Past Performance (Literature Review)
Composite pavements have been implemented worldwide in the last few decades. In
Europe, composite pavements have been used extensively; countries such as Germany, France,
and Spain are known for their wide use of long-life semi-rigid structures in their main road
networks, which account for 30% to 50% of their highway systems (Thogersen et al., 2004).
The U.K. highway agencies have used two designs for their flexible composite
pavements for the past 20 years. The first design has a service life of up to 20,000,000
equivalent single-axle loads (ESALs) over 20 years and has a structure comprised of a lean
concrete base with a maximum thickness of 250 mm (10 in) surfaced with up to 150 mm (6 in)
of HMA. The second design is for service a life of more than 20,000,000 ESALs and consists of
a 200-mm thick HMA on top of a lean concrete base (Parry et al., 1997). The U.K. had, as of
1999, 649 km of composite pavements in their main road network, which had been constructed
between 1959 and 1987 and had carried between 8 and 97 million single-axle (MSA) loads. A
composite pavement performance study published by Parry et al. (1999) concluded that there
was considerable variability in the performance of these composite structures. In particular, the
required thickness of the asphalt overlays during maintenance was highly variable. The new U.K.
Pavement Design Guide includes a new section that deals with flexible composite pavement
design and that aims to design pavement structures for traffic levels of 100 MSA or more (U.K.,
2006).
A study by Merrill et al. (2006) reviewed the experiences of composite pavements in
Europe. The authors found that composite pavements from the U.K., the Netherlands, and
Hungary were performing satisfactorily in terms of rutting, cracking, and deflections. The
expected life of a semi-rigid pavement structure was found to be statistically longer than that of a
comparable flexible one. Semi-rigid structures with relatively thin layers (250 mm [10 in] total
thickness) performed satisfactorily for a long-life even under heavy traffic. Moreover, field
observations confirmed that composite structures tend to have longer lives (i.e., they may be
classified as long-life pavements).
There is a very wide use of composite pavements in Spain as documented by Jofre and
Fernandez (2004). Composite pavement structures in Spain are called semi-rigid pavements
because they do not tend to use a portland cement concrete pavement (PCCP) as the base.
Instead they use different types of rigid bases that mainly differ from one another in the cement
content and aggregate type. The typical rigid base characterization presented by Jofre and
Fernandez is summarized in Table 1.
In the United States, composite pavements usually have been the result of PCCP
rehabilitation, consisting of HMA overlays on top of deteriorated rigid pavements and thus
creating a composite structure. This type of rehabilitation action has been used to restore the
functional performance of an existing pavement and/or to increase the structural capacity in
order to handle additional and heavier traffic. The performance of composite pavements may
vary due to different factors, such as design of the rigid base, selection of an adequate HMA type,
constructability, and maintainability. A study of composite pavements presented by Hein et al.
(2002) concluded that:
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• The use of an open-graded HMA interlayer does not mitigate reflection cracking
• There is an early (3 to 5 years) deterioration due to reflective cracking on the HMA
from the underlying rigid layer’s discontinuities
• The pavement condition ratings based only on the HMA surface do not accurately
reflect the condition of the overall pavement structure and/or concrete base, e.g.,
faulting and spalling may be effectively hidden from view.
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