A stable, non-erodible, drainable base layer is crucial to maintain uniform support under concrete pavements and ensure satisfactory performance. This paper presents findings from a recent study aimed at investigating possible improvements in concrete pavement base layers in terms of stability, stiffness, and permeability. Moisture regimes in PCC pavement foundation layers and corresponding predicted pavement performance were first evaluated using different types of base course materials with varying hydraulic and mechanical properties. A previously validated discrete element method (DEM) model was subsequently employed for evaluating the gradation effect on both packing characteristics and load-carrying performance of unbound aggregate materials. The calibrated DEM model has the potential for optimizing the selection of size and shape properties of various types of unbound aggregates to achieve desired shear strength (stability) and drainage characteristics (drainability) for open-graded permeable aggregate base. DEM simulations were performed on different gradations chosen from the current Minnesota Department of Transportation (MnDOT) specified gradation band for unbound permeable aggregate base (UPAB). It was found that depending on the specific gradation and material hydraulic properties, different types of unbound permeable aggregate bases resulted in varying performance improvements. The benefits of maintaining adequate permeability and stability of base course proved to be evident. The DEM model simulation results indicated that a gravel to sand (G/S) ratio of 1.6 yielded the highest coordination number due to the achieved densest packing (indicated by the lowest porosity). Therefore, the optimal G/S ratio of 1.6 also determined previously from experimental results agreed well with the results of DEM simulations, which utilized three-dimensional polyhedral particles with realistic size distributions and aggregate shape properties. The use of such optimal size and shape properties is expected to achieve cost-effective open-graded aggregate base designs for long-life concrete pavements.
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