Guide to Using Existing Pavement in Place and Achieving Long Life (2014)

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Guide to Using Existing Pavement in Place and Achieving Long Life S2-R23-RW-2

TRANSPORTATION RESEARCH BOARD 2014 EXECUTIVE COMMITTEE* OFFICERS Chair: Kirk T. Steudle, Director, Michigan Department of Transportation, Lansing Vice Chair: Daniel Sperling, Professor of Civil Engineering and Environmental Science and Policy; Director, Institute of Transportation Studies, University of California, Davis Executive Director: Robert E. Skinner, Jr., Transportation Research Board MEMBERS Victoria A. Arroyo, Executive Director, Georgetown Climate Center, and Visiting Professor, Georgetown University Law Center, Washington, D.C. Scott E. Bennett, Director, Arkansas State Highway and Transportation Department, Little Rock Deborah H. Butler, Executive Vice President, Planning, and CIO, Norfolk Southern Corporation, Norfolk, Virginia (Past Chair, 2013) James M. Crites, Executive Vice President of Operations, Dallas–Fort Worth International Airport, Texas Malcolm Dougherty, Director, California Department of Transportation, Sacramento A. Stewart Fotheringham, Professor and Director, Centre for Geoinformatics, School of Geography and Geosciences, University of St. Andrews, Fife, United Kingdom John S. Halikowski, Director, Arizona Department of Transportation, Phoenix Michael W. Hancock, Secretary, Kentucky Transportation Cabinet, Frankfort Susan Hanson, Distinguished University Professor Emerita, School of Geography, Clark University, Worcester, Massachusetts Steve Heminger, Executive Director, Metropolitan Transportation Commission, Oakland, California Chris T. Hendrickson, Duquesne Light Professor of Engineering, Carnegie Mellon University, Pittsburgh, Pennsylvania Jeffrey D. Holt, Managing Director, Bank of Montreal Capital Markets, and Chairman, Utah Transportation Commission, Huntsville, Utah Gary P. LaGrange, President and CEO, Port of New Orleans, Louisiana Michael P. Lewis, Director, Rhode Island Department of Transportation, Providence Joan McDonald, Commissioner, New York State Department of Transportation, Albany Abbas Mohaddes, President and CEO, Iteris, Inc., Santa Ana, California Donald A. Osterberg, Senior Vice President, Safety and Security, Schneider National, Inc., Green Bay, Wisconsin Steven W. Palmer, Vice President of Transportation, Lowe’s Companies, Inc., Mooresville, North Carolina Sandra Rosenbloom, Professor, University of Texas, Austin (Past Chair, 2012) Henry G. (Gerry) Schwartz, Jr., Chairman (retired), Jacobs/Sverdrup Civil, Inc., St. Louis, Missouri Kumares C. Sinha, Olson Distinguished Professor of Civil Engineering, Purdue University, West Lafayette, Indiana Gary C. Thomas, President and Executive Director, Dallas Area Rapid Transit, Dallas, Texas Paul Trombino III, Director, Iowa Department of Transportation, Ames Phillip A. Washington, General Manager, Regional Transportation District, Denver, Colorado EX OFFICIO MEMBERS Thomas P. Bostick, (Lt. General, U.S. Army), Chief of Engineers and Commanding General, U.S. Army Corps of Engineers, Washington, D.C. Alison J. Conway, Assistant Professor, Department of Civil Engineering, City College of New York, New York, and Chair, TRB Young Members Council Anne S. Ferro, Administrator, Federal Motor Carrier Safety Administration, U.S. Department of Transportation David J. Friedman, Acting Administrator, National Highway Traffic Safety Administration, U.S. Department of Transportation LeRoy Gishi, Chief, Division of Transportation, Bureau of Indian Affairs, U.S. Department of the Interior, Washington, D.C. John T. Gray II, Senior Vice President, Policy and Economics, Association of American Railroads, Washington, D.C. Michael P. Huerta, Administrator, Federal Aviation Administration, U.S. Department of Transportation Paul N. Jaenichen, Sr., Acting Administrator, Maritime Administration, U.S. Department of Transportation Therese W. McMillan, Acting Administrator, Federal Transit Administration Michael P. Melaniphy, President and CEO, American Public Transportation Association, Washington, D.C. Victor M. Mendez, Administrator, Federal Highway Administration, and Deputy Secretary, U.S. Department of Transportation Cynthia L. Quarterman, Administrator, Pipeline and Hazardous Materials Safety Administration, U.S. Department of Transportation Peter M. Rogoff, Under Secretary for Policy, U.S. Department of Transportation Craig A. Rutland, U.S. Air Force Pavement Engineer, Air Force Civil Engineer Center, Tyndall Air Force Base, Florida Joseph C. Szabo, Administrator, Federal Railroad Administration, U.S. Department of Transportation Barry R. Wallerstein, Executive Officer, South Coast Air Quality Management District, Diamond Bar, California Gregory D. Winfree, Assistant Secretary for Research and Technology, Office of the Secretary, U.S. Department of Transportation Frederick G. (Bud) Wright, Executive Director, American Association of State Highway and Transportation Officials, Washington, D.C. Paul F. Zukunft, (Adm., U.S. Coast Guard), Commandant, U.S. Coast Guard, U.S. Department of Homeland Security * Membership as of July 2014.

THE SECOND STRATEGIC HIGHWAY RESEARCH PROGRAM Newton Jackson and Jason Puccinelli Nichols Consulting Engineers, Chtd. Joe Mahoney University of Washington, Seattle, Washington TRANSPORTATION RESEARCH BOARD Washington, D.C. 2014 www.TRB.org Guide to Using Existing Pavement in Place and Achieving Long Life SHRP 2 Report S2-R23-RW-2

SUBJECT AREAS Construction Highways Maintenance and Preservation Pavements

THE SECOND STRATEGIC HIGHWAY RESEARCH PROGRAM America’s highway system is critical to meeting the mobility and economic needs of local communities, regions, and the nation. Developments in research and technology—such as advanced materials, communications technology, new data collection technologies, and human factors science—offer a new opportunity to improve the safety and reliability of this important national resource. Breakthrough resolution of significant transportation problems, however, requires concentrated resources over a short time frame. Reflecting this need, the second Strategic Highway Research Program (SHRP 2) has an intense, large-scale focus, integrates mul- tiple fields of research and technology, and is fundamentally different from the broad, mission-oriented, discipline-based research programs that have been the mainstay of the high- way research industry for half a century. The need for SHRP 2 was identified in TRB Special Report 260: Strategic Highway Research: Saving Lives, Reducing Congestion, Improving Quality of Life, pub- lished in 2001 and based on a study sponsored by Congress through the Transportation Equity Act for the 21st Century (TEA-21). SHRP 2, modeled after the first Strategic High- way Research Program, is a focused, time-constrained, management-driven program designed to complement existing highway research programs. SHRP 2 focuses on applied research in four areas: Safety, to prevent or reduce the severity of highway crashes by understanding driver behavior; Renewal, to address the aging infrastructure through rapid design and construction methods that cause minimal disruptions and produce lasting facilities; Reli- ability, to reduce congestion through incident reduction, management, response, and mitigation; and Capacity, to integrate mobility, economic, environmental, and commu- nity needs in the planning and designing of new transporta- tion capacity. SHRP 2 was authorized in August 2005 as part of the Safe, Accountable, Flexible, Efficient Transportation Equity Act: A Legacy for Users (SAFETEA-LU). The pro- gram is managed by the Transportation Research Board (TRB) on behalf of the National Research Council (NRC). SHRP 2 is conducted under a memorandum of understand- ing among the American Association of State Highway and Transportation Officials (AASHTO), the Federal Highway Administration (FHWA), and the National Academy of Sci- ences, parent organization of TRB and NRC. The program provides for competitive, merit-based selection of research contractors; independent research project oversight; and dissemination of research results. SHRP 2 Report S2-R23-RW-2 ISBN: 978-0-309-12965-7 © 2014 National Academy of Sciences. All rights reserved. COPYRIGHT INFORMATION Authors herein are responsible for the authenticity of their materials and for obtaining written permissions from pub- lishers or persons who own the copyright to any previously published or copyrighted material used herein. The second Strategic Highway Research Program grants permission to reproduce material in this publication for classroom and not-for-profit purposes. Permission is given with the understanding that none of the material will be used to imply TRB, AASHTO, or FHWA endorsement of a particular product, method, or practice. It is expected that those reproducing material in this document for educa- tional and not-for-profit purposes will give appropriate ac- knowledgment of the source of any reprinted or reproduced material. For other uses of the material, request permission from SHRP 2. Note: SHRP 2 report numbers convey the program, focus area, project number, and publication format. Report num- bers ending in “w” are published as web documents only. NOTICE The project that is the subject of this report was a part of the second Strategic Highway Research Program, conducted by the Transportation Research Board with the approval of the Governing Board of the National Research Council. The members of the technical committee selected to moni- tor this project and to review this report were chosen for their special competencies and with regard for appropriate balance. The report was reviewed by the technical commit- tee and accepted for publication according to procedures established and overseen by the Transportation Research Board and approved by the Governing Board of the Na- tional Research Council. The opinions and conclusions expressed or implied in this report are those of the researchers who performed the re- search and are not necessarily those of the Transportation Research Board, the National Research Council, or the pro- gram sponsors. The Transportation Research Board of the National Acad- emies, the National Research Council, and the sponsors of the second Strategic Highway Research Program do not en- dorse products or manufacturers. Trade or manufacturers’ names appear herein solely because they are considered es- sential to the object of the report. SHRP 2 REPORTS Available by subscription and through the TRB online bookstore: www.mytrb.org/store Contact the TRB Business Office: 202.334.3213 More information about SHRP 2: www.TRB.org/SHRP2

The National Academy of Sciences is a private, nonprofit, self-perpetuating society of distinguished schol- ars engaged in scientific and engineering research, dedicated to the furtherance of science and technology and to their use for the general welfare. On the authority of the charter granted to it by the Congress in 1863, the Academy has a mandate that requires it to advise the federal government on scientific and techni- cal matters. Dr. Ralph J. Cicerone is president of the National Academy of Sciences. The National Academy of Engineering was established in 1964, under the charter of the National Academy of Sciences, as a parallel organization of outstanding engineers. It is autonomous in its administration and in the selection of its members, sharing with the National Academy of Sciences the responsibility for advis- ing the federal government. The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achieve- ments of engineers. Dr. C. D. Mote, Jr., is president of the National Academy of Engineering. The Institute of Medicine was established in 1970 by the National Academy of Sciences to secure the ser- vices of eminent members of appropriate professions in the examination of policy matters pertaining to the health of the public. The Institute acts under the responsibility given to the National Academy of Sciences by its congressional charter to be an adviser to the federal government and, upon its own initiative, to identify issues of medical care, research, and education. Dr. Victor J. Dzau is president of the Institute of Medicine. The National Research Council was organized by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy’s purposes of furthering knowledge and advising the federal government. Functioning in accordance with general policies determined by the Academy, the Council has become the principal operating agency of both the National Academy of Sci- ences and the National Academy of Engineering in providing services to the government, the public, and the scientific and engineering communities. The Council is administered jointly by both Academies and the Institute of Medicine. Dr. Ralph J. Cicerone and Dr. C. D. Mote, Jr., are chair and vice chair, respectively, of the National Research Council. The Transportation Research Board is one of six major divisions of the National Research Council. The mission of the Transportation Research Board is to provide leadership in transportation innovation and progress through research and information exchange, conducted within a setting that is objective, interdis- ciplinary, and multimodal. The Board’s varied activities annually engage about 7,000 engineers, scientists, and other transportation researchers and practitioners from the public and private sectors and academia, all of whom contribute their expertise in the public interest. The program is supported by state transpor- tation departments, federal agencies, including the component administrations of the U.S. Department of Transportation, and other organizations and individuals interested in the development of transportation. www.TRB.org www.national-academies.org

SHRP 2 STAFF Ann M. Brach, Director Stephen J. Andrle, Deputy Director Neil J. Pedersen, Deputy Director, Implementation and Communications Cynthia Allen, Editor Kenneth Campbell, Chief Program Officer, Safety JoAnn Coleman, Senior Program Assistant, Capacity and Reliability Eduardo Cusicanqui, Financial Officer Richard Deering, Special Consultant, Safety Data Phase 1 Planning Shantia Douglas, Senior Financial Assistant Charles Fay, Senior Program Officer, Safety Carol Ford, Senior Program Assistant, Renewal and Safety James Hedlund, Special Consultant, Safety Coordination Alyssa Hernandez, Reports Coordinator Ralph Hessian, Special Consultant, Capacity and Reliability Andy Horosko, Special Consultant, Safety Field Data Collection William Hyman, Senior Program Officer, Reliability Linda Mason, Communications Officer Matthew Miller, Program Officer, Capacity and Reliability David Plazak, Senior Program Officer, Capacity and Reliability Rachel Taylor, Senior Editorial Assistant Dean Trackman, Managing Editor Connie Woldu, Administrative Coordinator

This work was sponsored by the Federal Highway Administration in cooperation with the American Association of State Highway and Transportation Offi cials. It was con- ducted in the second Strategic Highway Research Program (SHRP 2), which is admin- istered by the Transportation Research Board of the National Academies. The project was managed by James Bryant, Senior Program Offi cer for SHRP 2 Renewal. The research team comprised Newton Jackson and Jason Puccinelli, Nichols Con- sulting Engineers, Chtd.; Dr. Joe Mahoney and Dr. Steve Muench, University of Wash- ington; Dr. Karim Chatti and Dr. Neeraj Buch, Michigan State University; Dr. Dan Zollinger and Dr. Tom Scullion, Texas A&M; George White, Pavia; Dr. Julie Vanden- bossche, University of Pittsburgh; Dr. E. B. Lee, University of California, Berkeley; and Dr. Katie Hall, ARA. Of particular importance to the outcome of this project were the contributions from a number of individuals who helped coordinate meetings and who provided comments and recommendations throughout the project: Gregory Stukel, Illinois Tollway Author- ity; Mike Eacker, Michigan Department of Transportation; Dr. Shongtao Dai, Minne- sota Department of Transportation; John Donahue and Bill Stone, Missouri Department of Transportation; Dr. Magdy Mikhall, Texas Department of Transportation; Trenton Clark and Alex Teklu, Virginia Department of Transportation; Jeff Uhlmeyer, Wash- ington State Department of Transportation; Larry Scofi eld, American Concrete Paving Association; and Dr. Dave Newcomb, National Asphalt Paving Association. ACKNOWLEDGMENTS

FOREWORD On roadways that have acceptable geometric features, renewal can be greatly accel- erated and costs reduced if the existing pavement can be incorporated into the new pavement structure. Transportation agencies need reliable procedures that allow them to identify when an existing pavement can successfully be used in place and how to incorporate it into the new pavement structure to achieve long life. This guide and the accompanying report and web tool provide guidance for selecting, designing, and constructing long-life pavements using existing pavement structure. The goal of this project was to develop reliable procedures and guidelines for identifying when existing pavements can be used in place and the methods necessary to incorporate the original material into the new pavement structure while achieving long life. “Long life” was defi ned as 50 years or longer from the time the pavement was renewed or rehabilitated until the next major rehabilitation. (The report and guide for this project do not provide guidance on the use of routine overlays designed for maintenance and preservation, which is included in the report and guide for SHRP 2 Renewal Project R26, Preservation Approaches for High-Traffi c-Volume Roadways.) The report and guide encourage longer-lasting renewed pavement designs; provide realistic, easy-to-use pavement thickness scoping assessments; and guide users through the data-gathering process needed for input into designing and constructing a long- life pavement using the existing pavement structure. The guide includes the follow- ing: project assessment manual; best practices for rehabilitation of fl exible pavements and rigid pavements; guide specifi cations; life-cycle cost analysis; and emerging pave- ment technology. All the guidance has been incorporated into the web-based pave- ment design scoping tool, which is meant to complement, not replace, a transportation agency’s normal processes for design and pavement-type selection. The guide and web tool were developed with the support of several transportation agencies, including the James W. Bryant, Jr., PhD, PE SHRP 2 Senior Program Offi cer, Renewal

Illinois Tollway Authority, Michigan DOT, Minnesota DOT, Missouri DOT, Texas DOT, Virginia DOT, and Washington DOT. As a result of outreach to transportation agencies, a set of enhancements is cur- rently under way and will be included as a future addendum to the report and guide. Those enhancements will include providing guidance on pavement thickness for 30 to 50 years of rehabilitated design life and updating the guidance and design table to incorporate precast concrete pavements and composite pavement as options for the rehabilitation strategy.