4/23/2020

Concrete Overlay Design Overlay Design Process

(Design Functions and Thickness)
• Pavement Evaluation
• Determine Overlay Type
• Determine Design Life and Traffic
• Use Pavement Design Software
• Consider Additional Design Features
• Consider Construction Process
• Create Construction Documents

Evaluation Informs Design Evaluation and Survey Information

Maintenance
Resurfacing • Existing Pavement History Evaluation
Reconstruction
• Layer materials, properties, depths, & age
• Widening material type, depths, widths, & age
• History of full depth patching by location, type & age

• “As Built” Plan Information

• Vertical & horizontal alignment
• Previous test sections in project limits
• Previous drainage structure remains

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Overlay Type Selection

Overlay Design Process
Concrete Overlays
• Pavement Evaluation
Asphalt / Composite Concrete
• Determine Overlay Type
• Determine Design Life and Traffic Unbonded Bonded Unbonded Bonded
Concrete Concrete Concrete Concrete
• Use Pavement Design Software Overlay of Overlay of Overlay of Overlay of
Asphalt / Asphalt / Concrete Concrete
• Consider Additional Design Features Composite Composite (UCOC) (BCOC)

• Consider Construction Process

• Create Construction Documents
Applicable for poor to Applicable for good Applicable for fair to Applicable for excellent
deteriorated asphalt to fair asphalt deteriorated concrete to good concrete
pavements pavements pavements pavements

Up to ~100 M ESALs Up to ~15 M ESALs Up to ~100 M ESALs Up to ~15 M ESALs

4 – 11 in. 3 – 6 in. 4 – 11 in. 3 – 6 in.
5

Bond Breaker Selection Overlay Design Process

• Nonwoven Geotextile or Asphalt Interlayer
• Pavement Evaluation
• Determine Overlay Type
• Determine Design Life and Traffic
• Use Pavement Design Software
• Consider Additional Design Features
• Consider Construction Process
• Create Construction Documents

• https://cptechcenter.org/geotextiles/
• http://www.acpa.org/wp-content/uploads/2018/10/ACPAGeotextileGuideSpec-v1-5.pdf

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Design Life and Traffic Overlay Design Process

Planning Information • Pavement Evaluation
• Determine Design Life • Determine Overlay Type
• Usually between 20 – 40 years • Determine Design Life and Traffic
• Current & Projected Traffic – ADT & ADTT • Use Pavement Design Software
• Directional & lane distribution • Consider Additional Design Features
• Current & Expected Adjacent Land Use • Consider Construction Process
• Create Construction Documents

10

Selecting a Pavement Design Tool AASHTO 93

AASHTO 93
(software as Can Design: • Utilizes AASHTO 93/86 design
ACPA WinPAS) FREE Industry equations with modifications
Unbonded on Change in Serviceability
Developed Asphalt Overall
Standard Thickness
Method Standard Deviation
Normal Deviate   PSI  
 Log  4.5  1.5  
Log ( ESAL)  Z R * so  7.35 * Log ( D  1)  0.06    
 1.624 *10 
7
Unbonded on
 1 
Concrete “Traffic”
 ( D  1)8.46 

11
Modulus of
Rupture Drainage
AASHTOWare Terminal Coefficient
 
Pavement ME Bonded on Serviceability  
Concrete  S c' * Cd * ( D 0.75  1.132) 
(previously known as  (4.22  0.32 * pt ) * Log
  0.75 18.42  
 215.63 * J *  D  
( Ec / k ) 0.25  
DARWin-ME and FREE – FHWA Pooled
MEPDG) Fund TPF-5(165)  
Google “BCOA ME” Load Modulus Modulus of
Transfer of Elasticity Subgrade Reaction
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AASHTO 93 AASHTO 93

• Wholly empirical – AASHO Road Test

Can Design:
• Unbonded Concrete on Asphalt (UCOA) • Limited inference space:
Unbonded on
Asphalt
• Treats existing asphalt as a subbase layer • Materials
• Structural sections
• Soils
• Unbonded Concrete on Concrete (UCOC) • Traffic
Unbonded on
• Climate
ܶ௥௘௤௨௜௥௘ௗ ଶ െ ܶ௘௙௙௘௖௧௜௩௘ ଶ
Concrete
• ܶ௎஼ை஼ ൌ • Failure is “Serviceability”

Bonded on
Concrete
• Bonded Concrete on Concrete (BCOC)
• ܶ஻஼ை஼ ൌ ܶ௥௘௤௨௜௥௘ௗ െ ܶ௘௙௙௘௖௧௜௩௘

PavementDesigner PavementDesigner
PavementDesigner.org PavementDesigner.org

Can Design: Can Design:

• Utilizes PavementDesigner Method • Unbonded Concrete on Asphalt (UCOA)
Unbonded on
Asphalt
(formerly StreetPave/PCA method) Unbonded on
Asphalt
• Treats existing asphalt as a subbase layer
developed for JPCP with modifications
• FREE, industry-developed, mechanistic-
empirical design method • Unbonded Concrete on Concrete (UCOC)
Unbonded on Unbonded on
ܶ௥௘௤௨௜௥௘ௗ ଶ െ ܶ௘௙௙௘௖௧௜௩௘ ଶ
Concrete • Primarily for cities, counties, streets, Concrete
• ܶ௎஼ை஼ ൌ
and roads
• Allows for the use of synthetic macrofibers
Bonded on • Joint spacing provided as an output Bonded on • Bonded Concrete on Concrete (BCOC)
Concrete Concrete
• Failure mechanisms of Cracking and • ܶ஻஼ை஼ ൌ ܶ௥௘௤௨௜௥௘ௗ െ ܶ௘௙௙௘௖௧௜௩௘
Erosion
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PavementDesigner.org
BCOA – ME
Can Design:
• FREE Mechanistic – Empirical design tool
Bonded on specifically for Concrete Overlays of Asphalt
Asphalt
• Assumes a partially bonded condition
• Developed at University of Pittsburgh under
FHWA Pooled Fund TPF-5(165)
• Incorporates climatic distresses
• Joint spacing is featured as an input
• Allows for design with synthetic macrofibers
directly
https://www.engineering.pitt.edu/Sub-Sites/Faculty-Subsites/J_Vandenbossche/BCOA-ME/BCOA-ME/
Or google “BCOA ME”

BCOA – ME BCOA ME Design

Can Design:
10 x 12 ft
5 to 7 ft 12 x 12 ft
< 4.5 ft 12 x 15 ft
Corner Break Long. & Diag Crack
Trans. Crack
Bonded on
Asphalt

Positive ΔT
Negative ΔT Positive ΔT
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BCOA ME Design BCOA ME Design

Pavement ME
A.K.A. MEPDG AASHTO 93 vs. ME

Can Design: Wide range of structural and

• AASHTO’s current design/analysis tool rehabilitation designs 50+ million load reps
Unbonded on
Asphalt • Current version is 2.5.5
• License is yearly-based subscription
• Incorporates climate data Limited structural sections 1.1 million load reps
Bonded on Asphalt AASHTO 93
• Allows most control of all design tools
“SJPCP”
• Features joint spacing as an input AASHTO Pavement ME

Unbonded on
• Failure mechanisms include IRI, Faulting, 1 climate/2 years 1 set of materials
Concrete and Cracking
• SJPCP only includes longitudinal cracking
All climates over 20-50 years New and diverse materials
Bonded on
Concrete • https://me-design.com/MEDesign/
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Design Tool Summary Typical Design &

AASHTO 93 PavementDesigner BCOA – ME Pavement ME Software Parameters
Designs for:
Unbonded on Asphalt Yes1 Yes1 Yes
Bonded on Asphalt Links to BCOA-ME Yes Yes (SJPCP)
Unbonded on Concrete Yes1 Yes1 Yes
Bonded on Concrete Yes1 Yes1 Yes
Failure Criteria:
Cracking Yes Yes Yes
Faulting Yes Yes2
IRI Yes2
Additional Design Information:
Mechanistic – Empirical Yes Yes Yes
Climatic Loading Yes Yes
Joint Spacing Output Input Input
Design with Fibers in Tool Yes Yes
1 Via modifications to conventional JPCP design 26
2 Not in SJPCP Module

Overlay Jointing Practices Overlay Design Process

Joint Spacing • Pavement Evaluation

• Thinner overlays tend to have shorter joint spacings • Determine Overlay Type
• See Guide to Overlays for detailed information • Determine Design Life and Traffic
• Use Pavement Design Software
• Consider Additional Design Features
Dowel & tie bar use • Consider Construction Process
• Dowels normally not necessary for overlay • Create Construction Documents
thicknesses < 7 in.
• For unbonded overlays > 5 in., use tie bars at
longitudinal joints
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Additional Considerations in Overlay Design Foreslope Adjustment Options

• Shoulders / Widening
• Safety Edge
• Vertical Grade Changes
• Overhead Clearance
• Barriers and Rails
• Safety Edge
• Drainage Structures

• Transitions

Materials – Mixture Design Overlay Design Process

• Performance Engineered Mixtures - https://cptechcenter.org/performance-engineered-mixtures-pem/ • Pavement Evaluation

• Standard concrete mixtures • Determine Overlay Type
whenever possible
• Determine Design Life and Traffic
• Minimize the use of accelerated
• Use Pavement Design Software
Percent Passing

mixtures
• Focus on project sequencing to • Consider Additional Design Features
accommodate maintenance of • Consider Construction Process
traffic
• Optimized gradation – Tarantula • Create Construction Documents
Curve / Shilstone Chart
• Reduced paste content –
durability and shrinkage Sieve Size

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Concrete Overlay Quantities

Concrete Overlay Quantity Control IDEAL SITUATION
•Quality of PCC is Uniform
(set milling depth to remove
PCC OVERLAY
exactly overlay depth and
not worry about profile or Minimum
smoothness) Thickness

•Profile is Perfect Acceptable

Grade
(never is)

•Concrete is bid in sq. yards;

Uniform Surface
(Should be cu. yds for
material & sy.yds. for
placement)
EXISTING PAVEMENT

Concrete Overlay Quantities

-REALITY SITUATION- Concrete Overlay Approach
If existing surface needs some improvement in
•Concrete is bid in PCC OVERLAY cross slope or profile grade and want minimum
sq. yards for Hold
survey:
Minimum
placement, cubic Thickness
• Must maintain minimum
yards for material pavement thickness
Profile needs
corrected
• Contractor sets
•Profile is not recommended grade
perfect and needs
• Allow to mill to get cross
corrected
slope and profile

•Cross slope
needs correction EXISTING PAVEMENT
Slope Varies
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Quantity Estimates Overlay Design Process

• Estimating plan quantity • Pavement Evaluation
 Overlay cubic yard pay item is to adjust the theoretical volume by an
appropriate factor that accounts for the non-uniformity of the existing
• Determine Overlay Type
surface • Determine Design Life and Traffic
½” Placement
Additional % Total Adjustment • Use Pavement Design Software
Concrete Adjustment for Factor to be
Tolerance as a % • Consider Additional Design Features
Overlay Gross Surface Applied to
of Design
Thickness Irregularities in the Theoretical
Thickness
Existing Surface Volume • Consider Construction Process
4” 12.5% 5% 17.5% • Create Construction Documents
6” 8.3% 5% 13.3%
8” 6.3% 5% 11.3%
10” 5.0% 5% 10.0%
12” 4.2% 5% 9.2%

38

Specifications and Construction Documents Next Up: The Colorado

• Guide specifications and
standard drawings and
Experience
design details available
in CP Tech Center
Resources
• Plans can be simple
• Typical Section

• https://cptechcenter.org/concrete-overlays/
• https://intrans.iastate.edu/app/uploads/2018/09/overlay_construction_doc_dev_guide_w_cvr.pdf
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 Harmony Road near Fort Collins, CO - 1990
1st Thin Whitetopping Test Section in CO
Concrete Overlays in
Colorado & Wyoming
Angela Folkestad, PE
CO/WY Chapter - ACPA
• 3.5” & 5” thick sections • 18,200 AADT
• Paved Saturday & open Monday • 4% Truck Traffic
• 3,750 psi compressive strength • 105,000 ESALs per year

Harmony Road near Fort Collins, CO Parker Road in SE Denver - 1994

Donated by Industry for 2 Year Test 4 – 200’ Test Sections (5” thick)

Condition in 1995
(5 years old)

• Joint Spacing: 6’ x 6’ and 10’ x 12’

Condition in 2006
(Removed from service
at 14 years old)
• 1,500 ADT with 25% Trucks
• Milled & Non-milled
• Tied Longitudinal
Joints
SH 119 near Longmont, CO - 1996 SH 119 near Longmont, CO

• 20,000 ADT with

8% trucks
• 6" truck lane
• 4.5" passing lane
& shoulder Condition in 2009

US 287 Near Campo, CO in SE CO – 1997 US 6 – Fleming to Holyoke

“The Lone Mile”
• 6” Concrete Overlay
• 6’ x 6’ Joint spacing
• 2,300 AADT with 60% trucks
• Test section removed (not due to
distress)
NE Colorado
1997: E. of Fleming to Haxtun
• MP 429 – 441
• 5.5” Concrete Overlay
• 12 years RDL – High (in 2019)
• IRI: 78.5 in./mile (in 2017)

2001: Haxtun to Holyoke

• MP 441 – 454
• 8” Concrete Overlay
• 11-17 years RDL – High (in 2019)
• IRI: 97.5 in./mile (in 2017)
 SH 121 (Wadsworth Blvd.) in SW Denver - 2001 SH 121 (Wadsworth Blvd.) in SW Denver - 2001
• 6” Overlay • 4” test section with 4’ x 4’
• 3.5 miles long joint spacing
• 45,000 AADT with • 4.5” test section with 6’ x 6’
3% trucks joint spacing

Research Contributes to Improving CDOT’s

SH 121 (Wadsworth Blvd.) in SW Denver
Thin Whitetopping Procedure
• 12 years RDL – High (in 2019)
• 47,000 AADT

Project
Location
I-70 West of Grand Junction, CO (near UT) I-70 West of Grand Junction, CO (near UT)
• 12 years RDL – High (in 2019)
• 11,000 ADT

Project
Location
• 4.4 miles long • Built in 2012
• 20-year design life • 6” Concrete overlay
• Mill existing asphalt 0.5” – 4” • 6’ x 6’ Joint spacing

US 30 near Cokeville, WY US 30 near Cokeville, WY

• 6” thickness
• 6’ x 6’ joint spacing
SH 13 N. of Craig, CO - 2015 SH 13 N. of Craig, CO
• Alternate bid project –
concrete pavement 1st cost low
• Smoothness: IRI < 50 in./mile
• 6” concrete overlay
• 6’ x 6’ joint spacing
• 6 miles long
• 20-year design

Pikes Peak Parking Lot • 4.5” - 5” overlay Parker Road Corridor • 5” – 6” thickness
at Denver International Airport • 6’ x 6’ joint spacing SE Denver • 6’ x 6’ joint spacing
• 146,000 SY
• Constructed in 2019
US 287 Corridor • Full depth overlays 9” – 12”
• 12’ x 15’ joint spacing US 287 Corridor – SE Colorado
SE Colorado • More than 150 miles of OLs

Where can Concrete Overlays be Built? What Have We Learned?

• Divided highways • Farm to market routes • Tie longitudinal joints
• Urban arterials • Heavy truck routes
• Milling is beneficial
• Rural 2-lane highways • Commuter routes
• Interstates • Industrial areas
• Material selection is important
• Parking lots • Lower annual maintenance costs
• Performance typically exceeds design life
Anywhere you need a durable surface to make
• Concrete overlays save time during construction
your infrastructure investment go further!
Thank you!

Angela Folkestad, P.E.

afolkestad@pavement.com