INDIANA DEPARTMENT OF TRANSPORTATION—2013 DESIGN MANUAL

CHAPTER 601

Pavement Design

Design Revision
Sections Affected
Memorandum Date
20-01 Jan. 2020 Previously 304-1.0 through 5.0

The design memorandum applicable revision date is noted in brackets next to each section heading
below.
TABLE OF CONTENTS

TABLE OF CONTENTS ................................................................................................................ 2

LIST OF FIGURES ......................................................................................................................... 3
601-1.0 INTRODUCTION ............................................................................................................ 4
601-2.0 HISTORY ......................................................................................................................... 4
601-3.0 ABBREVIATIONS .......................................................................................................... 6
601-4.0 INDOT PAVEMENT PHILOSOPHY ............................................................................. 8
601-5.0 PAVEMENT ANALYSIS AND DESIGN DEVELOPMENT ........................................ 9
601-5.01 INDOT Pavement Design Process ........................................................................... 11
601-5.01(01) INDOT Preliminary Pavement Scope ............................................................ 11
601-5.01(02) INDOT Pavement Design Analysis Assignment ........................................... 12
601-5.01(03) INDOT Preliminary Pavement Design .......................................................... 13
601-5.01(04) INDOT Final Pavement Design ..................................................................... 13
601-5.02 Local Public Agency (LPA) Pavement Design Process ............................................ 15
601-5.02(01) LPA Final Pavement Design for Locally-Owned, Non-NHS Routes ............. 15
601-5.02(02) LPA Final Pavement Design for State and NHS Routes ................................ 15
601-5.02(03) Standard Pavement Designs for Low Volume Roads and Trails .................... 16
601-5.02(04) Notification of Pavement Design Approval [Rev. Feb. 2018] ........................ 16
601-6.0 PAVEMENT DESIGN REQUEST AND INSTRUCTIONS ........................................ 16
Figures........................................................................................................................................... 17

Page 2 2013 Indiana Design Manual, Ch. 601

LIST OF FIGURES

Figure Title

601-4A Pavement Design Life

601-4B Performance Criteria for New or Rehabilitation HMA Pavement
601-4C Performance Criteria for New or Rehabilitation Concrete Pavement
601-4D MEPDG General Input Values for Asphalt Pavement
601-4E ESAL Category for QC/QA-HMA Mixtures
601-4F Mixture Type HMA Mixtures
601-5A INDOT Pavement Design Process
601-5B INDOT Pavement Design Process-LPA Projects Flowchart

2013 Indiana Design Manual, Ch. 601 Page 3

CHAPTER 601

PAVEMENT DESIGN

601-1.0 INTRODUCTION

This chapter provides guidance for the investigation, evaluation, and analysis of pavements for the
public roadway system under the jurisdiction of the Indiana Department of Transportation. It can
also be used by local governments in Indiana at their discretion. The pavement analysis should be
based on, but not limited to, sound pavement engineering principles, concepts, and economics, as
well as geotechnical conditions, environmental conditions, pavement material properties, and
traffic loadings. It is the ultimate goal and primary purpose of the pavement designer to determine
a pavement treatment that provides an appropriate level of service while yielding the least cost of
ownership to the Department unless otherwise directed by INDOT pavement staff. In the instance
that the most cost-effective pavement treatment lacks viability from either a project budget or
constructability standpoint, the pavement designer should work with INDOT pavement staff to
determine if a different pavement treatment should be recommended or if the programmatic intent
should be altered through change management.

601-2.0 HISTORY

The history of pavements in Indiana has transcended a number of types and configurations from
surfaces using bricks, aggregates, and Kentucky rock asphalt, to the most modern Superpave
Asphalt Binders. Kentucky rock asphalt is naturally occurring asphalt that has not been used in
recent years but can be found within an existing pavement structure when coring the roadway.
Sand surfaces were used extensively on asphalt pavements in the 1970’s and 1980’s. Both sand
surfaces and Kentucky rock asphalts appear as a relatively thin black dense layer in the core,
typically less than an inch thick.

Most of the initial interstate pavement constructed in the 1960’s and early 1970’s was either
continuously reinforce concrete (CRC) or jointed reinforced concrete pavement (JRCP) with 40-
ft joint spacing. In the early 1980’s these concrete pavements were undersealed and overlaid with
at least two lifts of HMA as a first rehabilitation measure. In the 1990’s the HMA was milled or
removed and new HMA applied as a rehabilitation measure. Also, in the 1990’s the HMA was
removed and the concrete pavements on the interstates were either cracked and seated, or rubblized
as a new method of slab reduction emerged, these concrete pavements were then resurfaced with
at least two lifts of HMA. INDOT did not get good performance from the cracked and seated

Page 4 2013 Indiana Design Manual, Ch. 601

pavements as the technology in equipment used to crack the concrete had not advanced enough.
However, it is not sound engineering to fully rely on a pavement’s history without obtaining
pavement cores, non-destructive tests, etc.

The National Highway System (NHS) routes were also constructed with different typical cross-
sections; such as variable thickness 9-7-9 in. from edge to center to edge with portland cement
concrete. These NHS routes were also typically 18 - 20 ft wide. Tilt sections were also common
in the early interstate and NHS pavements. As the tilt section pavements reached the point of
rehabilitation INDOT typically converted them to crown sections by milling and applying variable
thickness of HMA overlays.

Pavements on most state routes were initially 9-ft lanes, with little to no shoulders. Some of these
routes were initially county roads that were given to the State. Asphalt pavements used sand
surfaces, hot asphalt emulsions (HAE), bituminous coated aggregate (BCA) or “Greasy 5’s” on
these routes in the early days. The majority of all pavements today have been widened to at least
10-ft, 11-ft, or 12-ft lanes, with or without shoulders. Beginning in about 1992, SuperPave
Performance Grade (PG) binders were being used and replaced the Marshall Method of HMA
binder design. Beginning in 2011 most HMA pavement applied to these state routes with aggregate
or earth shoulders had the safety edge incorporated.

Underdrains have been utilized since the 1950’s. Transverse underdrains were some of the first
underdrains installed. Beginning in the 1960’s, longitudinal pipes were constructed along the
edges of the pavement and outlet to the side ditches. Geocomposite edge drains were used as
retrofit underdrains from the mid 1980’s to the mid 1990’s. From the mid 1990’s to present retrofit
underdrains consist of open graded material and 4-in. or 6-in. pipe along the pavement’s edge.
Little or no maintenance has been performed on the underdrain systems and studies show that poor
performance of the underdrain systems is a primary cause of failures of pavement structures.
INDOT has also improved on the design of underdrain systems since the mid 1990’s to facilitate
better maintenance. This includes 45º elbows to facilitate video logging, paved outlet protector
pads, and rodent screens. INDOT district maintenance now has underdrain maintenance as an
activity on the Work Management System (WMS).

2013 Indiana Design Manual, Ch. 601 Page 5

601-3.0 ABBREVIATIONS

AADT Average Annual Daily Traffic

AADTT Average Annual Daily Truck Traffic
AASHTO American Association of State Highway and Transportation Officials
AC Asphaltic Concrete
ACPA American Concrete Pavement Association
ADA Americans with Disabilities Act
ARRA Asphalt Recycling and Reclaiming Association
APAI Asphalt Pavement Association of Indiana
ASR Alkali-Silica Reactivity
ASTM American Society for Testing and Materials
BARM Basic Asphalt Recycling Manual
BCA Bituminous Coated Aggregate
CAB Compacted Aggregate Base
CAP Compacted Aggregate Pavement
CBR California Bearing Ratio
CCPR Cold Central Plant Recycling
CIR Cold In-Place Recycling
CPP Concrete Pavement Preservation
CPR Concrete Pavement Restoration
CR Cold Recycling
CRCP Continuously Reinforced Concrete Pavement
CTE Coefficient of Thermal Expansion
DMF Design Mix Formula (for HMA)
HAE Hot Asphalt Emulsion
ERC Employee of Responsible Charge
ERMS Electronic Records Management System
ESAL Equivalent Single Axle Load (18-kip)
EUAC Equivalent Uniform Annual Cost
FDR Full Depth Reclamation
FHWA Federal Highway Administration
FN Friction Number
FWD Falling Weight Deflectometer
GPR Ground Penetrating Radar
HIR Hot In-Place Recycling
HMA Hot Mix Asphalt
ICM Integrated Climatic Module
IHCP Interstate Highway Congestion Policy
ID Identification
IRI International Roughness Index

Page 6 2013 Indiana Design Manual, Ch. 601

JMF Job Mix Formula (for HMA)
JPCP Jointed Plain Concrete Pavement
JTRP Joint Transportation Research Program
PLCC Pavement Life-Cycle Cost
LCPCA Life-Cycle Pavement Cost Analysis
LL Liquid Limit
LOI Loss on Ignition
LPA Local Public Agency
LTE Load Transfer Efficiency
LTPP Long-Term Pavement Performance
MEPDG Mechanistic Empirical Pavement Design Guide
MOT Maintenance of Traffic
NCHRP National Cooperative Highway Research Program
NDT Non-Destructive Testing
NHS National Highway System
NMAS Nominal Maximum Aggregate Size
OG Open-Graded
PCC Portland Cement Concrete
PCCP Portland Cement Concrete Pavement
PG Binder Performance-Graded Binder
PI Plasticity Index
PM Preventive Maintenance
PMS Pavement Management System
PPG Pavement Peer Group
PPI Pavement Preservation Initiative
PV Present Value
PW Present Worth
QC/QA-HMA Quality Control / Quality Assurance Hot Mix Asphalt
QC/QA-PCCP Quality Control / Quality Assurance Portland Cement Concrete Pavement
RCBA Reinforced-Concrete Bridge Approach
RFC Ready for Contract
RH Relative Humidity
SMA Stone Matrix Asphalt
SUPERPAVE Superior Performing Asphalt Pavements
SV Salvage Value
TWRG Truck Weight Road Group
TCO Thin Concrete Overlay
UBWC Ultrathin Bonded Wearing Course
USCS Unified Soil Classification System
WMS Work Management System (INDOT Maintenance)

2013 Indiana Design Manual, Ch. 601 Page 7

601-4.0 INDOT PAVEMENT PHILOSOPHY

INDOT pavement analysis and design philosophy are based on producing the most effective
pavement section that provides acceptable service life at the least cost of ownership, represented
by cost/lane mile/year of life. INDOT pavements should be investigated, evaluated, analyzed, and
designed to cost the least amount of money over the design life of the treatment, and constructed
using Quality Control/Quality Assurance (QC/QA) materials to be durable and be structurally and
functionally sound through that entire period. This pavement design process includes, but is not
limited to:

1. Investigation
a. Determination of pavement history, age, treatment history, etc.
b. Falling Weight Deflectometer (FWD)
c. Generation and assessment of pavement cores
d. Geotechnical investigation
e. Pavement condition data
f. Traffic data forecast
g. Other special testing

2. Evaluation
a. Identify types of distresses; severity and extent
b. Identify causes of distresses
c. Identify functional versus structural distress

3. Analysis
a. Multiple pavement treatment alternatives
i. See Figure 601-4A, Pavement Design Life for details regarding the
minimum design life expected for various pavement treatments.
b. Mechanistic-Empirical Pavement Design Guide (MEPDG), AASHTOWare
Pavement ME Design Software
i. See Figure 601-4B, Performance Criteria for New or Rehabilitation HMA
Pavement for MEPDG performance inputs for asphalt pavement
ii. See Figure 601-4C, Performance Criteria for New or Rehabilitation
Concrete Pavement for MEPDG performance inputs for concrete pavement
iii. See Figure 601-4D, MEPDG General Input Values for Asphalt Pavement
for MEPDG general asphalt pavement input values
iv. See Figure 601-4E, ESAL Category for QC/QA-HMA Mixtures for
determining specific asphalt categories to be used in MEPDG analysis for
401 mixtures

Page 8 2013 Indiana Design Manual, Ch. 601

 v. See Figure 601-4F, Mixture Type HMA Mixtures for determining specific
asphalt types to be used in MEPDG analysis for 402 mixtures
c. Cost of ownership analysis for each pavement treatment
d. Life-Cycle Pavement Cost Analysis (LCPCA) for alternate bid projects. An
LCPCA example is available on the Pavement Engineering section of Standards
and Specifications webpage, http://www.in.gov/dot/div/contracts/standards/.
e. Maintenance considerations

601-5.0 PAVEMENT ANALYSIS AND DESIGN DEVELOPMENT

The pavement analysis and design process should be a continuous development flow as data is
collected, assessed and analyzed, converted to decision-support information and alternatives are
considered. The overall pavement design development process varies depending on whether the
project is an INDOT project or an LPA project. However, regardless of the project type and the
development requirements associated with the project type, there are general milestones to be
considered during the pavement design development process. The milestones include Preliminary
Pavement Design (no later than 30% (Stage 1) of overall project development), Final Pavement
Design (by 60% (Stage 2) of overall project development), and Pavement Design Validation at
90% (Stage 3) of overall project development).

The pavement designer will recommend the pavement type and thickness of the pavement layers
of the pavement structure based on subgrade conditions, materials, traffic, climate, economics, and
other considerations.

A Pavement Design Engineer is a qualified licensed engineer who has been trained in pavement
design analysis. Throughout this chapter the Pavement Design Engineer will be referred to as the
pavement designer. A pavement designer will be an INDOT Approved Consultant, a District
Pavement Engineer, or Central Office Pavement Engineer. For consultant pavement designers,
prequalification is required. See the INDOT Consultant Prequalification Manual for Pavement
Analysis – Design Services prequalification requirements. The manual is available on the INDOT
Consultants Prequalification webpage at https://www.in.gov/indot/2732.htm.

A pavement designer is responsible for the following:

1. Identification of the extent and severity of distresses,

2. Review and understand INDOT’s programming intent for the project

The pavement designer should determine feasible, acceptable, and suitable potential pavement
treatment solutions to address the project’s programming intent.

2013 Indiana Design Manual, Ch. 601 Page 9

3. Collection of pavement history

4. Determination of estimated cost of proposed pavement treatment alternatives,

5. Requests that other pertinent data, including but not limited to, the following be obtained:
a. Falling Weight Deflectometer (FWD)
b. Department’s pavement condition
c. Maintenance records
d. Cores
e. Geotechnical
f. Traffic data from appropriate source, with % truck
g. Ground Penetrating Radar (GPR)

6. Analysis
a. The pavement designer should provide multiple pavement design alternatives in
accordance with the Mechanistic-Empirical Pavement Design Guide (MEPDG)
methodology utilizing AASHTOWare Pavement ME Design software. The
pavement design analysis provided with the pavement report should support the
chosen alternative by depicting service lives and cost of ownership of the
alternative treatments.
i. Functional treatments must show a 30-year projection or until functional
failure is observed, whichever is further.
ii. Structural treatments must show a 50-year projection.
iii. When in doubt, show a 50-year projection.
b. Life-Cycle Pavement Cost Analysis (LCPCA)
c. Alternate Pavement Types/Treatments Determination (this will require
coordination with INDOT pavement staff)
d. Specifying pavement material properties and/or pay items

7. Future Maintenance Considerations

8. Pavement Design Validation at 90% of overall project development

9. Pavement Design Life: Functional and Structural

Page 10 2013 Indiana Design Manual, Ch. 601

601-5.01 INDOT Pavement Design Process

Every INDOT proposed pavement project is generally evaluated for proper treatment prior to being
added to a construction and funding program as a project in the Call for Projects. The project
intent and its impacts on the existing or new pavement structure should be understood by the
pavement designer prior to developing the pavement treatment recommendation.

Utility projects and other small projects that address isolated pavement issues that result in small
cuts of no more than 100 ft wide or long, will require that the pavement designer check the
structural adequacy of the existing pavement to carry the current and future projected traffic loads.
This minimal pavement design, unless otherwise directed, will include pavement history or cores,
pavement condition assessment, and appropriate drainage and subsurface drainage provisions.

601-5.01(01) INDOT Preliminary Pavement Scope

The project intent is not always driven by the pavement design, e.g., improved safety, addition of
travel lanes, interchange construction, improved sight distance, ADA compliance, correction of
deficient drainage, bridge projects, correction of geometric deficiencies, etc. The scoping engineer
must collaborate with the Central Office and District Pavement Engineer to determine the project
scope.

Pavement distresses are the first characteristics that should be determined and described in
consideration of the appropriate treatment for the project. See the Distress Identification Manual
for the Long-Term Pavement Performance Program, Publication Number: FHWA-RD-03-031,
latest edition for additional information.

The preliminary pavement treatment defined in the scope should identify potential pavement
alternatives to correct pavement structural or functional problems at the start of a project. The
preliminary pavement scope for INDOT projects will come from the data produced from the
Department’s Pavement Management System, such as International Roughness Index (IRI), rut
depth, Friction Number (FN), cracking, pavement history, maintenance history, as well as any
additional data that is available or recommendations from INDOT pavement personnel. It may not
include FWD data, cores and geotechnical investigation.

2013 Indiana Design Manual, Ch. 601 Page 11

The preliminary pavement scope will fall into one of the following four project categories:

1. New Alignment,

2. Pavement Reconstruction,

3. Pavement Rehabilitation

4. Preventive Maintenance

Each category has numerous alternative treatments to be considered to accomplish the intent of
the project. Added travel lanes projects may be included in Pavement Reconstruction, Pavement
Rehabilitation or Preventive Maintenance (Mill and Fill) Projects.

601-5.01(02) INDOT Pavement Design Analysis Assignment

INDOT Central Office Pavement Engineering will assign a preliminary pavement design project
or a final pavement design project to an INDOT Pavement Engineer or an INDOT Approved
Consultant Pavement Engineer and notify the District Project Manager of the assignment. INDOT
Approved Consultant Pavement Engineers who receive a pavement design assignment should
follow steps 1-4 below, while INDOT Pavement Engineer should proceed to step 4 below.

1. Receive project specific information from INDOT Central Office Pavement Engineering

2. Review the available project specific information, determine the Project Manager, and
determine the Design Engineer for the project.

3. Review the project type and scope, prepare a scope and fee to complete the pavement
design process, and submit the proposed scope and fee to INDOT Central Office Pavement
Engineering and the District Project Manager.

4. Prepare a pavement design for the project assignment

a. If a preliminary pavement design project has been assigned proceed with the
preliminary pavement design process, see Section 601-5.01(03).
b. If a final pavement design project has been assigned, complete a final pavement
per the final pavement design process, see Section 601-5.01(04).

See Figure 601-5A, INDOT Pavement Design Process-INDOT Projects Flowchart for details
regarding the pavement design process.

Page 12 2013 Indiana Design Manual, Ch. 601

601-5.01(03) INDOT Preliminary Pavement Design

The pavement designer, in collaboration with the Pavement Area Engineer, should submit a
preliminary pavement proposal for review no more than 30 days after the acceptance of the
proposed pavement design scope and fee. The preliminary pavement design should consist of the
following:

1. clear identification of pavement type, extent, and severity of distresses;

2. core report, if available, with core photographs to determine pavement structure;
3. site visit findings and recommendations with photographs;
4. other pavement history and data, such as original construction and all rehabilitations;
5. recommended pavement treatment alternatives based on distresses;
6. structural capacity of the pavement treatment alternatives based on initial AASHTOWare
Pavement ME software iterations, using assumed input data based on engineering
judgement where technical data is unavailable;
7. determination of estimated cost of recommended pavement treatment alternatives; and
8. traffic data, with % truck.

The preliminary pavement design should state what subsequent additional activities or testing must
be obtained, i.e., a geotechnical investigation, FWD data, cores, projected construction year traffic
data, and/or other testing data. The subsequent activities should be as appropriate to further identify
the causes of distress and obtain necessary data to help select the appropriate alternative and to
finalize the design to achieve the most effective solution at least cost of ownership.

601-5.01(04) INDOT Final Pavement Design

The pavement designer will determine if all pertinent data to complete a final pavement design is
available. If all pertinent data to complete a pavement design is not available, the pavement
designer will work with the Pavement Area Engineer, the District Pavement Engineer, and when
necessary the District Project Manager to obtain the necessary information required to complete a
final pavement design. Once all pertinent project data has been provided to the pavement designer,
a draft of final pavement design should be completed and submitted to INDOT Central Office
Pavement Engineering for review.

The final pavement design memorandum should include the intent of the project, existing
pavement type, history of the pavement from initial construction through the last treatment,
thickness of all layers, site visit findings and recommendations, test data findings and
recommendations, key professional engineering assumptions and facts, table of design data,
pavement design recommendations, patching summary table, and other pertinent information, i.e.,
critical utilities issues, recommend future maintenance schedule, and key constructability issues.
Constructability issues may include temporary widening, temporary runarounds, temporary ramps,

2013 Indiana Design Manual, Ch. 601 Page 13

 assumed pavement thicknesses or variations, profile grade assumptions, and other challenges. A
patching summary table should be approved by the District Pavement Engineer and the design
engineer and included in the contract documents before the letting.

A pavement designer contracted by INDOT should submit the final pavement design by
memorandum on their letterhead including a report with the information listed below. The
submittal should provide evidence that all pavement designs are checked and signed by a qualified
peer. The executive summary should be clear and concise and only include the necessary pavement
information to implement the design.

1. Executive Summary;
2. Project Description;
3. Pavement History;
4. Methodology for selecting preferred pavement strategy;
5. Assessment of Current Pavement Condition (Functional and Structural) with photographs;
6. Pavement Design and Recommendations, including at least one feasible Alternate
Pavement treatment;
7. Life-Cycle Pavement Cost Analysis (LCPCA) for projects equal to or greater than 10,000
yd²;
8. Functional and Structural life of the pavement alternatives analyzed;
9. Construction and Maintenance Issues and Concerns; and
10. Appendices as follows:
a. Traffic Data;
b. Geotechnical Investigation Report;
c. Pavement Cores with Photographs and Pavement Distress Photographs;
d. Non-Destructive Testing Results, such as FWD;
e. HMA Binder Selection using LTPPBind;
f. Typical Sections;
g. AASHTOWare Pavement ME Design Input Summary;
h. AASHTOWare Pavement ME Design output, at least the optimal design and then one
failure iteration; and
i. LCPCA Results.

After the draft of the final pavement design has been reviewed and approved by the INDOT Central
Office Pavement Engineering Assigned Reviewer, the final pavement design should be signed,
stamped, and sealed with an active Indiana Professional Engineer (PE) stamp by the responsible
Engineer for the project. The final pavement design should then be routed by the Central Office
pavement designer through the District Pavement Engineer for their review and approval. After
district approval, a copy of the design will be sent to the Pavement Area Engineer and Pavement
Director. Finally, the pavement design will be reviewed and approved by the Manager of the

Page 14 2013 Indiana Design Manual, Ch. 601

Pavement Division. The approved final pavement design is then returned to the designer and
project manager. This process assures that all pavement designs are checked by a qualified peer.

601-5.02 Local Public Agency (LPA) Pavement Design Process

The qualifications of the pavement designer noted in Section 601-5.0 apply to LPA
Projects that involve federal funding. The project intent and its impacts on the pavement structure
should be understood prior to developing the pavement treatment recommendation. LPA pavement
designs may be reviewed by INDOT as noted in the following sections.

601-5.02(01) LPA Final Pavement Design for Locally-Owned, Non-NHS Routes

Projects that include work on a locally-owned, non-NHS route do not require review and
approval by INDOT.

The LPA may follow the INDOT pavement design process (Section 601-5.01), or choose
to use their own pavement design criteria. If the INDOT pavement design process is chosen, it is
the LPA’s responsibility to request FWD testing and analysis through ITAP.

Where an LPA chooses to use their own pavement design criteria, the following will apply:

• The LPA is responsible for the design and performance of the pavement section.
• A Life-Cycle Pavement Cost Analysis in accordance with Section 606-1.0 is not required.
• It is the LPA’s responsibility to ensure that the pavement pay items are compatible with
the INDOT Standard Specifications.
• If the LPA uses a standard typical pavement section, it must be included in the final
pavement design.
• The final pavement design must be initialed by the Employee in Responsible Charge
(ERC) sealed, signed, and dated by a licensed Indiana Professional Engineer and
uploaded to ERMS as the Final Pavement Design.
See Figure 601-5B, INDOT Pavement Design Process-LPA Projects Flowchart for details
regarding LPA pavement design process requirements.

601-5.02(02) LPA Final Pavement Design for State and NHS Routes

Projects that include work on a State route or NHS route must be reviewed and approved
by a Central Office Pavement Design Engineer and follow the INDOT pavement design
process. See Section 601-5.01.

2013 Indiana Design Manual, Ch. 601 Page 15

601-5.02(03) Standard Pavement Designs for Low Volume Roads and Trails

Standard pavement sections may be used in lieu of project-specific pavement designs for
low volume roads and trails as follows:

1. Aggregate Pavement on Low Volume Roads, AADTT ≤ 50 trucks. The pavement section
will consist of:

4 in. Compacted Aggregate No. 73, on

6 in. Compacted Aggregate No. 53, on
Subgrade Treatment, Type III, or as specified in the geotechnical report

2. Trails and other Non-Vehicular Use Facilities. The pavement sections will consist of the
section as shown on the INDOT Standard Drawings series 502-NVUF for concrete
pavement and 604-NVUF for HMA pavement.

601-5.02(04) Notification of Pavement Design Approval [Rev. Feb. 2018]

For projects reviewed and approved by INDOT, the Central Office pavement engineer will
send a Letter of Pavement Analysis/Design Acceptance (acceptance letter) to the ERC,
INDOT project manager, and the LPA pavement designer.

The acceptance letter should be initialed by the ERC, combined with the final pavement
design, and uploaded into ERMS as the Final Pavement Design. Preferably, the file
should be uploaded within two weeks of receiving the acceptance letter. The pavement
designer should notify the district coordinator, INDOT project manager, INDOT Central
Office Pavement Design Coordinator, and the ERC when the file has been uploaded.

601-6.0 PAVEMENT DESIGN REQUEST AND INSTRUCTIONS

A Pavement Design Request should be submitted to the Pavement Design Coordinator. An

editable version of the Pavement Design Request and instructions are available for download from
the Department’s website at www.in.gov/dot/div/contracts/design/dmforms/. An incomplete
Pavement Design Request will be returned without review.

Page 16 2013 Indiana Design Manual, Ch. 601

 Minimum Acceptable Design Life,
Pavement-Work Type
Years2
CRCP (Continuously Reinforced Concrete Pavement) 50
PCCP 30
PCCP over Existing Pavement 25
HMA Pavement with SMA 20
HMA with Surface Overlay on Rubblized PCCP 20
HMA Pavement 20
HMA Overlay on CRCP 20
HMA Overlay on Rubblized PCCP 20
Thin Concrete Overlay (TCO) 20
HMA Overlay on Cracked and Seated PCCP 12
HMA Overlay over Asphalt
Rehabilitation ( ≥ 3 layers) 18
Rehabilitation ( 2 layers) 15
Preventative Maintenance (1 layer) 1 9
HMA Overlay over PCCP
Rehabilitation ( ≥ 3 layers) 15
Rehabilitation (2 layers) 12
Full Depth Reclamation
FDR with Surface Treatment 6
FDR with HMA Overlay 15
Cold In-Place Recycling (CIR) 10
Cold Central Plant Recycling 10
Hot In-Place Recycling (HIR) 6
PCCP Joint Sealing 8

PAVEMENT DESIGN LIFE

Figure 601-4A
(Page 1 of 2)
 Minimum Acceptable Design Life,
Pavement-Work Type
Years2
Ultrathin Bonded Wearing Course (UBWC) 9
Microsurface Overlay 8
Thin HMA Overlay with Profile Milling 9
Concrete Pavement Rehabilitation (CPR) Techniques 6
Chip Seal 4
Asphalt Crack Sealing, Rout and Seal 3
Asphalt Crack Filling 1

1
The performance period should be decreased to 8 yr for existing composite HMA.

2
It is the ultimate goal and primary purpose of the pavement designer to determine a
pavement treatment that yields the least cost of ownership to the Department unless
otherwise directed by INDOT pavement staff. In the instance that the most cost-
effective pavement treatment lacks viability from either a project budget or
constructability standpoint, the pavement designer should work with INDOT pavement
staff to determine if a different pavement treatment should be recommended or if the
programmatic intent should be altered through change management.

PAVEMENT DESIGN LIFE

Figure 601-4A
(Page 2 of 2)
 Performance Performance Limit at End of Reliability Reliability
Criteria Design Life New Pavement Design Overlay Design

Freeway: 160 90% 90%

Arterial, Urban: 190 90% 90%
Terminal IRI Arterial, Rural: 200 85% 85%
(in./mi.) Collector, Urban: 190 80% 80%
Collector, Rural: 200 75% 75%
Local: 200 70% 70%
Freeway: 2000 90% 90%
Arterial, Urban: 2000 90% 90%
AC Top-Down Arterial, Rural: 2000 85% 85%
Fatigue Cracking
(ft./mi.) Collector, Urban: 2000 80% 80%
Collector, Rural: 2000 75% 75%
Local: 2000 70% 70%
Freeway: 10 90% *50%
Arterial, Urban: 20 90% *50%
AC Bottom-Up Arterial, Rural: 25 85% *50%
Fatigue Cracking
(% lane area) Collector, Urban: 30 80% *50%
Collector, Rural: 35 75% *50%
Local: 35 70% *50%
Freeway: 500 90% *50%
Arterial, Urban: 500 90% *50%
AC Thermal Arterial, Rural: 500 85% *50%
Cracking (ft/mi/lane) Collector, Urban: 500 80% *50%
Collector, Rural: 500 75% *50%
Local: 500 70% *50%

PERFORMANCE CRITERIA FOR NEW OR REHABILITATION HMA PAVEMENT

Figure 601-4B (Page 1 of 2)

 Performance Performance Limit at End of Reliability Reliability
Criteria Design Life New Pavement Design Overlay Design

Freeway: 0.75 90% 90%

Arterial, Urban: 0.75 90% 90%
Permanent
Deformation - Total Arterial, Rural: 0.75 85% 85%
Pavement Collector, Urban: 0.75 80% 80%
(in.)
Collector, Rural: 0.75 75% 75%
Local: 0.75 70% 70%
Freeway: 0.40 90% 90%
Arterial, Urban: 0.40 90% 90%
Permanent
Deformation - AC Arterial, Rural: 0.40 85% 85%
Only Pavement Collector, Urban: 0.40 80% 80%
(in.)
Collector, Rural: 0.40 75% 75%
Local: 0.40 70% 70%
Freeway: 10 - 90%
Arterial, Urban: 20 - 90%
AC Total Fatigue
Cracking: Bottom- Arterial, Rural: 25 - 85%
Up + Reflective Collector, Urban: 30 - 80%
(% Lane Area)
Collector, Rural: 35 - 75%
Local: 35 - 70%
Freeway: 2500 - 90%
Arterial, Urban: 2500 - 90%
AC Total Transverse
Cracking: Thermal + Arterial, Rural: 2500 - 85%
Reflective Collector, Urban: 2500 - 80%
(ft./mi.)
Collector, Rural: 2500 - 75%
Local: 2500 - 70%
* AC Bottom-Up Cracking and AC Thermal Cracking reliability for overlays are for analysis
purposes only and should not be used as a criteria, because they cannot be visually distinguished
from reflective cracking.

PERFORMANCE CRITERIA FOR NEW OR REHABILITATION HMA PAVEMENT

Figure 601-4B (Page 2 of 2)

 Performance Performance Limit at End of
Reliability
Criteria Design Life
Freeway: 160 90%
Arterial, Urban: 190 90%
Terminal IRI Arterial, Rural: 200 85%
(in./mi) Collector, Urban: 190 80%
Collector, Rural: 200 75%
Local: 200 70%
Freeway: 10 90%
Arterial, Urban: 10 90%
Transverse Slab Arterial, Rural: 10 85%
Cracking
(%) Collector, Urban: 10 80%
Collector, Rural: 10 75%
Local: 10 70%
Freeway: 0.15 90%
Arterial, Urban: 0.20 90%

Mean Joint Faulting Arterial, Rural: 0.22 85%

(in.) Collector, Urban: 0.25 80%
Collector, Rural: 0.25 75%
Local: 0.25 70%

PERFORMANCE CRITERIA FOR NEW OR REHABILITATION CONCRETE

PAVEMENT

Figure 601-4C
 Asphalt General Input Value
Reference Temperature, °F 70
Thermal Conductivity, Asphalt, BTU/h-ft-°F 0.63
Heat Capacity, Asphalt, BTU/lb-°F 0.31
Poisson Ratio 0.35

Volumetric NMAS,
Value
Properties as Built mm
25.0 8.7
19.0 9.5
Effective Binder
12.5 10.7
Content, %
9.5 11.6
SMA 9.5 13.4
25.0 8
19.0 8
Air Voids, % 12.5 8
9.5 8
SMA 9.5 7
25.0 144.4
19.0 143.8
Total Unit Weight,
12.5 143.08
lb/ft3
9.5 142.6
SMA 9.5 160

MEPDG GENERAL INPUT VALUES

FOR ASPHALT PAVEMENT

Figure 601-4D
 Initial AADTT, Design ESALs, QC/QA-HMA
trucks per day millions* Category**
AADT < 510 ESAL < 3 2
510 ≤ AADTT < 1700 3 ≤ ESAL < 10 3
AADTT ≥ 1700 ≥ 10 4
2-LANE ROAD

Initial AADTT, Design ESALs, QC/QA-HMA

trucks per day millions* Category**
AADTT < 570 <3 2
570 ≤ AADTT < 1900 3 ≤ ESAL < 10 3
AADTT ≥ 1900 ≥ 10 4
4-LANE ROAD

Initial AADTT, Design ESALs, QC/QA-HMA

trucks per day millions* Category**
AADTT < 870 <3 2
870 ≤ AADTT < 2900 3 ≤ ESAL < 10 3
AADTT ≥ 2900 ≥ 10 4

6-LANE ROAD

Initial AADTT, Design ESALs, QC/QA-HMA

trucks per day millions* Category**
AADTT < 1140 <3 2
1140 ≤ AADTT < 3800 3 ≤ ESAL < 10 3
AADTT ≥ 3800 ≥ 10 4

8-LANE ROAD

*ESAL values based on INDOT calculations of ESALs

**For open-graded mixtures OG 19.0 and 25.0, the QC/QA-HMA Category is 4

ESAL CATEGORY FOR QC/QA-HMA MIXTURES

Figure 601-4E
 Initial AADTT, Design ESALs, HMA
trucks per day millions* Category

AADT < 510 <3 B

510 ≤ AADTT < 1700 3 ≤ ESAL < 10 C
AADTT ≥ 1700 ≥ 10 D
2-LANE ROAD

Initial AADTT, Design ESALs, HMA

trucks per day millions* Category
AADTT < 570 <3 B
570 ≤ AADTT < 1900 3 ≤ ESAL < 10 C
AADTT ≥ 1900 ≥ 10 D
4-LANE ROAD

Initial AADTT, Design ESALs, HMA

trucks per day millions* Category
AADTT < 870 <3 B
870 ≤ AADTT < 2900 3 ≤ ESAL < 10 C
AADTT ≥ 2900 ≥ 10 D
6-LANE ROAD

Initial AADTT, Design ESALs, HMA

trucks per day millions* Category
AADTT < 1140 <3 B
1140 ≤ AADTT < 3800 3 ≤ ESAL < 10 C
AADTT ≥ 2900 ≥ 10 D
8-LANE ROAD

*ESAL values based on INDOT calculations of ESALs

MIXTURE TYPE FOR HMA MIXTURES

Figure 601-4F
 NOTES:

1. This flowchart diagram outlines the general steps to be taken when

completing a pavement design for INDOT projects. Detailed
Central Office Pavement Engineering Initiates Pavement Design Process 2
information regarding the pavement design process and the necessary
requirements can be found in Chapter 600 of the Indiana Design
Manual.
Central Office Pavement Engineering Assigns
Pavement Design to In-House or INDOT
INDOT Consultant In-House 2 The entire process, from the time Central Office pavement engineering
Approved Consultant Pavement Engineer and
Process Process assigns the pavement design to either a consultant or to an in-house
Notifies District Project Manager of
engineer to the submittal of the final pavement design report is
Assignment Within (1) Week
typically (120) days.
Consultant to Receive, from
Central Office Pavement Engineering 3 See specifics outlined in Chapter 600 of theIndiana Design Manual
.
or the District, Project Specific Information

4 The "design engineer" or "consultant designer" for each project is the

designer preparing the roadway plans and geometrics for the project,
Consultant to Review Project Type,
sometimes referred to as the site designer.
Prepare Scope and Fee for
Assigned Project and Submit to
5 PM = Project Manager
Central Office Pavement Engineering

6 PE = Professional Engineer

Cental Office Pavement Engineering

5 to Send Approval to Consultant
for Scope/Fee and Copy District PM Final Pavement Design
Report is Routed
for Approval Signatures
Following the INDOT
Pavement Design Engineer
Final Approval Process
to Submit Draft of
Prepare Preliminary pavement 3 Final Pavement Design
design report using interim technical Report to Cental Office
Is assignment for Design Engineer Submits
datafor missing technical data, Proceed Pavement Engineering
Proceed with Preliminary Preliminary final design or Final the Approved Pavement
gather information from past projects with Final Pavement
Pavement Design Process preliminary design? Design Report Into
or data from other readily available sources. Design Process
ERMS by Stage 2
The preliminary pavement design Draft of Final 4 or No Later than
report is to be complete within (30) days. Pavement Design Report (1) Year Prior to Letting
is Reviewed/Approved
by Cental Office
Design Engineer to Submit Pavement Engineering
Central Office Pavement
Preliminary Pavement Design Report Assigned Reviewer
Is all necessary Engineering Sends Final
to Central Office Pavement Engineering Yes
project data available? Pavement Design Report
for Review and Approval
to the Design Engineer
Final Pavement Design
and District PM for
Report is Signed,
Inclusion in the
Entire ProcessTakes Stamped, and Sealed
Final Project File
Approximately (45) Days Work with Cental Office with Active PE
6
Pavement Engineering Stamp by the
No
to Obtain Needed Data and Responsible Engineer
Entire Process Takes
Begin Pavement Analysis for the Project
Approximately(120) Days
Using Interim Technical Data
for Missing Technical Data

INDOT PAVEMENT DESIGN PROCESS

INDOT PROJECTS

Figure 601-5A
 INDOT Cental Office
Pavement Engineering Receives
from the LPA the Pavement
Design Report and the
Request for Accptance
of Pavement Design

LPA Design Engineer

to Address INDOT Comments Submitted Final Pavement
Design Report Shall Is the LPA INDOT Will Not Review
Yes Is the project on No using their own Yes
Adhere to the Requirements the Pavement Design but
a State or NHS route? design standards?
for LPA Projects, is Available for Assistance
Yes Outlined in Chapter 600-5.0(02) or Guidance, if Needed
of the Indiana Design Manual

No
Work on a State or NHS Route
Does Cental Office Must be Submitted to,

pavement engineering Reviewed, and Approved

by a Cental Office Pavement Unless Requested by the LPA, Final Pavement Design
have comments that Report Must be Initialed
Design Engineer and INDOT Will Not Reveiw the
need to be addressed? Follow the INDOT Pavement Design but is Available by the ERC, Sealed, Signed,
Pavement Design Process for Assistane or Guidance, If Needed and Dated by a Licensed
Indiana Professional Engineer
and Uploaded Into ERMS

Final Pavement Design

No
Report Must be
Initialed by the ERC,
Central Office Pavement
Sealed, Signed, and Dated
Engineering to Send
by a Licensed LPA Standard Drawing(s)
Final Accepted Design
Indiana Professional Engineer Must be Included in the
to LPA Design Engineer,
and Uploaded into ERMS Final Pavement Design
District Project Manager,
and ERC Report Submittal

Acceptance Letter Shall be

LPA is to Follow
Intialted by the ERC,
Pavement Design Standards
Combined With the
within Chapter 304
Final Pavement Design,
of the Indiana Design Manual
and Uploaded Into ERMS
as the Final Pavement
Design and Notify
All Necessary Individuals
NOTES:

1. This flowchart diagram outlines the general steps to be taken when

Acceptance Letter and Design completing a pavement design for LPA projects, detailed information
Shall be Submitted With the Final Tracings regarding the pavement design process and the necessary
INDOT PAVEMENT DESIGN PROCESS requirements can be found in Chapter 600 of theIndiana Design
Manual
.
LPA PROJECTS
2. The "design engineer" or "consultant engineer" for each project is the
Figure 601-5B
designer preparing the roadway plans and geometrics for the project,
sometimes referred to as the site designer.