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Treatments

Chapter 4 Amendments – April 2012 Revision Register

Issue/

Rev No.

Reference

Section Description of Revision Authorised

by Date

1 – First Issue. – June 1992

2 – Manual completely reviewed and

rewritten. See sign-off

page above.

Also Principal Engineer (Pavement Rehabilitation)

July 2011

3 – Manual checked See sign-off

page above.

Also Principal Engineer (Pavement Rehabilitation)

April 2012

4

Contents of Pavement Rehabilitation Manual

Chapter 1 Overview

Chapter 2 Pavement Evaluation

Chapter 3

Selection of Alternative Rehabilitation Options

Chapter 4

Technical Details of Specific Rehabilitation Treatments

Chapter 5

Design of Pavement Rehabilitation Treatments: Mechanistic and Deflection

Reduction Methods Chapter 6

Comparison of Alternative Rehabilitation

Strategies

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Table of Contents

Page 4.1 INTRODUCTION... 4-1 4.2 MATERIALS... 4-1 4.3 DRAINAGE... 4-3 4.4 TREATMENTS APPLIED TO THE SURFACE AND/OR TO THE EXISTING PAVEMENT... 4-7 4.4.1 Bituminous sprayed seals - sealing and resealing... 4-7 4.4.1.1 Functions... 4-8 4.4.1.7 Expected Performance and Comments... 4-10 4.4.1.8 Further reading... 4-11 4.4.2 Surface Enrichment of Sprayed Bituminous Seals... 4-12 4.4.2.1 Appropriate Uses... 4-12 4.4.2.2 Inappropriate Uses... 4-12 4.4.2.3 Materials... 4-13 4.4.2.4 Design Consideration... 4-13 4.4.2.5 Construction Considerations... 4-13 4.4.2.6 Expected Performance or Comments... 4-15 4.4.2.7 Further reading... 4-15 4.4.3 Rejuvenation of Sprayed Bituminous Seals... 4-16 4.4.3.1 Functions... 4-16 4.4.4 Crack Filling and Sealing - Bituminous Seals or Asphalt... 4-19 4.4.4.1 Function... 4-20 4.4.4.7 Expected Performance or Comments... 4-23 4.4.4.8 Further reading... 4-23

4.4.5 Treatment of Existing Reflective and Surface Cracking for pavements other than concrete... 4-23 4.4.5.1 Materials... 4-26 4.4.6 Geotextile SAMs and SAMIs... 4-26 4.4.6.1 Functions... 4-27 4.4.6.7 Expected Performance or Comments... 4-41 4.4.6.8 Further reading... 4-41 4.4.7 Geogrids in asphalt... 4-42 4.4.7.1 Function... 4-42 4.4.7.7 Expected Performance or Comments... 4-45 4.4.7.8 Further reading... 4-45 4.4.8 Geogrid and geotextile composites... 4-46 4.4.9 Open Graded Asphalt Surfacing... 4-47 4.4.9.1 Functions... 4-47 4.4.9.7 Expected Performance or Comments... 4-49 4.4.9.8 Further reading... 4-50 4.4.10 Stone Mastic Asphalt... 4-51 4.4.11 Ultra thin asphalt surfacings... 4-51 4.4.12 High Friction Surfacings... 4-51 4.4.13 Slurry Seals/Surfacing and Microsurfacing... 4-51 4.4.13.1 Functions... 4-52

4.4.14.1 Functions... 4-56 4.4.14.2 Inappropriate Uses... 4-57 4.4.14.3 Materials... 4-59 4.4.14.4 Design Considerations... 4-59 4.4.14.5 Construction Considerations... 4-63 4.4.14.6 Expected Performance or Comments... 4-65 4.4.14.7 Further reading... 4-66 4.4.15 Cold In-Place Recycling of Asphalt... 4-66 4.4.15.1 Function... 4-67 4.4.15.2 Appropriate and Inappropriate Uses... 4-67 4.4.15.3 Materials... 4-67 4.4.15.4 Design Considerations... 4-68 4.4.15.5 Construction Considerations... 4-68 4.4.15.6 Expected Performance or Comments... 4-69 4.4.15.7 Further reading... 4-69 4.4.16 Cold milling, planing or profiling... 4-69 4.4.16.1 Functions... 4-69 4.4.16.2 Appropriate Uses... 4-69 4.4.16.3 Inappropriate Uses... 4-70 4.4.16.4 Materials... 4-71 4.4.16.5 Design Considerations... 4-71 4.4.16.6 Construction Considerations... 4-71 4.4.16.7 Expected Performance or Comments... 4-72 4.4.16.8 Further reading... 4-72 4.5 ASPHALT OVERLAY... 4-72 4.5.1 Functions... 4-73 4.5.2 Appropriate Uses... 4-73 4.5.3 Inappropriate Uses... 4-73 4.5.4 Materials... 4-74 4.5.5 Design Considerations... 4-74 4.5.6 Construction Considerations... 4-75 4.5.7 Expected Performance or Comments... 4-75 4.5.8 Further reading... 4-76 4.6 ASPHALT INLAY... 4-76 4.6.1 Construction considerations... 4-77 4.7 GRANULAR OVERLAY... 4-77 4.7.1 Functions... 4-78 4.7.2 Appropriate Uses... 4-78

4.7.4 Materials... 4-79 4.7.5 Design Considerations... 4-80 4.7.5.1 Overlay or Reconstruct... 4-80 4.7.5.2 Structural design... 4-81 4.7.5.3 Design of the geometry... 4-81 4.7.6 Construction Considerations... 4-81 4.7.6.1 Laying of granular corrector material... 4-82 4.7.6.2 Locations and alignment of culvert headwalls... 4-82 4.7.6.3 Draining Pavement Layers at Culverts... 4-82 4.7.6.4 ‘Daylighting’ Pavement Layers... 4-82 4.7.6.5 Using Double-Double Bitumen Seals... 4-82 4.7.6.6 Other aspects... 4-82 4.7.7 Expected Performance or Comments... 4-83 4.7.8 Further reading... 4-84 4.8 TREATING CONCRETE PAVEMENTS... 4-84 4.8.1 Slab Undersealing (grouting of voids)... 4-85 4.8.1.1 Functions... 4-85 4.8.1.7 Expected Performance or Comments... 4-86 4.8.1.8 Further reading... 4-86 4.8.2 Crack and Seat with asphalt overlay... 4-87 4.8.2.1 Functions... 4-87 4.8.2.7 Expected Performance or Comments... 4-90 4.8.2.8 Further reading... 4-90 4.8.3 Full-depth concrete patching... 4-90 4.8.3.1 Functions... 4-91 4.8.3.7 Expected Performance or Comments... 4-94

4.8.4 Joint sealing and joint repairs... 4-95 4.8.4.1 Joint Sealing... 4-95 4.8.4.2 Priming... 4-96 4.9 IN SITU STABILISATION OR MODIFICATION OF GRANULAR MATERIALS AND SOILS... 4-96 4.9.1 Appropriate Uses - General... 4-97 4.9.2 Inappropriate Uses - General... 4-98 4.9.3 Construction Considerations... 4-99 4.9.4 Expected Performance or Comments... 4-99 4.9.5 Granular (mechanical) stabilisation... 4-99 4.9.5.1 Functions... 4-99 4.9.5.7 Expected Performance or Comments... 4-101 4.9.5.8 Further reading... 4-101 4.9.6 Stabilisation and modification using cement or cementitious binders... 4-101 4.9.6.1 Functions... 4-102 4.9.6.2 Appropriate Uses... 4-102 4.9.6.3 Inappropriate Uses... 4-103 4.9.6.4 Materials... 4-103 4.9.6.5 Requirements for modified materials, including testing and design methodology... 4-104 4.9.6.6 Design Considerations... 4-108 4.9.6.7 Construction Considerations... 4-109 4.9.6.8 Expected Performance or Comments... 4-111 4.9.6.9 Further reading... 4-111 4.9.7 In situ treatment of clay subgrades using lime... 4-111 4.9.7.1 Functions... 4-111 4.9.7.7 Expected Performance or Comments... 4-122 4.9.7.8 Further reading... 4-124 4.9.8 Foamed Bitumen Stabilisation of Pavement Materials... 4-125 4.9.8.1 Mechanics of Foamed Bitumen... 4-125 4.9.8.2 Appropriate uses... 4-126 4.9.8.3 Inappropriate Uses... 4-126 4.9.8.4 Materials... 4-127

4.9.8.6 Construction Considerations... 4-139 4.9.8.7 Expected Performance and Comments... 4-147 4.9.8.8 Further reading... 4-147 4.9.9 Stabilisation using chemical stabilising agents... 4-148 4.9.9.1 Functions... 4-148 4.9.9.2 Appropriate Uses... 4-148 4.9.9.3 Inappropriate Uses... 4-149 4.9.9.4 Materials... 4-149 4.9.9.5 Design Considerations... 4-149 4.9.9.6 Expected Performance or Comments... 4-149 4.9.9.7 Further reading... 4-149 4.10 PLANT MIXED STABILISATION OF GRANULAR MATERIALS AND SOILS... 4-150 4.11 SELECTION AND USE OF POLYMER MODIFIED AND MULTIGRADE BINDERS... 4-150 4.11.1 Materials... 4-150 4.11.2 Further reading... 4-151 REFERENCES ... 4-152

List of Tables

Table 4.1 – Some drainage problems and possible solutions... 4-3 Table 4.2 –Treatments to mitigate the effects of cracking (for non-rigid pavements) ... 4-25 Table 4.3 – Paving Grade Geotextile Requirements modified from MRTS57 (TMR 2009j)... 4-31 Table 4.4 – Example of a geotextile SAM (single seal) design ... 4-35 Table 4.5 – Slurry mix types and their typical application(s) ... 4-53 Table 4.6 – Guide indicating suitability of stabilising agents for use with different soils (Austroads 2009f). 4-96 Table 4.7 – Minimum thickness and strength of unbound granular pavement material required below the

modified layer... 4-105 Table 4.8 – Trial pavement for the design example for pavement with modified material ... 4-105 Table 4.9 – Maximum modulus of unbound granular pavement layer / sub-layers below modified layer.. 4-107 Table 4.10 – Properties of granular sub-layers and top of subgrade design example for pavement with

modified material... 4-107 Table 4.11 – Properties of sub-layers of modified material for design example ... 4-108 Table 4.12 – General grading limits for foamed bitumen stabilisation (modified from CSIR 2002) ... 4-128 Table 4.13 – Initial modulus mix design limits for foamed bitumen stabilised material ... 4-136 Table 4.14 – Cured modulus mix design limits for a foamed bitumen stabilised base... 4-136 Table 4.15 – Cured modulus mix deign limits for a foamed bitumen stabilised sub-base ... 4-136 Table 4.16 – Temperature correction factors to calculate foamed bitumen design modulus... 4-139

List of Figures

Figure 4.1 – Comparison of some rehabilitation treatments by relative cost ... 4-1

Figure 4.3 – Example of how seals can be described... 4-14 Figure 4.4 – Relative compositions of original and aged bitumen (not to scale)... 4-18 Figure 4.5 – Paving geotextile in a SAM over a cracked existing pavement ... 4-27 Figure 4.6 – Paving geotextile in SAMI over a cracked existing pavement ... 4-28 Figure 4.7 – Example of wide strip tensile test used to determine tensile strength and elongation (Pickering

2000)... 4-32 Figure 4.8 – Diagram of longitudinal geotextile joints for a floodway... 4-36 Figure 4.9 – Overlapping of geotextiles... 4-38 Figure 4.10 – Transverse lap direction... 4-39 Figure 4.11 – ‘Remix’ process (Wirtgen 2007a)... 4-55 Figure 4.12 – ‘Remix plus’ process (Wirtgen 2007a) ... 4-56 Figure 4.13 – Flow chart for HIPAR mix design ... 4-61 Figure 4.14 – Cold in-place recycling (Wirtgen 2007b) ... 4-67 Figure 4.15 – Aggregate interlock (rough-faced) joint... 4-93 Figure 4.16 – Dowelled (working and fixed) joints ... 4-93 Figure 4.17 – Flocculation: Reorientation of clay particles... 4-112 Figure 4.18 – Longitudinal cracking caused by an expansive soil subgrade ... 4-113 Figure 4.19 – Longitudinal cracking of a CTB on an expansive soil embankment ... 4-113 Figure 4.20 – Typical shrinkage cracking of expansive soils ... 4-114 Figure 4.21 – Example of strength development over a period of time for a lime stabilised subgrade ... 4-114 Figure 4.22 – Example of the effect of lime on the Plastic Limit (PL), Liquid Limit (LL) and PI of a typical clay

... 4-117 Figure 4.23 – Lime demand test results ... 4-117 Figure 4.24 – UCS test results to determine the LSO... 4-118 Figure 4.25 – Spreading of quicklime... 4-119 Figure 4.26 – Slaking of quicklime ... 4-119 Figure 4.27 – Slaking of quicklime ... 4-119 Figure 4.28 – Steam cloud generated during slaking of lime ... 4-120 Figure 4.29 – Lime stabilisation of an expansive-soil subgrade in the outer region of a pavement ... 4-120 Figure 4.30 – Example of equipment used to inject lime into expansive soils ... 4-123 Figure 4.31 – Effect of lime injection into a railway embankment ... 4-123 Figure 4.32 – The creation of a ‘lime curtain’ formed via injection of lime ... 4-123 Figure 4.33 – Example of lime injection pods... 4-124 Figure 4.34 – Injected lime under pressure exiting through cracks in the pavement... 4-124 Figure 4.35 – Example of foamed bitumen production (Wirtgen 2004) ... 4-126 Figure 4.36 – Laboratory foaming process... 4-129 Figure 4.37 – MATTA testing machine... 4-129 Figure 4.38 – Example of influence of water content on bitumen foaming properties ... 4-132 Figure 4.39 - Influence of lime on MATTA test results ... 4-133

Figure 4.41 – Example of reduction in deflection of a foamed bitumen stabilised pavement ... 4-134 Figure 4.42 – Example of increase in back-calculated moduli of a foamed bitumen stabilised pavement 4-135 Figure 4.43 – Example of influence of bitumen content on ‘soaked’ cured MATTA modulus... 4-137 Figure 4.44 – Diagram of typical construction process for foamed bitumen stabilisation ... 4-141 Figure 4.45 – Preliminary pulverising ... 4-142 Figure 4.46 – Grading to receive additive (i.e. before spreading or addition of any stabilising agent) ... 4-142 Figure 4.47 – Tray test to check the additive content of quicklime... 4-142 Figure 4.48 – Spreading of quicklime ... 4-143 Figure 4.49 – Tray test in operation... 4-143 Figure 4.50 – Emission of steam during slaking of lime ... 4-144 Figure 4.51 – Slaking of lime ... 4-144 Figure 4.52 – Closer view of slaked lime... 4-144 Figure 4.53 – Temperature test to check completion of slaking... 4-145 Figure 4.54 – Foam bitumen stabilisation in progress... 4-145 Figure 4.55 – Bitumen tanker coupled to recycler ... 4-145 Figure 4.56 – Compaction with pad foot rollers ... 4-146

List of Equations

Equation 4.1 - Maltene Composition Parameter... 4-17 Equation 4.2 – Pozzolanic reaction showing formation of Calcium-Silicate Hydrate ... 4-112 Equation 4.3 – Pozzolanic reaction showing formation of Calcium-Aluminate Hydrate... 4-113 Equation 4.4 – Foamed bitumen design modulus ... 4-138

Pavement Rehabilitation Manual

Chapter 4 - Technical Details of Specific Rehabilitation