Design of

overlays
HMA OVERLAYS ON ASPHALT PAVEMENTS
HMA OVERLAYS ON PCC PAVEMENTS
PCC OVERLAYS ON ASPHALT PAVEMENTS
PCC OVERLAYS ON PCC PAVEMENTS

Types of overlays

As the nations highways age and deteriorate, some

type of treatment is eventually required to provide
a safe and serviceable facility for the users. The
types
of
treatments
can
range
from
simple
maintenance to complete reconstruction, depending on
the circumstances.
For pavements subjected
to
moderate and heavy traffic, the most prevalent
treatment is to place an overlay on the existing
pavement. Depending on the types of overlay and
existing pavement, four possible designs may serve:
1. HMA OVERLAYS ON ASPHALT PAVEMENTS
2. HMA OVERLAYS ON PCC PAVEMENTS

3. PCC OVERLAYS ON ASPHALT PAVEMENTS

4. PCC OVERLAYS ON PCC PAVEMENTS

WHAT IS
HMA?

Asphalt pavement refers to any paved road surfaced with

asphalt. Hot Mix Asphalt (HMA) is a combination of
approximately 95% stone, sand, or gravel bound together by
asphalt cement, a product of crude oil. Asphalt cement is
heated aggregate, combined, and mixed with the aggregate
at an HMA facility. The resulting Hot Mix Asphalt is loaded
into trucks for transport to the paving site. The trucks dump
the Hot Mix Asphalt into hoppers located at the front of paving
machines. The asphalt is placed, and then compacted using
a heavy roller, which is driven over the asphalt. Traffic is
generally permitted on the pavement as soon as the pavement
has cooled.

1. HMA Overlays on Asphalt Pavements the predominant type of resurfacing on

asphalt pavements.
2. HMA Overlays on PCC Pavements Although HMA overlays have been used
extensively on PCC pavements, this type of overlay is the most difficult to
analyze mechanistically because it involves two different types of materials.
A major problem in the design of HMA overlays on PCC pavements is reflection
cracking, defined as the fractures in an overlay or surface that reflect the
crack or joint pattern in the underlying layer.
3. PCC Overlays on Asphalt Pavements The use of PCC overlays on asphalt
pavements is somewhat uncommon. This method can be used if the vertical
clearance does not pose a problem. It can be cost effective if the asphalt
pavement is severely distressed and must be used only as a foundation for the
PCC overlay.
4. PCC Overlays on PCC Pavements Three types of PCC overlay may be used for PCC
pavements:
a. Unbonded or Separated Overlay
b. Bonded or Monolithic Overlay
c. Partically Bonded or Direct Overlay

Unbonded
overlays
are
typically placed on pavements that
are badly cracked. Prior to the
pverlay, the surface of the existing
pavement mmust be cleaned of debris
and
excess
sealing
materials.
A
separation layer, usually consisting
of HMA or sand asphalt of less than 2
in. thick, ia then placed between the
new overlay and the existing pavement
to prevent refelection cracking. The
separation layer can also serve as a
leveling course so that a more
uniform thickness of concrete can be
obtained.
Unbonded overlay may be
plain,
reinforced,
continuously
reinforced, or prestressed concrete.
It is not necessary to match the
location or type of joints in the
overlay with those in the existing
pavement. The
minimum thickness of
unbonded overlay is 6 in.

Bonded or monolithic overlay

Bonded overlays should be used only when the existing pavement is in
good condition or when serious distress has been repaired. To achieve a fully
bonded overlay, it is necessary to carefully prepare the existing surface before
placing the overlay. All oil, grease, paint, and surface contaminants must be
removed by cold milling, sandblasting, or waterblasting. Then a thin layer of
cement grout should be placed on the cleaned dry surface just in front of the
concrete paver. A liquid epoxy resin of low viscosity may also be used as a
bonding agent.
Irrespective of the type of existing PCC pavements, plain concrete is
the most commonly used bonded overlay, although steel reinforcements may be used
in thicker overlays to supplement the steel in the existing pavements. The
location of the joints in the overlay must match that in the existing pavement.

Partially bonded or direct overlay

Partially bonded overlays are obtained when the fresh concrete is
placed directly on relatively sound and clean existing slabs. Unless steps are
taken to prevent bond, some degree of bonding can be assumed, so the overlay can
be designed slightly thinner than unbonded overlays to take advantage of the
resulting stress reduction.
If the existing pavement is jointed, a joint should be placed
immediately above the existing joint to prevent reflection cracking. It is also
important to keep the joint spacing of a partially bonded overlay as short as
possible by providing additional joints in the overlay to minimize temperature
stresses caused by the stiff underlying slabs.