The steep uphill section of an interstate highway had experienced considerable damage in the form of serious rutting due to slow-moving heavy vehicles. The asphalt pavement had had to be rehabilitated every 4 years and a decision was made to mill and replace the top 180mm of the slow lane with a CRCP inlay. The inlay design was based on an anticipated 6 million equivalent 80 kN axles over five years and it was envisaged that a concrete overlay would be placed over the full width of the road at the end of this period. However, at the end of six years only approximately 0.25% of the area of the inlay had shown serious distress. It was decided to determine the remaining structural life of the pavement with a view to repairing failed areas permanently, rather than temporarily, if the remaining structural life was found to be significant. This paper describes the testing of behaviour and performance on a relatively highly cracked section of the inlay using the Heavy Vehicle Simulator (HVS). Although the test section had narrowly spaced transverse cracking prior to testing, no punch-outs could be created using the HVS. A detailed survey of the 26 lane km of inlay showed that failure did not necessarily occur at closely spaced cracks, but was more associated with edge loading, loss of slab support and poor quality concrete. It also became very clear that a high variation in concrete characteristics (and in particular concrete strength) resulted in a high risk of structural failure. The results were translated into transfer functions that have been included in cncPave, a mechanistically-based design method for concrete pavements developed for South African conditions.
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