TABLE OF CONTENTS

Page

Preface................................................................. vii
Executive Summary ..................................................... ix

PART I PAVEMENT DESIGN AND MANAGEMENT PRINCIPLES

Chapter 1 Introduction and Background .................................. 1-3
1.1 Scope of the Guide ................................................. 1-3
1.2 Design Considerations .............................................. 1-5
1.3 Pavement Performance .............................................. 1-7
1.4 Traffic ........................................................... 1-10
1.4.1 Evaluation of Traffic ......................................... 1-10
1.4.2 Limitations ................................................. 1-12
1.4.3 Special Cases ............................................... 1-13
1.5 Roadbed Soil ...................................................... 1-13
1.6 Materials of Construction ........................................... 1-15
1.6.1 Flexible Pavements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I- 16
1.6.2 Rigid Pavements ............................................ 1-21
1.6.3 Shoulders .................................................. 1-22
1.7 Environment ...................................................... 1-22
1.8 Drainage ......................................................... 1-27
1.8.1 General Design Considerations ................................ 1-28
1.8.2 Design of Pavement Subsurface Drainage ........................ 1-28
1.8.3 Incorporation of Drainage Into Guide ........................... 1-28
1.9 Shoulder Design ................................................... 1-29

Chapter 2 Design Related Project Level Pavement Management .............. 1-31

2.1 Relationship of Design to Pavement Management........................ 1-31
2.2 The Guide as Structural Subsystem for a State Project-Level PMS . . . . . . . . . 1-34
2.3 Pavement Type Selection ............................................ 1-39
2.4 Network Level Pavement Management................................. 1-39

Chapter 3 Economic Evaluation of Alternative Pavement Design Strategies .... 1-41

3.1 Introduction....................................................... 1-41
3.2 Life-Cycle Costs ................................................... 1-41
3.3 Basic Concepts .................................................... 1-41
3.4 Definitions Related to Economic Analysis .............................. 1-42
3.4.1 Transport Improvement Costs .................................. K-42
3.4.2 User Benefits ............................................... 1-42
3.5 Factors Involved in Pavement Cost and Benefits ......................... 1-44
3.6 Initial Capital Costs (Investment Costs) ................................ 1-44
3.6.1 Maintenance Cost ........................................... 1-44
3.6.2 Rehabilitation and Resurfacing Cost ............................ 1-44

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 Contents-Continued
3.6.3 Salvage or Residual Value..................................... 1-45
3.6.4 User Cost .................................................. 1-45
3.6.5 Traffic Delay Cost to User .................................... 1-46
3.6.6 Identification of Pavement Benefit .............................. 1-46
3.6.7 Analysis Period ............................................. 1-46
3.7 Methods of Economic Evaluation ..................................... 1-47
3.8 Discussion of Interest Rates, Inflation Factors and Discount Rates . . . . . . . . . 1-47
3.8.1 Discounting and the Opportunity Cost of Capital . . . . . . . . . . . . . . . . . 1-47
3.8.2 Inflation ................................................... 1-48
3.9 Equations for Economic Analysis ..................................... 1-49
3.9.1 Equivalent Uniform Annual Cost Method ........................ 1-49
3.9.2 Present Worth Method ....................................... 1-49
3.9.3 Summary .................................................. 1-51

Chapter 4 Reliability ................................................... 1-53

4.1 Definitions ....................................................... 1-53
4.1.1 General Definition of Reliability ............................... 1-53
4.1.2 Definition of Design Pavement Section .......................... 1-53
4.1.3 Definition of Pavement Condition. Accumulated Axle Loads. and
Pavement Performance Variables ............................... 1-54
4.2 Variance Components and Reliability Design Factor ..................... 1-56
4.2.1 Components of Pavement Design-Performance Variability .......... 1-56
4.2.2 Probability Distribution of Basic Deviations ..................... 1-57
4.2.3 Formal Definition of Reliability Level and Reliability
Design Factor ............................................... 1-60
4.3 Criteria for Selection of Overall Standard Deviation ..................... 1-62
4.4 Criteria for Selection of Reliability Level .............................. 1-62
4.5 Reliability and Stage Construction Alternatives ......................... 1-63

Chapter 5 Summary .................................................... 1-65

References for Part I ..................................................... 1-47

PART I1 PAVEMENT DESIGN PROCEDURES FOR

NEW CONSTRUCTION OR RECONSTRUCTION
Chapter 1 Introduction ................................................. 11-3
1.1 Background ....................................................... 11-3
1.2 Scope ............................................................ 11-3
1.3 Limitations ....................................................... 114
1.4 Organizations ..................................................... 114
Chapter 2 Design Requirements .......................................... 11-5
2.1 Design Variables ................................................... 11-5
2.1.1 Time Constraints ............................................ 11-5
2.1.2 Traffic ..................................................... 11-6
2.1.3 Reliability .................................................. 11-9
2.1.4 Environmental Effects ........................................ 11-10
2.2 Performance Criteria ............................................... 11-10
2.2.1 Serviceability ............................................... 11-10
2.2.2 Allowable Rutting ........................................... 11-12
2.2.3 Aggregate Loss ............................................. II- 12

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2.3 Material Properties for Structural Design .............................. 11-12
2.3.1 Effective Roadbed Soil Resilient Modulus ....................... 11-12
2.3.2 Effective Modulus of Subgrade Reaction ........................ ii-16
2.3.3 Pavement Layer Materials Characterization ...................... 11-16
2.3.4 PCC Modulus of Rupture ..................................... 11-16
2.3.5 Layer Coefficients ........................................... 11-17
2.4 Pavements Structural Characteristics .................................. 11-22
2.4.1 Drainage ................................................... 11-22
2.4.2 Load Transfer .............................................. 11-25
2.4.3 LOSSof Support ............................................. 11-27
2.5 Reinforcement Variables ............................................ 11-27
2.5.1 Jointed Reinforced Concrete Pavements ......................... 11-27
2.5.2 Continuously Reinforced Concrete Pavements .................... 11-28

Chapter 3 Highway Pavement Structural Design ........................... 11-31

3.1 Flexible Pavement Design ........................................... 11-31
3.1.1 Determine Required Structural Number ......................... 11-3 1
3.1.2 Stage Construction .......................................... 11-33
3.1.3 Roadbed Swelling and Frost Heave ............................. 11-33
3.1.4 Selection of Layer Thickness .................................. 11-35
3.1.5 Layered Design Analysis ..................................... 11-35
3.2 Rigid Pavement Design ............................................. 11-37
3.2.1 Develop Effective Modulus of Subgrade Reaction ................. 11-37
3.2.2 Determine Required Slab Thickness ............................ 11-44
3.2.3 Stage Construction .......................................... 11-44
3.2.4 Roadbed Swelling and Frost Heave ............................. 11-47
3.3 Rigid Pavement Joint Design ......................................... 11-48
3.3.1 Joint Q p e s ................................................. 11-48
3.3.2 Joint Geometry ............................................. 11-49
3.3.3 Joint Sealant Dimensions ..................................... 11-50
3.4 Rigid Pavement Reinforcement Design ................................ 11-5 1
3.4.1 Jointed Reinforced Concrete Pavements ......................... 11-5 1
3.4.2 Continuously Reinforced Concrete Pavements .................... 11-5 1
3.4.3 Transverse Reinforcement..................................... 11-62
3.5 Prestressed Concrete Pavement ....................................... 11-65
3.5.1 Subbase ................................................... 11-65
3.5.2 Slab Length ................................................ 11-65
3.5.3 Magnitude of Prestress ....................................... 11-66
3.5.4 Tendon Spacing ............................................. 11-66
3.5.5 Fatigue .................................................... 11-66
3.5.6 PCP Structural Design ....................................... 11-66

Chapter 4 Low-Volume Road Design ..................................... 11-69

4.1 Design Chart Procedures ............................................ 11-69
4.1.1 Flexible and Rigid Pavements ................................. 11-69
4.1.2 Aggregate-Surfaced Roads .................................... 11-69
4.2 Design Catalog .................................................... 11-77
4.2.1 Flexible Pavement Design Catalog .............................. 11-77
4.2.2 Rigid Pavement Design Catalog ................................ 11-81
4.2.3 Aggregate-Surfaced Road Design Catalog ....................... 11-8 1

References for Part I1 .................................................... 11-87

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PART I11 PAVEMENT DESIGN PROCEDURES FOR
REHABILITATION OF EXISTING PAVEMENTS
Chapter 1 Introduction ................................................. 111-3
1.1 Background ....................................................... 111-3
1.2 Scope ............................................................ 111-3
1.3 Assumptions/Limitations ............................................ 1114
1.4 Organization ...................................................... 111-4

Chapter 2 Rehabilitation Concepts ....................................... 111-7

2.1 Background ....................................................... 111-7
2.2 Rehabilitation Factors .............................................. 111-7
2.2.1 Major Categories ............................................ 111-7
2.2.2 Recycling Concepts .......................................... 111-7
2.2.3 Construction Considerations................................... 111-7
2.2.4 Summary of Major Rehabilitation Factors ....................... 111-7
2.3 Selection of Alternative Rehabilitation Methods ......................... 111-8
2.3.1 Overview .................................................. 111-8
2.3.2 Problem Definition .......................................... 111-9
2.3.3 Potential Problem Solutions ................................... 111-12
2.3.4 Selection of Preferred Solution ................................ 111-15
2.3.5 Summary .................................................. 111-16

Chapter 3 Guides for Field Data Collection .............................. .I11.19

3.1 Overview ......................................................... 111-19
3.2 The Fundamental Analysis Unit ...................................... 111-19
3.2.1 General Background ......................................... 111-19
3.2.2 Methods of Unit Delineation .................................. 111-19
3.3 Drainage Survey for Rehabilitation.................................... 111-21
3.3.1 Role of Drainage in Rehabilitation.............................. 111-21
3.3.2 Assessing Need for Drainage Evaluation ........................ 111-25
3.3.3 Pavement History. Topography. and Geometry .................... 1n-25
3.3.4 Properties of Materials ....................................... 111-25
3.3.5 Climatic Zones ............................................. 111-26
3.3.6 Summary .................................................. III-28
3.4 Condition (Distress) Survey ......................................... 111-28
3.4.1 General Background ......................................... 111-28
3.4.2 Minimum Information Needs .................................. 111-28
3.4.3 Utilization of Information ..................................... 111-28
3.5 NDT Deflection Measurement ....................................... 111-30
3.5.1 Overview .................................................. 111-30
3.5.2 Uses of NDT Deflection Results ............................... 111-32
3.5.3 Evaluating the Effective Structural Capacity ..................... 111-35
3.5.4 Joint Load Transfer Analysis .................................. 111-38
3.55 Use in Slab-Void Detection ................................... 111-44
3.6 Field Sampling and Testing Programs ................................. 111-45
3.6.1 Test Types ................................................. 111-45
3.6.2 Major Parameters ........................................... 111-45
3.6.3 Necessity for Destructive Testing .............................. 111-49
3.6.4 Selecting the Required Number of Tests ......................... 111-49

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Contents-Continued
Chapter 4 Rehabilitation Methods Other Than Overlay .................... 111-59
4.1 Evaluation of Pavement Condition ................................... 111-59
4.1.1 Surface Distress ............................................ 111-59
4.1.2 Structural Condition ........................................ 111-59
4.1.3 Functional Condition ....................................... 111-60
4.2 Development of Feasible Alternatives and Strategies .................... 111-60
4.3 Major Nonoverlay Methods ......................................... III-62
4.3.1 Full-Depth Repair .......................................... 111-62
4.3.2 Partial-Depth Pavement Repair ............................... 111-64
4.3.3 Joint and Crack Sealing ..................................... 111-65
4.3.4 Subsealing of Concrete Pavements ............................. III-66
4.3.5 Diamond Grinding of Concrete Surfaces and Cold Milling of
Asphalt Surfaces ........................................... 111-67
4.3.6 Subdrainage Design ......................................... 111-68
4.3.7 Pressure Relief Joints ....................................... 111-69
4.3.8 Restoration of Joint Load Transfer in Jointed Concrete Pavements . . 111-70
4.3.9 Surface Treatments ......................................... 111-71
4.3.10 Prediction of Life of Rehabilitation Techniques Without Overlay . . . 111-73

Chapter 5 Rehabilitation Methods With Overlays ......................... 111-79

5.1 Overlay Type Feasibility ........................................... 1n-79
5.2 Important Considerations in Overlay Design ........................... 111-80
5.2.1 Pre-overlay Repair .......................................... 111-80
5.2.2 Reflection Crack Control .................................... 111-80
5.2.3 Traffic Loadings ........................................... 111-80
5.2.4 Subdrainage ............................................... 111-81
5.2.5 Rutting in AC Pavements .................................... 111-81
5.2.6 Milling AC Surface ......................................... 111-81
5.2.7 Recycling the Existing Pavement .............................. 111-81
5.2.8 Structural versus Functional Overlays .......................... 111-81
5.2.9 Overlay Materials .......................................... 111-81
5.2.10 Shoulders ................................................. 111-81
5.2.11 Existing PCC Slab Durability ................................ 111-82
5.2.12 PCC Overlay Joints ......................................... 111-82
5.2.13 PCC Overlay Reinforcement ................................. 111-82
5.2.14 PCC Overlay BondinglSeparation Layers ....................... 111-82
5.2.15 Overlay Design Reliability Level and Overall Standard Deviation . . . 111-82
5.2.16 Pavement Widening ......................................... 111-82
5.2.17 Potential Errors and Possible Adjustments to Thickness
Design Procedure .......................................... 111-83
5.2.18 Example Designs and Documentation .......................... 111-83
5.3 Pavement Evaluation for Overlay Design .............................. 111-83
5.3.1 Design of Overlay Along Project .............................. 111-84
5.3.2 Functional Evaluation of Existing Pavement..................... 111-84
5.3.3 Structural Evaluation of Existing Pavement ..................... 111-85
5.3.4 Determination of Design MR ................................. 111-91
5.4 AC Overlay of AC Pavement ........................................ 111-94
5.4.1 Feasibility................................................. 111-94
5.4.2 Pre-overlay Repair .......................................... III-94
5.4.3 Reflection Crack Control .................................... 111-95
5.4.4 Subdrainage ............................................... 111-95
5.4.5 Thickness Design .......................................... 111-95

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5.4.6 Surface Milling ............................................ 111-105
5.4.7 Shoulders ................................................. 111-105
5.4.8 Widening ................................................. III- 106
5.5 AC Overlay of Fractured PCC Slab Pavement ......................... 111-106
5.5.1 Feasibility. ................................................ 111-107
5.5.2 Pre-overlay Repair .......................................... III-108
5.5.3 Reflection Crack Control .................................... 111-108
5.5.4 Subdrainage ............................................... III- 108
5.5.5 Thickness Design .......................................... 111-108
5.5.6 Shoulders ................................................. III- 111
5.5.7 Widening ................................................. III-111
5.6 AC Overlay of JPCP. JRCP. and CRCP ............................... III-113
5.6.1 Feasibility................................................. III-113
5.6.2 Pre-overlay Repair .......................................... III-113
5.6.3 Reflection Crack Control .................................... III-114
5.6.4 Subdrainage ............................................... III- 115
5.6.5 Thickness Design .......................................... III-115
5.6.6 Shoulders ................................................. III- 125
5.6.7 Widening ................................................. III- 125
5.7 AC Overlay of AC/JPCP. AC/JRCP. and AC/CRCP ..................... 111-125
5.7.1 Feasibility................................................. 111-125
5.7.2 Pre-overlay Repair .......................................... 111-127
5.7.3 Reflection Crack Control .................................... 111-127
5.7.4 Subdrainage ............................................... III-128
5.7.5 Thickness Design .......................................... 111-128
5.7.6 Surface Milling ............................................ 111-135
5.7.7 Shoulders ................................................. III- 135
5.7.8 Widening ................................................. III-136
5.8 Bonded Concrete Overlay of JPCP. JRCP. and CRCP ................... 111-136
5.8.1 Feasibility................................................. III- 136
5.8.2 Pre-overlay Repair .......................................... III- 137
5.8.3 Reflection Crack Control .................................... III- 137
5.8.4 Subdrainage ............................................... III- 137
5.8.5 Thickness Design .......................................... 111-137
5.8.6 Shoulders ................................................. III- 143
5.8.7 Joints .................................................... III-143
5.8.8 Bonding Procedures and Material ............................. III-145
5.8.9 Widening ................................................. III-145
5.9 Unbonded JPCP. JRCP. or CRCP Overlay of JPCP. JRCP. CRCP.
or AClPCC ...................................................... III-145
5.9.1 Feasibility................................................. HI- 145
5.9.2 Pre-overlay Repair .......................................... HI-145
5.9.3 Reflection Crack Control .................................... III-145
5.9.4 Subdrainage ............................................... III-146
5.9.5 Thickness Design .......................................... 111-146
5.9.6 Shoulders ................................................. 111-151
5.9.7 Joints .................................................... 111-151
5.9.8 Reinforcement ............................................. 111-153
5.9.9 Separation Interlayers ....................................... 111-153
5.9.10 Widening ................................................. 111-153
5.10 JPCP. JRCP. and CRCP Overlay of AC Pavement ...................... 111-153
5.10.1 Feasibility................................................. III-153

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Contents-Continued
5.10.2 Pre-overlay Repair ......................................... III- 153
5.10.3 Reflection Crack Control ................................... 111-153
5.10.4 Subdrainage .............................................. 111-154
5.10.5 Thickness Design ......................................... 111-154
5.10.6 Shoulders ................................................ 111-155
5.10.7 Joints ................................................... 111-155
5.10.8 Reinforcement ............................................ III- 155
5.10.10 Widening ................................................ III- 155

References for Chapter 5 ............................................... . III-157

PART IV MECHANISTIC-EMPIRICAL DESIGN PROCEDURES

1.1 Introduction ..................................................... 1v-3
1.2 Benefits ......................................................... 1v-4
1.3 Framework for Development and Application .......................... 1v-4
1.4 Implementation ................................................... 1v-7
1.4.1 Design Considerations ...................................... 1v-8
1.4.2 Input Data ................................................ 1v-8
1.4.3 Equipment Acquisition ...................................... 1v-9
1.4.4 Computer Hardware and Software............................. 1v-9
1.4.5 Training Personnel ......................................... 1v-9
1.4.6 Field Testing and Calibration ................................. 1v-10
1.4.7 Testing ................................................... 1v-10
1.5 Summary ........................................................ 1v-10

References for Part IV .................................................. 1v-11

APPENDICES
A. Glossary of Terms ................................................ A1
B. Pavement Type Selection Guidelines ................................. B1
C. Alternate Methods of Design for Pavement Structures . . . . . . . . . . . . . . . . . . . C1
D . Conversion of Mixed Traffic to Equivalent Single Axle Loads for
Pavement Design ................................................. D1
E. Position Paper on Shoulder Design .................................. El
F. List of Test Procedures ............................................ F1
G. Treatment of Roadbed Swelling and/or Frost Heave in Design ............ G1
H. Flexible Pavement Design Example .................................. H1
I. Rigid Pavement Design Example .................................... I1
J. Analysis Unit Delineation by Cumulative Differences ................... J1
K. vpical Pavement Distress Type-Severity Descriptions . . . . . . . . . . . . . . . . . . K1
L. Documentation of Design Procedures ................................ 11
M. An Examination of the AASHTO Remaining Life Factor . . . . . . . . . . . . . . . . M1
N. Overlay Design Examples .......................................... N1

Index ................................................................. 1

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