Network Outcomes Contract

Rehabilitation Catalogue Design and Treatment Approach

SUBJECT
Over time the Transport Agency has seen an increasing cost for rehabilitation treatments, an increase in the quantum of investigation, design and reporting, a
reduction in the construction productivity of our supply chain, some poorly performing rehabilitation treatments and a disproportionate level of risk transfer
To assist the Agency and the supply chain to address these concerns the Agency in consultation with the industry is proposing to move in part to a catalogue design
approach
This paper sets out the proposal for the implementation of rehabilitation catalogue design approach

GENERAL
This approach assumes a need to treat a site has already been identified through network inspections and forward works programming
The intent of the Catalogue Design approach is to;
• Provide Agency and Contractor staff with a quick guide to options that could be considered when a site requires rehabilitation
• Take account of the structural capacity in existing pavements
 • Assess whether an option being promoted is realistic and considers possible site constraints
• Enable Agency and Contractor staff to agree rates (as tendered or negotiated) which would be more closely aligned to the final outturn cost
• Use the catalogue designs as a basis for developing more realistic AP/NLTP budget requests
• Use the catalogue designs as a basis for checking whether an NPV realistically reflects the right rehabilitation option and cost
• Rationalise the effort and reporting requirements of the pavement guide where a catalogue design is considered an appropriate treatment
• Enable Agency and Contractor staff to understand and agree suitable risk transfer conditions
• Focus attention on the quality of the construction process
The catalogue design approach is not trying to replace the 2017 New Zealand Guide to Pavement Evaluation and Treatment Design it is effectively an addendum to
the guide. The 2017 Guide will be undergoing a full review and will take account of the catalogue design approach
Where a catalogue design is selected then investigation, testing, design requirements and reporting can be rationalised in accordance with the following. Where a
catalogue design is not chosen then full compliance with 2017 New Zealand Guide to Pavement Evaluation and Treatment Design is required
A design report is still required to support the chosen catalogue treatment and design method. It should still set out the evaluation process used to decide the
recommended treatment.
Drainage improvements will most likely be necessary. No pavement rehabilitation treatments should be undertaken without concurrent drainage improvements
being considered

EVALUATION AND TREATMENT DESIGN

The processes detailed in Figure 1 of the 2017 New Zealand Guide to Pavement Evaluation and Treatment Design should still be followed. For catalogue designs
the risk-based treatment selection referred to in Figure 1 should be the catalogue design options
Preliminary treatment options should be selected to eliminate the root causes of the pavement failure
In combination with the existing pavement structure, the current and future forecast traffic will somewhat dictate the pavement design options. Designs with
unreasonable levels of risk should be eliminated from the list of possible treatments, examples include;
• Unable to reasonably identify homogenous segments through deflection results or treatment length segmentation
• Significant areas of weak subgrade (CBR<3) identified through scala testing which cannot be easily isolated and treated
• Using marginal materials with higher shearing potential on higher classification roads
For catalogue designs typically only one option needs to be considered but this should be extended to two if the site boarders two ESA envelops or site constraints
require an alternative catalogue treatment.

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Given the site characteristics, some treatment options can be eliminated based on traffic criticality, early pavement failure (well before end of life), or physical
constraints (e.g. high stresses, barriers, kerb and channel).

CATALOGUE DESIGN CRITERIA

Greater
25 year design traffic Less than Between 5×106 Between 1×107 Between 2×107
Catalogue Treatment than
volume (ESAs) 5×106 and 1×107 to 2×107 to 2.5×107
2.5×107

Structural Asphalt 110mm Overlay 60mm AC14 with 50mm Low Risk Low risk
SMA (mill off surface layer) Unlikely to be
Unlikely to be Unlikely to be Low risk Low risk
economic
economic economic

Structural Asphalt Inlay (requires site specific design) Low Risk Low risk
Unlikely to be
Unlikely to be Unlikely to be Low risk Low risk
economic
economic economic

Foamed bitumen 1%cement/3% Bitumen 75mm make up Low risk

basecourse material, stabilise to 200mm Unlikely to be
Unlikely to be Low risk Low risk Medium risk
economic
economic

Unbound aggregate overlay 150mm overlay over 4% cement Low risk

and bound sub-base stabilised 200mm sub-base
Unlikely to be Low risk Low risk Medium risk High risk
economic

Unbound aggregate overlay 150mm over high spot

Low risk Low risk Medium risk High risk High risk

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 Greater
25 year design traffic Less than Between 5×106 Between 1×107 Between 2×107
Catalogue Treatment than
volume (ESAs) 5×106 and 1×107 to 2×107 to 2.5×107
2.5×107

Unbound aggregate overlay 100mm over high spot

Low risk Medium risk High risk High risk High risk

Recycle Multiple seal layers <30% treatment

depth, 2% cement, 50mm make up
Medium risk High risk High risk High risk High risk
material

1. It is assumed that the catalogue treatments will have a design life of 25 years when constructed (for use in NPV)
2. Number of Axle Groupings per Heavy will use actual WIM station for axle loadings if these are known on the network
3. High Risk can be interpreted that, for the given traffic levels, the treatment is likely to achieve project reliability of the road classification two down from the
design classification. For example, reliability will decrease from 97.5% to 90% for a National (high volume) road.
4. Medium Risk can be interpreted as, for the given traffic levels, the treatment is likely to achieve the project reliability of the next lower road classification
design life. Medium risk treatments may be considered, where for example, future traffic volumes and configurations may reduce over the life of the
pavement or plant or expertise to construct low risk treatments is not available
5. Low Risk can be interpreted as, for the given traffic levels, the treatment is likely to achieve the project reliability for the design life.

TESTING OF PAVEMENT AND IN SITU MATERIALS

Typically, investigations will be conducted in three stages: general inspection, detailed inspection, and field and laboratory testing. These stages may overlap or be
entirely concurrent.
The detail of testing required depends on the catalogue treatment. An outline of different levels of investigation and testing is given in the table below.

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 In-situ
Testing Catalogue Design FWD/Deflection Test Pit Core Scala
Material Tests

Structural Asphalt 110mm Overlay 60mm AC14 20m centres Excavate weak Use FWD results Undertake scala in
with 50mm SMA (mill off sections, to target coring each test pit, weak
Determine the
surface layer) section and cores
homogeneity of the site • log pavement • look for
structure homogenous
Identify weak spots
• target for segments
Beam testing may be additional • target cores at
required when surface treatment good and bad
layer has been milled areas within
off homogenous
segments

Structural Asphalt Inlay Follow requirements of 2017 NZ Guide to Pavement Evaluation and Treatment Design

Foamed bitumen 1% cement/3% Bitumen 20m centres Minimum of 1 test Undertake scala in Mix Design
basecourse 75mm make up material, pit per each test pit, weak
Determine the Plasticity
stabilise to 200mm homogenous section
homogeneity of the site
segment Grading
Identify weak spots
Excavate weak ITS
sections and
target for
additional
treatment

Unbound 150mm overlay over 4% 20m centres Minimum of 1 test Undertake scala in Subbase Mix
aggregate overlay cement stabilised 200mm pit per each test pit Design
Determine the
and bound sub-base homogenous
homogeneity of the site ITS
subbase segment

Unbound 150mm over high spot 20m centres Excavate weak Use FWD results Undertake scala in
aggregate overlay sections, to target coring each weak section
Determine the
and cores
homogeneity of the site • log pavement • look for
structure homogenous

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 In-situ
Testing Catalogue Design FWD/Deflection Test Pit Core Scala
Material Tests

Identify weak spots • target for segments

additional • target cores at
treatment good and bad
areas within
homogenous
segments

Unbound 100mm over high spot 20m centres Excavate weak Use FWD results Undertake scala in
aggregate overlay sections, to target coring each weak section
Determine the
and cores
homogeneity of the site • log pavement • look for
structure homogenous
Identify weak spots
• target for segments
additional • target cores at
treatment good and bad
areas within
homogenous
segments

Recycle Multiple seal layers <30% 20m centres Use FWD results Undertake scala in
treatment depth, 2% cement, to target coring each weak section
Determine the
50mm make up material and cores
homogeneity of the site • look for
homogenous
Identify weak spots
segments
• target cores at
good and bad
areas within
homogenous
segments

Additional Testing - The test requirements detailed in the table above are minimum requirements and it is expected that the pavement engineer may require
additional testing should they consider this to be necessary or the catalogue treatment is not considered a suitable option

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Coring – Cores will have a diameter of 200mm and be to a depth of 400mm. Location and number of cores will be determined based on the FWD/Deflection results.
Cores will be targeted at homogenous segments covering both good and bad areas of each homogenous segment. Where cores do not penetrate subbase more
invasive or alternative testing may be required
FWD/Deflection - Deflection testing can use either a Falling Weight Deflectometer (FWD) or a Benkelman Beam (BB). The default test frequency is a test every 20
metres alternating between outer wheel paths. Tests shall be performed on all lanes. Purpose of the deflection survey is to be able to divide the site into
homogeneous sections. This can be performed using statistical techniques such as cumulative sum or a moving average.
Mix Design is for required for all SAC treatments
Normal source material testing is still required for replacement or additional material
Site geometry – geometrics and site survey are required but the level of detail will diminish with road classification
Subbase Investigation - The Scala shall be used to a depth of 1.3 metres below the top of the subbase or to rejection, whichever occurs first. CBR < 3 pose higher
risk to site and the extent of low CBR results may require a full design
Test Pits – refer 2017 New Zealand Guide to Pavement Evaluation and Treatment Design for test pit size and location
Treating Weak Spots – Weak spots to be dugout and brought up to a similar pavement strength as the surrounding material

PAVEMENT DESIGN REPORT

Section 10 of the 2017 New Zealand Guide to Pavement Evaluation and Treatment Design is still appropriate for catalogue treatments. The report should contain
enough investigation information and a clearly documented decision-making process
Where a catalogue treatment is proposed modelling support is not required. Where a catalogue treatment is not considered appropriate then a modelling report is
required to demonstrate why the catalogue is discounted and why the proposed design is more appropriate
The level of detail required for a catalogue design report should be worked through collaboratively. Agreement on the level of detail and report format may be an
iterative process to start and once in place should form the standard going forward for any future catalogue design reports
As a starting point design reports should generally not exceed 20 pages (excluding appendices) and include:
Deflection Results
ESA Calculation
Walkover results
Photos
Core/Test pit results

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 Grading, Plasticity, ITS
Mix Design results
Imported source material test results
Optioneering
Safety in Design
Recommendation
To improve efficiency, it is recommended that designs are signed off through targeted group meetings of key specialists (local and national)

CONSTRUCTION QUALITY RIGHT

CM4 is the minimum construction monitoring service level required for catalogue treatments
The purpose of pavement construction quality right process is to identify those areas of the construction process for which monitoring/hold points will minimise the
risk of pavement failure and achieve the pavement performance. For those sites where a catalogue treatment is proposed it is critical that the Principal has
confidence that the site has the best opportunity to achieve a good long-term performance
The following elements have been identified as quality right requirements to ensure a good long-term site performance
Method Statements (for revamped Renewal Plan). Each Catalogue Design has a specific method statement detailing the construction technique which is then further
customised for site specific issues, detailing:
1. Construction methodology including hold points
2. Specific Plant to be used and present on site during various phases, including make and model detailing machine control capabilities
3. Material testing of in situ and imported materials including any hold points
4. Inspection Test Plan (ITP’s) specific for each site with hold points for use on site with crews
Verification Plan, which will be developed by the Principal and undertaken by Principal representatives. As an example, the Principals representatives will check
30% of testing, some of this will be by observation of the Contractors tests and on occasions there will be random verification testing. Testing may increase or
decrease dependant on the level of confidence the Principal’s representative has with the Contractors works
Quality Data Management, the Principal will require all laboratory test results be emailed to the Principal’s representative and the Principal at the same time as they
are issued to the Contractor. The Principal also requires access to a cloud-based environment that stores the same quality records as used by the Contractor. This
is for:
1. Lab test results

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 2. Onsite quality records
3. Machine control records
4. Any RVT data will also be shared with the Contractor
The Contractor will investigate utilising options on a cloud environment to collect, store and visualise quality records. At completion all quality files will be provided to
the Principal
Quality Meetings, the Quality Right project for major projects identifies that the following contributed to a step change in quality:
1. Site meetings, weekly “toolbox” focused on quality, site work programme, achievement and lessons learnt
2. Monthly Quality Meeting (formal meetings with minutes), MCM/Contractor/Principal Representative monthly meeting focused on quality and not part of the
CMT. Focus is to understand what is happening and areas for improvement, issues. Continual Improvement learning focus. The Principal’s representative
will provide any relevant reports for the meeting
Logistics Plan, the Principal expects the Contractor to develop a Logistic Plan for renewals on how to implement methodology, resources, plant, materials and
contingency. This is reviewed monthly to ensure the works are resourced adequately and provide surety that the programme is going to be delivered

POST CONSTRUCTION TESTING AND MONITORING

It is important that the performances of rehabilitations from each year’s pavement renewal programme are monitored annually. The review’s purpose is to determine
whether the catalogue treatments used are performing. If there are indications of early failure, the causes need to be investigated and whether catalogue designs
and construction methodologies need to be adjusted
For each rehabilitation treatment constructed the Principal will produce an exception report from Juno based on the performance metrics detailed in the NOC
maintenance specification. The Contractor will provide commentary on failure mode analysis, feedback by exception and discussion on corrective actions

RISK ALLOCATION FOR CATALOGUE DESIGNS

The following table details risk allocation when applying a catalogue design. For those risk allocations which sit with the Contractor the appropriate mechanisms
within the relevant contract documentation will apply. Where a catalogue treatment has not been adopted then the risk allocation will be applied in accordance with
the contract documentation.

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 Texture / Cracking
Materials and Ongoing
Risk Catalogue Design Rutting Roughness Skid
construction Maintenance
Resistance

Structural Asphalt 100mm Overlay60mm

AC14 with 50mm SMA Contractor Principal Contractor Contractor Contractor Principal
(mill off surface layer)

Structural Asphalt Inlay Contractor Contractor Contractor Contractor Contractor Contractor

Foamed bitumen 1%cement/3% Bitumen

basecourse 75mm make up material, Contractor Principal Contractor Contractor Contractor Contractor
stabilise to 200mm

Unbound aggregate 150mm overlay over 4% Principal AC

overlay and bound cement stabilised 200mm surfacing
subbase sub-base Contractor Principal Contractor Contractor Contractor
Contractor chip
seal

Unbound aggregate 150mm over high spot Principal AC

overlay surfacing
Contractor Principal Contractor Contractor Contractor
Contractor chip
seal

Unbound aggregate 100mm over high spot Principal AC

overlay surfacing
Contractor Principal Contractor Contractor Contractor
Contractor chip
seal

Recycle Multiple seal layers <30% Principal AC

treatment depth, 2% surfacing
cement, 50mm make up Contractor Principal Contractor Contractor Contractor
Contractor chip
material
seal

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