MnDOT Pavement Design Manual, Oct 31, 2014

MNDOT PAVEMENT DESIGN MANUAL

Chapter 9 Construction and Rehabilitation Alternates

MnDOT Pavement Engineer

Date

MnDOT Pavement Design Manual, Oct 31, 2014

Contents
Introduction ........................................................................................................................................................ 1
900 Existing Pavement-Types ...................................................................................................................... 2
910 Rehabilitation with HMA Overlay (>2 inches) .................................................................................. 3
920 Rehabilitation with PCC Overlay ......................................................................................................... 5
930 Rehabilitation with FDR/SFDR/CIR ...............................................................................................10
940 Rehabilitation with Rubblization/Crack & Seat ...............................................................................13
950 New/Reconstruction ............................................................................................................................15
960 Noneconomic Factors ..........................................................................................................................16

MnDOT Pavement Design Manual, Oct 31, 2014

Introduction

This chapter contains alternates to consider for new construction/reconstruction or rehabilitation of

existing pavements. It is intended to be used to develop the pavement alternates required by
Pavement-Type Selection (see Chapter 7 Pavement-Type Selection) and may be used as an aid
to the scoping process.

Process
STEP 1.

Find the existing pavement-type and the possible rehabilitation alternates in Table
900.1.

STEP 2.

Use the tables in Sections 910-950 to determine which alternates are applicable.
Additionally, consult Table 960.1 for noneconomic factors

MnDOT Pavement Design Manual, Oct 31, 2014

900 Existing Pavement-Types

Table 900.1 Existing Pavement-Types and Possible

Rehabilitation Alternates
Existing
Pavement-type

Possible
Rehabilitation*

Description

HMAonAggregate HMApavement,includinganyHMAoverlays,
Base
placedonseveralinchesofaggregatebase.

HMAoverlay(>2inches)
PCCoverlay
FDR/SFDR/CIR
New/Reconstruction

FullDepthHMAon HMApavement,includinganyHMAoverlays,
Subgrade
placedonsubgrade.

HMAoverlay(>2inches)
PCCoverlay
FDR/SFDR/CIR
New

HMApavementplacedonpreviously
constructedPCCPavement.

HMAoverlay(>2inches)
PCCoverlay
CIR
Rubblization
CrackandSeat
New/Reconstruction

PCCpavementplacedoneitheraggregate
baseorsubgrade.

HMAoverlay(>2inches)
PCCoverlay
Rubblization
CrackandSeat
New/Reconstruction

PCCpavementplacedonpreviously
constructedHMAPavement.

HMAoverlay(>2inches)
PCCoverlay
FDR/SFDR
New/Reconstruction

PCCpavementplacedonpreviously
constructedPCCPavement.

HMAoverlay(>2inches)
PCCoverlay
Rubblization
CrackandSeat
New/Reconstruction

HMAonPCC

PCConAggregate
BaseorSubgrade

PCConHMA

PCConPCC

* This list includes typical, available rehabilitation alternates. It is not intended to exclude any
alternates that may be available for a project.
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MnDOT Pavement Design Manual, Oct 31, 2014

910 Rehabilitation with HMA Overlay (>2 inches)

Table 910.1 - HMA Overlay on Existing HMA

ManualLocation

Section460.

Description

Paving>2ofHMAonanexistingHMApavementssurface.Itisintendedto
improveride,reducesurfacedistress,mayimprovepavementstructure,and
preservetheexistingpavement.ExistingHMAmaybemilledpriortotheHMA
overlaytoremovesurfacedistressesandtoreducetheroadsprofile.

DesignLife

Typically,MnDOTprojectsuseadesignlifeof1319yearsdependingon
existingpavementcondition,traffic,andHMAoverlaythickness.

GoodCandidate

Structurallysoundpavementthatneedsonlyminorimprovements.
Projectsinwhichalimiteddesignlifeisacceptable.

PoorCandidate

Pavementsthatexhibitstructuralproblemssuchas:
o Deformingorruttingsubsurfacelayers.
o Largeamountsofbottomupfatiguecracking.
o Subgradefailuresand/orseasonalheavingissues.
Pavementswithalargeamountofsurfacedistress(rutting,cracking,and
poorride)thatwillnotbesufficientlyimprovedbyanHMAoverlay.
Projectsinwhichalongdesignlifeisdesired..

Pros

Cons

Limitedabilitytoimprovestructureandfunction.
Mayraiseroadprofile.
Limiteddesignlife.

Mayaddstructure.
Improvesrideandreducessurfacedistresses.
Relativelyinexpensive.
Shortconstructionperiod.
Reducesshorttermmaintenance.

MnDOT Pavement Design Manual, Oct 31, 2014

Table 910.2 - HMA Overlay on Existing PCC

ManualLocation

Section460.

Description

Paving>2ofHMAonanexistingPCCpavementssurface.Itisintendedto
improveride,reducesurfacedistress,mayimprovepavementstructure,and
preservetheexistingpavement.AnyexistingHMAmaybemilledpriortothe
HMAoverlaytoremovesurfacedistressesandtoreducetheroadsprofile.

DesignLife

Typically,MnDOTprojectsuseadesignlifeof1317yearsdependingon
existingpavementcondition,traffic,andHMAoverlaythickness.

GoodCandidate

Structurallysoundpavementthatneedsonlyminorimprovements.
Projectsinwhichalimiteddesignlifeisacceptable.

PoorCandidate

Pros

Mayaddstructure.
Improvesrideandreducessurfacedistresses.
Relativelyinexpensive.
Shortconstructionperiod.
Reduceshorttermmaintenance.

Cons

Limitedabilitytoimprovestructureandfunction.
Limiteddesignlife.
JointsandcracksintheexistingPCCwillreflectthroughtheHMAoverlay.
MayinducePCCblowups.
TheHMAoverlaymayspallatsevereexistingPCCjointsorcracks.
Probablereflectivecrackingoverjointsandcracksintheconcrete.
Raisesinthepavementprofile.

Pavementswithrockingormovingpanels.
Pavementsonsubgradeswithseasonalheavingissues.
Pavementswithlargeamountsofcrackedorshatteredpanels.
Projectsinwhichalimiteddesignlifeisunacceptable.

MnDOT Pavement Design Manual, Oct 31, 2014

920 Rehabilitation with PCC Overlay

PCC overlays may be used to rehabilitate existing HMA and existing PCC pavements. PCC
overlays of HMA pavements, or whitetopping, may be designed using two different
procedures. One procedure, using the BCOA-ME, requires a durable bond between the PCC
overlay and the existing HMA. The other whitetopping design procedure, using
MnPAVE-Rigid, doesnt consider a bond and may be used on more deteriorated HMA
pavement than the bonded design. PCC overlays of existing PCC pavement, or UBOL, use an
interlayer to prevent the bonding of the PCC overlay to the existing PCC pavement.

MnDOT Pavement Design Manual, Oct 31, 2014

Table 920.1 Bonded PCC Overlay of Existing HMA Designed

using BCOA-ME
ManualLocation

Section510.

Description

ThistypeofdesigncountsonthebondbetweenthePCCoverlayandthe
existingHMAtoensurethattheybehaveasasinglemonolithicpavement
layer.BCOAthicknessestypicallyrangefrom4.0to6.0.Thesurfaceofthe
existingHMAmaybemilledtoremovesurfacedistressesandtoreduceor
eliminateincreasesintheprofileoftheoverlaidpavement.AnyexistingPCC
overlaymayberemoved,theexistingHMAprepared,andreplacedwithanew
PCCoverlay.

DesignLife

20years

GoodCandidate

TheexistingHMApavementhasstablesupportconditionswithonly
localizedweakareasthatmayberepairedpriortoplacingthePCCoverlay.
TheprimarydistressesintheexistingHMApavementaresurfacedistresses.
ThermalcracksintheHMApavementarepredominatelynondeteriorated
thermalcracks.Deterioratedthermalcrackswillrequirerepairpriorto
placingthePCCoverlay.
ThereisasufficientexistingHMAthicknesssothatafteranyproposed
milling:

o 85%ofthecoresare4.0orthicker.
o Anyindividualcoremustbeaminimumof3.0thick.Any
areasoflessthan3.0ofHMAmaybetreatedbyremoving
theexistingHMApavementandconstructinga6.0
(minimum)PCCsection.

PoorCandidate

TheexistingHMApavementhassignificantstructuraldeteriorationand
areasofunevensupportconditions.
ExistingHMAoverlayofPCCPavement.
Theexistingpavementexhibitsdifferentialfrostmovements.
TheexistingHMAhasbeenwidened,orwillrequirewidening,withinthe
areaofthedrivinglane.
TheHMApavementthatwillremainafteranymillingexhibitsstripping
and/ordebondedlayers.
HMApavementswithpredominatelydeterioratedthermalcracksthatwill
requirerepairpriortoplacingthePCCoverlay.
ThereisaninsufficientexistingHMAthicknesssothatafteranyproposed
milling:

o Morethan15%ofthecoresarelessthan4.0thick.
o Thereareindividualcoreslessthan3.0thick.However,any
areasoflessthan3.0ofHMAmaybetreatedbyremoving

MnDOT Pavement Design Manual, Oct 31, 2014

theexistingHMApavementandconstructinga6.0
(minimum)PCCsection.
Pros

Addsstructure.
Improvesrideandreducessurfacedistresses.
Relativelyinexpensive.

Cons

RequiresasufficientthicknessofsoundHMApavement.
Requiresstablesupport.
Mayrequireariseinroadprofile.
ExistingactivecracksintheHMAmayreflectthroughtothePCCoverlay.

MnDOT Pavement Design Manual, Oct 31, 2014

Table 920.2 Non-Bonded PCC Overlay of Existing HMA Designed

using MnPAVE-Rigid
ManualLocation

Section510.

Description

ThisdesignmethoddoesnotrequireabondbetweenthePCCOverlayandthe
existingHMA.Theminimumthicknessis6.0.AnyexistingHMAmaybemilled
priortotheHMAoverlaytoremovesurfacedistressesandtoreducethe
roadsprofile.AnyexistingPCCoverlaymayberemoved,theexistingHMA
prepared,andreplacedwithanewPCCoverlay.

DesignLife

20or35years

GoodCandidate

Theexistingpavementhasstablesupportconditionsorwillrequireonly
localizedrepairs.

PoorCandidate

PoorlydrainingroadsthatwillnotprovidestablesupportforthePCC
overlay.
Theexistingpavementexhibitsdifferentialfrostmovements.

Pros

Addsstructure.
Improvesrideandreducessurfacedistresses.
MaybeusedonmostexistingHMApavements.

Cons

MoreexpensivethanabondedPCCoverlay.
Mayrequirearaiseinroadprofile.
ExistingactivecracksintheHMAmayreflectthroughtothePCCoverlay.

MnDOT Pavement Design Manual, Oct 31, 2014

Table 920.3 Unbonded PCC Overlay of Existing PCC - UBOL

ManualLocation

Section520.

Description

APCCoverlaythatusesabondbreakertoseparateitfromexistingPCC
pavement.Theminimumpavementthicknessis6.0inches.

DesignLife

20or35years

GoodCandidate

Theexistingpavementhasstablesupportconditionsorwillrequireonly
localizedrepairs.
Theroadwayhasroomtopermitasignificantraiseinroadprofile.

PoorCandidate

SignificantareasthatwillrequirerepairpriortoplacingthePCCoverlay.
Existingpavementhasrockingormovingpanels.
Theexistingpavementexhibitsdifferentialfrostmovements.
Roadwayswithasignificantnumberofbridgesrequiringprofileadjustments.

Pros

Improvesrideandpavementdistress.
MaybeusedonmostexistingPCCpavements.
Maybeusedonfaultedpavementsorpavementswithmaterialrelated
distresses.
Significantlystreamlinedconstructionascomparedtoreconstruction.

Cons

Requiresstablesupportconditions.
Willrequireasignificantraiseinroadprofile.

MnDOT Pavement Design Manual, Oct 31, 2014

930 Rehabilitation with FDR/SFDR/CIR

Note: MnPAVE-Flexible must be used to design theses options.

Table 930.1 Full-Depth Reclamation (FDR)

ManualLocation

Section420.

Description

FDRinvolvesusingareclaimingmachinetocrushandblendtogetherexisting
HMApavementandaggregate.Theblendedmaterialismovedasnecessaryto
allowittobecompactedin6inchlifts.Aftercompactionandshaping,itwill
thenactasbasefornewHMApavement.

DesignLife

20years

GoodCandidate

Aroadwaywithfewornosubgradeproblems.
Thepavementhassufficientexistingaggregatebasetocoolthereclaimer
teethandtoreclaimwithexistingHMA.HMAmaybemilledoraggregate
addedtothepavementsurfacepriortoreclaimingtohelpmeetthis
proportion.
Aroadwaythathasroomtopermitasignificantraiseinroadprofile.

PoorCandidate

Aroadwaythatrequiresalargeamountofsubgraderepair.
Theroadwaydoesnothaveroomtopermitasignificantraiseinroadprofile.
Thepavementexhibitsdifferentialfrostmovements.

Pros

Typically,lessexpensivethanreconstruction.
Rehabilitatespavementsthatarestructurallyandfunctionallyunsound.
Removesallpavementdistressesandpavementmaterialproblems.

Cons

Notintendedtorepairsubgradeproblems(however,localizedareascanbe
addressedduringdesignandconstruction).
Requiressufficientthicknessexistingaggregate.
Willrequireasignificantraiseinroadprofile.

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MnDOT Pavement Design Manual, Oct 31, 2014

Table 930.2 Stabilized Full-Depth Reclamation (SFDR)

ManualLocation

Section420.

Description

SFDRisFDRthathashadastabilizingagentadded.Aftertheroadwayhasbeen
reclaimed,asecondpassofthereclaimingmachineismadetoapplyandblend
inastabilizer.Thestabilizeristypicallyemulsifiedasphaltwithadditivesor
foamedasphaltcement.Thislayerwillthenbecompacted,shaped,and
allowedtocurebeforebeingpavedwithnewHMApavement.

DesignLife

20years

GoodCandidate

Aroadwaywithfewornosubgradeproblems.
AnHMApavementwithatleast3inchesofexistingaggregatebase.

PoorCandidate

Aroadwaythatrequiresalargeamountofsubgraderepair.
Apavementwithoutaggregatebase.
Thepavementexhibitsdifferentialfrostmovements.

Pros

Cons

Notintendedtorepairsubgradeproblems(however,localizedareascanbe
addressedduringdesignandconstruction).
Requiressomeexistingaggregate.
StabilizationaddstothecostascomparedtoFDR.

Rehabilitatespavementsthatarestructurallyandfunctionallyunsound.
UsesthinnerHMAascomparedtoFDR.
WillrequirelessofaraiseinroadprofilethanFDR.
RequireslessinplaceaggregatethanFDR.
Typically,lessexpensivethanreconstruction.
Removesallpavementdistressesandpavementmaterialproblems.

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MnDOT Pavement Design Manual, Oct 31, 2014

Table 930.3 Cold In-place Recycling (CIR)

ManualLocation

Section420.

Description

CIRinvolvesmillingaportionoftheexistingHMA,mixingthemilledmaterial
withemulsifiedasphaltandadditives,andpavingtheroadwaywiththe
milled/emulsifiedmix.TheseactivitiesareallperformedinonepassofaCIR
train.ThepavedCIRmaterialisthencompactedand,afterasuitablecuring
time,itispavedwithHMApavement.

DesignLife

20years

GoodCandidate

Aroadwaywithfewornosubgradeproblems.
WillsupporttheCIRtrain.

PoorCandidate

Aroadwaythatrequiresalargeamountofsubgraderepair.
SupportfortheheavyCIRtraincannotbeprovidedduringconstruction.
Thepavementexhibitsdifferentialfrostmovements.

Pros

CIRlayermayretardreflectivecracking.
Removessurfacedistresses.

Cons

Willnotrepairsubgradeproblems.
Retainsthedistressesandanymaterialsproblemsofmaterialthatisleft
remaining.

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MnDOT Pavement Design Manual, Oct 31, 2014

940 Rehabilitation with Rubblization/Crack & Seat

Table 940.1 Rubblization

ManualLocation

Section430.

Description

RubblizationisintendedtoreducetheexistingPCCmodulusinordertoprevent
reflectivecrackingofthenewHMApavementandallowittoactasnewbase.
RubblizationinvolvesbreakingtheexistingPCCslabintopieces(3.0inches
maximumatsurfaceand9.0inchesmaximumatthebottomofpavement),
compactingtherubblizedmaterial,andpavinganHMApavement.

DesignLife

20years

GoodCandidate

SubgradewithanaverageRValueofatleast17oratleast12inchesof
granularmaterial.
Roomtopermitaraiseinroadprofile.

PoorCandidate

Thepavementexhibitsdifferentialfrostmovements.
SubgradewithanRValueoflessthan17andlessthan12inchesofgranular
material.
Riseinroadprofilenotpermissible.

Pros

Lessexpensivethanreconstruction.
RemovessurfacedistressesandallowstheexistingPCCpavementtoactas
baseforanewHMApavement.
RubblizedPCCisstrongerthanaggregatebase.

Cons

Requiresasolidsubgradethatdoesntrequiresubgraderepairs.
Significantriseinroadprofile.
Edgedrainsmustbeinstalledpriortorubblization.

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MnDOT Pavement Design Manual, Oct 31, 2014

Table 940.2 Crack and Seat

ManualLocation

Section430.

Description

TheCrack&SeatprocessinvolvescrackingtheexistingPCCpavementinto3to
4footpieces,firmlyseatingthepieces,andpavingHMApavement.The
intentionistoreducethesizeofthePCCpiecestominimizemovementsat
existingcracksandjoints.Thiswillminimizethefrequencyandseverityof
reflectivecracking.Itisanespeciallyusefultechniquewhenmovingorrocking
panelshavebeenidentified.

DesignLife

Typically,MnDOTprojectsuseadesignlifeof1317yearsdependingon
existingpavementcondition,traffic,andHMAoverlaythickness.

GoodCandidate

Roadwaywithagoodsubgradethatdoesnotrequireextensiverepairs.
Roomtopermitaraiseinroadprofile.

PoorCandidate

Saturatedsubgradewhichcannotbeaddressedthroughedgedrain
installation.
Thepavementexhibitsdifferentialfrostmovements.
Riseinroadprofilenotpermissible.

Pros

Lessexpensivethanreconstruction.
RemovessurfacedistressesandallowstheexistingPCCpavementtoactas
baseforanewHMApavement.
CrackedPCCisstrongerthanaggregatebase.

Cons

Requiresasolidsubgradethatdoesntrequiresubgraderepairs.
Significantriseinroadprofile.
EdgedrainsneedtobeinstalledpriortoCrackandSeat.

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MnDOT Pavement Design Manual, Oct 31, 2014

950 New/Reconstruction

Table 950.1 New/Reconstruction

ManualLocation

Section400(HMA)orSection500(PCC).

Description

Removalofanyexistingpavementandconstructionofnewpavementplaced
onneworexistingbaseandsubbase.

DesignLife

20or35(PCConly)years.

GoodCandidate

PoorCandidate

Projectsinwhichlessexpensiveoptionsareavailable.

Newalignment.
Structurallyandfunctionallyunsoundpavement.
Requireschangesingeometry.
Requireswidespreadsubgraderepairs.
Doesnthaveroomtopermitariseintheroadprofile.

Pros

Cons

Typically,themostexpensivealternate.
Generally,alongerconstructionperiodthanotheralternates.
Constructionoperationsaresusceptibletoelements.

Subgraderepairsmaybeperformedandsubsurfacedrainageinstalled.
Geometricproblemsmaybeaddressed.
Pavementsubsurfacemaybeconstructedwithfrostresistantmaterials.
Removespreviousdistressesandpoormaterials.
Controlsfinalroadprofile.
Longdesignlife.
Provideasoundplatformforfuturerehabilitations.

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MnDOT Pavement Design Manual, Oct 31, 2014

960 Noneconomic Factors

Table 960.1 Noneconomic Factors to Consider When Evaluating

Pavement Alternates
Technical

Other

Roadwaygeometrics(e.g.,varyinglanewidths,
presenceofverticalcurves,longitudinalgrades)
Continuityofadjacentpavementsandlanes
Characteristicsofsubgradesoils
Trafficduringconstruction
Futureneedsongeometricorcapacitychanges
Safetyconsiderations,suchasdelineatingthe
contrastbetweenpavementandshoulder

Availabilityoflocalmaterialsandexperience
Conservationofmaterialsandenergy
Localgovernmentpreferencesorlocal
politics
Stimulationofcompetitionamongpaving
materialssuppliers
Noiseissuesduetoworkzoneconstruction
ortirepavementfriction
Experimentalmaterialsordesignconcepts
Maintenanceexperienceandequipment
Industrycapabilitytoperformtherequired
work
Sustainability,suchasthroughenergy
efficiency,emissionsreduction,and
resourceconservation.

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