Development of Design Guide for Thin and Ultrathin Concrete Overlays of Existing Asphalt Pavements

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General Information
Study Number: TPF-5(165)
Lead Organization: Minnesota Department of Transportation
Contract Start Date: Sep 12, 2008
Solicitation Number: 1068
Partners: IADOT, KS, MN, MO, MS, NC, NY, PADOT, SD, TX
Status: Closed
Est. Completion Date: Jan 13, 2013
Contract/Other Number:
Last Updated: Apr 05, 2018
Contract End Date: Sep 11, 2013
Financial Summary
Contract Amount: $360,000.00
Total Commitments Received: $515,200.00
100% SP&R Approval: Approved
Contact Information
Lead Study Contact(s): Lisa Jansen
lisa.jansen@state.mn.us
Phone: 651-366-3779
Organization Year Commitments Technical Contact Name Funding Contact Name Contact Number Email Address
Iowa Department of Transportation 2012 $12,500.00 Chris Brakke Cheryl Cowie 515-239-1447 Cheryl.Cowie@iowadot.us
Kansas Department of Transportation 2012 $25,000.00 Greg Schieber David Behzadpour 785-291-3847 David.Behzadpour@ks.gov
Minnesota Department of Transportation 2006 $20,000.00 Tom Burnham Lisa Jansen 651-366-3779 lisa.jansen@state.mn.us
Minnesota Department of Transportation 2007 $20,000.00 Tom Burnham Lisa Jansen 651-366-3779 lisa.jansen@state.mn.us
Minnesota Department of Transportation 2008 $20,000.00 Tom Burnham Lisa Jansen 651-366-3779 lisa.jansen@state.mn.us
Minnesota Department of Transportation 2011 $9,200.00 Tom Burnham Lisa Jansen 651-366-3779 lisa.jansen@state.mn.us
Minnesota Department of Transportation 2012 $12,500.00 Tom Burnham Lisa Jansen 651-366-3779 lisa.jansen@state.mn.us
Mississippi Department of Transportation 2007 $20,000.00 Bill Barstis James Watkins 601-359-7650 jwatkins@mdot.state.ms.us
Mississippi Department of Transportation 2008 $20,000.00 Bill Barstis James Watkins 601-359-7650 jwatkins@mdot.state.ms.us
Mississippi Department of Transportation 2009 $20,000.00 Bill Barstis James Watkins 601-359-7650 jwatkins@mdot.state.ms.us
Mississippi Department of Transportation 2011 $9,200.00 Bill Barstis James Watkins 601-359-7650 jwatkins@mdot.state.ms.us
Missouri Department of Transportation 2007 $20,000.00 John Donahue Bill Stone 573-526-4328 william.stone@modot.mo.gov
Missouri Department of Transportation 2008 $20,000.00 John Donahue Bill Stone 573-526-4328 william.stone@modot.mo.gov
Missouri Department of Transportation 2009 $20,000.00 John Donahue Bill Stone 573-526-4328 william.stone@modot.mo.gov
Missouri Department of Transportation 2011 $9,200.00 John Donahue Bill Stone 573-526-4328 william.stone@modot.mo.gov
Missouri Department of Transportation 2012 $12,500.00 John Donahue Bill Stone 573-526-4328 william.stone@modot.mo.gov
New York State Department of Transportation 2007 $20,000.00 William Cuerdon Gary Frederick 518-457-4645 gary.frederick@dot.ny.gov
New York State Department of Transportation 2008 $20,000.00 William Cuerdon Gary Frederick 518-457-4645 gary.frederick@dot.ny.gov
New York State Department of Transportation 2009 $20,000.00 William Cuerdon Gary Frederick 518-457-4645 gary.frederick@dot.ny.gov
New York State Department of Transportation 2011 $9,200.00 William Cuerdon Gary Frederick 518-457-4645 gary.frederick@dot.ny.gov
North Carolina Department of Transportation 2012 $12,500.00 Nilesh Surti Mrinmay Biswas 919-508-1865 biswas@ncdot.gov
Pennsylvania Department of Transportation 2007 $20,000.00 Scott Nazar Lisa Tarson (717) 705-2202 ltarson@pa.gov
Pennsylvania Department of Transportation 2008 $20,000.00 Scott Nazar Lisa Tarson (717) 705-2202 ltarson@pa.gov
Pennsylvania Department of Transportation 2009 $20,000.00 Scott Nazar Lisa Tarson (717) 705-2202 ltarson@pa.gov
Pennsylvania Department of Transportation 2011 $9,200.00 Scott Nazar Lisa Tarson (717) 705-2202 ltarson@pa.gov
Pennsylvania Department of Transportation 2012 $12,500.00 Scott Nazar Lisa Tarson (717) 705-2202 ltarson@pa.gov
South Dakota Department of Transportation 2012 $12,500.00 Darin Hodges David Huft 605-773-3358 dave.huft@state.sd.us
Texas Department of Transportation 2006 $20,000.00 Hua Chen Ned Mattila 512-416-4727 ned.mattila@txdot.gov
Texas Department of Transportation 2007 $20,000.00 Hua Chen Ned Mattila 512-416-4727 ned.mattila@txdot.gov
Texas Department of Transportation 2008 $20,000.00 Hua Chen Ned Mattila 512-416-4727 ned.mattila@txdot.gov
Texas Department of Transportation 2011 $9,200.00 Hua Chen Ned Mattila 512-416-4727 ned.mattila@txdot.gov

Study Description

Thin (TCOAP) and ultra-thin (UTCOAP) concrete overlays of existing asphalt pavement (also known as whitetoppings) are a pavement rehabilitation option that has been increasing in popularity in the U.S. over the past 15 years. The recent International Conference on Best Practices for Ultra-thin and Thin Whitetoppings (April 2005) demonstrated that many states now have experience with at least a couple of completed COAP projects. The recently completed NCHRP Synthesis 338 on Thin and Ultra-thin Whitetopping also shows the use of this product is currently of great interest to the transportation community.

The one area of deficiency in the application of TCOAP and UTCOAP (TWT and UTW whitetoppings) is the lack of a unified national design guide. While several local and industry design guides have been formulated, few are based on mechanistic-empirical research born out of actual field performance. To address this issue, many research studies on the accelerated and field performance of TCOAP and UTCOAP are either in progress, or have been recently completed. The Minnesota Road Research (MnROAD) Project has contributed significantly to the understanding of the field performance of TCOAP and UTCOAP. The results from MnROAD and other accelerated loading facilities (ex. FHWA) can now be utilized to develop a unified comprehensive mechanistic-empirical based design method for thin and ultra-thin concrete overlays of existing asphalt pavement.

Most of the existing TCOAP and UTCOAP test sections have been built on top of structurally sound asphalt pavements. Researchers and pavement designers still question the service life of these overlays when placed on older, distressed asphalt pavements. This study will have an opportunity to utilize early performance data from a thin concrete overlay of a distressed full-depth asphalt pavement to be constructed at MnROAD in 2008 (funding for the construction and monitoring of the test cell is not part of this study). Experience and knowledge from other related case histories will also be utilized.

Objectives

The primary purpose of this project is to create a unified national design guide for thin and ultrathin concrete overlays of existing asphalt pavements. This consists of the following distinct objectives:

1. Study and understand the field performance history of TCOAP and UTCOAP as demonstrated by various research test sections. These include current (and future) test sections at the MnROAD facility, accelerated loading facility test sections (FHWA), and other test sections installed and monitored by various local, national and international agencies.

2. Develop a design guide for concrete overlays of existing asphalt pavements utilizing existing validated performance models, as well as new analytical models derived to address design aspects not currently considered in existing methods. The design guide will be based on mechanistic-empirical principles, including the effects of various concrete overlay and existing asphalt materials, panel thickness and geometry, joint opening and stiffness, traffic loads, and climates under which they must perform.

3. Create a user-friendly design guide software program and user¿s manual. The program format should be such that it could become a module in the future national Mechanistic-Empirical Pavement Design Guide (MEPDG) for highway pavements.

Scope of Work

This research project would be carried out in 5 tasks:

1. Literature review of existing TCOAP and UTCOAP (TWT and UTW) design methods and field experiments.

2. Development of layer bonding degradation model(s) based on field testing results (and limited laboratory testing if beneficial).

3. Development of new, or improvement of existing, TCOAP and UTCOAP pavement response and performance prediction models that incorporate slab thickness and geometry, joint opening and stiffness, axle load configuration, condition of the existing asphalt pavement, and degradation of layer bonding with time (if any).

4. Development of a unified national mechanistic-empirical design guide for thin and ultrathin concrete overlays of existing asphalt pavements. The design guide, in the form of a user-friendly software program and user¿s manual, will accommodate a variety of climate conditions, axle load configurations, existing asphalt material conditions, and time dependent bonding conditions between layers.

5. Provide guidance on how the design guide can be implemented into future versions of the national MEPDG for highway pavements.

Comments

Formally titled "Analysis Of MnROAD Whitetopping Performance data For A Module In The Design Guide"

This study will provide a unified national design process that could eventually be incorporated into the national MEPDG for highway pavements. States and Agencies will benefit from this process of developing a user-friendly design process through the synergistic machinery of a multi-state pooled fund.

Additional funds are required to complete Task 3. States should commit an addiontal $9,200 for CY 2011 to complete this task.

Documents Attached
Title File/Link Type Privacy Download
Final Report Part 1 BCOA-ME Theory Manual BCOA ME Theory Manual.pdf Final Report Public
Final Report Part 2 BCOA-ME Users Guide BCOA ME User's Guide.pdf Final Report Public
Acceptance Memo Acceptance_Letter_TPF-5165.pdf Memorandum Public
TPF-5(165) Closeout Letter TPF-5(165) Closeout Letter - Signed.pdf Memorandum Public
TAP Meeting Minutes 12-02-08 TAP_Meeting_Minutes_12-02-08.pdf Other Public
TAP Meeting Minutes 10-15-2011 TAP Meeting Minutes 10-5-11.docx Other Public
TPF-5(165) Closeout Funding Spreadsheet TPF-5(165) Closeout Funding Spreadsheet.pdf Other Public
Quarterly Report: January - March 2008 Quarterly_Report_2008-03.pdf Quarterly Progress Report Public
Quarterly Report: April-June 2008 Quarterly_Report_2008-06.pdf Quarterly Progress Report Public
Quarterly Report: July - September 2008 Quarterly_Report_2008-09.pdf Quarterly Progress Report Public
Quarterly Report: October-December 2008 Quarterly_Report_2008-12.pdf Quarterly Progress Report Public
Quarterly Report: January - March 2009 Quarterly_Report_2009-03.pdf Quarterly Progress Report Public
Quarterly Report: April - June 2009 Quarterly_Report_2009-06.pdf Quarterly Progress Report Public
Quarterly Report: July - September 2009 Quarterly_Report_2009-09.pdf Quarterly Progress Report Public
Quarterly Report: October - December 2009 Quarterly_Report_2009-12.pdf Quarterly Progress Report Public
Quarterly Report: January - March 2010 ProgressReport_Jan-Mar_2010.pdf Quarterly Progress Report Public
Quarterly Report: January - March 2011 Quarterly_Report_2011-03.pdf Quarterly Progress Report Public
Quarterly Report: April - June 2011 Quarterly_Report_2011-06.pdf Quarterly Progress Report Public
Quarterly Report: July-September 2011 TPF 5-165 Quarterly Report - July-September 2011.pdf Quarterly Progress Report Public
Quarterly Report: October - December 2011 TPF 5-165 Quarterly Report - October-December 2011.pdf Quarterly Progress Report Public
Quarterly Report: January - March 2012 TPF 5-165 Quarterly Report - January-March 2012.pdf Quarterly Progress Report Public
Quarterly Report: April - June 2012 TPF 5-165 Quarterly Report - April-June 2012.pdf Quarterly Progress Report Public
Quarterly Report: July - September 2012 TPF 5-165 Quarterly Report - July-September 2012.pdf Quarterly Progress Report Public
Quarterly Report: October - December 2012 TPF 5-165 Quarterly Report - October-December 2012.pdf Quarterly Progress Report Public
Quarterly Report: January - March 2013 TPF 5-165 Quarterly Report - January-March 2013.pdf Quarterly Progress Report Public
Quarterly Report: April - June 2013 TPF 5-165 Quarterly Report - April-June 2013.pdf Quarterly Progress Report Public
Quarterly Report: July-September 2013 TPF 5-165 Quarterly Report - July-September2013.pdf Quarterly Progress Report Public

Development of Design Guide for Thin and Ultrathin Concrete Overlays of Existing Asphalt Pavements

General Information
Study Number: TPF-5(165)
Lead Organization: Minnesota Department of Transportation
Contract Start Date: Sep 12, 2008
Solicitation Number: 1068
Partners: IADOT, KS, MN, MO, MS, NC, NY, PADOT, SD, TX
Status: Closed
Est. Completion Date: Jan 13, 2013
Contract/Other Number:
Last Updated: Apr 05, 2018
Contract End Date: Sep 11, 2013
Financial Summary
Contract Amount: $360,000.00
Total Commitments Received: $515,200.00
100% SP&R Approval:
Contact Information
Lead Study Contact(s): Lisa Jansen
lisa.jansen@state.mn.us
Phone: 651-366-3779
Commitments by Organizations
Organization Year Commitments Technical Contact Name Funding Contact Name Contact Number Email Address
Iowa Department of Transportation 2012 $12,500.00 Chris Brakke Cheryl Cowie 515-239-1447 Cheryl.Cowie@iowadot.us
Kansas Department of Transportation 2012 $25,000.00 Greg Schieber David Behzadpour 785-291-3847 David.Behzadpour@ks.gov
Minnesota Department of Transportation 2006 $20,000.00 Tom Burnham Lisa Jansen 651-366-3779 lisa.jansen@state.mn.us
Minnesota Department of Transportation 2007 $20,000.00 Tom Burnham Lisa Jansen 651-366-3779 lisa.jansen@state.mn.us
Minnesota Department of Transportation 2008 $20,000.00 Tom Burnham Lisa Jansen 651-366-3779 lisa.jansen@state.mn.us
Minnesota Department of Transportation 2011 $9,200.00 Tom Burnham Lisa Jansen 651-366-3779 lisa.jansen@state.mn.us
Minnesota Department of Transportation 2012 $12,500.00 Tom Burnham Lisa Jansen 651-366-3779 lisa.jansen@state.mn.us
Mississippi Department of Transportation 2007 $20,000.00 Bill Barstis James Watkins 601-359-7650 jwatkins@mdot.state.ms.us
Mississippi Department of Transportation 2008 $20,000.00 Bill Barstis James Watkins 601-359-7650 jwatkins@mdot.state.ms.us
Mississippi Department of Transportation 2009 $20,000.00 Bill Barstis James Watkins 601-359-7650 jwatkins@mdot.state.ms.us
Mississippi Department of Transportation 2011 $9,200.00 Bill Barstis James Watkins 601-359-7650 jwatkins@mdot.state.ms.us
Missouri Department of Transportation 2007 $20,000.00 John Donahue Bill Stone 573-526-4328 william.stone@modot.mo.gov
Missouri Department of Transportation 2008 $20,000.00 John Donahue Bill Stone 573-526-4328 william.stone@modot.mo.gov
Missouri Department of Transportation 2009 $20,000.00 John Donahue Bill Stone 573-526-4328 william.stone@modot.mo.gov
Missouri Department of Transportation 2011 $9,200.00 John Donahue Bill Stone 573-526-4328 william.stone@modot.mo.gov
Missouri Department of Transportation 2012 $12,500.00 John Donahue Bill Stone 573-526-4328 william.stone@modot.mo.gov
New York State Department of Transportation 2007 $20,000.00 William Cuerdon Gary Frederick 518-457-4645 gary.frederick@dot.ny.gov
New York State Department of Transportation 2008 $20,000.00 William Cuerdon Gary Frederick 518-457-4645 gary.frederick@dot.ny.gov
New York State Department of Transportation 2009 $20,000.00 William Cuerdon Gary Frederick 518-457-4645 gary.frederick@dot.ny.gov
New York State Department of Transportation 2011 $9,200.00 William Cuerdon Gary Frederick 518-457-4645 gary.frederick@dot.ny.gov
North Carolina Department of Transportation 2012 $12,500.00 Nilesh Surti Mrinmay Biswas 919-508-1865 biswas@ncdot.gov
Pennsylvania Department of Transportation 2007 $20,000.00 Scott Nazar Lisa Tarson (717) 705-2202 ltarson@pa.gov
Pennsylvania Department of Transportation 2008 $20,000.00 Scott Nazar Lisa Tarson (717) 705-2202 ltarson@pa.gov
Pennsylvania Department of Transportation 2009 $20,000.00 Scott Nazar Lisa Tarson (717) 705-2202 ltarson@pa.gov
Pennsylvania Department of Transportation 2011 $9,200.00 Scott Nazar Lisa Tarson (717) 705-2202 ltarson@pa.gov
Pennsylvania Department of Transportation 2012 $12,500.00 Scott Nazar Lisa Tarson (717) 705-2202 ltarson@pa.gov
South Dakota Department of Transportation 2012 $12,500.00 Darin Hodges David Huft 605-773-3358 dave.huft@state.sd.us
Texas Department of Transportation 2006 $20,000.00 Hua Chen Ned Mattila 512-416-4727 ned.mattila@txdot.gov
Texas Department of Transportation 2007 $20,000.00 Hua Chen Ned Mattila 512-416-4727 ned.mattila@txdot.gov
Texas Department of Transportation 2008 $20,000.00 Hua Chen Ned Mattila 512-416-4727 ned.mattila@txdot.gov
Texas Department of Transportation 2011 $9,200.00 Hua Chen Ned Mattila 512-416-4727 ned.mattila@txdot.gov

Study Description

Study Description

Thin (TCOAP) and ultra-thin (UTCOAP) concrete overlays of existing asphalt pavement (also known as whitetoppings) are a pavement rehabilitation option that has been increasing in popularity in the U.S. over the past 15 years. The recent International Conference on Best Practices for Ultra-thin and Thin Whitetoppings (April 2005) demonstrated that many states now have experience with at least a couple of completed COAP projects. The recently completed NCHRP Synthesis 338 on Thin and Ultra-thin Whitetopping also shows the use of this product is currently of great interest to the transportation community.

The one area of deficiency in the application of TCOAP and UTCOAP (TWT and UTW whitetoppings) is the lack of a unified national design guide. While several local and industry design guides have been formulated, few are based on mechanistic-empirical research born out of actual field performance. To address this issue, many research studies on the accelerated and field performance of TCOAP and UTCOAP are either in progress, or have been recently completed. The Minnesota Road Research (MnROAD) Project has contributed significantly to the understanding of the field performance of TCOAP and UTCOAP. The results from MnROAD and other accelerated loading facilities (ex. FHWA) can now be utilized to develop a unified comprehensive mechanistic-empirical based design method for thin and ultra-thin concrete overlays of existing asphalt pavement.

Most of the existing TCOAP and UTCOAP test sections have been built on top of structurally sound asphalt pavements. Researchers and pavement designers still question the service life of these overlays when placed on older, distressed asphalt pavements. This study will have an opportunity to utilize early performance data from a thin concrete overlay of a distressed full-depth asphalt pavement to be constructed at MnROAD in 2008 (funding for the construction and monitoring of the test cell is not part of this study). Experience and knowledge from other related case histories will also be utilized.

Objectives

The primary purpose of this project is to create a unified national design guide for thin and ultrathin concrete overlays of existing asphalt pavements. This consists of the following distinct objectives:

1. Study and understand the field performance history of TCOAP and UTCOAP as demonstrated by various research test sections. These include current (and future) test sections at the MnROAD facility, accelerated loading facility test sections (FHWA), and other test sections installed and monitored by various local, national and international agencies.

2. Develop a design guide for concrete overlays of existing asphalt pavements utilizing existing validated performance models, as well as new analytical models derived to address design aspects not currently considered in existing methods. The design guide will be based on mechanistic-empirical principles, including the effects of various concrete overlay and existing asphalt materials, panel thickness and geometry, joint opening and stiffness, traffic loads, and climates under which they must perform.

3. Create a user-friendly design guide software program and user¿s manual. The program format should be such that it could become a module in the future national Mechanistic-Empirical Pavement Design Guide (MEPDG) for highway pavements.

Scope of Work

This research project would be carried out in 5 tasks:

1. Literature review of existing TCOAP and UTCOAP (TWT and UTW) design methods and field experiments.

2. Development of layer bonding degradation model(s) based on field testing results (and limited laboratory testing if beneficial).

3. Development of new, or improvement of existing, TCOAP and UTCOAP pavement response and performance prediction models that incorporate slab thickness and geometry, joint opening and stiffness, axle load configuration, condition of the existing asphalt pavement, and degradation of layer bonding with time (if any).

4. Development of a unified national mechanistic-empirical design guide for thin and ultrathin concrete overlays of existing asphalt pavements. The design guide, in the form of a user-friendly software program and user¿s manual, will accommodate a variety of climate conditions, axle load configurations, existing asphalt material conditions, and time dependent bonding conditions between layers.

5. Provide guidance on how the design guide can be implemented into future versions of the national MEPDG for highway pavements.

Comments

Formally titled "Analysis Of MnROAD Whitetopping Performance data For A Module In The Design Guide"

This study will provide a unified national design process that could eventually be incorporated into the national MEPDG for highway pavements. States and Agencies will benefit from this process of developing a user-friendly design process through the synergistic machinery of a multi-state pooled fund.

Additional funds are required to complete Task 3. States should commit an addiontal $9,200 for CY 2011 to complete this task.

Title File/Link Type Private
Final Report Part 1 BCOA-ME Theory Manual BCOA ME Theory Manual.pdf Final Report Public
Final Report Part 2 BCOA-ME Users Guide BCOA ME User's Guide.pdf Final Report Public
Acceptance Memo Acceptance_Letter_TPF-5165.pdf Memorandum Public
TPF-5(165) Closeout Letter TPF-5(165) Closeout Letter - Signed.pdf Memorandum Public
TAP Meeting Minutes 12-02-08 TAP_Meeting_Minutes_12-02-08.pdf Other Public
TAP Meeting Minutes 10-15-2011 TAP Meeting Minutes 10-5-11.docx Other Public
TPF-5(165) Closeout Funding Spreadsheet TPF-5(165) Closeout Funding Spreadsheet.pdf Other Public
Quarterly Report: January - March 2008 Quarterly_Report_2008-03.pdf Quarterly Progress Report Public
Quarterly Report: April-June 2008 Quarterly_Report_2008-06.pdf Quarterly Progress Report Public
Quarterly Report: July - September 2008 Quarterly_Report_2008-09.pdf Quarterly Progress Report Public
Quarterly Report: October-December 2008 Quarterly_Report_2008-12.pdf Quarterly Progress Report Public
Quarterly Report: January - March 2009 Quarterly_Report_2009-03.pdf Quarterly Progress Report Public
Quarterly Report: April - June 2009 Quarterly_Report_2009-06.pdf Quarterly Progress Report Public
Quarterly Report: July - September 2009 Quarterly_Report_2009-09.pdf Quarterly Progress Report Public
Quarterly Report: October - December 2009 Quarterly_Report_2009-12.pdf Quarterly Progress Report Public
Quarterly Report: January - March 2010 ProgressReport_Jan-Mar_2010.pdf Quarterly Progress Report Public
Quarterly Report: January - March 2011 Quarterly_Report_2011-03.pdf Quarterly Progress Report Public
Quarterly Report: April - June 2011 Quarterly_Report_2011-06.pdf Quarterly Progress Report Public
Quarterly Report: July-September 2011 TPF 5-165 Quarterly Report - July-September 2011.pdf Quarterly Progress Report Public
Quarterly Report: October - December 2011 TPF 5-165 Quarterly Report - October-December 2011.pdf Quarterly Progress Report Public
Quarterly Report: January - March 2012 TPF 5-165 Quarterly Report - January-March 2012.pdf Quarterly Progress Report Public
Quarterly Report: April - June 2012 TPF 5-165 Quarterly Report - April-June 2012.pdf Quarterly Progress Report Public
Quarterly Report: July - September 2012 TPF 5-165 Quarterly Report - July-September 2012.pdf Quarterly Progress Report Public
Quarterly Report: October - December 2012 TPF 5-165 Quarterly Report - October-December 2012.pdf Quarterly Progress Report Public
Quarterly Report: January - March 2013 TPF 5-165 Quarterly Report - January-March 2013.pdf Quarterly Progress Report Public
Quarterly Report: April - June 2013 TPF 5-165 Quarterly Report - April-June 2013.pdf Quarterly Progress Report Public
Quarterly Report: July-September 2013 TPF 5-165 Quarterly Report - July-September2013.pdf Quarterly Progress Report Public

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