As of 2012, there are 17,336 lane miles of Portland cement concrete (PCC) pavement managed by the Texas Department of Transportation (TxDOT), out of a total 196, 821 lane miles in Texas. Many miles of PCC pavement have approached or exceeded their design lives and need rehabilitation. PCC pavements that need rehabilitation now or in the near future were built thinner than today’s standard and are accordingly structurally deficient. Bonded concrete overlay (BCO) provides an optimal rehabilitation option for pavements that are structurally deficient. Over the years, BCO has been utilized in Texas to strengthen existing continuously reinforced concrete pavement (CRCP), with overlay thickness from 2 inches to 8 inches. In general, the performance has been satisfactory; however, in several projects, distresses occurred at early ages and forensic evaluations were conducted, which included continuous deflection testing using rolling dynamic deflection (RDD) and total pavement acceptance device (TPAD), deflection testing using Falling Weight Deflectometer (FWD), and other testing including bond strength testing. The findings include (1) BCO performance depends, to a large extent, on the structural condition of the existing CRCP as indicated by slab deflections evaluated by FWD or TPAD, (2) adequate amount of longitudinal steel reinforcement in BCO layer significantly improves CRCP BCO performance, (3) coarse aggregate type in BCO concrete has a significant effect on BCO performance, and (4) discontinuities in existing pavement, such as joints at bridge approach slabs, were problem areas with distresses in BCO. To ensure good performance of CRCP BCO on PCC pavement, it is recommended that (1) the entire project be evaluated with deflection testing device to identify areas with deflections more than 8 mils at 9,000 lbs for strengthening by removal of existing concrete and base layers and replacement with new concrete, (2) deflection threshold values be developed for CRCP BCO on jointed concrete pavement, and (3) longitudinal steel be provided in BCO.
Read full abstract