where
differential movement, subsidence or appreciable
settlement are expected. This includes areas where
mines are currently worked, or may be worked in
the next 20 years. Flexible and JRC construction
are suitable in ah applications, except where large
differential movements or large settlements caused
by compressible ground, or considerable subsidence
caused by mining are expected. CRCP and CRCR
constructions are suitable in ail applications. They
may be particularly suitable where large differential
movements are expected because they can
accommodate significant strains while remaining
substantially intact.

Alternative Designs

2.22 If any pavement design other than


those given in this section is to be
considered, approval is required from the
Overseeing Department at the preliminary
design stage. Submissions seeking
approval for alternative designs shall
include a Justtftcation for the choice of
non-standard materials and/or
thicknesses, supporting calculations and
an indicatton of any additional
spedftcatton requtrements or testing
reghne whtcb may be necessary for their
validation. Analytical pavement design
(see Chapter 6) may be used in support of
Pwo=b.

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Volume 7 Section 2 chapter 3
Part 3 HD 26194 Roadbase Materials

3. ROADBASE MATERIALS
FLJZXIBLE FLEXIBLE COMPOSITE

3.1 Flexible pavements shall contain 3.8 The standard cement bound material
only those roadbase materials given in to be used in flexible composite design is
paragraph 2.1 of Chapter 2. Details of CBM3 (see Specification, (MCHWl), Series
composition, manufacture and laying of 1000). However, when the layer thickness
each are given in the Specification exceeds 230 mm, it may prove difficult to
(MCHWl) Series 900 and in British comply with the Specification with some
Standards. mixes and compaction plant. For this reason,
a 230 mm layer of CBM4 is considered to be
an adequate alternative and shall be offered,
so that the contractor can make a choice
3.2 The following brief descriptions outline the based on cost and the capacity of available
differing properties of the permitted roadbase plant.
alternatives.

3.3 DBM is a continuously graded material of


relatively low binder content (100 penetration RIGID AND RIGID COMPOSITE
grade). It is a deformation resistant material but
has leas resistance to fatigue cracking than the other
standard materials. 3.9 For all rigid and rigid composite
pavement alternatives the concrete slab shall
3.4 HRA is a gap graded material with be Pavement Quality Concrete @QC),
relatively high binder content (50 penetration manufactured, laid and cured in accordance
grade). It is easier to lay and compact than the with the Specification (MCHWl) Series 1000.
other materials, has good resistance to fatigue
cracking, but can be susceptible to deformation
under heavy traffic, especially when moving slowly
(eg uphill). 3.10 The factors influencing the performance of
rigid and rigid composite pavements include:-
3.5 m is a continuously graded material
with a greater percentage of fine material than a) Magnitude of wheel loading and position
DBM and a 50 penetration grade binder. It is less b) Underlying support to the surface slab
easy to lay and compact than DBM or HRA but has c) Temperature and moisture changes
the highest stiffness and good resistance to both d) Strength of concrete
fatigue cracking and deformation. e) Fatigue behaviour of concrete
n Thickness of surface slab
3.6 DBM5Q contains 50 penetration grade g) Amount of reinforcement
binder and has the composition of DBM. It has
marginally inferior properties to HDM, but is 3.1 I Load induced stresses at slab corners and edges
superior to 100 penetration DBM. are greater than in the slab centre, necessitating dowel
bars to distribute loads between slabs. Joint associated
3.1 DTM is similar to DBM but uses tar binder distress occurs principally when dowels do not function
grade C50 or C54. It is more temperature properly. The benefit of using a tied shoulder is
susceptible. apparent since the free edge is then remote from the
wheelpaths, with a consequent reduction in stress.

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chapter 3 Volume 7 Section 2
Roadbase Materials Part 3 I-ID 26/94

3.12 The stress generated in a concrete slab However, longitudinal joints are of the e type
partly depends on the stiffness ratio between the only. These tie the slabs together, and can be thought
slab and its underlying support. To maximise the of as acting as ‘hinges’ in the slab.
pavement life, all rigid pavements are specified
with a relatively stiff cemented sub- base. This
type of sub-base erodes less than an unbound
material and is leas water susceptible should joint
sealants fail.

3.13 Temperature and, to a lesser extent,


moisture changes cause shrinkage/expansion of the CONlXACllON
slab which, if restrained induce stresses in the
concrete. With the exception of continuously
reinforced concrete pavements a separation layer is
applied between the slab and underlying sub-base in
order to reduce this restraint. However the
non-uniform nature of temperature changes results
in slab curvature and their cyclic nature leads to
EXF’ANSION
stressreversal from day to night. These stresses
are restrained by the slab self weight and the dowel
bars.

3.14 Concrete is inherently strong in


compression, but weak in tension. Repeated
stressing will eventually load to crack initiation
unless the stress is very low. Thicker slabs result WARPINO
in lower stressesbeing generated under the
combined influence of vehicular and temperature
loading. - FIGURE 3.1 Joints in Concrete Pavements

3.15 A better distribution of loads occurs where 3.17 The permitted spacing of transverse joints is a
tbe concrete pavement extends lm or more beyond function of slab thickness aggregate type, and, for
the edge of lanes carrying commercial vehicles. JRC, the quantity of reinforcement. Joint spacing
This distribution occurs whether or not a reflects the capacity of the slab to distribute strain
longitudinal construction joint or wet-formed joint rather than allow damaging strain concentrations.
is included adjacent to the edge line as permitted by
Highway Construction Details (MCHW3). 3.18 Limestone aggregate has a lower coefficient of
thermal expansion than other aggregate types, resulting
Joints in Concre4e Pavements in less expansion/contraction of the slab. Therefore
greater joint spacings can be used. The effectiveness
3.16 Three different types of joints (see Figure of reinforcement, as a distributor of strain, increases
3.1) are used in concrete pavements. They are with tbe amount used. Greater joint spacings can be
contraction, expansion and warping joints, typical used with larger areas of reinforcement, although this
details of which are illustrated in Highway results in greater movement at each joint, necessitating
Construction Details (MCHW3). All three types appropriate selection of sealants.
permit warping movement. Contraction joints
enable the slab to shorten when its temperature falls
and allow the slab to expand subsequently by
approximately the same amount. Exoansion joints
allow the slab to shorten and also cater for the
expansion movement that would naturally occur at
temperatures higher than that of tbe concrete at the
time the slab was constructed. Transverse joints
are either expansion or contraction types.

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Volume 7 Section 2 chapter 4
Part 3 IID 26194 Surfacing Materials

4. SURFACING MATERIALS
Wearing Course

4.1 Except where con&e is used as 4.3 pA is an open graded material designed to
the surface layer, all Trunk Roads shall enable rapid drainage of surface water from the road,
he surfaced with a wearing course of reducing spray. It also reduces the effect of tyre noise.
either Hot Rolled Asphalt @IRA) or The material is inherently less stiff and durable than
Porous Asphalt (PA). Details of the HRA and a 50 mm layer contributes only 2Omm to the
composition, manufacture and laying of combined bituminous layer thickness. Further advice
each are given in the Specitication is given in HD 27 (DMRB 7.2.4.5).
(MCHWl) Series 900 and in British
Standards. The following paragraphs Basecourse
briefly describe the properties of each
material (see also Pigure 4.1). 4.4 A separate basecourse layer is optional under
an HRA wearing course, but should always be
provided under PA. The materials permitted are HRA,
DBM, DTM, DBMS0 and HDM. Only HDM or
DBMS0 basecourse may be used over HDM or
9 *ggregak DBMS0 roadbase respectively. Composition,
manufacture and laying details are given in the
m Binder / Sand / Filler Specification (MCHWI) Series 900 and in BS4987
(1988). A basecourse layer is classed as part of the
0 Void structural bituminous layer thickness given in Chapter
2. Consideration should be given to specifying the
maximum nominal particle size of the basecourse or
roadbase in relation to the layer thickness.

Porous

FIGURE 4.1 Wearing Course Materials

4.2 m is a gap graded material with high


binder content (50 penetration grade). It is dense
and has good resistance to fatigue cracking but can
be susceptible to deformation. The surface texture
is formed by rolling precoated chippings into the
asphalt mat. This technique requires careful
judgement to achieve the correct combination of
rate of spread and amount of rolling. An
excessively high spread rate leads to rapid loss of
chippings under trafftc. Excessive rolling produces
excessive embedment of the chippings into the
asphalt and consequent loss of texture depth. HRA
is sufficiently stiff and durable to be considered
structurally as part of the combined bituminous
layer thickness given in Chapter 2. Further advice
on laying HRA is given in HD 27 (DMRB
7.2.4.4).

lmmv 1994 4/l

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Volume 7 Section 2 Chapter 5
Part 3 HD 26/94 Design Criteria

5. DESIGN CRITERIA
BASIS OF THE DESIGN 5.6 Appropriate staged construction can minimise the
whole life cost and provide the required serviceable life.
5.1 The designs given in this chapter are based on the The first stage of construction for flexible composite
work of the TRL; in particular on the reports LR1132 pavements is normally designed for the traffic loading
(1984), for flexible and flexible composite construction, predicted to occur over 20 years. Major maintenance in
and RR87 (1987), for rigid and rigid composite the form of overlaying and/or partial reconstruction will
construction. They also take account of some later then be required to carry the traffic loading predicted to
research on new pavement materials. occur over the succeeding 20 years. In addition to major
maintenance, surface treatment in the form of surface
5.2 LR1132 is based on observations and dressing or resurfacing would be expected to be
measurements of full scale road experiments over a 20 required at about 10 years and 30 years. The period
year period, supplemented by structural analysis to until surface treatment is required will also vary
rationalise and extend the data. The analysis uses the depending on the site's requirement for skidding
elastic stiffness modulus of the various pavement and resistance. For some fully flexible pavements, the first
foundation layers, to calculate the strains developed stage would normally be 20 years as for flexible
within the structure. The strains are related to pavement composite pavements. However for many pavements
life. with heavy design traffic in relation to the capacity of
the layout, and for schemes where whole life costing
5.3 RR87 is largely empirical, based on the will be taken into account, a 40 year design life should
performance of full scale experimental roads. For be included as an option. A flexible pavement designed
continuously reinforced concrete there is little for a 40 year life should, with a well maintained
performance data and designs have been extrapolated surfacing, give a long life with little major maintenance
by a comparison between jointed unreinforced and required. Porous asphalt surfacing is likely to have a
reinforced concrete. For rigid composite structures, an shorter life than hot rolled asphalt. Therefore where
allowance has been made for the structural contribution porous asphalt is used, allowance should be made for
and thermal insulation effected by the bituminous more frequent maintenance. Rigid and rigid composite
surfacing. pavements are designed not to require major
maintenance for 40 years, although surface treatments
COST IMPLICATIONS and repairs will still be required.

5.4 A Whole Life Cost assessment of a pavement USE OF POROUS ASPHALT


considers the following elements:
5.7 A number of factors need to be considered before
Works Costs: using Porous Asphalt (PA) surfacing. Most decisions
a) New Construction will be based on a broad judgement, having regard to
b) Maintenance the objectives required for each site. It is not possible to
c) Residual Value quantify all the costs or benefits in monetary terms with
any degree of confidence. Judgement is still needed to
User Costs: interpret the results of any assessment. The following
a) Traffic Delay points should assist in deriving costs and benefits in
b) Accidents at Roadworks order that a decision can be made.
c) Skidding Accidents
d) Fuel Consumption/Tyre Wear Relative Costs
e) Residual Allowance
5.8 PA may be more expensive initially than
5.5 A minimum whole life cost is generally achieved conventional road surfacings, for the following reasons:
when a design life of approximately 40 years is
assumed. For this reason, the standard design life for all a) A greater quantity of high quality aggregates is
types of pavement, with appropriate maintenance, is 40 required, compared with rolled asphalt, to
years. maintain the required level of skid resistance.
Bitumen content is significantly reduced and pre-
coated chippings are not required, resulting in a
counter-balancing cost saving;

February 1998 5/1


Volume 7 home page
Chapter 5 Volume 7 Section 2
Design Criteria Part 3 HD 26/94

b) It also contributes less to the structural strength of 5.14 The Overseeing Organisation may be consulted
the pavement than conventional HRA surfacing for advice on the suitability of using PA in particular
increasing overall thickness of the pavement by circumstances. Further details on PA are contained in
approximately 25mm. The consequential effects HD 27 (DMRB 7.2.4.5) and also will be available in
of this increase on the earthworks and drainage HD 37 (DMRB 7.5.2)
design and their costs needs to be considered.
DEFINITIONS OF FAILURE AND
5.9 To determine the relative costs of surfacing INVESTIGATORY CONDITIONS
pavements with PA, compared with other materials, it is
necessary to take account of the durability of the 5.15 All pavements in this Volume are designed to
surfaces. PA may require replacement at an earlier date carry the traffic estimated to occur over 40 years, with
than hot rolled asphalt but current indications are that appropriate maintenance over that period. A well
the expected life can be in excess of 7 years (although it constructed flexible pavement though, that has been
is expected the use of modified binder will give longer built above a threshold strength, will have a very long
life expectancy), compared with about 10 years for structural life, provided that distress in the form of
rolled asphalt. There is no maintenance treatment for PA cracks and ruts appearing at the surface, is treated
surfacing if all the properties of the material are to be before it begins to affect the structural integrity of the
retained, other than replacement. The consequential road.
traffic delay costs brought about by this increased
frequency of maintenance treatment need to be taken Fully Flexible and Flexible Composite Pavements
into account in addition to those aspects already
considered above. 5.16 Appropriate maintenance for flexible (20 year)
and flexible composite (determinate) pavements
5.10 While the quantifiable benefits obtained may be includes a strengthening overlay after about 20 years -
modest, the use of PA is considered worthwhile on trunk when these pavements are expected to reach the onset of
roads at accident sites where skidding accidents, which the “investigatory” phase. Whole life costing studies
may have been attributed to wet weather spray, have showed that if these pavements are designed to reach
occurred. Although TRL research does not indicate a the investigatory phase after about twenty years, then an
strong link between accidents and spray on road overlay applied during the investigatory phase
surfaces in wet weather, the relative costs and benefits minimised whole life costs. It is for this reason that a 20
of reducing accidents at the site, need to be assessed for year initial design life to strengthening was chosen and
each case. why pavements are designed to carry the traffic loading
(in millions of standard axles - msa) estimated to occur
5.11 The use of PA in noise sensitive areas may reduce over this initial 20 year period.
noise from traffic travelling on high-speed roads. Any
extra cost associated with the use of PA at a site should Critical and Investigatory
be compared with alternative means of securing an
equivalent reduction in noise levels as, for example, 5.17 The term “critical” is no longer used. For
would be obtained by moving the line or level of the information on the relationship between “investigatory”
road or providing or increasing the amount of provision and “critical”, refer to Annex 3 of HD29 (DMRB
for noise barriers or noise insulation to affected 7.3.2). For flexible and flexible composite pavements,
buildings. the onset of critical conditions was defined as the stage
in the pavement’s life when the deterioration in its
5.12 The use of PA for noise reduction purposes on structural strength, as measured by its deflection,
trunk roads should only be considered where the became unpredictable. Critical was never a single
intention is to use PA at the outset and to re-use PA moment, but a period lasting some time, and was never
when renewal becomes due. Costs of the use and re-use meant to imply that a treatment was definitely required.
of PA should be taken into account when considering
relative merits of various forms of noise attenuation 5.18 In a similar manner, should treatment not be
(insulation, barriers, bunds, PA etc). Other low-noise carried out during the “investigatory” phase, there is a
surface options should always be considered. risk that subsequent deterioration will occur at an
increasing rate, and failure conditions rapidly reached.
5.13 A decision on whether or not to use PA should be This may require reconstruction of the whole
taken only after consideration of all the above relevant pavement. Whole life costing studies have shown that
factors. reconstruction will be less economic than intervention
during the investigatory phase, and the full design life

5/2 February 1998


Volume 7 home page
Volume 7 Section 2 Chapter 5
Part 3 HD 26/94 Design Criteria

to failure (20 mm rut or severe cracking) will not be d) The pavement deteriorates to a condition from
achieved. Because of the above risk, it is advised that a which it can be strengthened only by total
flexible or flexible composite pavement should usually reconstruction. Once this phase has been reached
be strengthened when 15% of a suitable treatment the pavement has reached “failure” conditions. It
length has entered the investigatory phase. On average, is important to realise however that such
up to 15% of such pavements, designed according to pavements may not need reconstruction
this Volume, can be expected to have reached the immediately, but will probably have several years
investigatory condition by the time the design traffic has of life left in them before maintenance is
been carried. required.

Residual Life During the second phase, the rate of deterioration can be
predicted with reasonable accuracy, but in the third
5.19 Residual life is the time period before a pavement phase, the rate of deterioration to structural failure is
is expected to enter its investigatory phase. Although difficult to forecast with any certainty. This does not
residual life is given in years it is dependent on the mean that the pavement is necessarily in immediate
traffic loading that the pavement has carried, an danger of failure - there may be many years of useful
estimate of future traffic loading it is likely to carry, and life left in it before a strengthening overlay is required.
the actual measured deflection. For example, a Pavements entering the third phase must therefore be
pavement may have been designed to carry 80msa in 20 monitored and investigated to ensure that any
years. If by year 12 it had carried 70msa, and is maintenance treatment is, in fact, required.
estimated to carry 10msa in the next two years, the
remaining life is not necessarily 2 years but will depend Flexible Composite Pavements
on the measured deflection and may indicate a total
carrying capacity greater or less than the 80msa design. 5.22 In flexible composite construction, transverse
shrinkage cracks will tend to occur in the cement bound
5.20 A pavement that has zero residual life is just at, material (CBM) roadbase very early in the life of a
or has passed into, the investigatory phase of its life. pavement. Observations have indicated that these
The rate of structural deterioration may stay the same or primary transverse cracks will not have a significant
decrease slowly or rapidly. At some time after a effect on the structural performance of the pavement,
pavement has entered the investigatory phase there will unless the soil beneath the sub-formation is moisture
be an optimum time at which to overlay. Unfortunately, susceptible. They are not therefore taken into account in
one cannot predict with certainty when this will occur; determining the onset of the investigatory phase even if
one can only monitor deflection and surface condition they reflect through the bituminous layers and become
trends, and look for changes which signal an increase in visible at the surface.
structural deterioration.
5.23 Typically, the combined effect of traffic and
Life Cycle temperature will result in a gradual deterioration of the
CBM roadbase from both secondary transverse cracking
5.21 There are four main phases of structural and longitudinal cracking, generally in the wheelpaths.
deterioration of a flexible pavement: Pavement designs where this gradual deterioration is
anticipated are described as having a “determinate” life,
a) A period when a new or strengthened pavement is and are designed on the same basis as fully flexible (20
stabilising; strength is variable but generally year) pavements, ie they are designed to reach the
increasing; investigatory phase of their life after about 20 years.
Some reconstruction and replacement of the roadbase
b) A period of stability when strength may remain may then be required together with a strengthening
stable or slowly increase or decrease, and the overlay to extend its life in a predictable manner.
pavement’s rate of structural deterioration may be
predicted with some confidence; 5.24 Research has shown that if the pavement is
designed so that the strength and thickness of the CBM
c) A period when a pavement’s structural roadbase are both sufficient to resist the combined
deterioration becomes less predictable. Strength effects of traffic and temperature, the roadbase will
may either continue as before or gradually or have a long but indeterminate life, and should not
rapidly decrease. Pavements entering this phase generally need replacement at the end of the first stage
should be monitored and investigated to ensure of the design life. Pavement designs of this type are
that the next phase is not reached; hence this
phase is termed the “investigatory” phase;
February 1998 5/3
Volume 7 home page
Chapter 5 Volume 7 Section 2
Design Criteria Part 3 HD 26/94

termed “indeterminate”. Designs for indeterminate life Rigid: Continuously Reinforced Concrete
are intended to be used for design traffic loadings Pavements. Rigid Composite (CRCR) Pavements
greater than 20 msa and/or where traffic delays due to
future maintenance are likely to be severe. 5.28 Since there are relatively few old examples of
Continuously Reinforced Concrete (CRCP and CRCR)
Rigid Pavements: Jointed Reinforced Concrete pavements of appreciable age in the UK, it is difficult to
Pavements define the condition expected at the end of the design
life. However, the period before the pavement requires
5.25 The failure condition of a Jointed Reinforced structural strengthening is expected to be at least the
Concrete (JRC) pavement represents the end of its design life, if designed in accordance with this Volume.
serviceable life, and the point where the rate of cracking Likely maintenance will be localised full depth repairs
begins to increase rapidly. At that stage the life of the for punchouts, and spalling of CRCP as well as surface
pavement might be extended by suitable strengthening treatments to restore skidding resistance for both CRCP
measures rather than excavation and complete and CRCR. The criteria for structural strengthening are:
reconstruction. During the life of the road, some
replacement of the concrete slabs will be required in a) When most cracks are wide, reinforcement is
addition to the resealing of joints and any arris and thin showing signs of corrosion; sub-base or subgrade
bonded repairs that may be required, see HD 32 is affected by water penetration;
(DMRB 7.4.2).
b) Settlement has resulted in a profile which
5.26 In Jointed Reinforced Concrete (JRC) pavements, seriously affects surface water drainage.
individual bays are judged to have failed when the
length of wide cracking per bay exceeds one lane width. SPECIAL CONSIDERATIONS
On average, up to 50% of bays can be expected to reach
the failure condition by the end of the design life. 5.29 A factor which is likely to be of primary
importance is the degree to which future maintenance is
Rigid Pavements: Unreinforced Concrete likely to cause disruption. In some cases, it may be
Pavements necessary to consider a slightly more expensive
pavement solution, to reduce traffic disruption
5.27 In Unreinforced Concrete (URC) pavements, associated with future maintenance works.
individual bays are judged to have failed if any one of
the following defects are present:

a) A medium or wide crack crossing the bay


longitudinally or transversely. A medium crack is
defined as greater than 0.5mm wide and
accompanied by a partial loss of aggregate
interlock across the fracture. A wide crack is
defined as greater than 1.5mm wide and
associated with complete loss of aggregate
interlock;

b) A medium longitudinal and medium transverse


crack intersecting, both starting from an edge and
longer than 200mm;

c) Wide corner cracking, more than 200mm radius


centred on the corner.

On average, up to 30% of bays can be expected to have


reached one of the failure conditions by the time the
design traffic loading has been carried.

5/4 February 1998


Volume 7 home page
Volume 7 Section 2 Chapter 6
Part3 HD26/94 The Analrtical Aooroach

6. THE ANALYTICAL APPROACH


6.4 Cracking of a bituminous layer arises from
6.1 The design charts presented in repeated tensile strain, e,, the maximum value of which
Chapter 2 have been developed from theoretically occurs near the bottom of the layer. The
work done on experimental roads but also crack, once initiated, propagates causing gradual
with the assistance of an analytical weakening of the structure and reduction in stiftitess
pavement design method. This chapter modulus.
outlines the general principles of
analytical design. However, the 6.5 For a lean concrete base or concrete slab, the
Overseeing Department must be consulted design criterion relating to fatigue cracking is
before such methods are used to produce maximum tensile stress (uJ at the bottom of the layer.
designs other than those given in Chapter In addition, for concrete slabs, in particular, the
2. enhanced stressesgenerated at edges or corners of the
bay are assessed. Using this method, the influence of
temperature induced stresses can also be considered.

6.2 The philosophy of the analytical approach 6.6 The development of a rut arises from the
to pavement design is that the structure should be accumulation of permanent strain throughout the
treated in the same way as other civil engineering structure. Its prediction is complicated and is still the
structures, the procedure for which may be subject of research. However, if the compressive
summarised as follows:- strain in the subgrade, &, is limited, experience has
shown that excessive rutting will not occur unless poor
a) Specify the loading. bituminous mix design or inadequate compaction are
b) Estimate the size of components. involved.
cl Consider the materials available.
d) Carry out a structural analysis using 6.7 The design task then, is to proportion the
theoretical principles. pavement strncture so that the critical levels of stress or
e) Compare critical stresses, strains or strain will not be exceeded in the design life. To
deflections with allowable values. achieve this, the designer needs information on the
0 Make adjustments to materials or geometry engineering properties of the materials, particularly:-
until a satisfactory design is achieved.
ia Consider the economic feasibility of the a) Effective stiffness modulus, which governs load
result. spreading behaviour.
b) Deformation resistance, which governs rutting
6.3 Figure 6.1 illustrates diagrammatically the behaviour.
two modes of failure caused by trafficking of a d Fatigue resistance, which governs cracking
pavement, which the designer seeks to avoid within behaviour.
the design life. The concept of a design life is
particularly important for pavements, since they do Procedure
not fail suddenly but gradually deteriorate over a
period of time. 6.8 Analytical pavement design relies upon the use
of a multi-layer linear elastic solution to the pavement
structure, generally using a sophisticated computer
program. A standard axle load (40kN wheel load) is
applied. Appropriate stiffness moduli have to be
chosen for the various pavement layers, either on the
basis of known mix properties etc. or from laboratory
or field tests. The relevant critical strains or stresses,
as described above, are found.

FIGURE 6.1 Critical Stresses and Strains

January 1994 6/l

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Chapter 6 Volume 7 Se&ion 2
The Analytiepl Approach Part3 HD 26194

6.9 Relationships between pavement life and


these critical strains or stresses have been derived
from a combination of laboratory testing and
pavement performance monitoring. The references
given at the end of this section all give such
relationships. However, it is generally necessary to
make further judgements, particularly regarding the
fatigue properties of the materials before an
analpicai methods will yield an appropriate answer
in terms of pavement life.

6.10 For example two very different bituminous


mixes such as Hot Rolled Asphalt and Dense
Bitumen Macadam would be expected to yield
different lives in fatigue for the same tensile strain.
This will in reality depend particularly on the
bier grade and content. Similarly, the permanent
deformation behaviour of a sandy subgrade will
differ from (and generally be better than) a clay of
the same stiffness and same strain e,.

6.11 It should be noted that several different


analytical design methods have been proposed,
differing slightly in their mathematical formulation.
Besides LR1132 (1984) these include (Brunton et
al, 1987; Monismith et al, 1987; Freeme et al,
1987). Experience is required in their application
since errors can arise if elements from different
methods are inappropriately combined.

Volume 7 home page


Volume 7 ktion 2 Chapter 7
Part 3 HD 26/94 References and Bibliography

7. REFERENCES AND BIBLIOGRAPHY


References Freeme C R, De Beer M and Vilijoen A W, “The
Behaviour and Mechanistic Design of Asphalt
1984 Pavements”, Proc 6th Int Conf Structural Design of
Asphalt Pavements, Ann Arbor, Michigan, pp 333-343.
LR1132; Powell W D, Potter J F, Mayhew H C
and NUM M E, “The Structural Design of Monismith C L, Finn F N, Ahlbom G and Markevich
Bituminous Roads”, TRRL. N, “A General Analytically Based Approach to the
Design of Asphalt Concrete Pavements”, Proc 6th Int.
1987 Conf. Structural Design of Asphalt Pavements, AM
Arbor, Michigan, pp 344-365.
RR87; Mayhew H C and Harding H M, “Thickness
Design of Concrete Roads”, TRRL.

1988

BS4987; Parts 1 and 2 “Coated Macadam for Roads


and other Paved Areas”, BSI.

BS594; Part 1, Hot rolled asphalt for roads and


other paved areas. BSI.

1994

HD 24 @MRB 7.2.1) Trafl% Assessment,

HD 27 @MRB 72.4) Pavement Construction


Methods.

HD 32 (DMRB 7.4.2) Maintenance of Concrete


Roads.

Specification for Highway Works (MCHW l),

Highway Construction Details (MCHW3).

1987

Brunton J M, Brown SF and Pell P S,


“Developments to the Nottingham Analytical
Design Method for Asphalt Pavements”, Proc 6th
Int. Conf. Structural Design of Asphalt Pavements,
AM Arbor, Michigan, pp 366-377.

hnuary 1994 711


Volume 7 home page
Volume 7 Section 2 Chapter 8
Part 3 HD 26/94 Enquiries

8. ENQUIRIES
All technical enquiries or comments on this Part should he sent in writing as appropriate to:-

Chief Highway Engineer


The Department of Transport
St Christopher House v
Southwark Street T A ROCHESTER
LONDON SE1 OTE Chief Highway Engineer

The Deputy Chief Engineer


The Scottish OftIce Industry Department
Roads Directorate
New St Andrew’s House 1 INNES
EDINBURGH EH 13TG Deputy Chief Engineer

The Director of Highways


Welsh Office
Y Swyddfa Gymreig
Government Buildings
Ty Glas Road
Llanishen K 1 THOMAS
CARDIFF CF4 SPL Director of Highways

Chief Engineer - Roads Service


Department of the Environment for Northern Ireland
Roads Service Headquarters @k@-+$
Clarence Court
lo-18 Adelaide Street W J McCOUBREY
BELFAST BT2 8GB Chief Engineer - Roads Service

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