Summary. Structurally, an 8 inch (203 mm) thick overlay should satisfy the design conditions. The overlay thickness calculated from structural considerations should be compared with that required to satisfy geometric requirements. Geometric requirements include, for example, provision of drainage, correcting crown and grade, meeting grade of other adjacent pavements and structures, etc. The most difficult part of designing hot mix asphalt overlays for flexible pavements is the determination of the properties of the existing pavement. Subgrade and subbase properties can be measured by conducting NDT. The subgrade and subbase must be at the equilibrium moisture content when field tests are conducted. Normally, a pavement that has been in place for at least 3 years will be in equilibrium. Procedures for calculating properties from nondestructive tests are contained in AC 150/5370-11.
b.
Nonstructural Hot Mix Asphalt Overlays. In some instances overlays are required to correct nonstructural problems such as restoration of crown, improve rideability, etc. Thickness calculations are not required in these situations, as thickness is controlled by other design considerations or minimum practical overlay thickness. Although the overlay in this case is not necessary for structural requirements it may be included when computing pavement strength (PCN). Information concerning runway roughness correction can be found in FAA Report No. FAA-RD-75-110, Methodology for Determining, Isolating and Correcting Runway Roughness (see Appendix 4).
c.
Concrete Overlay of an Existing Flexible Pavement. The design of a concrete overlay on an existing flexible pavement is essentially the same as designing a new rigid pavement. The existing flexible pavement is characterized by assigning the appropriate thicknesses and moduli of the existing layers. A trial thickness of overlay is selected and the program iterates until a CDF of 1.0 is reached. The overlay thickness required to achieve a CDF of 1.0 is the design thickness. The design process is relatively simple; however, the characterization of the existing pavement layers requires judgment by a qualified engineer. The program assumes the interface between the concrete overlay and the existing flexible surface is frictionless. When frost conditions require additional thickness, the use of nonstabilized material below the rigid pavement overlay is not allowed, as this would result in a sandwich pavement. Frost protection must be provided by stabilized material. The minimum thickness for a concrete overlay of an existing flexible pavement should be 5 inches (130 mm).