Structural Pavement Design of MSR Aspen Road Using Aashto and Pcase Methods

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STRUCTURAL PAVEMENT DESIGN OF MSR

ASPEN ROAD USING AASHTO AND PCASE
METHODS
Technical Report · January 2014

DOI: 10.13140/RG.2.2.23396.58244
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Amjad Albayati Abbas AbdulMajeed Allawi

University of Baghdad University of Baghdad
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Consulting Engineering Bureau
College of Engineering
University of Baghdad
STRUCTURAL PAVEMENT DESIGN

OF
MSR ASPEN ROAD
Prepared by:
Dr. Amjad Al-Bayati
E-Mail: cebbeng@Yahoo.com
Office Phone: 7782003, Fax. 7782054
Mobile: 07901423189
Structural Pavement Design/MSR Aspen Road 1
CONTENTS Page
 Abstract 2
 Requirements of the Road 3
 Minimum Pavement Section 5
 Flexible Pavement Design Criteria 5
 Existing Subgrade Soil Properties 6
 Evaluation of Existing Soil as a Subgrade Material 8
 Properties of Aggregate Base Course 11
 Bearing Ratios for Selected Aggregate Base Courses 12

 Hot-Mix Asphalt Concrete 15
 Traffic Analysis 18
 Design of Flexible Pavement Structure
19
(CBR-Design Index Method/PCASE Program)
 Design of Flexible Pavement Structure
21
(Elastic Layered Method/PCASE Program)
 Verification of the PCASE Program Design Method with
27
AASHTO Guide for Design of Pavement Structures
 Comparison Between Obtained Design Results 30
 Conclusions and Recommendations 31
 Appendix 34
ABSTRACT
The redesign of the flexible pavement for the 2-Lane MSR Aspen Road ( Class
D / Rolling Terrain , Design Index 5) is required to be prepared in accordance with the
results obtained by the Geotechnical Investigation of the project which showed a natural
subgrade CBR less than that used in preparing the Minimum Pavement Section included
in the Technical Requirement of the project .
The Geotechnical Report of MSR Aspen Road showed an existing subgrade soil
of class (SC) Group (Clayey Sand with Gravel) with a soaked CBR of (8) at 95% max.
Lab .density (85th percentile value).
The desired properties of Aggregate Base Course in accordance with the Technical
Requirements of the project are shown after evaluating the soaked CBR values at 100%
max. Lab. density on materials from (Abu Ghar) quarry to justify the possibility of
obtaining a minimum CBR of 80.
The PCASE program (Pavement transportation Computer Assisted Structural
Engineering) has been employed in pavement design of MSR Aspen Road using the two
methods included in the program; the “CBR-Design Index Method” and the “Elastic
Layered Method”.
The results of both Design Methods are verified employing the “AASHTO Guide for
Design of Pavement Structures”.
It has been concluded that the PCASE “CBR-Design Index Method” has the
shortcoming of adopting a fixed minimum Asphalt Concrete thickness above each Base
CBR for each Design Index regardless of variations in traffic influence ( Equivalent
Standard Single Axle Load Applications; ESAL).
The PCASE “Elastic Layered Method”, dealing with the fundamental properties of
pavement materials, and limiting the vertical and horizontal strains induced by traffic
loadings, has shown more reliable design results as verified by the “AASHTO Guide for
Design of Pavement Structures”.
For an ( ESAL) Applications of 5.75X106 ,the following Design Cross Section
has been obtained:
 19 cm Compacted Subgrade (CBR≥8)
 31 cm Aggregate Base Course (CBR≥80)
 9 cm Asphalt Concrete Leveling Course ( Marshall stability ≥500 kg)
 7 cm Asphalt Concrete Wearing Course ( Marshall stability ≥600 kg)
REQUIREMENTS OF THE ROAD
The new construction of pavement shall include sections (from D to

K), about 57.875 km, as shown in sheet C-2 (Fig. No.1). The two-lane road
shall have a total width of 13 meters with a paved width of 8 meters.
The road is considered as class "D" road in Rolling Terrain with a
Design Hourly Volume (DHV) range from 150 to 450, and an Equivalent
Standard Single Axle Load Applications (ESAL) from 1.30 x 106 to 5.75 x
106 with a Pavement Design Index of(5).
The value of the Pavement Design Index represents the combined effect of
the loads as defined by Traffic category IVA (%Trucks>25%) and traffic
Volume associated with Class D Road (DHV=150-449).
Fig. No. (1) ROAD LAYOUT

MINIMUM PAVEMENT SECTION
Based on a Natural Subgrade CBR of 13 and a pavement Design

Index of 5,the Technical Requirements of the project specified a minimum
pavement section as follows:
 20 cm Aggregate Base course (CBR=80),
 7 cm asphalt concrete wearing course (Type III-State of Kuwait). In
addition to the need for compacting the top 15 cm of existing
Subgrade below Base Course to 95% of.max.lab.density
 Granular materials has been suggested for shoulders.
The Technical Requirements of the project stated also the following
(section 01015):
"If the contractor’s Geotechnical Investigations show that the Natural
Subgrade CBR is less than CBR 13, the contractor shall Redesign the
cross section and submit it for approval".
FLEXIBLE PAVEMENT DESIGN CRITERIA
It is intended to select the proper qualities and thicknesses of

available construction materials (compacted Subgrade Soil, Aggregate
Base Course and Hot Mix Asphalt Concrete Surfacing) in order to design a
structure resistant to the heavy axle repetitions during the design life under
prevailing environmental conditions.
Axle load repetitions cause the pavement structure to deflect creating
both compressive and tensile stresses and strains. The main criteria
considered in any pavement design are to:
1. Minimize vertical compressive strain at the top of subgrade
soil in order to limit permanent deformation (rutting).
2. Minimize horizontal tensile strain at the bottom of asphalt
concrete course in order to limit the development of cracking.
EXISTING SUBGRADE SOIL PROPERTIES
In accordance with the results of the (Geotechnical Report) of MSR

Aspen Road, the following properties of the existing subgrade soil are
summarized:
Properties Range Mean
Soil Composition
- % Retained on sieve No.4 (gravel) 8-66 24.3
- % Passing sieve No.4 and retained on
sieve No.200 (sand) 25-82 63.0
- % Passing sieve No.200 (Fines) 1.5-40.0 12.7
Atterberg limits
- Liquid limit, % 19-29 24.8
- Plasticity Index, % 6-21 14.0
Density
- Field dry density, gm/cm3 1.34-1.83 1.627
- Max. Lab. Dry density, gm/cm3 1.86-2.31 2.046
Contents of Gypsum and Salts
- gypsum, % : 4-38
- chlorides, % : 0-22
Bearing Ratio
Soaked CBR value corresponding to 85th
percentile
= 3 at filed density
= 8 at 95 % Max. Lab. Density
The frequency of occurrence of CBR value at 95% Max. Lab. Density is

shown in Fig. (2).
7
Structural Pavement Design/MSR Aspen Road
Fig. No. (2) Cumulative Distribution of CBR Values of Encountered Soils at 95% Dry Density
(From the Geotechnical Report of MSR Aspen Road)
EVALUATION OF EXISTING SOIL AS A SUBGRADE MATERIAL
The existing soil has been classified in accordance with ASTM

D2487 (Classification of Soils for Engineering Purposes), based on the
Unified Soil Classification System.
The mean results show that:
% sand > % gravel
% fines > 12 %
% gravel > 15 %
The fine-grained fraction consists of Lean Clay (CL) with low-
medium plasticity (plasticity index > 7 and plots above the A-line);
L.L.=24.8, P.I.=14.0
Therefore the soil is classified as (SC) group, (CLAYEY SAND
WITH GRAVEL) .
Figures (3) and (4) show the Plasticity Chart and the Flow Chart
employed in soil classification.
Considering the overall properties of the existing soil, it can be
evaluated as follows:
 Fair subgrade material after compaction.
 Slight compressibility and expansion.
 Fair-poor drainage characteristics.
 The suitable compaction equipments include: rubber-tired roller and
sheepsfoot roller.
 At least 15 cm of the top existing satisfactory subgrade soil has to be
compacted at optimum moisture (+ 2% or - 1%) to 95% of the
ASTM D1557 max. density.
 Pockets of soil with gypsum or soluble salts in excess of 15% are
considered unsatisfactory and required to be replaced by satisfactory
materials.
Fig. No. (3): Plasticity Chart

10
Fig. No. (4): Flow chart for classifying coarse-grained soils

(More than 50% retained on No. 200 sieve)
PROPERTIES OF AGGREGATE BASE COURSE
 The technical requirements of the project (section 02722) specified

the use of any of the three Gradations shown as percentages finer by
weight:
Gradation Gradation Gradation
Sieve
No. 1 No. 2 No. 3
2" (50 mm) 100
1 ½ " (37.5 mm) 70-100 100
1" (25.0 mm) 45-80 60-100 100
1/2" (12.5 mm) 30-60 30-65 40-70
No.4 (4.75 mm) 20-50 20-50 20-50
No.10 (2.00 mm) 15-40 15-40 15-40
No.40 (0.425 mm) 5-25 5-25 5-25
No.200 (0.075 mm) 0-8 0-8 0-8
Silt size (0.020 mm) 0-3 0-3 0-3
 The coarse aggregate portion (retained on No.4 sieve), required to be

used within the range of (50-80)% shall consist of:
- Crushed stone or crushed gravel with more than 50% crushed
pieces.
- % wear ≤ 40
- Flat and elongated pieces (3:1): ≤30%
 The binder material portion (passing No.4 sieve), required to be used
within the range of (20-50) % shall consist of:
- Angular sand, screenings, and natural sand.
- Liquid limit ≤ 25
- Plasticity Index ≤ 5
 The aggregate base course shall be compacted in layers not
exceeding 20 cm and not less than 7.5 cm at optimum moisture (+
2% or – 1%).
 Each layer of aggregate base course including shoulders shall be
compacted to 100% of ASTM D1557 lab. Max. density.
 The minimum soaked CBR value at 100% max. lab. density shall be
not less than 80.
 The suitable compaction equipments may include rubber-tired roller,
steel wheeled roller, and crawler-type tractor.
BEARING RATIOS FOR SELECTED AGGREGATE BASE

COURSES
 For the mid requirements of the three gradations specified for the
project, aggregate samples have been prepared for the evaluation of
CBR values. The selected gradations are plotted in Fig. (5) and
shown below:
% passing by weight of selected gradation

Sieve
No.1 No.2 No.3
2" (50 mm) 100
1 ½ " (37.5 mm) 85 100
1" (25.0 mm) 62 80 100
1/2" (12.5 mm) 45 48 55
No.4 (4.75 mm) 35 35 35
No.10 (2.00 mm) 27 27 27
No.40 (0.425 mm) 15 15 15
No.200 (0.075 mm) 4 4 4
 Laboratory specimens are prepared in accordance with ASTM

D1557 at optimum moisture content and soaked in water for a period
exceeding 24 hours. The standard 4-day soaking period is not
required due to the nature of the granular materials that drain readily
at shorter period without affecting the final results.
 The CBR tests are conducted on the crushed aggregate (brought from
Abu Ghar quarry) to justify the possibility of obtaining the minimum
CBR value employed in the structural design of pavement, (in
general). Aggregates from any other nearby quarries, satisfying the
Technical Requirements of the project, can be used.
 The results of testing are as shown:
Test results Gradation 1 Gradation 2 Gradation 3

Max. dry density,
2.17 2.14 2.16
(gm/m3)
Optimum moisture, % 5.1 5.4 4.8
Soaked CBR value 88 82 70
% Swelling 0.12 0.13 0.17
14
Figure No.(5): Mid Gradation Requirements for Aggregate Base Course

(MSR Aspen Road)
HOT-MIX ASPHALT CONCRETE
 The highest pavement temperature expected during summer in

southern part of Iraq, necessitates the use of relatively coarse
combined gradation of crushed aggregate (within the specification
requirements of the road) with the desired consistency of asphalt
cement.
 In Basrah District: the extracted result from (WorldIndex) software is
enclosed indicating the following:
Max. Air temperature = 50 oC
Min. Air temperature = -2.5 oC
Mean Annual Air temperature = 25.3 oC , the mean pavement
temperature is expected to be about 32 oC (90 oF)
 The main requirements of the General Specifications for Kuwait
Motorway/Expressway System, 1987 are shown:
Combined Gradation (including  1.5 % Hydrated Lime):
% passing by weight
Sieve size Type II Type III
(Leveling) (Wearing)
1" (25.0 mm) 100
3/4" (19.0 mm) 82-100 100
1/2" (12.5 mm) 60-84 66-95
3/8" (9.5 mm) 49-74 54-88
No.4 (4.75 mm) 32-58 37-70
No.8 (2.36 mm) 23-45 26-52
No.16 (1.18 mm) 16-34 18-40
No.30 (0.60 mm) 12-25 13-30
No.50 (0.30 mm) 8-20 8-23
No.100 (0.15 mm) 5-13 6-16
No.200 (0.075 mm) 4-7 4-10
Mixture Type
Mixture Type II
Property III
(Leveling)
(Wearing)
- % Asphalt (60-70)▀ by weight
4.0-6.5 4.5-6.5
of total Agg.
- Marshall stability, 75 Blows,
 500  600
kg
- Marshall flow, mm 2-4 2-4
- Air voids, %▀ ▀ 3-8 4-6
- V.M.A., %▀ ▀ ▀  14  15
- Index of retained strength  70  70
- Degree of compaction  97%  97%
- Deviation of surface evenness ≤ 4mm/4m ≤ 4mm/4m
RECOMMENDED REMARKS:
(Related to the Desired Properties of Asphalt Concrete Mixtures)
▀ It is desirable to replace the (60-70) asphalt binder by one of the
following grades:
- Performance Graded PG 64-10 (AASHTO Designatin:MP1)
- Viscosity-Graded AC-40 (ASTM D3381, Table 2)
- (40-50) Penetration Graded (ASTM D946)
▀ ▀ It is desirable to make the range of % Air Voids from (3-5) for
both Mixtures.
▀ ▀ ▀ It is desirable to specify V.M.A. as  13% for type II Mixture
and  14% for type III Mixture.

TRAFFIC ANALYSIS
Road Class :D
Terrain : Rolling
Design Hourly Volume, DHV : 150-449
Annual Average Daily Traffic, AADT : 1000-2993
Traffic Category : IV A (% Trucks > 25 %)
Pavement Design Index :5
Equivalent Standard Single Axle Load Applications, ESAL= (1.30-5.75) x
106
Worksheet for Estimating the 18-Kip Equivalent Single-Axle Load
Application (ESAL) as a Typical (Assumed)Case:
Road : 2-lane road
Traffic Analysis Period = 15 years
Assumed current AADT = 2500 (during the first year)
Directional distribution factor = 50 %
% Trucks = 80
Annual growth rate = 4 %
Number of
Vehicle Growth ESAL
Vehicle type % vehicles/lane
factor factor applications
per year
p-vehicles 20 91250 0.0008 20.02 1461
Single-unit
trucks:
2-axle, 4-tire 5 22812 0.003 20.02 1370
2-axle, 6-tire 15 68437 0.21 20.02 287723
3-axle or more 20 91250 0.61 20.02 1114363
Tractor semi-
trailers and
combinations:
4-axle or less 5 22812 0.62 20.02 283164
5-axle 15 68438 1.09 20.02 1493440
6-axle or more 20 91250 1.23 20.02 2246995
Total= 100 456250 5428516
The Estimated Design ESAL Applications = 5.43 x 106
DESIGN OF FLEXIBLE PAVEMENT STRUCTURE

( CBR-Design Index (DI) Method /PCASE Program)
 The Design Thicknesses of Flexible Pavement Structure using the

(CBR-DI Method) of PCASE program have been obtained assuming
the following :
Aggregate Base Course CBR=80
Compacted Subgrade Soil CBR =8
Natural Subgrade Soil CBR =3
Pavement Design Index =5 (for ESAL Applications of 2.5x106 and
5.75x106)
ESAL Applications
Thickness of
2.5x106 5.75x106
Asphalt Concrete 2.5″(7cm) 2.5″(7cm)
Aggregate Base course 9.89″(26cm) 10.71″(28cm)
Compacted Subgrade Soil 10.68″(28cm) 11.22″(29cm)
Total Thickness (Above Natural
61cm 64 cm
Soil)
 Using the Same Method of Design mentioned above , employing the

input data used in preparing the Minimum Pavement Section shown
in the Technical Requirements of the Project ( Natural Subgrade
CBR = 13,Base Course CBR = 80,D.I.=5), the following results are
obtained :
ESAL Applications
Thickness of
2.5x106 5.75x106
Aggregate Base Course 5.41″(14cm) 6.0″(16cm)
In the Technical Requirement of MSR Aspen Road ,(Sheet C-3) , the

thickness of the Aggregate Base Course has been reported to be (20cm)
instead of the (16cm) obtained by the Program Output. In addition to that ,it
has been suggested also to compact the top (15cm) of Existing Subgrade
Soil below Base Course to 95%of max.lab.density ,which cannot be
justified by the assumed input data.
Besides, the above results show that the (CBR-DI method ) of
PCASE Program adopts a fixed minimum Asphalt Concrete thickness of
2.5 inches ,regardless of traffic effects as evaluated by ESAL Applications,
which is considered as a remarkable shortcoming due to the expected early
destructive damages in asphalt pavement when improper thicknesses are
used .
DESIGN OF FLEXIBLE PAVEMENT STRUCTURE

(Elastic Layered Method/PCASE Program)
The Thickness Design of Flexible Pavement Structure using the Latest
Version of PCASE Program (Elastic Layered Method) has been prepared
on the basis of the following Input Data :
 Road Class: D (Rolling Terrain)
Traffic Category: IV A
Pavement Design Index: 5
Design ESAL = 2.5 x 106, 5.75x106 Applications
 Natural Subgrade Soil:
Design soaked CBR at field density =3
Resilient (Elastic) Modulus =2.1x103
Poisson’s ratio =0.5
 Compacted Natural Subgrade:
Design Soaked CBR at 95 % max. density = 8
Resilient (Elastic) Modulus = 5.6 x 103 psi
Poisson’s ratio = 0.50
 Aggregate Base Course:
Design soaked CBR at 100% Max. Density =80
Resilient (Elastic) Modulus = 28 x 103 psi
 Hot-Mix Asphalt Concrete:
Marshall Stability = 600 kg
Resilient (Elastic) Modulus = 300 x 103 psi
ESAL Applications
Thickness of
2.5x106 5.75x106
Compacted Subgrade Soil 6.24″(16cm) 7.34″(19cm)
Total Thickness (Above Natural
64cm 66 cm
Soil)
 For the Input Data employed in preparing the Minimum Pavement

Section Shown in the Technical Requirements of the project:
Natural Subgrade CBR=13 (E=9.1x103, ==0.5)
Base Course CBR =80 (E=28x103, =0.45)
Design Index=5
And using the Elastic Layered Method /PCASE Program, the following
results are obtained :
ESAL Applications
Thickness of
2.5x106 5.75x106
 The Thicknesses obtained for a range of ESAL Applications (from

1.5 x 106 to 5.75 x 106) for three types of Aggregate Base Courses
are tabulated and plotted in Fig. (6), on the basis of the following
assumptions:
Subgrade CBR = 8 , E = 5.6 x 103 psi , =0.5
Base course CBR = 50,80,100
E= 25,28,30 x 103 psi ,  =0.45
Asphalt Concrete E= 300 x 103 psi ,  =0.4
Terrain: Rolling
Design Index: 5
Road Class: D
Design Thicknesses of Asphalt Concrete (A.C.) and Base Course at ESAL Applications of:
Base 1.5x106 2.5x106 3.5x106 4.5x106 5.5x106 5.75x106
CBR A.C Base A.C Base A.C Base A.C Base A.C Base A.C Base
value
4.63, 5.38, 5.92, 6.33, 6.67, 6.74, 11.37,
14.12, 13.26, 12.62, 12.05, 11.51,
50 12 14 15 16 17 18 29cm
36 cm 34 cm 32 cm 31 cm 30 cm
cm cm cm cm cm cm
4.16, 4.95, 5.49, 5.92, 6.25, 6.32, 12.07,
14.57, 13.73, 13.08, 12.59, 12.07,
80 11 13 14 15 16 16 31 cm
37 cm 35 cm 34 cm 32 cm 31 cm
cm cm cm cm cm cm
6.06, 12.41,
3.86, 4.66, 5.2, 5.63, 5.98,
14.8, 14.05, 13.40, 12.92, 12.49, 16 32 cm
100 10 12 14 15 16
43 cm 36 cm 34 cm 33 cm 32 cm cm
cm cm cm cm cm
Typical extracted results from the output of PCASE Program are enclosed
herewith and in the Appendix.
24
40
35 Agg. Base Course
Thickness(cm)
30
CBR=50%
25
CBR=80%
20
Asphalt Concrete
15 CBR=100%
10
5
0.5 1.5 2.5 3.5 4.5 5.5 6.5
ESAL x 106
Fig. No. (6) Design Thicknesses of Asphalt Concrete and Aggregate Base Course for Different
Base CBR Values and ESAL Applications
VERIFICATION OF THE PCASE PROGRAM DESIGN METHODS

WITH AASHTO GUIDE METHOD FOR DESIGN OF PAVEMENT
STRUCTURES
The (PCASE Program) results of pavement design for MSR Aspen

Road is verified by comparison with design results of the well-known
(AASHTO Guide for Design of Pavement Structures) published by the
American Association of the State Highway and Transportation Officials,
1993.
Subgrade Layer SN3

SN4
CBR = 8 M.S.= 600 kg A.C.
E1 = 300 x 103 Wearing D1
3
Resilient Modulus E4 = 5.6 x 10 psi M.S.= 500 kg A.C. D2
E2 = 280 x 103 Leveling
Aggregate Base Course CBR= 80

E3 = 28 x 103 psi
Aggregate
Base
D3
CBR = 80
Resilient Modulus, E3 = 28 x 103 psi
Structural Layer Coeff., a3 = 0.115 CBR= 8
E4 = 5.6 x 103 psi
Subgrade
Drainage Coefficient, m3 = 1.0

(Fair drainage quality, saturation: 5% of time)
Asphalt Concrete Leveling Course

Structural Layer Coeff., a2 = 0.39
Asphalt Concrete Wearing Course

Structural Layer Coeff., a1 = 0.40

- Equivalent 18-Kip Single Axle Load Applications, W18 = 5.75 x 106
- Reliability, R = 75 %
- Overall Standard Deviation, So = 0.30
- Design Loss in Present Serviceability Index,  PSI=Po-Pt
- Initial Serviceability, Po = 4.5
- Terminal Serviceability, Pt = 2.5
-  PSI = 4.5-2.5=2.0
Using the AASHTO basic Design Equation solved by the
Nomograph shown in Fig. (7), The Structural Number SN4 (above layer 4)
= 4.0
The Structural Number SN3 (above layer3) = 2.4
Let the A.C. Wearing Course Thickness, D1= 7 cm
7
Effective SN 2   0.40  1.102
2.54
2.4  1.102
Leveling Course Thickness, D 2   2.54  8.45 cm
0.39
Use D2 = 9.0 cm
9
Effective SN 3  1.102   0.39  2.48
2.54
4.0  2.48
Aggregate Base Course Thickness, D 3  x 2.54  33.57 cm
0.115 x 1.0
Use D3 = 34 cm
The difference in design results between the (Elastic Layered Method) of
PCASE Program and AASHTO Guide is considered Negligible.Remarkable
differences have been noticed between the design results of the (CBR-DI Method)
of PCASE Program and other two design methods ( The Elastic Layered Method
and the AASHTO Guide Method )
Fig. No. (8): Design chart for flexible pavements.

(From Guide for Design of Pavement Structures, American
Association of State Highway and Transportation Officials,
Washington, D.C., 1993).
COMPARISON BETWEEN OBTAINED DESIGN RESULTS

- Compacted Subgrade CBR =8
-Aggregate Base Course CBR=80
 Design Thicknesses
For an ESAL Applications of 5.75 x 106
PCASE Program AASHTO
Elastic Guide
Pavement Layer CBR –DI
Layered Method
Method
Method
Asphalt Concrete 7cm 16cm 16cm
Aggregate Base course 28cm 31cm 34cm
 Design Thicknesses
For an ESAL Applications of 2.5 x 106
PCASE Program AASHTO
Elastic Guide
Pavement Layer CBR –DI
Layered Method
Method
Method
Asphalt Concrete 7cm 13cm 13cm
Aggregate Base course 26cm 35cm 33cm
CONCLUSIONS AND RECOMMENDATIONS
In accordance with the results obtained from the different methods used
in the structural pavement design of MSR Aspen Road , the following are
concluded :
1. The (CBR – Design Index Method ) of PCASE Program has shown a

fixed minimum asphalt concrete thickness of (2.5 inches) for a (Base
Course CBR of 80 and a Design Index of 5) , with no ability to
consider the traffic variations (ESAL Applications ) on fatigue
resistance and horizontal tensile strain limitation at the bottom of
asphalt layer to prevent fatigue cracking .
A remarkable difference in design results of asphalt concrete
thickness selected by the ( CBR –DI Method) and the design results
obtained by the ( Elastic Layered Method ) and ( AASHTO Guide
Method ) , has been noticed .
2. The design results obtained from the (Elastic Layered Method) of

PCASE program are very close to the results obtained by the well-
known ( AASHTO Design Method ).
3. The ( CBR-Design Index Method) showed the following results for

the required Pavement Cross Section (Design Index =5) and also
presented in Fig.(8A):
 29 cm of compacted Subgrade (CBR=8).
 28 cm of Aggregate Base Course ( CBR=80 ).
 7 cm of Asphalt Concrete Surfacing.
 Total thickness = 64cm above the natural Subgrade.
4. The recommended design cross section of MSR Aspen Road

Pavement required for maximum possible applications of traffic ;(
ESAL = 5.75x106 ) for a pavement design index of 5 has been
determined to be as follows in accordance with the Elastic Layered
Method of PCASE Program :
 19 cm of compacted Subgrade (Existing Soil below Base Course)
to 95% of ASTM D1557 Max. Lab. Density with a soaked CBR
of (8).
 31 cm of compacted Aggregate Base Course (Replacing the
Existing Materials) in two layers to 100% of ASTM D1557 Max.
Lab. Density with a soaked CBR of (80).
 9 cm of Hot-Mix Asphalt Concrete Leveling Course (25 mm
max. size) with a minimum Marshall Stability of 500 kg., after
applying the Prime Coat (MC-70) at a rate of 0.45-1.50 l/m2.
 7 cm of Hot-Mix Asphalt Concrete Wearing Course (19 mm
max. size) with a minimum Marshall Stability of 600 kg., after
applying the Tack Coat (CSS-1h) at a rate of 0.15-0.75 l/m2.
 Total thickness =66cm above the natural subgrade.
 The surface layer of Shoulders shall be compacted to 100% of
ASTM D1557 Max. Lab. Density using the same Aggregate Base
Materials.
The Typical Design Cross Section is shown in Fig. (8).

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Structural Pavement Design of MSR Aspen Road Using Aashto and Pcase Methods

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Structural Pavement Design of MSR Aspen Road Using Aashto and Pcase Methods

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STRUCTURAL PAVEMENT DESIGN OF MSR

Technical Report · January 2014

Amjad Albayati Abbas AbdulMajeed Allawi

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STRUCTURAL PAVEMENT DESIGN

 Properties of Aggregate Base Course 11

 Bearing Ratios for Selected Aggregate Base Courses 12

REQUIREMENTS OF THE ROAD

The new construction of pavement shall include sections (from D to

Fig. No. (1) ROAD LAYOUT

MINIMUM PAVEMENT SECTION

Based on a Natural Subgrade CBR of 13 and a pavement Design

It is intended to select the proper qualities and thicknesses of

EXISTING SUBGRADE SOIL PROPERTIES

In accordance with the results of the (Geotechnical Report) of MSR

The frequency of occurrence of CBR value at 95% Max. Lab. Density is

EVALUATION OF EXISTING SOIL AS A SUBGRADE MATERIAL

The existing soil has been classified in accordance with ASTM

Fig. No. (3): Plasticity Chart

Fig. No. (4): Flow chart for classifying coarse-grained soils

PROPERTIES OF AGGREGATE BASE COURSE

 The technical requirements of the project (section 02722) specified

 The coarse aggregate portion (retained on No.4 sieve), required to be

BEARING RATIOS FOR SELECTED AGGREGATE BASE

% passing by weight of selected gradation

 Laboratory specimens are prepared in accordance with ASTM

Test results Gradation 1 Gradation 2 Gradation 3

Figure No.(5): Mid Gradation Requirements for Aggregate Base Course

HOT-MIX ASPHALT CONCRETE

 The highest pavement temperature expected during summer in

and  14% for type III Mixture.

DESIGN OF FLEXIBLE PAVEMENT STRUCTURE

 The Design Thicknesses of Flexible Pavement Structure using the

 Using the Same Method of Design mentioned above , employing the

In the Technical Requirement of MSR Aspen Road ,(Sheet C-3) , the

DESIGN OF FLEXIBLE PAVEMENT STRUCTURE

 For the Input Data employed in preparing the Minimum Pavement

 The Thicknesses obtained for a range of ESAL Applications (from

VERIFICATION OF THE PCASE PROGRAM DESIGN METHODS

The (PCASE Program) results of pavement design for MSR Aspen

Subgrade Layer SN3

Aggregate Base Course CBR= 80

Drainage Coefficient, m3 = 1.0

Asphalt Concrete Leveling Course

Asphalt Concrete Wearing Course

Structural Layer Coeff., a1 = 0.40

Fig. No. (8): Design chart for flexible pavements.

COMPARISON BETWEEN OBTAINED DESIGN RESULTS

CONCLUSIONS AND RECOMMENDATIONS

1. The (CBR – Design Index Method ) of PCASE Program has shown a

2. The design results obtained from the (Elastic Layered Method) of

3. The ( CBR-Design Index Method) showed the following results for

4. The recommended design cross section of MSR Aspen Road

The Typical Design Cross Section is shown in Fig. (8).

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