Lecture 20 Bituminous Overlay

Design of Bituminous Overlay Using FWD FWD: IRC115-2014

 Falling Weight Deflectometer (FWD)
(ASTM D4694/ IRC115)
Parameters:
• Impulse load (40 kN) (Different magnitude can be applied)
• Loading period: 25-30 milli sec
• Measure surface deflection profile
• Backcalculate material modulus (by comparing measured and
estimated deflection profile (Using assumed elastic modulus and
passion ratio). This is a trial and error process

Uses of FWD
• Find strength of existing pavements
• Estimate LTE
• Estimate material properties for pavement
• Maintenance/rehabilitation/quality control
 Falling Weight Deflectometer

• Sensors at distance: 0, 200, 300, 600, 900, 1200, 1500, 1800 mm

• Drop height: 100-600 mm Check Video
• Drop weight: 50 to 350 kg
• Target peak load: 40 kN
• Circular plate: 300 mm (rubber pad)
• Record: Peak load and deflection bowl
Understanding Back-calculation - FWD

1. Assume range of initial modulus and Poisson ratio for each layer materials,
and select a value
HMA: 800- 3000 MPa; Poisson ratio: 0.5
Aggregate: 100-500 MPa, Poisson ratio: 0.4
Soil: 40-80 Mpa, Poisson ratio: 04
2. Estimate deflection at each point
3. Compare measured and estimated deflection profile
For finding modulus of different layers (both should match), If they do not, change
modulus, and repeat procedure until the measured and estimated deflection matches
 KGP BACK
Backcalculation Modulus from FWD
KGPBACK WINDOW
 FWD Testing - Data
• FWD Testing was done on a road, composed of three layers system (BT, Aggregate, Subgrade)
• No. of Layers = 3
• Layer thickness (mm) = 170 , 575
• Poisson ratio values = .50 .40 .40
• FWD No. of Deflection points = 7
• Radial distances from centre of load(mm) = .0 300.0 600.0 900.0 1200.0 1500.0
1800.0
• Deflections measured (mm) = 0.481 0.294 0.216 0.163 0.134 0.107 .080
• Layer Modulus (MPa) Ranges Selected :-
(a) Bituminous Surfacing = 750.0 3000.0
(b) Granular Base = 100.0 500.0
(c) Subgrade = 57.2 83.4
We need to find back-calculated Layer Moduli (at test temperature):
Surface (MPa) = ?
Base (MPa) = ?
Subgrade (MPa) = ?
Standard load and Tire Pressure
No. of FWD Deflection Points
Location of Deflection Points
Deflection Measured at Each Point
Layered Thickness of Old Pavement
Poisson Ratio of Layered Materials
Range of Layered Materials Modulus
All Required Value Entered – Data Processing
OUTPUT OF KGPBACK
 Correction Factors – Modulus Value
(FWD)
Temperature Correction Moisture Correction

Bituminous Layer Subgrade

Aggregate Layer
 Correction Factors - Falling Weight Deflectometer

1.Temperature correction (Bituminous layer)

• Standard temperature: 35 C
• Correction for modulus (MPa)

• Should not be applied for bituminous layer less than 40 mm thick or poor (cracked
or damage) pavement section
The deflection in the field is measured at different
Example: temperatures, thus Modulus is estimated at recorded field
• Field temperature: 48 C pavement temperature, therefore, temp correction is
• Estimated modulus of HMA: 1000 MPa required to estimated modulus at 35 C
• Corrected modulus of HMA at 35 C: ….. MPa
 Correction Factors - Falling Weight Deflectometer

2. Seasonal Correction for Subgrade Example:

• Correction modulus of elasticity (MPa) • FWD test was conducted in summer
• Estimated modulus of subgrade: 80 MPa
• Corrected modulus of subgrade to
monsoon season: ….. MPa

3. Seasonal Correction for Granular base/Sub-base

𝐸𝑔𝑟𝑎𝑛𝑢𝑙𝑎𝑟_𝑀𝑜𝑛𝑠𝑜𝑜𝑛 = -0.0003 (𝐸𝑔𝑟𝑎𝑛𝑢𝑙𝑎𝑟_𝑠𝑢𝑚𝑚𝑒𝑟 )2 +0.9584 (𝐸𝑔𝑟𝑎𝑛𝑢𝑙𝑎𝑟_𝑠𝑢𝑚𝑚𝑒𝑟 )-32.989

𝐸𝑔𝑟𝑎𝑛𝑢𝑙𝑎𝑟_𝑀𝑜𝑛𝑠𝑜𝑜𝑛 = 10.5523(𝐸𝑔𝑟𝑎𝑛𝑢𝑙𝑎𝑟_𝑤𝑖𝑛𝑡𝑒𝑟 )0.624 −113.857

The deflection in the field is measured at different seasons (winter, summer), thus modulus is estimated at recorded
moisture conditions. However, to consider worst scenario, modulus is corrected to monsoon seasons
 Steps - Overlay Design Using FWD
Step 1: Buy/rent a FWD
Step 2: Identify pavement stretch
Step 3: Measure FWD deflection of pavement sections
Step 4: Normalize deflection to standard load of 40 kN (Usually deflection may be conducted at different loading)
Step 5: Collect pavement temperature/air temperature/thickness of layers/moisture data/season/time of the
day/location of the site – latitude and longitude
Step 6: Back-calculate pavement layer moduli using KGPBack Software (IRC 115)
• Typical range for calculation
• Subgrade: 40-80 MPa, Poisson ratio: 0.4
• Aggregate: 100-500 MPa, Poisson ratio: 0.4
• HMA: 800-3000 MPa, Poisson ratio: 0.5
Consider all HMA layer as 1 layer, aggregate layer as 1 layer.
 Steps - Overlay Design Using FWD

Step 7: Apply temperature correction to estimated HMA modulus

Step 8: Apply moisture correction to estimated aggregate and subgrade modulus
Step 9: Select 15 percentile elastic modulus (i.e., only 15% value will be less than this value) for HMA, aggregate, and
subgrade
Ascending Percentile (Lower 100
Order Rank Than) 90
80
1022 1 10

% less than equal to

70
1085 2 20
60
1138 3 30 50
1214 4 40 40
1297 5 50 30
1354 6 60 20
1428 7 70 10
0
1504 8 80 0 500 1000 1500 2000 2500
1524 9 90 Modulus (MPa)
1912 10 100
FWD , Asphalt MR (15 percentile), it means, 15% are lower than this value.
Same concept: Traffic 85%, means 85 percentile, 85% passenger are lower than this value, use this
concept
Step 10: Analysis in-service pavement using IITPAVE (find critical strain for rutting and fatigue), assume 40 kN load, 0.56
MPa tire pressure
Step 11: Estimate remaining life using fatigue/rutting equation (select which one is less) (IRC 37-2012)

Nf = 0.711 * 10-04 x [1/εt]3.89 * [1/MR]0.854

Nr = 1.41x 10-8x [1/εv] 4.5337

Step 12: Estimate design traffic for new overlay
Step 13: Assume trial thickness of a new HMA overlay, consider it as a fourth layer in existing 3 layers HMA
Step 14: Conduct analysis of this pavement section, find critical strain for rutting and fatigue at bottom of HMA of the
existing pavement (old pavement)
Step 15: Find allowable no. of load repetition using fatigue or rutting criteria, considering E of the old HMA pavement, and
E of subgrade (Estimated in Step 9)
Step 16: Compare, if allowable no. of load repetition ≥ actual traffic load repetition (Design is safe), if not, increase
thickness or HMA layer material, and repeat steps 13-16, until the design is safe.

Nf = 0.711 * 10-04 x [1/εt]3.89 * [1/MR]0.854

Nr = 1.41x 10-8x [1/εv] 4.5337

 Overlay Design Using FWD – Class Exercise #

Deflection measurement were made using FWD on a national highway/state highway In the month of January.
Based on the deflection data and other parameters such as subgrade strength and pavement layer thicknesses
different homogeneous sections have identified.

The existing pavement has two bituminous layers with a total thickness of 170 mm. Total granular layers: 575
mm. Design traffic: 100 msa

Step 1: FWD Test Normalized Deflection at a radial distance (mm) Pavement

S No. 0 300 600 900 1200 1500 1800 temp (C )
1 0.481 0.294 0.216 0.163 0.134 0.107 0.08 35
2 0.478 0.317 0.231 0.186 0.156 0.13 0.106 35
Check Sheet for Example 3 0.481 0.34 0.242 0.201 0.17 0.139 0.105 36

and Do Calculation
4 0.5 0.321 0.233 0.198 0.151 0.13 0.093 36
5 0.477 0.324 0.24 0.19 0.159 0.138 0.109 36
6 0.485 0.319 0.23 0.194 0.152 0.141 0.101 37
7 0.473 0.315 0.229 0.191 0.149 0.131 0.097 37
8 0.46 0.301 0.223 0.188 0.151 0.13 0.093 38
9 0.48 0.365 0.251 0.19 0.17 0.152 0.108 38
10 0.487 0.327 0.245 0.187 0.161 0.148 0.102 38
Step 2: Back-calculate layers properties KGPBACK
(consider three layer pavement)

Back-calculated Layer Moduli (MPa) Pavement Temp Corrected Layer Moduli (MPa)
S No. HMA Granular Layer Subgarde C S No. HMA Granular Layer Subgarde
1 1214.1 171.7 59.7
1 1214.1 197.4 70.8 35
2 1022.7 220.6 46.4
2 1022.7 254.4 57.3 35
3 1524.7 186.9 44.1
3 1458.2 214.6 55 36
4 1354.5 169.9 49.7
4 1295.5 195.4 60.6 36
5 1297.0 213.0 44.5
5 1240.5 245.1 55.4 36
6 1085.2 217.1 46.3
6 991.9 250.1 57.2 37
7 1138.2 219.0 49.7
7 1040.3 252.4 60.6 37
8 1504.4 213.3 49.2
8 1313 245.5 60.1 38
9 1912.8 174.5 42.7
9 1669.4 200.5 53.7 38
10 1428.9 199.7 45.2
10 1247.1 229.4 56.1 38

Corrected Layer Moduli (MPa)

Step 3: Apply temperature and moisture correction S No. HMA Granular Layer Subgarde
1
2
3
4
5
6
7
8
9
10
Step 4: Select 15 percentile value (Values are provided Layer Modulus (MPa)
below) Bituminous 1112
Aggregate Layer 173
Subgrade 44.3

Aggregate Subgrade
HMA
100 100
100 90
80 80
80 70
Percentile

Percentile
60
Percentile

60 60
50
40
40 40
20 30
20 20
0 10
0 0 50 100 150 200 250 300 0
0 1000 2000 3000 4000 Modulus (MPa) 0 20 40 60 80 100
Modulus (MPa) Modulus (MPa)
Step 5: Analyze existing pavement system using IITPAVE
HMA : 170 mm, E= 1112 MPa, Poisson ratio: 0.5 Nf = 0.711 * 10-04 x [1/εt]3.89 * [1/MR]0.854
Aggregate : 575 mm, E = 173 MPa, Poisson ratio: 0.4
Subgrade : Infinite, E = 44.3 MPa, Poisson ratio: 0.4
Dual wheel: 20 kN each, tire pressure: 0.56 MPa, wheel spacing: 310 mm Nr = 1.41x 10-8x [1/εv] 4.5337

Critical tensile strain at bottom of HMA: -------------- micro-strain

Critical vertical strain on top of subgrade:-------------- micro-strain

Step 6: Remaining life (using IRC 37 Equations for rutting and fatigue) (90 percent
reliability)
Rutting life (based on vertical strain): ----- msa
Fatigue life (based on tensile strain): ------- msa
Step 7: Life of pavement: ------- msa
Expected traffic: 100 msa ( Is existing pavement satisfactory to handle this traffic ??)
Existing Pavement Section
Overlay Design - 1
Overlay Design – 2 (VG40)
Overlay Design – 3 (Thickness Increase)
Step 8: Assume overlay thickness (say 95 mm,VG30, Modulus: 1695 MPa)

Step 9: Analyze the new pavement section using IITPAVE (Four layer system)
HMA new : 95 mm, E= 1695 MPa, Poisson ratio: 0.5
HMA old : 170 mm, E= 1112 MPa, Poisson ratio: 0.5
Aggregate : 575 mm, E = 173 MPa, Poisson ratio: 0.4
Subgrade : Infinite, E = 44.3 MPa, Poisson ratio: 0.4
Dual wheel: 20 kN each, tire pressure: 0.56 MPa, wheel spacing: 310 mm

Critical tensile strain at bottom of old HMA: -------------- micro-strain

Critical vertical strain on top of subgrade:-------------- micro-strain Nf = 0.711 * 10-04 x [1/εt]3.89 * [1/MR]0.854

Step 10: New life of pavement (using IRC 37 Equations for rutting and Nr = 1.41x 10-8x [1/εv] 4.5337
Rutting life (based on vertical strain): ----- msa
fatigue) Fatigue life (based on tensile strain): ------- msa

Step 11: Life of pavement: ------- msa

Expected traffic: 100 msa ( Is existing pavement satisfactory to handle this traffic ??)
Step 12: Designed Overlay thickness:………mm
 FWD
BBD

FWD versus BBD

1. IRC 115-2014 1. IRC 81-1997
2. Dynamic Load 2. Static Load
3. Capture realistic field loading condition 3. Does not capture realistic field loading condition
4. Deflection measurement at several points (Deflection bowl) 4. Deflection measurement at one point
5. Non-destructive in nature 5. Non-destructive in nature
6. Fast to conduct 6. Time consuming
7. Can be a quality test 7. Be cautious to use it as a quality test
8. Cover long distance in a single day 8. Becomes difficult to cover long distance
9. Easy – less effort 9. Labor intensive
10. Guidelines developed recently 2014, can be used for all types 10. Guidelines developed in 1984-1990 (under MORTH research
of bituminous layers (BC and DBM etc.) scheme), for thin, less stiff, BM, premix carpet (not like today DBM
11. Works well for BC and DBM and BC so applicability is questioned
12. Good repeatability 11. Underestimate strength of BC and DBM
13. Back-calculate modulus of all layers 12. Repeatability is an issue: Sensitive to traffic movement
14. Expensive (around 70-150 lakh) 13. Does not back-calculate modulus of different layers
15. Maintenance is tedious and expensive 14. Not expensive (around 2-3 lakhs)
16. Calibration is expensive 15. Maintenance is easy
17. Need skilled/trained personal to operate/data analysis 16. Calibration is simple
18. Carrying this instrument needs a dedicated vehicle 17. Need skilled/trained personal to operate/data analysis simple
(transportation/logistic is an issue) 18. It does not need dedicated vehicle (transportation/logistic is
19. Can be used for rigid pavements (load transfer simple)
efficiency/structural evaluation) 19. Not suitable for rigid pavements
 FWD, TSD, RWD, RAPTOR

Ref. The available approaches for using traffic speed Deflectometer data at network level pavement management
system (sciencedirectassets.com)
https://www.youtube.com/watch?v=Vo5I3830b7E